Plant Engineering November 2013

64 Longer life for VFDs 75 Value of wireless M2M 81 Asset hierarchy validation

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The new ViewMarq LED message boards can displaypreformatted and real-time factory fl oor data messages sentby a PLC, PC, or other master device. The text messagedisplays can be controlled by:

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The Viewmarq line off ers:

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FINALISTS

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www.plantengineering.com PLANT ENGINEERING November 2013 • 3

What’s INsideWhat’s INside

6 Interactive

9 In Focus

22 Apps for Engineers

23 Media Showcase

85 Product Mart

86 Internet Connection

87 Advertiser Contacts

88 In Conclusion

November 2013Volume 67, No. 9

21 System integration

PLANT ENGINEERING (ISSN 0032-082X, Vol. 67, No. 0, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and addi-tional mailing offices. Circulation records are main-tained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: [email protected]. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: [email protected]. Rates for nonqualified subscriptions, includ-ing all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

What’s INside

2013 Product of the Year

Meet this year’s � nalists

27 Introduction

28 Apps for Engineers

29 Automation & Controls

31 Compressed Air

33 Electric Motors & Drives

35 Electrical Controls

36 Electrical Safety

39 Energy Management

40 Environmental Health

41 Fluid Handling

43 Lighting

46 Maintenance Tools & Equipment

48 Manual Material Handling

49 Material Handling Systems

50 Power Transmission

51 Productivity & Training

53 Safety

There are more than 100 finalists across 16 categories in the 26th annual Product of the Year program. Review their product descrip-tions here in print, and then go to www.plantengineering.com/poy

to cast your vote for this year’s best products.

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www.plantengineering.com PLANT ENGINEERING November 2013 • 5www.plantengineering.com

PlantEngineering.com1111 W. 22nd St. Suite 250, Oak Brook, IL 60523Ph 630-571-4070, Fax 630-214-4504

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ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, [email protected]

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MICHAEL SMITH, Creative Director 630-779-8910, [email protected]

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LETTERS TO THE EDITOR Please e-mail your opinions to [email protected]. Letters should include name, company, and address, and may be edited for space and clarity.

INFORMATION For a 2013 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected].

REPRINTS For custom reprints or electronic usage, contact: Nick Iademarco, Wright’s Media 877-652-5295 x102, [email protected]

PUBLICATION SALES Tom Corcoran, West, TX, OK [email protected] 1111 W. 22nd St., Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax 484-631-0598

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Stuart Smith, International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588

9 In Focus� 5 things to consider when selecting a safety system� The 28 metrics every plant needs to monitor� Maintenance must take lead in machine guarding checks� Condition-based maintenance offers a system check-up� 8 ways electronic work instructions are transforming the shop floor� IT-manufacturing convergence accelerates

Electrical Solutions64 VFDs: The path to prolonged life

Proper maintenance and attention to detail can stretch productivity.

70 Six strategies to mitigate arc flash incidents

From analysis to equipment, you can reduce the exposure to a dangerous event.

Automation Solutions75 Wireless M2M increases value of wired infrastructure

New technology overcomes limitations ofprevious systems to deliver value.

Maintenance Solutions81 Finding the hidden value in asset hierarchy validation

Make the effort now to save time andmoney down the line.

84 4 keys to a successful supply chain

At the 2013 Association for Manufacturing Excellence Conference in Toronto in October, Michael Rackley, head of supply chain solutions for Ryder Systems, talked about the increasing demands by manufac-turers and consumers on the supply chain.

Editorial research

People and training

Services available� Site search engine: Search current and past articles at www.plantengineering.com by topic, keyword, author or company name to � nd solutions to your plant issues.

� Channels, new productsVisit our specialized microsites providing feature news, products, applications, tutorials and research for engineering professionals.

� e-NewslettersKeep current with the latest informationand news with our weekly PlantMail and topic-speci� c electronic newsletters.

� System Integrator GuideConsult our listing of more than 2,300 automation system integrators. You can � nd a speci� c company or run a seven-way multi-parameter search.

� Digital editionPlant Engineering is delivered every month in a digital format, with enhanced features to bring the print product alive on your screen.

� On-demand videos� Upcoming and on-demand Webcasts� Online training center� Case studies—130+ all in one place on dozens of topics� eGuides� White papers

Product of the YearFinalists announced Nov. 15

The � nalists for the 2013 Plant Engineering Product of the Year awards will be announced in the November issue and online on Nov. 15.

It’s the plant manager’s source for the best new products of the year, and their chance to vote on

the best of the best in manufacturing.www.plantengineering.com/poy

� Workforce development� Energy management

On a quarterly basis, Plant Engineering conducts research studies on various industry topics.

Access the following full reports atwww.plantengineering.com/research:

6 • November 2013 PLANT ENGINEERING www.plantengineering.com

Industry NewsHere are the top 10 articles for October at www.plantengineering.com based on reader clicks:

� Calculating proper rolling resistance a safer move for material handling� The new Hazard Communications Standard: What you need to know to be compliant� Electrical safety from the ground up� Fall protection again leads OSHA’s Top 10 violations� SAIC announces split into SAIC and Leidos� Stirling engines show promise� Rotary screw or reciprocating air compressor: Which one is right?� If only OSHA regulations are law, what are ANSI consensus standards?� 9 reasons why hydraulic hoses fail� Study identi� es 10 ways to improve supply chain ef� ciency

To keep up with important industry news, go to www.plantengineering.com/industry-news.

LinkedIn membership hits 3,000! Now what?Plant Engineering has doubled its membership on its LinkedIn page, Plant Engineering Professionals. We value the insight of these global professionals, and we will be tapping into that knowledge in the coming month, and sharing that knowledge throughout our communication channels. Members can use this forum as a place to share those best practices. We want to be a resource to help resolve your questions and problems with manufacturing, and as a place to get peer-to-peer help with your issues.

Point, click, watchHow to be a Top Plant winnerAs Plant Engineering prepares to announce its 2013 Top Plant winners next month, we thought we’d take a look back at our 2011 winner to show those plants looking to enter the 2014 Top Plant competition what it takes to be recognized as an outstand-ing manufacturing plant. Scan the QR code at right or go towww.plantengineering.com/videos. The 2014 Top Plant entries open April 1, 2014, at www.plantengineering.com/top-plant.

Trending New Products Maintenance Electrical Mechanical Energy Management Plant Automation Safety People and Training

NOVEMBER

www.plantengineering.com

Editorial research

People and training

Services available� Site search engine: Search current and past articles at www.plantengineering.com by topic, www.plantengineering.com by topic, www.plantengineering.comkeyword, author or company name to � nd solutions to your plant issues.




� Digital editionPlant Engineering is delivered every month in a Plant Engineering is delivered every month in a Plant Engineeringdigital format, with enhanced features to bring the print product alive on your screen.


Product of the YearFinalists announced Nov. 15

The � nalists for the 2013 Plant EngineeringProduct of the Year awards will be announced in the November issue and online on Nov. 15.

It’s the plant manager’s source for the best new products of the year, and their chance to vote on

the best of the best in manufacturing.www.plantengineering.com/poy


On a quarterly basis, Plant Engineering conducts Plant Engineering conducts Plant Engineeringresearch studies on various industry topics.


Editorial research

People and training

Services available� Site search engine: Search current and past articles at www.plantengineering.com by topic, keyword, author or company name to � nd solutions to your plant issues.




� Digital editionPlant Engineering is delivered every month in a digital format, with enhanced features to bring the print product alive on your screen.


2013 Salary SurveyTell us about your plantThe Plant Engineering Salary Survey is

recognized as the most complete barometer of manufacturing attitudes and trends from the perspective of the plant manager. The 2013

Salary Survey will be sent via email to all Plant Engineering subscribers. Please take the time to

� ll out this survey, share your insights onmanufacturing, and look for the results in the

Forecast issue in February 2014.


On a quarterly basis, Plant Engineering conducts research studies on various industry topics.


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Safety is among the top priori-ties in any manufacturing facil-ity, and given the changes in the industry, technology and even standard, there are a lot of con-cerns starting with the selection of a safety system.

The performance based safety standards (IEC61508 and IEC61511/ISA84) have changed the way safety system selection should happen. Gone are the days of simply choosing a certified product, or selecting a preferred architecture; today’s system selection is driven by per-formance requirements.

1: Hazard understandingCorrect, this has nothing to do with

the safety system hardware. It is critical in the process to understand the scope of the process hazards and to determine the necessary risk reduction required. This should be done to create the Safety Requirements Specification (SRS) nec-essary to start a system selection. Even when replacing an existing system, this is critical as the risk profile of the plant may have changed since installation.

2: The more diverse the betterTechnology diversity: There has been

a long standing requirement that a safety system must be different (or diverse) technology from its process automation counterpart to avoid common cause fail-ures. But most safety systems rely on component redundancy (hardware fault tolerance, or HFT) to meet reliability and availability requirements, introducing a degree of common cause failure directly into the safety system.

Rather than redundancy, lead-ing systems now provide diversity of

technologies designed into logic solversand I/O modules, along with a high degree of diagnostics, to allow a sim-plex hardware configuration to meet SIL3 requirements.

Product implementation diversity: The standards are imposing diversity on the way manufacturers deliver the product you buy. Even though most safety sys-tems are manufactured by process auto-mation vendors, organizational diversity between the two product teams is only the first level of separation.

Within the safety product team, lead-ing suppliers will also be separating the design group from product development group and then again from product testing group. Ask your potential suppliers how diverse they really are.

3: Systematic safeguardsThis addresses how much protection

against mistakes is built into the safety system. You should be asking for:

� Certified software libraries that offer functions according to the SIL require-ments of the application,

� Compiler restrictions to enforce imple-mentations according to the SIL requirements,

� User security management to separate approved from non-approved users for overrides, bypass and other key functions, and

� Audit trail capability to record and document changes to aid in compliance with functional safety standards.

4: AvailabilityAs mentioned above, previous

generations of safety systems met reliability requirements through HFT. This feature helped to provide availability and kept plants running in the event of a component failure with the safety system. Whether you needed it or not, you paid for

it. Understand if you need high availabil-ity or not as some processes can easily tolerate shutdowns from spurious trips when using simplex configurations that still deliver appropriate SIL coverage.

If you know you need availability, look for a system supporting firmware update or upgrade and maintenance without dis-rupting the process.

5: Separate, interfaced, or integrated?Using the SRS and your business

requirements, make a clear determina-tion of one of these three requirements. Integrated offers many key benefits, drawing on common capabilities of the process automation system not related to the safety functions directly. But only being interfaced or even kept completely separate are options, and need to be thor-oughly considered.

However, achieving the desired risk reduction involves more than just choosing a system. On our next posting we’ll cover implementation, security, operation, and maintenance of a safety system. PE

Luis Duran is Product Marketing Man-ager at ABB for the Safety Automation System business.

5 things to considerwhen selecting a safety systemPerformance requirements now drive the selection process.

INFOCUS

Figure 1: Hazard management in places like offshore drilling is critical to the safety of people and proper-ty, and is one of five considerations when choosing a safety system. Courtesy: ABB

By Luis Duran, ABB

10 • November 2013 plant engineering www.plantengineering.com

When it comes to metrics, it’s often said that what gets measured gets done. Part of this is human nature. Everyone has more piled on their plate than ever, and many workers find themselves constantly re-prioritizing their work activities. Therefore, metrics that have the attention of business and manufacturing leaders tend to be those that get measured and improved upon by their employee teams.

Effectively measuring, analyzing, and improving manufacturing metrics is not as simple as it may appear. While there are certain metrics that work well for specific job roles, it’s often the case that there are multiple combinations of metric indicators needed to ensure that a larger business objective is being met.

For this reason, metrics need to be aligned to larger goals and objectives. Think “SMART” goals—Specific, Measurable, Actionable, Realistic, Time-Based. This mnemonic contains some key concepts.

It’s important to understand the inter-relationships between high-level goals and objectives as well as what actions or methods are required for an organiza-tion to achieve them—this falls under Specific. Measurable and Actionable are when metrics come into play—any desired result must have a set of defined measurements, targets, and actions that can be taken in order to “move the nee-dle” on the metrics that are leading or lagging indicators of results.

In manufacturing, each major goal typically requires multiple metrics. The 28 metrics that appear in this post are grouped together relating to specific higher-level goals and objectives (e.g., increase quality).

The Realistic component of the acro-nym can present a significant area of challenge. Leaders want teams to stretch and achieve more than what is individu-ally perceived as possible. However, if goals are too lofty and workers don’t believe they can be achieved, they may give up and disengage.

Since every goal needs to be driven by some type of deadline or period to achieve the target, a Time-Based aspect is important to keeping everyone focused.

Sustainable metrics improvements require a continuous improvement methodology—a cycle that is never fully complete. As can be seen, measurement and metrics is a central pillar of this con-tinuous improvement cycle.

Which metrics matter most?The MESA (Manufacturing Enterprise

Solutions Association) organization has sponsored research over the past years to help the manufacturing marketplace

identify the most important metrics, and help decision makers understand metrics improvements and their relation-ships to metrics programs and the use of software solutions. As part of the most recent metrics survey, 28 manufacturing metrics were identified as being the most utilized by discrete, process, and hybrid/batch manufacturers.

Below, we’ve grouped these metrics with the associated top-level area of improvement/goal for each.

Improving customer experience and responsiveness

1. On-time delivery to commit: This metric is the percentage of time that man-ufacturing delivers a completed product on the schedule that was committed to customers.

2. Manufacturing cycle time: Measures the speed or time it takes for manufactur-ing to produce a given product from the time the order is released to production, to finished goods.

3. Time to make changeovers: Mea-sures the speed or time it takes to switch over a manufacturing line or plant from making one product to making a differ-ent product.

Improving quality4. Yield: Indicates a percentage of prod-

ucts that are manufactured correctly and to specifications the first time through the manufacturing process without scrap or rework.

5. Customer rejects/return material authorizations/returns: A measure of how many times customers reject prod-ucts or request returns of products based on receipt of a bad or out-of-specification product.

6. Supplier’s quality incoming: A mea-sure of the percentage of good-quality materials coming into the manufactur-ing process from a given supplier.

Improving efficiency7. Throughput: Measures how much

product is being produced on a machine, line, unit, or plant over a specified period of time.

8. Capacity utilization: Indicates how much of the total manufacturing output capacity is being utilized at a given point in time.

9. Overall equipment effectiveness (OEE): This multi-dimensional metric is a multiplier of Availability x Performance x Quality, and it can be used to indicate the overall effectiveness of a piece of production equipment, or an entire pro-duction line.

10. Schedule or production attainment: A measure of what percentage of time a target level of production is attained within a specified schedule of time.

Reducing inventory11. WIP inventory/turns: A common-

ly used ratio calculation to measure the efficient use of inventory materials. It is calculated by dividing the cost of goods sold by the average inventory used to produce those goods.

INfOCUS

The 28 metrics every plant needs to monitorSMART: Specific, Measurable, Actionable, Realistic, and Time-based

By Mark Davidson, LNS Research

Any desired result must have a set of defined measure-ments, targets and actions that

can be taken in order to ‘move the needle.’


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Ensuring compliance12. Reportable health and safety incidents: A measure of

the number of health and safety incidents that were either actual incidents or near misses that were recorded as occur-ring over a period of time.

13. Reportable environmental incidents: A measure of the number of health and safety incidents that were recorded as occurring over a period of time.

14. Number of non-compliance events per year: A measure of the number of times a plant or facility operated outside the guidelines of normal regulatory compliance rules over a one-year period. These non-compliances need to be fully documented as to the specific non-compliance time, reasons, and resolutions.

Reducing maintenance15. Percentage planned versus emergency maintenance

work orders: This ratio metric is an indicator of how often scheduled maintenance takes place, versus more disruptive/unplanned maintenance.

16. Downtime in proportion to operating time: This ratio of downtime to operating time is a direct indicator of asset availability for production.

Increasing flexibility and innovation17. Rate of new product introduction: Indicates how rap-

idly new products can be introduced to the marketplace and typically includes a combination of design, development, and manufacturing ramp-up times.

18. Engineering change order cycle time: A measure of how rapidly design changes or modifications to existing products can be implemented all the way through documentation pro-cesses and volume production.

Reducing costs and increasing profitability19. Total manufacturing cost per unit excluding materials:

This is a measure of all potentially controllable manufactur-ing costs that go into the production of a given manufactured unit, item, or volume.

20. Manufacturing cost as a percentage of revenue: A ratio of total manufacturing costs to the overall revenues produced by a manufacturing plant or business unit.

21. Net operating profit: Measures the financial profitability for all investors/shareholders/debt holders, either before or after taxes, for a manufacturing plant or business unit.

22. Productivity in revenue per employee: This is a measure of how much revenue is generated by a plant, business unit, or company, divided by the number of employees.

23. Average unit contribution margin: This metric is cal-culated as a ratio of the profit margin that is generated by a manufacturing plant or business unit, divided into a given unit or volume of production.

24. Return on assets/return on net assets: A measure of financial performance calculated by dividing the net income from a manufacturing plant or business unit by the value of fixed assets and working capital deployed.

INfOCUS

Continued on pg. 18

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At first glance, OSHA’s list of the Top 10 most common citations for 2013 (Plant Engineering,

October 2013, page 38) seems to con-vey good news for machine guarding violations: they have dropped four spots from sixth to 10th compared to last year. However, this drop in rank says machine guarding infractions actually increased by 28% over the past year.

There were approximately 56% more citations overall in 2013 compared to 2012 among the top ten categories.

So what accounts for the rise? Regulations and government agencies responsible for enforcing them tend to be in constant flux. The recent shutdown of the U.S. Federal Government, for example, forced OSHA to furlough 90% of its inspectors and created a sizeable backlog of un-enforced cases.

But the nature of machine guarding regulations suggests that something

else may be at work. Guards, electronic shutoffs, and other measures are put in place to protect workers from hazards “created by point of operation, ingoing nip points, rotating parts, flying chips and sparks,” according to OSHA.

So companies must either be failing to fit new equipment with the proper safety devices, or neglecting maintenance on safeguards that are already in place. Identifying the cause of these violations is no small matter, as these incidents are considered particularly serious and carry some of the OSHA’s heftiest fines.

A manufacturing firm in Fort Worth Texas was slapped with 17 violations amounting to $88,000 in fines—13 of which stemmed from safety infractions like failing to equip a lathe with a foot guarding device.

Given the regulatory burden already facing manufacturers, it’s not neces-sarily hard to imagine why machine

guarding tends to be overlooked: once safeguards are in place, the focus shifts toward other, more pressing needs. Companies may even consider efforts beyond the initial installation of machine guards to be a waste of resources.

This mentality will have to change, however, if companies hope to reverse the upward trend in these violations. Establishing a thorough preventive maintenance checklist is a critical first step.

Implementing checks of machine guards into a preventive maintenance routine is the best way to ensure that they do not slip through the cracks. Having the maintenance staff check machine guards while performing related inspections or fixes is an efficient way to make ensure that they get done without expending excess resources. PE

Chris Mumford is a marketing assis-tant for ManagerPlus.

INfOCUS

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sets tolerance levels and automatically issues work orders to make the repairs. Another CBM process fulfilled.

The idea behind CBM is to perform the necessary maintenance when the machine tells you to do so. But if you

make an investment in equipment-based monitoring hardware, it should be used in conjunction with CMMS. PE

Paul Lachance is president and CTO for Smartware Group.

plant engineering November 2013 • 15

For most drivers, it’s the mileage sticker that reminds them that it is time to change the oil. It’s hard to imagine the average car owner waiting until his engine ceases before he realizes he’s four quarts low. Even if he waits till the lantern icon flashes on the dashboard, he’ll no doubt raise some eyebrows at the gas pump.

Likewise on the plant floor, if a gear box low in oil costs production time and product output, the culprit may be looking for a new job. The production machine equivalent of the 3,000 mile oil change reminder is condition-based maintenance (CBM): one part native technology to monitor all equipment pieces and parts, and two parts computer-ized maintenance management software (CMMS) to set the thresholds and issue the work orders. Keeping equipment in optimal condition is done with the help of CMMS by implementing a predic-tive maintenance plan and schedule, and completed work orders.

Let’s say a compressor is out of align-ment. The machine’s vibration detec-tion system continually monitors the machine. It picks up the imbalance and forwards the data in numerical form to a server where a CMMS retrieves the data and converts it to actionable information. A CMMS not only tracks the compres-sor’s maintenance and repair history, but sets up a CBM if the alignment falls below tolerance levels, and issues a work order to make the adjustments.

CBM utilizes the combined vibrational analysis and corresponding maintenance tasks dictated by the CMMS to fine-tune machine performance and keep the asset humming.

A thermal camera picks up a heat signature in a motor which indicates a pending failure. Now what? The analysis from the infrared camera is an impetus for further action by the CMMS, which sets threshold levels and spits out work orders as needed. A pressure gauge shows two different pressure readings for both sides of an air handler filter. Again, CMMS grabs the data from the server and makes sense out of it. CMMS

Condition-based maintenance offers a system check-upBy Paul Lachance, Smartware Group

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Today, electronic work instructions soft-ware is instrumental to the shop floor. And market leaders are investing in the integra-tion of electronic work instructions (EWIs) with 3D visualization and simulation soft-ware, so operators aren’t just following along with instructions, they’re able to view animations of each step and sometimes even improve things right on the spot.

Here’s what you need to know about the past, present, and future of electronic work instructions in manufacturing opera-tions management, as well as discuss eight ways they’re transforming the shop floor.

From paper-based to next-generationIt’s vital that you have clear and

repeatable instructions for every manu-facturing process. Traditionally, shop-floor workers would hang laminated pieces of paper on the wall with dia-grams and explanations of each step. The shortcomings of this are obvious, particularly when an engineering change order (ECO) was required and those changes needed to be sent to engineer-ing, revamped, sent back to manufactur-ing, reprinted, relaminated, and so on. If

we’re talking about a global operation, this becomes even more of a challenge.

The more complex something you’re building is, generally the more com-plex those instructions have to be, and a paper-based approach can be limiting. But computer technology on the shop floor wasn’t always as easily accessible and widespread as it is today.

Since document control software has become widely adopted, however, EWIs have made their way into the manufactur-ing environment. EWIs have improved the way supervisors and operators build products, and the way they interact with engineers and maintenance personnel. The technology enables a centralized, standardized, and automated document management system, and can be found on most modern manufacturing shop floors.

In addition to improving communica-tion and collaboration on the shop floor, streamlining EWIs mitigates many of the traditional risks associated with changing a work order. In the past, an engineering change may have been ordered, but never completed or at least never communi-cated to the appropriate personnel once completed. With automated workflows, notifications can be triggered to ensure

the process is completed and the appro-priate personnel are notified. Workflows can also ensure that the right instructions are being followed on time and in the context of the manufacturing process.

As the use of simulation and 3D visual-ization software becomes more prevalent, moving from engineering onto the shop floor, EWIs are becoming an even more effective tool. By integrating EWIs with this technology, an operator can watch each step of a process played out via animations. In some cases, operators and supervisors are trained to actually make changes and improvements to these processes in real time rather than waiting for an ECO.

With the continuous advancement of technology, we expect to see further integration between plant and process design, 3D visualization, simulation soft-ware, workflow software, manufacturing execution systems, and electronic work instruction software.

The role of EWIsIncreasingly, modern manufacturing

operations management (MOM) plat-forms offer EWIs as an application within a broader portfolio of applications that integrate via the same software platform.

INfOCUS8 ways electronic work instructions are transforming the shop floorBy Mike Roberts, LNS Research

SOFTWARE & SERVICESIT INFRASTRUCTURE

www.rittal.us

Standardization on the MOM platform facilitates the sharing of information and workflows, and is often a driver of great-er collaboration capabilities in globally distributed manufacturing environments and even between functional units.

Eight benefits of EWIsMoving from paper-based work

instructions to EWIs, there are many benefits. When accounting for the centralization, standardization, and automation capabilities offered by today’s MOM software platforms, those benefits increase dramatically. Below are eight ways EWIs are improving shop-floor operations and making manufacturers more effective:

1. Reduced downtime: Because com-munication is easier with an electronic routing and delivery system, less time is required to take maintenance actions or make engineering change orders.

2. Stronger communication: A cen-tralized document management system enables greater ability to share docu-ments within the manufacturing envi-ronment, across facilities, and between functional units. Stronger communica-tion creates fewer errors.

3. Closed-loop manufacturing and quality processes: With a centralized platform, EWI/ECO content and data can be more easily shared with correc-tive and preventive action management and audit management processes.

4. Closed-loop manufacturing and engineering processes: With a central-ized platform, EWI/ECO content and data can be more easily shared with the failure more and effects analysis processes.

5. Reduced waste/scrap: The ability to communicate and collaborate with engineering more effectively helps to improve first-time quality and reduce waste in the manufacturing environment.

6. Easier communication of regula-tory changes: Because many industries

face dynamic regulatory environments, EWIs help to quickly communicate changes required for shop-floor processes and validate that personnel have been made aware of and are following them.

7. Faster new product introduction process: Streamlining communication and collaboration between manufacturing and engineering reduces the time required to develop, test, and build new products.

8. Reduced risk and improved effi-ciency: With automatic notifications triggered for both shop-floor and engi-neering workers, the likelihood of a non-conformance or compliance issue is much lower. PE

Mike Roberts is a research associate at LNS Research.

As part of the 2014 Global Auto-mation & Manufacturing Summit, Control Engineering and Plant

Engineering are looking for manufactur-ers who want to share their success stories with a global manufacturing audi-ence. They are issuing a Call for Pre-sentations for the 2014 Summit.

Control Engineering and Plant Engi-neering, in partnership with Hannover Fairs USA, will present the 2014 Global Automation & Manufacturing Summit on Tuesday, Sept. 9, 2014, at the Industrial Automation North America Show, part of IMTS 2014 in Chicago.

Building off the success of the inau-gural 2012 event, the 2014 Global Automation & Manufacturing Summit will feature success stories from man-ufacturing around the country.

Submissions for presentation can include Word documents, videos, Power- Point presentations and any other con-tent you think will be helpful in evaluat-ing your plant for inclusion in the 2014 Summit.

Go to www.plantengineering.com/summit for the form to submit to your proposal today. Proposal submissions are due by Dec. 20, 2013.

Tell your plant’s success story at 2014 event


A recent study by the ManpowerGroup found that manufacturers are integrat-ing IT and engineering roles, changing the way plant data is managed and acted upon. In an age where manufac-turing lead times are shrink-ing, this change promises to have a profound impact how things are made when how manufacturers schedule their time.

Jorge Perez, senior vice president at ManpowerGroup, discussed this study and its implications with Plant Engineering:

PE: The Manpower Manufacturing study seems to indicate the proliferation of data is coming fast in manufacturing. What are the barriers to using data more effectively?

Perez: From the talent perspective, the proliferation of data is accelerating both the speed of technology development and its integration on the manufacturing floor. As such, educational programs are not modernizing fast enough to manufacture a steady supply of talent with the right skills.

Today’s talent needs to clearly under-stand why they need to be lifetime learn-ers and continually add skills in order to be employable. Likewise, companies and local educational systems need to col-laboratively define comprehensive and scalable skills-training programs that will maintain a healthy pipeline of talent for area employers.

PE: We hear so much about how tech-savvy the younger generations are, and manufacturing is clearly a high-tech business today. Why is there still a dis-connection between young workers and high-tech manufacturing jobs?

Perez: Great question. Our surveys and candidate feedback tell us that high-tech positions have not been perceived as great career opportunities. As a society, we have done a great job of encourag-ing students to earn four-year college degrees, but they are overlooking

the value and great career options offered by techni-cal and skilled vocations, which often require two-year degrees.

High-tech business and educational systems have to do a much better job at repositioning the value and real opportunities available within technical and skilled

trades. These jobs are critical and in sup-ply in today’s economy.

There is still a perception that manu-facturing is just hard and dirty work. The reality is that most high-tech facilities offer cutting-edge environments with a strong safety culture, high performance standards, and great career development opportunities.

PE: The line between IT and opera-tions also has been blurred or erased. What are the implications for manufac-turing operations?

Perez: The challenge for employers is to reposition the value of technical jobs in order to attract and retain talent. And they need to maintain a continuous training/educational program that keeps talent up to speed with the pace of their company’s innovation.

PE: One conclusion of the Manpower Manufacturing study is that while engi-neering and IT degrees will be valued,

some of this work can be done by well-trained people with aptitude. What’s the key to finding these kinds of workers, and what role do all the stakeholders in manufacturing have to play in filling those jobs?

Perez: Here is where the rebranding of manufacturing jobs from all industry stakeholders—including corporations, educational systems, and local govern-ments—is critical.

To build an essential pipeline of tal-ent, all stakeholders need to start working with kids at the middle-school level to demystify the intensive integrated work that happens on the manufacturing floor and expose the modern value of today’s manufacturing environment and jobs.

PE: What should manufacturers who are facing a worker shortage in high-tech jobs like the ones in your report be doing to address this issue?

Perez: They need to reach out to local educational systems and governments and create a regional plan for develop-ing the talent pipeline required by area employers.

There is no simple solution, but there is a very good opportunity to alleviate the skills shortage gap if stakeholders in a local economy can collaboratively customize a plan that meets their local needs. PE

INFOCUS

IT-manufacturing convergence acceleratesMANPOWERGROUP STUDY:

Jorge Perez

25. Energy cost per unit: A measure of the cost of energy (electricity, steam, oil, gas, etc.) required to produce a specific unit or volume of production.

26. Cash-to-cash cycle time: This metric is the duration between the pur-chase of a manufacturing plant or busi-ness unit’s inventory, and the collection of payments/accounts receivable for the sale of products that utilize that inven-tory: typically measured in days.

27. EBITDA: This metric acronym stands for Earnings Before Interest, Taxes, Depreciation, and Amortization.

It is a calculation of a business unit or company’s earnings, prior to having any interest payments, tax, depreciation, and amortization subtracted for any final accounting of income and expenses. EBITDA is typically used as top-level indication of the current operational prof-itability of a business.

28. Customer fill rate/on-time delivery/perfect order percentage: This metric is the percentage of times that customers receive the entirety of their ordered man-ufactured goods, to the correct specifica-tions and delivered at the expected time. PE

Mark Davidson is a principal analyst at LNS Research.

Continued from pg. 10

Answers for industry.

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Siemens is the world‘s proven innovative manufacturer of industrial automation systems, helping customers migrate to future platforms.• We take the time to understand your business• Customized scalable solutions for your timelines and budget • Migration Experts, providing training, service, and support both today and tomorrow

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© Copyright 2013 Atlas Copco Compressors LLC. All rights reserved.

Standing up and standing out

Small compressor, big ideasAtlas Copco introduces our new GA VSD+ range of air compressors. Designed with energyefficiency and customer needs in mind, the GA VSD+ can reduce energy consumption by 50%compared to a traditional load/unload compressor of the same type. Built upwards, like a miniskyscraper, the motor and drive train share a single drive shaft and are vertically aligned,reducing the total footprint by up to 55%. The new revolutionary design is also extremely quiet,down to 62 dBA. The result is a revolutionary air compressor that saves space and energywhile simultaneously achieving higher air capacities.

In 2013, Atlas Copco celebrates our 140th anniversary. To celebrate, we’re giving our customersgame-changing, energy-efficient solutions. Let Atlas Copco demonstrate to you just why, yearafter year, we have been listed as one of the top 20 most sustainable companies in the world.Check out the new technology at www.atlascopco.us/gamechangerusa or call 866-688-9611.



INPRACTICE

Working for a com-pany that executes large projects using a design-build philoso-

phy, I have witnessed the benefits of the traditional architect and engineer (A&E) approach to the design process. An A&E custom-er-focused approach uses design milestones for concept/feasibility and 30%, 60%, and 90% design reviews, with customer approvals at each stage. Key project disci-plines are represented throughout the process to ensure the design functions as one cohesive solution.

Frequently, system integrators aren’t brought into a project until the detailed design is nearly finalized and the project is moving into the construction phase. At this point in the project, the integrator is unable to positively influence a project without a significant cost impact. Alter-ing this approach and instead involving a systems integrator early can reduce project costs and risks compared to traditional methods, especially those that include a pre-selected productvendor.

The project cost influence curve presents the influence opportunity in correlation with project expenditure through-out any project lifecycle. Once the detailed design phase has been reached, the influence opportunity rapidly declines while the cost expenditure quickly increases. Executing a project in this manner causes system integration to be treated as a com-modity purchase similar to skilled tradesman and equipment purchases. As a result of the cost impact, projects are typically executed as designed, regardless of whether or not the design encompasses the best (or even feasible) solution.

Multidiscipline system integrators are required to properly design and integrate with various systems including commu-nications networks, systems interoperability, and communica-tions protocols. Also, the recent proliferation of information systems has increased project complexity. The expectation that information is available from all systems has become the norm. Even simple mechanical systems are expected to provide system-level integration capabilities.

During the project design, an integrator can apply expertise by leveraging legacy systems, performing a nonbiased analy-sis of product and architecture offerings, selecting solutions that decrease integration effort and increase sustainability, and determining if a common-off-the-shelf (COTS) product or a custom application should be developed.

System integrators are tasked with creating a design that matches a customer’s budget and requirements. To achieve this goal, it is necessary to not only evaluate the project at hand, but also analyze the customer’s lega-cy systems and consider possible

future enhancements. By leveraging an enterprise-wide view-point, an integrator can add more value in the overall design, delivering results that can improve the customer’s profit, growth, and corporate reputation. The following are some primary system integrator tasks executed throughout the typical project lifecycle:

Requirements analysisThe requirements analysis phase enables a team to accurately

determine the current and future customer requirements of the project. Tasks during this phase include:

� Current system architecture – Examine the existing network infrastructure, data pathways, and procedures

� Customer requirements – Identify the current system deficiencies and detail the customer requirements with regard to the existing system

� Interface coordination – Determine the system interfaces, including current and available hardware interfaces and pro-tocols to the system devices

� Identify project risks – Document project integration risks with mitigation plans

� Areas to be addressed – Detail the software, hardware, fieldbus input/output, interface descriptions and approaches, data table layouts, sequence of operations, and graphical user interface concept screens. See online, details on what a design should include. PE

Todd Williams is a vice president for the System Integration and Controls team at SAIC.

System integration is a criticalelement in project design

By Todd Williams, SAIC

Involve a system integrator early in project design to help ensure high-quality projects.

Figure 1: Project cost influence curve show that design changes cost more in later project stages. Courtesy: SAIC

APPS FOR ENGINEERS

Featured appsCFE Media’s Apps for Engineers is an interactive directory of more than 170 engineering-related applications for Android and iOS operating systems, created by various companies. The app helps users do their jobs better and save time, providing a “pre-sort” of relevant mobile engineering applications loaded with various calculators, catalogs, file viewers, measurement tools, and more. www.plantengineering.com/appsforengineers


Decibel 10thiOS 4.0+Cost: FreeCompany: SkyPaw Co. LtdCompany Website: www.skypaw.comWeb download link: http://bit.ly/156iEL9With Decibel 10th you can use your iPhone or iPad as a sound meter. Accurately measure the sound pres-sure levels around you.

Friction CalculatoriOS 4.0+Cost: FreeCompany: T2 Content WorksCompany Website: www.magnaplate.comWeb download link: http://bit.ly/14gVsoFBased on General Magnaplate’s popular friction calculation tool, this app provides dynamic as well as static coeffi cients of friction (COF) for many pairings of regularly used materials and engineered coatings.

Fit4FilterAndroid 2.3, iOS 4.0Cost: FreeCompany: Bosch Rexroth AGCompany Website: www.boschrexroth.com/en/xc/Web download link: http://bit.ly/16PcPj7 (Android), http://bit.ly/W3yoaR (iOS)This app can be used to quickly and easily fi nd and order a replacement your old fi lter elements. The fi lter database is periodically updated to ensure that the info you are viewing is always current and relevant.

TeslaSCADAAndroid 2.3-2.3.2Cost: FreeCompany: Tesla LLCCompany Website: www.teslascada.comWeb download link: http://bit.ly/1cmCK8u TeslaSCADA offers visualization between an Android device and indsitrual automation applications and equipment based on OPC UA, an effi cienct and scruity standard allow encrypted transmission, authentica-tion, and encrypted access. This application can be used as an OPC UA client.

MEDIA SHOWCASE FOR ENGINEER’S

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PLANT ENGINEERING November 2013 • 23

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ISO 55000: Why Do We Need a New Standard for Asset Management?Mike Poland, CMRP | Director, Asset Management Services, Life Cycle Engineering

With the expected introduction of the International Organization for Standardization (ISO) 55000 in early 2014, replacing the existing British Standards Institute (BSI) Publicly Available Specification (PAS) 55, many organizations are questioning the value of obtaining compliance with these standards. Why do we need a new standard for asset management?

Manufacturing, mining, petroleum, and power generation are some of the most asset-intensive industries in the world. Organizations in these industries and others like them are continuously facing increasing pressures to develop business objectives to meet their strategic plans while simultaneously managing massive physical portfolios of assets efficiently.

To a large extent, success hinges on whether or not asset-related risks to the value stream are adequately identified and managed in such a way that minimizes the total cost of ownership throughout an asset’s lifetime. By aligning corporate culture with an

integrated systems approach to managing assets from Concept to Decommissioning, organizations will not only uncover practical processes for getting the most out of capital investments but will realize immediate benefits after applying an asset management standard.

What benefits can be expected from developing and implementing an asset management system? • Increased availability• Reduced labor costs• Reduced material cost• Improved regulatory compliance

This whitepaper examines why so many organizations struggle with their asset management strategy, explains the need for a new standard, describes the core elements of developing an organization-level policy and provides guidance on successfully implementing the changes to the organization.

Download the whitepaper at www.LCE.com/ISO55000.

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• Reduced injuries• Capital project avoidance• Sustainable culture change


Four Things You Need to Know About Compressed Air Dew Point Sampling

Sampling is needed when direct measurement of the air is undesirable or is simply not feasible. This may be due to a high process temperature, the need to protect the sensor from water spikes, the added convenience of installing and removing the instrument from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location.

To get a representative sample of the process gas and avoid potential sources of errorcaused by incorrect sampling practices, the following aspects should be considered. • Changing the pressure of the gas changes the dew point• To avoid condensation the dew point must be below the ambient temperature in the sampling line• A leak-tight sampling system construction is essential• Sampling in still air should be avoided, however low air flow is okay

www.vaisala.com/compressedair [email protected]

Download the White Paper at knowledge.vaisala.com/SampleCell

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For more than 65 years, PLANT ENGINEERING has helped plant engineers, plant managers, maintenance supervisors and manufacturing leaders understand how to make their operations run more effi ciently and effectively.

PlantEngineering.com: The engineer’s most popular Website for up-to-the-minute information and the latest top stories, webcasts, podcasts, blogs, and videos.

Three unique programs honoring Manufacturing: ► Leaders Under 40 ► Top Plant ► Product of the Year

Webcasts: Plant Engineering’s successful Webcast series bring the top industry experts together to discuss key issues facing plant managers and examine best practices and strategies for improvement.

Subscribe today at

www.PlantEngineering.com/subscribe

SolutionsSupporting Engineers and Offering High-Value Content In-Print and Online

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2013 Finalists

What you make or process—every-thing from gasoline, to the metal pumps used to deliver it, to the cars that run on it—is affected by the products you add to your manu-

facturing plant each year in order to improve production and increase productivity.

The 26th annual Plant Engineer-ing Product of the Year competition is a celebration of all that is new and innovative in product development. It is also a time to evaluate your own needs within the plant to see what areas of your operation need improve-ment. Chances are, the solutions are on the following pages.

From pumps and hoses to automa-tion and electrical switches, your plant is a hybrid of products. This year’s 106 finalists cover every corner of the plant and offer ways to solve problems, provide better information, or deliver greater safety and reliabil-ity. Within the product mix that makes up your plant, no one single solution will solve every problem. Taken as a whole, however, they offer a path to improvement.

Just as each of our finalists have unique value propositions to offer, Product of the Year is unique in one special way: our readers are the jury

that will determine the winners. The only people eligible to vote on the Product of the Year final-ists are those who buy and/or specify products for the plant floor. We work diligently each year to secure votes from our qualified subscribers on the Product of the Year finalists because this

is the only way that we can ensure that Product of the Year remains the pre-eminent new products awards event in the industry. Prior to casting your vote using our online-only ballot located at www.plantengineering.com/poy, please take a few minutes to review the following 2013 finalists. Voting will conclude on Dec. 31, 2013.

The 2013 Product of the Year award winners will be invited to CFE Media’s annual Engineering Awards in Manufacturing dinner in Chicago. Attendees at this event will meet the Product of the Year winners, the Control Engineering 2014 Engineer’s Choice Award winners, and the Plant Engineering 2013 Top Plant recipients.

Your vote is what begins the annual process for these manufacturers, and we hope it also brings you insight on what’s new in the world of manufac-turing today. We know the process of improvement is a continuous one, and we continue as your partner in that journey as well.


By Amanda McLeman, Project Manager

production and increase productivity.

or deliver greater safety and reliabil-ity. Within the product mix that makes up your plant, no one single solution will solve every problem. Taken as a

is the only way that we can ensure that Product of the Year remains the pre-eminent new products awards event in the industry. Prior to casting your vote using our online-only ballot located at please take a few minutes to review the following 2013 finalists. Voting will conclude on Dec. 31, 2013.

award winners will be invited to CFE Media’s annual Engineering Awards in Manufacturing dinner in Chicago. Attendees at this event will meet the Product of the Year winners, the Control EngineeringChoice Award winners, and the Engineering

process for these manufacturers, and

journey as well.


Product of the YearProduct of the Year2013


Apps for Engineers

Mobile real-time operational intelligenceProficy Mobile, designed specifically for industry, drives

efficiency with real-time access to operational information. It features an easy-to-use standard interface with GE’s pat-ented GEO-intelligent technology that provides situational awareness typically found only in consumer applications, coupled with a powerful back-end server that transforms existing raw data into intelligent, actionable information. Proficy Mobile accesses structured information through equipment models that can be configured specifically to a company’s operations. The app also provides compa-nies with the option of allowing employees to use their own devices quickly, easily, and securely. Proficy Mobile is available on Android and Apple iOS mobile devices.

GE Intelligent Platformswww.ge-ip.com

Fault currentcalculator

The FC2 mobile appli-cation calculates avail-able fault current levels in single- or three-phase electrical systems. The app allows contractors, engineers, electricians, and electrical inspec-tors to quickly and easily determine available fault current levels anywhere in an electrical distribution system. Additionally, FC2 enables users to create and e-mail National Electric Code 110.24 compliant labels for marking service entrance equipment and one-line diagrams. The intuitive interface eliminates the need for costly software and time-con-suming manual calculations by guiding users through the calculating process, adding system components along the way. FC2 is available on Android and Apple iOS mobile devices.

Eaton’s Bussmann Businesswww.cooperindustries.com

Fuse, fuse blockcross-reference tool

The FuseFinder mobile application simplifies the search for the right fuse and fuse block replace-ment. Featuring a com-prehensive database of more than 130,000 fuses and fuse block parts, FuseFinder allows users to cross-reference prod-ucts, locate nearby Bussmann dis-tributors, and access fuse selection guides for motor protection applica-tions. The app also includes protection guides by motor types, for users who are unsure of a fuse selection for pro-tecting electric motors. Once the user chooses a product, he or she has the option to view and share product data sheets that contain product specifications. FuseFinder is available on Android and Apple iOS mobile devices.

Eaton’s Bussmann Businesswww.cooperindustries.com

Product informationresource

The Endress+Hauser Opera-tions mobile application allows users to quickly download specific documentation, such as operating instructions and technical information, for Endress+Hauser field instru-ments. The app offers easy access to up-to-date prod-uct information and device details, including order code, availability, spare parts, successor products for old devices, and general product information.Simply enter a serial number or scan the data matrix code using a mobile device. Any information accessed is auto-matically stored within a device list accessible to each individual user, and users can share information and docu-ments with e-mail contacts. Endress+Hauser Operations is available on Android and Apple iOS mobile devices.

Endress+Hauserwww.us.endress.com/operations-app

www.plantengineering.com plant engineering November 2012 • 29

Automation & Controls

Enterprise asset managementInfor EAM Mobile is an enterprise asset management

mobile application that enhances the efficiency and effec-tiveness of remote staff with accurate, real-time informa-tion. The app extends the value of Infor EAM for field service workers such as managers, clerks, and schedul-ers who are connected directly. For technicians working remotely, Infor EAM Mobile also delivers the functions needed to access, capture, and manage information directly from the job site. The app can be implemented out-of-the-box or configured, and can be accessed through a specially designed Infor handheld device or third-party hardware. Infor EAM Mobile is available on Apple iOS mobile devices.

Inforwww.infor.com

Machine vibration analysisMobius iVibe is an extensive vibration analysis mobile

application that assists machine analysts in identifying machine faults from various perspectives, including view-ing spectral symptoms and suspected fault conditions, by machine component or by browsing example spectra. This resource helps to diagnose most common machine fault conditions as well as obscure conditions such as cavita-tion, rubbing, eccentric rotating assemblies, resonance, soft foot, improperly installed bearings, and drive belt issues. Featuring a comprehensive database of machine fault profiles and an intuitive user interface, Mobius iVibe is available on Android and Apple iOS mobile devices.

Mobius Institutewww.mobiusinstitute.com/ivibe

Compact barcode readerThe DataMan 50L is a compact barcode reader that

features an IP65-rated housing. Measuring just 23.5 mm by 27 mm by 43.5 mm, this barcode reader is equipped with Hotbars, a proprietary image analysis technology that delivers the highest read rates of 1-D linear barcodes, including those that are damaged, distorted, blurred, scratched, low height, or low contrast. It allows the user to see what the reader sees, providing the ability to ana-lyze “no reads” either live on a monitor or through image archiving. The DataMan 50L also features a three-position lens and an integrated aimer for easy setup at different working distances.

Cognex Corporationwww.cognex.com/50L

Laser profiling systemThe DS1000 3D laser profiling system is factory cali-

brated to provide real-world units of measurement for inspections too difficult to perform with traditional two-dimensional machine vision. The sensor reads embossed or raised characters such as those on automobile tires, verifies the presence of low-contrast items in boxes or packages, identifies surface defects and chips with low or no contrast, measure heights and tilts of components to determine misalignment, and calculates volumes and dimensions for food portioning. The DS1000 3D sensor is integrated with VisionPro software, allowing users to add GigE cameras and 2D inspection tasks.

Cognex Corporationwww.cognex.com/DS1000




Automation & Controls

OEM visualization softwareGalileo 8.0 is a software platform for the XV Series of

human-machine interfaces from Eaton. This software is designed to help original equipment manufacturers expedite time to market with an easy-to-learn operator interface product design environment. Galileo software provides robust project design tools and functionality without graduated restrictions on tags and screens. It features data bridge functionality and multiple program-mable logic controller communication driver support. The Galileo software incorporates project simulation on the development computer and includes various interface styles, extensive recipe and alarm handling, enhanced password handling, as well as convenient series assign-ment of texts and images to tag.

Eatonwww.eaton.com

Multi-touch industrial flat panel monitorThe industrial flat panel SIMATIC IFP1900 MT features

new projected capacitive touch technology for the recog-nition of multi-finger gestures with up to 10 fingers and a highly luminous widescreen 19-in. display with glass front panel. It supplements the current product spectrum of the new industrial flat panels and is mounting compatible with the IFP1900. The units are connected to PCs via DVI or display port interface and USB, especially to SIMATIC IPCs. The SIMATIC IFP1900 MT was designed especially for industrial PC-based visualization and control solu-tions with innovative multi-finger operator input, where the computer and the HMI unit are mounted separately from one another.

Siemens Industry Inc.www.usa.siemens.com

Process automation systemThe latest release of the PlantPAx process automation

system allows companies across multiple industries to improve operator effectiveness with automated proce-dures, enhanced visualization, and new skid-integration capabilities. The system’s new sequencer tool enables companies to easily automate process procedures, per-form system modifications, and sequence actions directly through HMI faceplates. If a process change is necessary or an abnormal event occurs, a user with the appropriate login privileges can modify the sequence directly from the HMI screen, rather than waiting for a control system expert to modify the procedure. The PlantPAx system further extends operator effectiveness with a comprehen-sive HMI toolkit for effective display design and enhanced standards-based alarming.

Rockwell Automationwww.rockwellautomation.com

High-level PLC controllers

T h e S I M AT I C S7-1500 line of con-trollers expands the advantages of the exist ing SIMATIC S7-1200 controller into higher level PLC applications, add-ing functionality such as integration motion control. The controllers also have Drive Integration with STARTDRIVE, a commissioning tool for the SINAMICS drive family spe-cifically designed to be fully integrated into the TIA Por-tal v.12. The S7-1500 line offers integrated PROFINET interfaces, integrated web server, and a large number of functions ideal for various automation applications in discrete automation technology. They also offer increased performance with instruction processing times down to 1 nsec for bit instructions and 10 nsec for floating-point arithmetic, depending on the CPU type.




Controller programming softwareTIA Portal SIMATIC STEP 7 v.12 is the ultimate engi-

neering tool for configuration and programming for all SIMATIC controllers. The main feature in SIMATIC STEP 7 v.12 is the support of the new SIMATIC S7-1500 line, and it is particularly suited for customers looking to focus on innovative programming languages; benefit from scal-able programming between S7-1200, S7-300, S7-400, and S7-1500 PLCs; obtain more computing power for applications in the range of the CPU 317; and benefit from simpler maintenance and diagnostics. SIMATIC STEP 7 v.12 also offers better machine security, PROFINET as a standard interface, and the ability to engineer controllers, HMIs, and drives in one project.


Hybrid motor starterThe Sirius 3RM1 compact hybrid motor starter is

designed as both a direct-on-line starter and a revers-ing starter with integrated overload protection for smaller motors with a rating of up to 3 hp used for fans, pumps, lifting gear, and machine tools. At 22.5 mm wide, the Sirius 3RM1 reduces space requirements in modern plant and machinery construction for space-saving components. The starter is also characterized by economical hybrid technology that combines the benefits of semiconductor and relay systems in one device: the low-wear semicon-ductor components are responsible for connection and disconnection operations while an energy-efficient relay system is used during operation.


Compact, oil-injected rotary screw compressors

The GA VSD+ range of compact, oil-injected rotary screw compressors reduce energy consumption by 50% compared to a traditional load/unload compressor. The 7 to 15 kW (10 to 20 hp) GA VSD+ range, including a full-feature version with an integrated dryer, is also 15% more efficient than the previous generation and offers a 12% improvement in free air delivery. The range was designed with energyefficiency and customer needs in mind, with a motor that exceeds NEMA Premium effi-ciency requirements. The motor and drivetrain share a single drive shaft and are vertically aligned, reducing the total footprint by up to 55%.

Atlas Copcowww.atlascopco.com

Integrally gearedcentrifugal compressors

The TURBO-AIR NX 12000 line of integrally geared centrifugal (IGC) compressors optimizes flow and effi-ciency for the air separation, steel, mining, automotive, aerospace, and petrochemical industries. The robust and stout machine design features the MAESTRO Universal SP control system, a compact, high-performance lubri-cation system, five-axis milled impellers, a compression cooling system, tilting pad thrust bearings, horizontally split gas and oil seals, and variable inlet guide vanes. IGC compressors provide a wide operating range, can typically throttle back over 30% from design flow conditions, and ensure higher reliability as well as a decrease in lifetime maintenance costs due to the minimal number of rotating components.

Cameronwww.c-a-m.com/cs


Compressed Air



Compressed Air

Air-cooled, oil-free screw compressorsThe EnviroAire T/TVS Series of air-cooled, fixed and vari-

able speed screw compressors range from 75 to 160 kW and are completely oil- and silicone-free. ISO 8573-1 Class 0certified, the EnviroAire T/TVS Series offers improved efficiencies and are manufactured to meet the precise requirements of a diverse range of industries. Designed and built for continuous use in demanding application areas in up to 45 C ambient temperatures, the EnviroAire T/TVS Series uses a Gardner Denver designed and manufactured two-stage air-end that ensures exceptionally low power consumption while providing the highest outputs with absolute reliability and performance efficiency.

Gardner Denverwww.gardnerdenver.com

Flat air nozzleThe 1-in. Flat Super Air Nozzle produces a flat 1-in.-

wide airstream with a strong blowing force of 9.8 oz when mounted 12 in. from the target. The unique design of this super-efficient nozzle makes it an ideal fit for both tight spaces and tight budgets. The 1-in. Flat Super Air Nozzle maximizes entrained airflow while reducing noise levels. A precise amount of air is released through the 0.0150-in. air gap opening that is set with a stainless steel shim positioned between the body and removable cap. The airstream pulls in surrounding room air to product a wide, forceful stream of high-velocity, laminar flow.

EXAIR Corporationwww.exair.com

Rotary screw compressorsThe BSD Series of rotary screw compressors are avail-

able in 40, 50, and 60 hp with flows from 157 to 294 cfm and pressures up to 217 psig. These compressors deliver energy efficiency through a combination of true direct drive design, premium efficiency motors, and lower internal pres-sure differential and optimized air-ends. Specific power is improved by up to 6%, and the built-in heat recovery options add to the energy savings capabilities. The BSD Series features include an enhanced cooling design, eco-friendly filter element, integral moisture separator with drain, and an electronic thermal management system. They also come standard with Sigma Control 2.

Kaeser Compressorswww.us.kaeser.com


Two-stage,oil-free rotary screw compressors

The 75 to 160 kW air cooled CompAir D-Series of two-stage, oil-free rotary screw compressors feature flow rates between 8.88 and 23.56 m3/min. The D-Series offers air purity that meets the most stringent standards, has been certified ISO 8573-1 Class 0 (2010), and is silicone-free. Ideal for the pharmaceuticals, food and beverage, chemicals, and electronics industries, these compressors deliver outstanding reliability for demanding applications, state-of-the-art performance, and in-depth control from a Delcos XL controller. The design of the D-Series lowers lifecycle costs by working at constant low temperature levels, maximizing energy savings up to 25%.

CompAir

www.compair.com


Industrial blowersThe Com-paK BB69C/BB89C blowers from Kaeser

Compressors are fully integrated units that arrive on-site ready for use and include a motor with an automatic V-belt drive tensioning device, inlet/outlet silencers, a full sound enclosure, starts/drives, a full complement of sensors, and an onboard controller. These 5 and 20 hp units are designed, built, and tested to meet international and domestic performance and safety standards, and are available in both STC (wye-delta start) and OFC (variable frequency drive) versions. The BB69C and BB89C include Sigma Control 2 with Omega Control software. ModBus, Profibus, Profinet, and DeviceNet interfaces are available.


High-capacity refrigerated dryersThe TK-TM Series of modular high-capacity refriger-

ated dryers are ideal for large compressed air systems and utilize digital scroll refrigeration technology to offer effective energy savings. These water-cooled dryers have flow capacities that vary from 1,250 to 12,500 scfm, based on combinations of 2,500 and 1,250 scfm modules. Each module has air-side isolation valves, a cooling water control valve, and cooling water isolation valves, allowing indi-vidual modules to be serviced without disrupting the sys-tem airflow. Each module in the TK-TM Series features its own electrical disconnect switch for ease of maintenance.


Explosion-proof VFDsThe ACE Series of explo-

sion-proof variable frequency drives (VFDs) feature a NEMA 7 enclosure with patent pend-ing active cooling technol-ogy, allowing a traditional VFD to be housed inside the classified enclosure without the risk of overheating. The ACE Series are rated Class I, Divisions 1 and 2 for use in the most extreme hazardous environments, and the VFDs are designed to match the high requirements of pumps, com-pressors, fans, separators, and mixers in multiple process industries. ACE explosion-proof VFDs can be installed inside hazardous areas right next to the operation, elimi-nating expensive, complicated installations.

Eaton’s Crouse-Hinds Businesswww.cooperindustries.com

Explosion-proof motorsThe XRI Series of severe duty NEMA premium explosion-

proof motors feature Marathon Motors’ bearing current protection (BCP) system and provide maximum energy savings potential when used with VFDs. The XRI Series motors are UL listed and CSA certified for use in virtually any process application. The cast iron construction, epoxy interior and exterior paint, Max Guard insulation system, precision balance, and thermostats are other key features of the motor series.

Marathon Motorswww.marathonelectric.com


Electric Motors & Drives



Electric Motors & Drives

Integrated servo drive, servo motorThe Allen-Bradley Kinetix 5500 servo drive joins the

Kinetix 350 and Kinetix 6500 drives to provide users with more options to match motion control needs. Integration motion control on EtherNet/IP eliminates the need for a dedicated motion network, reducing cabling by up to 60% and removing the need to create gateways to get information to or from secluded networks. Additionally, the Kinetix VP low-inertia motors’ winding technology and DSL encoder, connected with the smart-cable technology, allow power transmission and feedback communication to and from the Kinetix 5500 drive to take place on a single cable.


Stand-alone servo driveLexium 32i is an integrated stand-alone servo drive for

machine and plant engineering. The drive combines the Lexium 32 servo controller and the Lexium BMH servo motor in a single unit. The Lexium 32i is installed directly in the machine as opposed to the control cabinet, reducing the installation effort and eliminating the need for shielded motor cables. The compact Lexium 32i is based on a strictly modular design which allows for the configura-tion of numerous individual drive versions with just a few components. Benefits include increased flexibility, simpli-fied engineering, less wiring, and reduced energy costs.

Schneider Electricwww.schneider-electric.com

Compact ac driveThe Allen-Bradley PowerFlex

525 ac drive helps machine build-ers and end users simplify equip-ment design and operation and speed installation and configura-tion. The drive features a modular design in power ranges from 0.5 to 30 hp or 0.4 to 22 kW at 100 to 600 V input. Its embedded Ether-Net/IP, safety, USB programming, energy savings, and a variety of motor control options are ideal for machine-level and stand-alone applications or simple system integration. Suitable for a wide range of applications, including conveyors, material han-dling, compressors, fans, and pumps, the PowerFlex 525 provides a variety of motor control options to accommo-date open- and closed-loop applications.


Geared motorsThe Simogear geared motor series features helical, par-

allel shaft, and helical bevel gear unit types with integral high-efficient and NEMA Premium-efficient motors. The series is especially well equipped to meet the requirements of modern conveyor systems, including those found in warehousing, logistics and distribution, airport handling, automotive manufacturing, food and beverage, and metals processing. The Simogear two-stage helical bevel unit, with a mechanical efficiency of up to 96%, averages 2% higher efficiency than competitive three-stage units. It is available in a wide range of rations, so it is ideal for replacing inefficient worm and spiroid units commonly found in conveying applications.




Single-axis compact driveThe Sinamics V20 is a single-axis drive for basic applica-

tions that features short commissioning times, easy opera-tion, and excellent cost and energy benefits. The drive is available in four frame sizes that cover the performance range from 1/6 to 20 hp and is used to operate pumps, fans, compressors, and conveyor systems. The Sinamics V20 can be connected directly in-line and mounted as a push-through installation in addition to the conventional wall-mounting method. The integrated basic operator panel enables trouble-free on-site commissioning and operation. The Sinamics V20 features an electrically and mechanically rugged design, making the drive ideal for harsh environments.


Medium-voltage MCCThe Ampgard XP3 is a medium-voltage motor control

center (MCC) designed to deliver industry-leading diag-nostics and enhanced safety in critical industrial environ-ments. By helping identify equipment fatigue and simplify preventative maintenance, this MCC helps meet the chal-lenges of today’s demanding motor control environments, including oil and gas, utility, water and wastewater, pet-rochemical, and mining applications. The Ampgard XP3 MCC incorporates patent-pending algorithms that are designed to monitor fuse, contactor, and motor fatigue to minimize unscheduled downtime, and support preventa-tive maintenance and reliable operations. The MCC also provides superior contactor-fuse coordination to quickly clear faults and minimize equipment damage upstream and downstream from the device.

Eatonwww.eaton.com

Motor control centerThe XT MCC provides users

with a powerful, flexible offering that is capable of servicing all motor control applications. The XT features a rugged, NEMA-rated contactor with a large installed base and improved reliability. Eaton’s FlashGard technology within the XT pre-vents and protects personnel and equipment from the dan-gers of arc flash by enabling the unit’s stabs to be retracted from or engaged onto the verti-cal bus while its door remains closed. Further, the XT’s com-pact unit footprint enables one MCC structure to be populated with a maximum of 12 units, making it ideal for applications where a limited installation footprint is available.

Eatonwww.eaton.com


Electrical Controls

Now the vote is yours…Qualified subscribers of Plant Engineering products are invited to submit their votes using the online 2013 Product of the Year ballot. Simply fill it out, and click ‘Submit.’ Then, in the April 2014 issue of Plant Engineering, meet the 2013 Product of the Year award winners honored at our 2014 Engineering Awards in Manufacturing Dinner in Chicago. Vote at www.plantengineering.com/poy.

20132013




Electrical Controls

Cabinet cooler systemThe Dual 316 Stainless Steel Cabinet Cooler system

keeps electrical enclosures cool with 20 F (-7 C) air while resisting heat and corrosion that could adversely affect the internal components. The wear, corrosion, and oxidation resistance of Type 316 stainless steel assures long life and maintenance-free operation. The high cooling capacity of up to 5,600 BTU/hr is ideal for large electrical enclosures and high heat loads. Models with lower cooling capaci-ties for NEMA 12, 4, and 4X enclosures are also available. Applications include cooling control panels used in food processing, pharmaceutical, foundries, heat treating, chemical processing, and other corrosive locations.


K-frame breakersThe Series C K-frame break-

ers are designed to enhance personnel safety, minimize equipment damage, and improve uptime. Engineered for original equipment manufac-turers and critical applications, the Series C K-frame circuit breakers combine two meth-ods of arc fault reduction with energy-reducing maintenance switching and zone selective interlocking to enhance safety for maintenance and opera-tions personnel. The 240- and 400-A K-frame breakers support essential applications with the ability to remain online and avoid tripping when a ground fault is present, while simultaneously alerting personnel. These breakers also include zone interlocking that is engineered to reduce fault-clearing times, enhancing personnel safety and mini-mizing equipment damage.

Eatonwww.eaton.com

Shunt trip safety switches

Eaton’s integrated shunt trip safety switch line enhances safety by providing a means to remotely open a safety switch electrically. The switches’ vis-ible means of disconnect—providing the ability to verify blade disengagement from the stationary contact when the switch is in the “off” position—further enhances safety. When incorporating an emergency stop, safety interlock with other equipment, or similar means, the remote operation capability of the shunt trip switch no longer requires personnel to manually open the switch with the handle. These switches can be configured to meet additional needs of safety applications in industrial and commercial environments.

Eatonwww.eaton.com

Electrical Safety

Wireless, battery-less pushbuttonsThe Harmony XB5R plastic wireless and battery-less

pushbuttons eliminate cabling and accessories between the pushbutton and the electric cabinet. The only wiring required is for the receiver in the cabinet. The access points operate as the intermediary between the transmitter and the PLC, providing open connectivity to the network. The Harmony XB5R rope pull switch can be mounted on a panel or between two ropes, and is particularly suitable for remote operation of automatic doors. The mushroom head pushbutton has a 40 mm diameter ergonomic head for easier operation by a gloved hand.



Large generator circuit breakersThe VCP-WG circuit breakers from Eaton are engineered

for large generator applications and interrupt high fault cur-rents of power systems. The circuit breakers were designed to protect high-powered generators with up to 75 kA inter-rupting capability and high dc fault content. Ideal for OEMs, these generator breakers can be applied across numerous industrial, process, and commercial systems. The VCP-WG circuit breakers are an Eaton Green Leaf solution and meet stringent standards of sustainability and efficiency. They incorporate environmentally friendly vacuum interruption technology and avoid the use of sulfur hexafluoride, which contributes to the greenhouse gas effect.

Eatonwww.eaton.com

Fuse selecting program

The Fuses Made Simple program is designed to help users easily select and spec-ify the right fuse. The platform is a group-ing of the Underwriters Laboratories (UL) low-voltage, branch circuit fuse portfolio into three tiers of protection and four fuse families—all based on key performance and protection characteristics. Each tier offers distinct levels of performance benefits to help cus-tomers speed up specification and selection, while clearly identifying the level of protection. Inside the protection tiers are four distinct fuse families, each represented by a unique color: Low-Peak (yellow), Fusetron (green), Limitron (black), and General Purpose (grey).

Eaton’s Bussmann Businesswww.cooperbussmann.com

Medium-voltage vacuum circuit breakerThe VCPW-HD medium-voltage (MV) vacuum circuit

breaker is designed for utility, industrial, and commercial applications. This 38 kV circuit breaker is engineered to provide reliable and robust circuit protection in a compact, environmentally friendly, and reliable package. The VCPW-HD breaker is designed to protect transformers, capacitor banks, motors, busbar sections, and cable. The compact MV breaker is engineered to withstand demanding environ-mental conditions, and is suitable for high altitude, shock, vibration, and high ambient temperatures. The VCPW-HD’s compact, modular design has dielectric strength with solid insulation that is encapsulated in epoxy resin material, eliminating live conductors in the breaker cell.

Eatonwww.eaton.com

Surge protective devices

The SurgePOD line of surge protective devices (SPDs) has been expanded to include Heavy Duty and Pro models. The Type 1 UL 1449 3rd Edition Listed SPDs are ideal for loadside and lineside protection. Both the Heavy Duty and Pro models feature a compact, UV resistant NEMA 4X enclosure that is easy to install and versatile for indoor or outdoor applications. The voltage specific models allow users to precisely match and protect electrical systems and equipment. Both models of SPDs include the easyID LED status indication allowing users to quickly and easily check the status of the device.

Eaton’s Bussmann Businesswww.cooperbussmann.com




Electrical Safety

Armoured cable glandThe Terminator II TMCX cable gland is an armoured

barrier, non-armoured barrier, and TECK armoured gland used to terminate cable in hazardous locations. The cable gland is designed to minimize the opportunity for incorrect assembly and to increase corrosion resistance while main-taining integrity in the harshest environments. A simple selection process and field preparation aid the user to ensure the right gland is selected for the application. The Terminator II TMCX is complete with an integral dam to facilitate liquid pour, and its union design reduces the number of times the gland has to be assembled and dis-assembled during installation.


Portable appliance testerThe PAT450 is a portable appliance tester designed

to test the safe operation of electrical equipment. This tester features 10- and 25-A bond tests with high duty-cycle designed for fast testing, easy operation, and all-day use. The PAT’s 250- and 500-V insulation tests sensitive electronics. A USB port enables convenient downloads, and a barcode scanner and thermal transfer barcode label printer can be used with the tester when hooked up to this port. A unique restart feature on the PAT450 allows the unit to restart instantly from the same menu where it was unplugged when moving from room to room.

Meggerwww.megger.com

Ground fault circuit interrupterThe SB6100 Series Industrial Shock-Block is a ground

fault circuit interrupter (GFCI) that meets UL 943C Class C and Class D requirements. With high trip level standards and advanced filtering technology, this GFCI protects industrial workers against dangerous electric shock. The interrupter senses a ground fault and then opens the circuit as quickly as possible, and is designed for systems up to 600 V and high leakage currents. Target applications of this industrial GFCI include electrical cabinets supplying power to pumps, paint booths, washers, mixers, welding equipment, and other high-voltage machinery subject to wet conditions or wash down cleaning.

Littelfusewww.littelfuse.com/isb


FuseholdersThe USGCC (class CC) and

USGM (midget class) UltraSafe fuseholders from Mersen are equipped with industry-proven and patented CAGE CLAMP technol-ogy. This technology significantly improves system reliability by maintaining a very low contact resistance easily withstanding corrosion, vibra-tion, and temperature cycling. The CAGE CLAMP technology also eliminates the need for routine torque maintenance required by standard screw-type terminations. The USCGG and USGM fuseholders feature IP20 finger-safe protection, a compact footprint, DIN-rail mounting, and quick, easy, and tool-free fuse change-outs. The fuseholders are tested and certified by global standards organizations UL, Canadian Standards Association (CSA), and International Electrotechnical Commission (IEC).

Mersenwww.mersen.com


Energy Management

Safety relaysSirius 3SK1 is a flexible and modular range of safety

relays for monitoring and controlling systems with simple safety requirements, such as emergency stop or protective door monitoring. The product range takes the form of a clearly structured modular system so that plant operators can quickly, simply, and economically assemble an appro-priate and safe configuration. The Standard and Advanced basic units are available with relay or semiconductor out-puts so that the Sirius 3SK1 is able to efficiently cover every kind of application situation. The system portfolio is rounded off by modules with additional connections for actuators or sensors and a power supply.


Uninterruptiblepower supply

The 93PM uninterruptible power supply (UPS) is a three-phase system engineered to offer the lowest total cost of owner-ship possible. It is designed with today’s data center and facil-ity managers in mind, featuring flexible deployment options that support integrated thermal man-agement solutions, a compact footprint, efficiency up to 99%, and simplified energy manage-ment features. As an integrated UPS solution, the 93PM can be strategically deployed and scaled to meet the specific needs of nearly any critical application, including grey or white space deployment, colocation facilities, mission-critical data centers, and cloud data center environments.

Eatonwww.eaton.com

Energy monitoring softwareThe Power Xpert Insight software is a power and energy

monitoring software that helps customers reduce energy consumption and control costs, and improve the reliability of facilities. Power Xpert Insight provides the big picture on energy usage, efficiency, and power quality for facility, energy, information technology, and health care manag-ers. With a user-centric design, Power Xpert Insight is designed to be intuitive to install, configure, and obtain power and energy information to make operating deci-sions proactively and efficiently. The software’s interface provides real-time and historical data to identify, track, and improve wasteful energy practices.

Eatonwww.eaton.com


Nowthe voteis yours…Qualified subscribers of Plant Engineering products are invited to submit their votes usingthe online 2013 Product of the Year ballot. Simply fill it out, and click ‘Submit.’ Then, in the April 2014 issue of Plant Engineering, meet the 2013 Product of the Year award winners honored at our 2014 Engineering Awards in Manufacturing Dinner in Chicago.Vote at www.plantengineering.com/poy.

20132013



Energy Management Environmental Health

Multi-point meterThe Power Xpert Multi-Point meter accurately tracks

facility energy use and is designed for use in industrial sites and other multi-tenant applications. The meter is also designed to accurately aggregate gas, water, and steam consumption data to enable a comprehensive review of a facility’s utility use and the development of energy savings solutions. The Power Xpert Multi-Point meter can be installed in new and retrofit applications and includes robust commissioning tools that support accurate installation and reliable operation. It provides a cost-effective, scalable approach to monitor energy in assemblies or power distribution equipment with a high density of metering points.

Eatonwww.eaton.com

Nano fiber filterThe HemiPleat eXtreme nano fiber filter offers high filtra-

tion efficiencies, durability, and increased resistance to pulse-cleaning to extend filter life and reduce operating and energy costs associated with industrial cartridge dust and fume collectors. A proprietary tri-layered technology applies two layers of fine-pored nano fibers that act as a pre-filter to the base media, capturing most of the dust at the surface before it imbeds in the filter. This technol-ogy increases the filter’s cleaning ability and allows the base materials to have larger pore sizes—reducing pres-sure drop while allowing the eXtreme fibers to provide a superior efficiency layer.

Camfil Air Pollution Controlwww.camfilapc.com

Industrial vacuum attachmentThe Heavy Duty HEPA Vac attaches to an ordinary 55-gal

open top drum to turn it into a powerful HEPA-quality industrial vacuum cleaner. The Heavy Duty HEPA Vac is designed to move more material with less wear. In addition, this vacuum has been engineered to filter contaminants to HEPA requirements in dusty environments requiring frequent cleaning. An economically, easily maintained pre-filter stops larger particles, while the HEPA filter handles the smaller matter. All filters are tested for minimum 99.97% filtration at the 0.3 micron level to meet HEPA standards in strict accordance to IEST-RP-CC-007.

EXAIR Corporationwww.exair.com/hepa



20132013


Fluid Handling

Fume extraction systemThe FILTAIR Capture 5 fume extraction system is

designed to capture welding fumes up to 5 ft away from the source. The FILTAIR Capture 5 system improves safety and enhances productivity by decreasing downtime for welders to adjust the fume extraction arm, especially when welding long, continuous welds. The system is well suited to applications in heavy equipment manufacturing and general fabrication, as well as in maintenance and repair operations. It can accommodate fume from Stick, Flux-Cored, MIG and TIG welding processes. The Capture 5 system features FilTek XL filters for capturing up to 85% of weld fume particles.

Miller Electric Manufacturing Companywww.millerwelds.com

Drain coverT h e P I G R a p i d

Response Drainblocker allows facilities to quick-ly respond to and contain spills without breaking budget. The drain cover is designed for both indoor and outdoor use and features a UV-resistant polypropylene top layer that will not stretch or tear when picked up. Ideal for quickly sealing floor and storm drains during spill emergencies, these cov-ers are ideal for fixed facilities, fleets, hazmat, and other response teams that need to meet the stringent EPA spill preparation and cleanup regulations.

New Pig Corporationwww.newpig.com

Cordless pumpsThe XC Series cordless pumps offer performance capa-

bilities of electric or pneumatic powered pumps with the convenient portability of a hand pump. These pumps pro-vide a portable, cost-effective solution for remote locations and deliver the speed, power and longevity of a corded pump. The XC Series pumps are constructed of lightweight materials, are equipped with a powerful 0.5 hp motor, and feature 28-V Lithium-ion battery technology. With its bladder reservoir, the XC Series eliminate venting and offer leak-free operation in any orientation. The pumps deliver oil flow of 15 in3 per minute when operating at full pressure, up to 10,000 psi.

Enerpacwww.enerpac.com

No-drip atomizing spray nozzlesThe no-drip external mix atomizing nozzles from EXAIR

have high flow rates and allow air and liquid flows to be adjusted independently. These nozzles are ideal where precise liquid flow is needed. External mix nozzles can be used on liquids with viscosity above 300 cp, and both air and liquid sides are pressure fed. The nozzles are constructed of stainless steel for durability and corro-sion resistance. When a system’s compressed air supply is shut off, the no-drip nozzle positively seals off the flow of liquid, eliminating the possibility of drips. No separate air line is needed to control the no-drip mechanism.





Fluid Handling

Composite couplingThe Style 171 flexible composite pipe coupling is an

engineered composite coupling for use where corrosive conditions exist. Ideal for reverse osmosis skids in vertical and horizontal installations, the Style 171 coupling enables quick and simple installation and provides substantial gains in productivity. The Style 171 does not require disassembly prior to installation; the coupling is simply pushed onto the pipe end as a fully assembled unit and tightened using standard hand tools. The coupling’s design reduces labor hours to complete system installation, eliminates loose components that could be dropped or lost, and reduces installation clearance requirements.

Victaulicwww.victaulic.com

Mass thermal flowmeterThe MT110 Insertion and MTL10 Inline Mass Thermal

Flowmeter provides an accurate measurement of clean, dry gases and air using constant temperature sensing for fast response and low flow accuracy. The MT110/MTL10 measures without the need for additional transmitters or flow computers, and is virtually immune to changes in temperature and pressure over a wide flow range. The MT110/MTL10 View software allows for quick setup, moni-toring, and data logging of the flowmeter using a PC. The Cal-V and Recalibration Verification allows users to per-form in-situ testing of the meter’s accuracy by testing the functionality of the sensor and the processing circuitry.

Spirax Sarcowww.spiraxsarco.com


Bladder sectionThe PIG Build-A-Berm Bladder Section helps facilities

meet secondary containment regulations while minimiz-ing the overall need to provide containment. When used with the PIG Build-A-Berm System, the Bladder Section provides an additional 55-gal sump capacity to the second-ary containment area. Ideal for use in small rooms where current systems cannot be expanded, the Bladder Section remains out of the way and deploys only when needed to contain spills. The Bladder Section is a Best Management Practice for Stormwater regulations (40 CFR 122.26) and provides passive containment to aid in Spill Control and Countermeasure compliance (40 CFR 112.7).



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Lighting

LED area/site luminaireThe McGraw-Edison Galleon LED luminaire offers a

choice of 12 specialized optical distributions and nine lumen packages, and comes standard with a wide array of specification grade design features. The performance and versatility of the Galleon luminaire provides significant energy and maintenance savings while delivering excep-tional value to the end user. Its unique optical design allows lumen output and energy consumption to be customized to fulfill the exact lighting needs of the area. Uplight, glare, obtrusive spill light, and overlit hot spots are replaced by uniform, application-tailored illumination for walkways, parking lots, roadways, building areas, and security light-ing applications.

Eaton’s Cooper Lighting Businesswww.cooperlighting.com

Outdoor/indoor floodlightsChamp Pro PFM Series floodlights are designed to pro-

vide full-spectrum, crisp, white light. Five versions of the Champ PFM LED are available, providing ideal solutions for a wide range of applications. Two color temperature range options are available: 3000 and 5600 K. An advanced heat sink design ensures the LED does not exceed manufactur-ers’ temperature ratings across all specified ambient condi-tions. The housing is made of copper-free aluminum with a Corro-free epoxy powder coating. The shatter-resistant glass lens, silicone gaskets, and stainless steel external hardware complete the fixture’s build. The Champ Pro PFM Series is ideal for outdoor or indoor flood illumination.


Ambient LED luminairesThe Metalux SkyRidge luminaires are an affordable

LED alternative to fluorescent fixtures and feature pat-ented WaveSteam technology to provide superior optical performance, efficiency, and visual comfort. Optimized for ambient lighting applications, the luminaires’ precise optical control directs lumens to the target area with the highest efficiency (up to 108 lumens per watt), resulting in maximum energy savings and improved uniformity. The SkyRidge luminaires have an 85 CRI and are available in three color temperatures (3000, 3500, and 4000 K), two configurations (2 ft by 2 ft and 2 ft by 4 ft), and feature two reflector choices (curved and straight).

Eaton’s Cooper Lighting Businesswww.cooperlighting.com


LED luminaireThe Champ VMV LED Series

luminaire is designed to provide full-spectrum, crisp, white light with custom IES Type I, III and V distribution. Five versions of the Champ VMV LED are available, providing ideal solutions for a wide range of applications. The luminaires have an ambient oper-ating range of -40 to 55 C, and pro-vide up to 60,000 hours rated life and up to 170,000 hours of economic life, eliminating the need for frequent lamp replacements. Designed to avoid a complete loss of illumination, the Champ VMV LED Series feature redundancy in drivers with multiple series circuits con-nected to each driver.


LED highbayThe hazardous classified HBL LED Highbay contains

the features of the standard location HBL offering multiple optical distributions and output ranges while maintaining efficacies as high as 100 lumens per watt. Its cast con-struction and sealed design make this fixture ideal for haz-ardous locations that require an efficient lighting solution. The hinged top cover with its no tool latch system makes the HBL LED Highbay very easy to install and service.

Hubbell Industrial Lightingwww.hubbelllighting.com

High ambient LED highbayThe HBLHA high ambient LED highbay is designed to

efficiently light large interior spaces in high ambient tem-perature environments. The fixture is rated from -40 to 65 C and delivers up to 100 lumens per watt of 2700 to 5000 K CCT light. The LED count ranges from 72 to 60 to 48, and all three LED counts are driven at 700 mA. The HBLHA comes in three distinct distributions: aisle, narrow, and wide; is available in five mounting options; and has a sealed optic for long life and durability. The fixture is CSA tested to UL 1598 Wet Location, IP56, DLC Approved, and has a 5-year warranty.



Lighting

Industrial highbaysThe Industrial High Bay LED Series of luminaires are

ideal for locations requiring continuous and consistent light levels; areas requiring frequent on-and-off of lights; areas that are difficult to relamp or that cause production to be stopped during the lamp maintenance process; ordi-nary clean, light industrial production facilities, packaging facilities, and warehouses; and indoor and dry locations only. These luminaires boast up to 69% energy savings over 400-W metal halide fixtures, an ambient operating temperature range of -30 to 40 C, a 347 to 480 Vac driver option, and 60,000 hours rated life of maintenance-free operation.


Hazardous LEDsThe Hazardous Kemlux III LED Series fixture is designed

to efficiently light hazardous applications such as chemi-cal, petrochemical, marine, and power generation plants. The fixture delivers up to 105 lumens per watt of 5000 K CCT light and its modular design provides six mounting options. The unique radical design with fins of durable, copper-free cast aluminum allows it to operate in -40 to 40 C ambient environments and keeps the LEDs cool, result-ing in an estimated 100,000 hours of life at L70. The fixture has high output LED counts of 18, 45, and 36 on up to six individual light engines, providing fail-safe redundancy.



Architectural LED wallpackThe Laredo LNC2-18LU is an expansion of the Laredo

LNC2 Architectural LED Wallpack that delivers a lumen out-put of up to 3306 lumens and efficiency of 74 lumens per watt. Designed as a high-performance wallpack for entry/perimeter applications, the Laredo LNC2 series includes multiple LED color temperatures, additional distributions, expanded photocontrol options, additional finishes, and a larger lumen package offering 29 and 45 W configura-tions. The Laredo LNC2-18LU conserves up to 85% energy savings over traditional metal halide sources. The energy-efficient LEDs deliver 60,000 hours of life at L96 lumen maintenance for a long-lasting, architecturally styled, and powerful LED perimeter security solution.

Hubbell Outdoor Lightingwww.hubbelloutdoor.com

Retrofit LED downlight kitThe Indy Retrofit LED Downlight Kit for commercial grade

applications allows facility managers, building owners, energy audit teams, contractors, and retailers to convert 6- or 8-in. commercial incandescent, CFL, or HID open-frame fixtures into energy-efficient LEDs, reducing power consumption by up to 75%. The ENERGY STAR qualified solution provides users with the ability to quickly gain significant return on investment through energy and cost savings. With an expected service life of 50,000 hours, the Indy Retrofit LED Downlight Kit provides over 10 years of maintenance-free operation, eliminating the need for a lamp inventory and incorrect lamp or color temperature installation.

Juno Lighting Groupwww.junolightinggroup.com/indyretrofit

Industrial LED seriesThe Kemlux III LED Series is rated for installation in

severe locations and is available for new installation or as a retrofit to existing Kemlux III fixtures. Designed to light the most complex environments, the Kemlux III LED Series fixture delivers up to 105 lumens per watt of 5000 K light and its modular design provides six mounting options. The unique radical design with fins of durable, copper-free cast aluminum allows it to operate in -40 to 40 C ambient environments and keeps the LEDs cool, resulting in an estimated 100,000 hours of life at L70. The fixture has high output LED counts of 18, 45, and 36 on up to six individual light engines, providing fail-safe redundancy.


High-efficiency LED luminaireThe Lightwatt LED luminaire provides comfortable, high-

efficiency illumination on vertical and horizontal surfaces and is ideal for warehouses, shipping docks, stairwells, and parking garages. Producing approximately 75 lumens per watt of low-glare, high-quality 5100 K CCT light, the fixture provides 7% uplight to soften the brightness dif-ference between the luminaire and the surrounding areas and provides a three-dimensional luminous environment. The Lightwatt LED refractor projects light into, underneath, and between industrial obstructions like HVAC ducts and electrical raceways. The fixture’s housing is 99% copper-free aluminum with a white Lektrocote finish.



Area site lightThe Cimarron LED CL1S is an area site light

that is designed for mounting heights of 12 to 20 ft and provides the perfect pedestrian scale luminaire for municipal, park and recreation, educational, and health care campus applica-tions. The Cimarron LED CL1S was designed with the most advanced LED lighting technol-ogy to deliver energy efficiency, safety, and security and complements the aesthetics and

performance of the larger Cimarron LED CL1. The energy-efficient fixture will perform virtually maintenance-free with an estimated 60,000 hours and uses less than 50% of the energy of an equivalent HID at full brightness.

Spaulding Lightingwww.spauldinglighting.com

Visual IT thermometerThe Fluke VT02 Visual IR Thermometer is a trouble-

shooting camera with an infrared (IR) heat map. This tool combines the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot con-venience of an IR thermometer. The VT02 displays and saves images as full visual, full IR, or in tree blended modes (25%, 50%, and 75%). Markers pinpoint hot and cold spots indicating the hottest temperature with a red box and the coldest with a blue box. A temperature reading is provided at the center point. Images are saved to the micro-SD card, eliminating the need to write down single or multiple measurements.

Fluke Corporationwww.fluke.com


Lighting

Recessed LED downlightThe MegaLum is a 12,000 lumen recessed LED down-

light, an ideal lighting upgrade for T4 quartz (up to500 W), metal halide (up to 250 W), and induction (up to 165 W) sources for ceiling heights of 40 to 60 ft. This 8-in. recessed LED downlight features up to 75 lumens per watt efficacy and multiple configurations for design flexibility and controllability. The MegaLum is offered in four lumen output options: 3000, 6000, 9000, and 12,000 lumens. The downlight is also available in 25-, 35-, 45- and 55-degree optical distributions; and 2700, 3000, 3500, 4000, and 5000 K color temperatures.

Prescolitewww.prescolite.com

Wireless test tool system

The F luke CNX Wireless System is a set of test tools that wirelessly connects multiple measurement modules and sends simultaneous readings to a master device up to 20 m away, allowing users to troubleshoot problems quickly and efficiently. The rugged, customizable tool set allows users to choose various measurement modules based on their specific troubleshooting scenario. At the core of the Fluke CNX Wireless System is a CAT III 1000 V / CAT IV 600 V multi-meter with a screen that displays its readings along with live readings from up to three other measurement modules.

Fluke Corporationwww.fluke.com


Maintenance Tools & Equipment

Tubing press toolThe RP 340 press tool is a small, lightweight pressing

option for joining copper and stainless steel tubing 1/2 to 4 in. in diameter and PEX tubing and black iron pipe 1/2 to 2 in. in diameter. Compatible with all RIDGID Stan-dard series pressing jaws and attachments, the RP 340 offers industry-exclusive bolt sensor technology to ensure jaws and attachments are securely connected to the tool before a press cycle is initiated. The RP 340 increases user maneuverability and reduces the potential for operator fatigue, while also featuring a quick cycle time, the ability to operate in extreme temperature ranges, and the abil-ity to rotate jaws up to 270-deg to access tight spaces.

RIDGIDwww.ridgid.com/pressing

Vibration, temperature monitorThe SKF Machine Condition Indicator is a low-cost

vibration and temperature monitoring device designed for rotating machinery with constant operating conditions. It provides the ability to track basic machine health on assets that are not currently being monitored on a regular basis. The device can be used indoors or outdoors where rotating machines are used. The SKF Machine Condition Indicator periodically makes two types of vibration measurements. Velocity measurements are made to keep track of overall machine health and highlight potential problems relating to misalignment and imbalance. The device also monitors machine operating temperature.

SKFwww.skf.com/mci

Gas turbine inlet filter cartridgeClearCurrent PRO is an innovative gas turbine inlet filter

cartridge that has been field tested and shown to positively affect gas turbine performance while helping to reduce the effects of turbine degradation. The cartridge filters are compatible with GE’s FlexEfficiency Portfolio, are avail-able in both galvanized and stainless steel, and have a long filter operating life. The PRO (predictable, reliable output) technology helps prevent water from reaching turbine blades, mitigating corrosion within the gas turbine. ClearCurrent PRO is available in self-cleaning and static systems and is fully compliant with GE original equipment manufacturer filter performance specifications.

GE Power & Waterwww.clearcurrentpro.com

Floating brush sealThe Sentinel Floating Brush Seal (FBS) for Elliot YR pro-

cess steam turbines was developed as a drop-in replace-ment to carbon rings. Utilizing brush seal technology, the Sentinel FBS comprises densely packed and flexible metal-lic bristles that “bend” with changing clearances between rotating and stationary surfaces. The brush serves as the primary shaft seal while a carbon element provides face sealing in the turbine’s casing. The Sentinel FBS technol-ogy offers an extra layer of protection that slows down the natural wear of downstream carbon rings and provides predictable leakage over an extended operating life.

Inpro/Sealwww.inpro-seal.com





Maintenance Tools & Equipment

Shaft alignment toolThe Fixturlaser NXA Pro is a laser-based shaft align-

ment tool that utilizes the latest technology in digital sig-nal processing as well as other innovations to provide fast and intuitive operation with advanced functions and capabilities. This tool features a display unit with a 6.5-in. touchscreen with video game style realistic graphics and a redesigned set of transmitters/detectors. A micro-electromechanical systems gyroscope in the display unit powers the OmniView function. OmniView changes the screen display in real time to always show the machine being aligned from the same viewing angle as seen by the operator.

VibrAlignwww.vibralign.com

Dock bumperThe Pneu dock bumper provides a pneumatic stop

using a rotational molded blend of polyolefin plastomer. This rugged material can withstand the constant abuse of dock collisions, and the pneumatic technology eliminates impact shock and releases impact energy via a pressure relief valve while minimizing load on the building. The Pneu dock bumper is easy to install, maintenance free, and weather resistant. Ideal for use with yard jockeys, this bumper reduces damage on truck trailers, reduces building loads, and reduces wear on dock seals.

DL Manufacturingwww.dlmanufacturing.com

Dock sealThe U-Seal non-

compression dock seal’s patented hol-low polyurethane foam core design reduces building load and wear and tear on the dock seal surface. The unique “U” shape features an inner and outer foam finder that folds and conforms to various trailer types creating a perfect seal to greatly reduce ener-gy loss. The innovative design also minimizes the footprint within the impact zone of the forklift and pallet loading area when engaged in the trailer. Constructed with 40-oz vinyl, the U-Seal features a secondary 40-oz vinyl wear face for added durability in the contact zone and triple-layered reinforced corners.

DL Manufacturingwww.dlmanufacturing.com

Manual Material Handling


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Electric end rider pallet trucksThe B60ZHD and B80ZHD 6,000- and 8,000-lb end

rider electric pallet tricks have been engineered to take on the most demanding, heavy-duty applications in a mul-titude of operating conditions. These electric end riders are equipped with Hyster i3 Technology which integrates commonality among Hyster warehouse products and sim-plifies the way in which operators and technicians alike handle and service the trucks. The end riders feature an enhanced frame for greater strength and steadier load handling, are reinforced with 25% more steel, and the fork tip is specifically designed for smooth pallet entry.

Hyster Corporationwww.hyster.com

Gasoline lift trucksThe 8-Series large-capacity gasoline lift truck line is ideal

for both indoor and outdoor applications like the paper, lumber, and concrete industries, and large distribution centers needing to move heavy loads. The four-cylinder engine features the latest electronic fuel injection system with Controller Area Network (CAN-BUS) technology to deliver substantial improvements. On average, the 8-Series models reduce fuel consumption by 20% for the 1FS gaso-line/LPG model. The powerful 1FS gasoline/LPG engine displaces 3.7 L, boasting a high-efficiency design offering up to 93 hp and 203 ft/lbs of torque.

Toyota Industrial Equipment Manufacturing Inc.www.toyotaforklift.com

Diesel lift trucksThe 8-Series large diesel lift truck line includes 8,000- to

17,500-lb internal combustion (IC) pneumatic tire models and a newly designed and advanced Toyota-built 3.0 L, four-cylinder, high-performance engine. The 8-Series large capacity IC lift trucks offer significant advances in dura-bility, ergonomics, productivity, and fuel efficiency, while meeting stringent federal EPA Tier 4-final diesel engine standards. The lift trucks offer Toyota’s exclusive System of Active Stability (SAS), which helps reduce the likelihood of lateral and longitudinal tipovers. When the SAS detects instability, its advanced sensors simultaneously signal and engage the appropriate controller.


Paper roll lift trucksThe 8-Series paper roll model lift trucks are designed

to meet the tough applications associated with the pulp and paper industry. To meet the paper industry’s need for damage-free roll handling with maximum efficiency, the trucks are equipped with paper roll clamps that are avail-able in a wide range of configurations to handle multiple diameters, weights, and types of paper. To ensure proper operation, a clamp release interlock system built into the control valve works to help prevent accidental activation of the release lever. In addition, an automatic clamp level-ing feature allows the operator to quickly level the clamp vertical to the paper roll with the touch of a button.



Material Handling Systems



Material Handling Systems Power Transmission

Bypass isolation contactor

The 1600-A bypass isolation contactor pro-vides robust monitoring, reporting, and transfer control operations to include an in-phase monitor. It’s equipped with dual automatic transfer switch (ATS) technology and sup-ports concurrent main-ta inabi l i ty through automatic control in the bypass mode for mission critical applications. ATSs are critical components to any emergency or standby power system because they can provide emergency power to life safety and other critical loads where maintenance of the main transfer switch, without interruption of power, is either desirable or required. The 1600-A bypass isolation contactor is UL1008 listed and CSA 22.222 No. 178-1978 listed.

Eatonwww.eaton.com



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Center rider lift truckThe MO25 center rider lift truck eases second level

order picking through its fully adjustable electronic power steering, automatic speed reduction in cornering, and its suspended platform with an operator sensing floor mat. The electric steering reduces steer effort by 90%. The MO25 truck features numerous operator compartment and platform advantages for efficiency and ergonomic benefits. The control handle reduces the arm movement needed to change directions, helping to reduce fatigue and increase productivity and allowing the operator to remain inside the truck footprint for protection. The truck’s electromechanical disc brakes are top mounted for ease of maintenance and inspection.

Yale Materials Handling Corporationwww.yale.com

Load-interrupterswitchgear

The ArcGard load-interrupter switchgear is engineered to enhance operator safety during maintenance operations for industrial, commercial, and utility customers. The ArcGard medium-voltage switchgear features arc-resistant enclosures that can be shipped in a single structure, reduc-ing customer costs and equipment space. This Eaton Green Leaf Label solution meets stringent standards of sustainability and efficiency. ArcGard is designed to protect personnel from dangerous arcing faults by controlling, collecting, and channeling the decom-position of the products from internal arcing faults to an area away from the perimeter of the gear. It incorporates arc chute and flicker blade tech-nology to increase equipment life.

Eatonwww.eaton.com


Metal-enclosed switchgear

The metal-enclosed load interrupt-er switchgear from Eaton provides reliable switching and fault protec-tion of the medium-voltage circuits for industrial, institutional, and health care customers. This switchgear is engineered to reduce the footprint of electrical distribution systems in an environmentally friendly and com-pact design. Its 18-in.-wide structure with front-accessible cable termina-tions incorporates Eaton fuses for accurate, calibrated short-circuit detecting and interrupting capabilities to support power reliability. The metal-enclosed load interrupter switchgear uses flicker blade and DE-ION arc chute technology to prolong the life of the main blades by minimizing arcing between the main blades and the stationary contacts.

Eatonwww.eaton.com

Solar combiner boxesThe second generation Solar Combiner Boxes from

Crouse-Hinds feature a busbar design and improved components and layout. The CCBF and CCBS models are designed and built to minimize system costs by pro-viding maximum flexibility. Designed for higher voltage circuits used in grid-tie applications, these boxes offer a range of 1 to 48 input circuits with a nonmetallic NEMA 4X enclosure that is engineered to perform in the harshest environmental conditions. The Solar Combiner Boxes are rated for 600 or 1000 Vdc and are configured for positive and negative grounded arrays, and bipolar arrays.


Combination panelboard

The Square D I-Line Combo Panelboard saves time and space by combining the I-Line and NQ/NF lighting sections into one panelboard. The I-Line Combo Panelboard features a smart, space-saving design for fast installation and a smaller footprint. The single panel-board is available in 26- and 32-in. widths with one NQ or NF lighting section. The duplex configuration is available in 32- and 44-in. widths, in either two hard-bussed lighting sections or one hard-bussed lighting section with open mounting space for field-installable options. The I-Line power section mounts horizontally, and is available in 18-, 22.5-, or 31.5-in. configurations.



Productivity & Training

Motor bearings protection handbook

The AEGIS Shaft Grounding Ring Bearing Protection Handbook is a 36-page, color hand-book that describes best practices for protecting motor bearings from electrical damage. The book explains how to diagnose electrical bear-ing damage caused by variable frequency drives or inverters. It then goes on to explain in detail best practices for preventing such damage to motors of various sizes and horsepower ratings. The AEGIS Shaft Grounding Ring Bearing Protection Hand-book is ideal for plant maintenance personnel as well as motor repair shops.

Electro Static Technologywww.est-aegis.com



Productivity & Training

Social collaboration platformInfor Ming.le is a comprehensive platform that resembles

the most widely used consumer social networking tools to offer businesses a means for social collaboration, busi-ness process improvement, and contextual analytics. InforMing.le is embedded within key systems like ERP, sup-ply chain management, human capital management, and enterprise asset management, so employees across all areas of the business can communicate and collaborate, and easily follow people, assets, and processes relevant to the task at hand. Information such as documents, plans, photos, and videos are maintained in a centralized loca-tion with relevant activity captured to allow easy access by those who need it.

Inforwww.infor.com

Reliability improvement training seriesiLearnReliability is a Web-based training series designed

to help industrial plants establish sustainable reliability improvement programs. It demonstrates how reliabil-ity improvement is achievable and sustainable through increased awareness of techniques and best practices among plant management and operators, proper guid-ance and training, and comprehensive skills training in condition monitoring and precision maintenance technolo-gies. With the knowledge, tools, and guidance provided by iLearnReliability, plants are empowered to change from continuously reacting to premature machine failure to having a more reliable plant with fewer repairs and a less-stressed environment.

Mobius Institutewww.mobiusinstitute.com/reliability

Data access mobile softwareWonderware InTouch Access Anywhere software enables

users to access plant floor data via Wonderware InTouch software. It runs entirely and securely inside a Web browser so users can connect to other InTouch applications at anytime from anywhere, using any mobile device, including Microsoft Surface tablets, iPads, iPhones, Androids, and others. The software also supports Macintosh and Linux-based computer systems, as well as Microsoft Windows PCs and laptops. There is no need to install any software on a mobile device in order to run Wonderware InTouch Access Anywhere. The software includes programs for workflow, reporting, analytics, visualization, maintenance management, operator training, data gathering, and pro-cedure management.

Invensyswww.invensys.com

Portable training systemVRTEX Mobile delivers a basic, hands-on entry-level

training and skills solution that is consistent with stan-dard industry methodology and evaluation criteria—all in an easily transportable, virtual package. The portable VRTEX Mobile is ideal for use in classrooms, the human resources department, or at off-site training or recruit-ment events. This system eliminates the risk and cost of hands-on initial learning. Students practice repetitive welding without the time needed to tack plate and toss scrap because the coupon isn’t real—it’s virtual, appearing with the press of a button. This system also helps students become comfortable with using a welding gun, increasing their confidence.

Lincoln Electricwww.lincolnelectric.com



Warehouse efficiency toolsiWAREHOUSE Essential and Enterprise are two solu-

tions that combine fleet efficiency, warehouse optimiza-tion, and professional services to optimize warehouse efficiency. iWAREHOUSE Essential provides access control and compliance, and monitors and collects lift truck and operator data in real time, allowing warehouse managers to increase visibility of assets and labor. iWAREHOUSE Enterprise turns collected asset and labor information into actionable data that helps warehouse managers identify opportunities for fleet and warehouse optimization. The solution integrates with select labor management sys-tems to help increase productivity and reduce operating costs, and can be used to enhance additional optimiza-tion decisions.

The Raymond Corporationwww.raymondcorp.com

Maintenancetesting tool

The Maintenance Planner Test assists in the hiring process, matching the right resources to com-plete tasks required for continuous oper-ation. This 60-item test assesses the knowledge of pro-spective mainte-nance planners and features multiple-choice questions in the following areas: electrical, mechanical, print reading, computer and computerized maintenance management software, planning, and safety. The test is available either for online administration through the Ramsay Corporation website or in paper format.

Ramsay Corporationwww.ramsaycorp.com

Worker safety softwareBigfoot OSH is an add-on solution to Bigfoot CMMS

(computerized maintenance management software) that helps maintenance organizations ensure worker health and safety, pass regulatory inspections, and avoid fines. With the addition of Bigfoot OSH, maintenance and safety data are centralized in one system. The program maintains safety information, including procedures, safety notes, emergency notes, and more for all assets and equipment. It provides a complete set of safety incident and audit features that are fully integrated with Bigfoot CMMS work orders, predictive maintenance, and assets and equipment.

Smartware Group Inc.www.bigfootcmms.com


Safety

Liquid level switch

The Liquiph-ant FLT8x level switch features a fail-safe design and high reliabil-ity for monitoring minimum and maximum liquid levels in safety applications up to SIL3. The FTL8x series of point level switches have two relay outputs, a 4 to 20 mA output that connects to a fail-safe switching unit with a two-channel output, safety contacts, and a safety locking function. For high reliability, built-in diagnostics monitor the tuning fork-type sensor for dam-age, corrosion, material buildup, and mechanical block-ing. If a problem occurs, the live signal changes to notify the operator, and a fault relay sends a signal switch to an annunciator or PLC.

Endress+Hauserwww.us.endress.com/liquiphant-failsafe



Safety

Hard hat interchange systemThe Jackson Safety Hard Hat Interchange System allows

users to easily add, remove, or switch between their weld-ing helmet and face shield, all without removing their hard hat. This system keeps workers protected continuously to help reduce injuries and maintain compliance. It works by touch only, so there is no need to remove the hat as the user changes his or her personal protective equip-ment (PPE). The vertical lock-in function on the Hard Hat Interchange System eliminates helmet/face shield creep. The easy-to-use system keeps productivity up and keeps workers compliant with ANSI Z87.1-2010 standards while reducing inventory of various parts and pieces.

Kimberly-Clark Professionalwww.kcprofessional.com

Overheadrotational boom anchor

The unique design of the Miller SkyORB overhead rotational boom anchor utilizesthe weight of the vehicle being loaded, unloaded, or serviced as a counterweight to provide a safe overhead anchor-age point. The unit features a 20-ft long telescoping mast and a boom that rotates 360 degrees, allowing it to be easily positioned above a worker’s head to minimize free-fall distance and swing fall when used with a self-retracting lifeline. In addition, its patented energy-absorbing technology reduces forces on the system. The Miller SkyORB anchor is designed for use with elevated platforms ranging from 6 to 14 ft above the ground and provides a working radius of up to 14 ft.

Honeywell Safety Productswww.honeywellsafety.com


Air conditioning vestThe re-designed and re-

engineered Personal Air Conditioning (PAC) vest is an innovative solution to protect industrial workers in extreme temperature environ-ments. Key design enhance-ments include an integrated belt with a heat-resistantNexus belt buckle and an adjustable waist belt that provides a quick connec-tion to cool or warm air with the Dual Action PAC switching quickly from hot to cold. The lightweight vest can be worn under other protective cloth-ing and can be adjusted easily by the user, even with gloved hands. The PAC vest is available in three sizes to accommodate a range of body types.

ITW Vortecwww.vortec.com

Harness withaluminum hardware

The Miller AirCore harness is available with lightweight, corrosion-resistant aluminum hardware to provide superior performance and comfort. The aluminum materials and com-ponents are designed to reduce fatigue for all-day endurance and increased productivity. The breathable, open-core padding technology provides optimal airflow while reducing heat and moisture entrapment, keeping a worker drier and cooler. The AirCore harness is designed with patented Miller DuraFlex stretch-able webbing that provides greater flexibility and increased comfort. The unique cam buckles on the shoulder straps allow for easy vertical webbing adjustments, and the webbing design creates an original and vibrant style for greater visibility.

Honeywell Safety Productswww.honeywellsafety.com


Pedestrian warning spotlightThe Safe-Lite is a pedestrian warning spotlight that

alerts workers of forklifts approaching blind corners or forklifts entering and exiting trailers. The blue LED light projects an intense spotlight 10 to 20 ft ahead of the forklift to alert the pedestrian of nearby traffic. The Safe-Lite can be installed on the front or back of any forklift, sweeper, or any other piece of industrial equipment. The spotlight has two LED lights and lenses to ensure a visible blue spot on the floor. The Safe-Lite has a 50,000-hr LED life rating, a 140-degree swivel mounting bracket, and an 8-ft cable length with clips.

Liftow Limitedwww.liftow.com

Latching pail lidThe PIG 5-gal Latching Pail Lid is designed to fit both

steel and poly 5-gal pails. The durable, powder-coated steel lid easily opens and closes with a single latching hasp. A reinforced hinge, latching mechanism, and nitrile gasket create a tight seal around the lid, helping to keep pail contents pure and decrease vapor emissions. The fast-latch ring makes installation easy on steel or poly open-headed 5-gal pails with an 11.25-in. inside diameter. The Latching Pail Lid helps users comply with 40 CFR 261.4, which requires excluded solvent contaminated wipes to be accumulated and stored in closed containers while they are managed on-site.



Superhydrophobic, oleophobic coatingUltra-Ever Dry is a superhydrophobic (water) and oleo-

phobic (hydrocarbon) coating that completely repels any liquid. It uses proprietary nanotechnology to coat an object and create a barrier of air on its surface. This coating can be used for various applications, such as to prevent wetting, corrosion, icing, and contamination, and for self-cleaning and extending product life. The two-part spray-on coating can be applied with a compressor/air sprayer or, for smaller applications, with available pump or trigger sprayers. Ultra-Ever Dry can be used on various materials, such as steel, aluminum, other metals, plastic, leather, fabric, wood, and concrete.

UltraTech Internationalwww.ultraeverdry.com

Welding helmetThe Jackson Safety Balder

W-70 BH3 ADF welding helmet provides a uni-form shade level over the entire viewing area without noticeable and annoying brightening at the edges of the filter, which creates a murky and hazy weld pool. The proprietary technology of the W-70 BH3 decreases angular dependence to vir-tually undetectable levels, increasing welder comfort and productivity. The 1.24-lb helmet meets the ANSI Z87.1 high impact 2010 standards and is solar-powered. The W-70 BH3 offers better protection of the face, ears, and throat, and an aerodynamic shell designed for better fume deflection.

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Product of the Year IndexProduct of the Year Index2013


Company Product Category Page

Atlas Copco GA VSD+ Compressed Air 31

Cameron TURBO-AIR NX 12000 Compressed Air 31

Camfil Air Pollution Control HemiPleat eXtreme Environmental Health 40

Cognex Corporation DataMan 50L Automation & Controls 29

Cognex Corporation DS1000 3D Sensor Automation & Controls 29

CompAir D-Series Compressed Air 32

DL Manufacturing PNEU Dock Bumper Manual Material Handling 48

DL Manufacturing U-Seal Manual Material Handling 48

Eaton 1600-A Bypass Isolation Contactor Power Transmission 50

Eaton 93PM UPS Energy Management 39

Eaton Ampgard XP3 Electrical Controls 35

Eaton ArcGard Power Transmission 50

Eaton Galileo 8.0 Automation & Controls 30

Eaton Metal-Enclosed Load Interrupter Switchgear Power Transmission 51

Eaton Power Xpert Insight Energy Management 39

Eaton Power Xpert Multi-Point Meter Energy Management 40

Eaton Series C K-Frame Breakers Electrical Safety 36

Eaton Shunt Trip Safety Switch Electrical Safety 36

Eaton VCP-WG Circuit Breakers Electrical Safety 37

Eaton VCPW-HD Circuit Breakers Electrical Safety 37

Eaton XT MCC Electrical Controls 35

Eaton’s Bussmann Business FC2 Available Fault Calculator Apps For Engineers 28

Eaton’s Bussmann Business FuseFinder Apps For Engineers 28

Eaton’s Bussmann Business Fuses Made Simple Electrical Safety 37

Eaton’s Bussmann Business SurgePOD Heavy Duty SPDs Electrical Safety 37

Eaton’s Cooper Lighting Business McGraw-Edison Galleon Lighting 43

Eaton’s Cooper Lighting Business Metalux SkyRidge Lighting 43

Eaton’s Crouse-Hinds Business ACE Series Electric Motors & Drives 33

Eaton’s Crouse-Hinds Business Champ Pro PFM Series Lighting 43

Eaton’s Crouse-Hinds Business Champ VMV Series Lighting 43

Eaton’s Crouse-Hinds Business Industrial High Bay LED Series Lighting 44

Eaton’s Crouse-Hinds Business Solar Combiner Boxes Gen II Power Transmission 51

Eaton’s Crouse-Hinds Business Terminator II TMCX Cable Glands Electrical Safety 38

Electro Static Technology AEGIS Shaft Grounding Ring Bearing Protection Handbook Productivity & Training 51

Endress+Hauser Endress+Hauser Operations Apps For Engineers 28

Endress+Hauser Liquiphant FailSafe FTL8x Series Safety 53

Enerpac XC Series Fluid Handling 41

EXAIR Corporation 1-in. Flat Super Air Nozzle Compressed Air 32

EXAIR Corporation Dual 316 Stainless Steel Cabinet Coolers Electrical Controls 36

EXAIR Corporation Heavy Duty HEPA Vac Environmental Health 40

EXAIR Corporation No Drip External Mix Atomizing Nozzles Fluid Handling 41

Fluke Corporation Fluke CNX Maintenance Tools & Equipment 46

Fluke Corporation Fluke VT02 Maintenance Tools & Equipment 46

Gardner Denver EnviroAire T/TVS Series Compressed Air 32

GE Intelligent Platforms Proficy Mobile Apps For Engineers 28

GE Power & Water ClearCurrent PRO Maintenance Tools & Equipment 47

Honeywell Safety Products Miller AirCore Harness Safety 54

Honeywell Safety Products Miller SkyORB Safety 54

Hubbell Industrial Lighting Hazardous Kemlux III LED Series Lighting 44

Hubbell Industrial Lighting HBL LED Highbay Lighting 44

Hubbell Industrial Lighting HBLHA High Ambient LED Highbay Lighting 44

Hubbell Industrial Lighting Kemlux III LED Series Lighting 45

Hubbell Industrial Lighting Lightwatt LED Lighting 45


Company Product Category Page

Hubbell Outdoor Lighting Laredo LNC2-18LU Lighting 45

Hyster Corporation B60-80Z Series Material Handling Systems 49

Infor Infor EAM Mobile Apps For Engineers 29

Infor Infor Ming.le Productivity & Training 52

Inpro/Seal Sentinel FBS Maintenance Tools & Equipment 47

Invensys Wonderware InTouch Access Anywhere Productivity & Training 52

ITW Vortec Personal Air Conditioning Vest Safety 54

Juno Lighting Group Indy Retrofit LED Downlight Kit Lighting 45

Kaeser Compressors Inc. BSD Series Compressed Air 32

Kaeser Compressors Inc. Com-paK BB69C/BB89C Compressed Air 33

Kaeser Compressors Inc. TK-TM Series Compressed Air 33

Kimberly-Clark Professional Jackson Safety Hard Hat Interchange System Safety 54

Kimberly-Clark Professional Jackson Safety W-70 BH3 Safety 55

Liftow Limited Safe-Lite Safety 55

Lincoln Electric VRTEX Mobile Productivity & Training 52

Littelfuse Inc. SB6100 Shock-Block Electrical Safety 38

Marathon Motors XRI Series Electric Motors & Drives 33

Megger PAT450 Electrical Safety 38

Mersen UltraSafe USGCC/USGM Electrical Safety 38

Miller Electric Manufacturing Co. FILTAIR Capture 5 Environmental Health 41

Mobius Institute iLearnReliability Productivity & Training 52

Mobius Institute Mobius iVibe Apps For Engineers 29

New Pig Corporation PIG 5-Gallon Latching Pail Lid Safety 55

New Pig Corporation PIG Build-A-Berm Bladder Section Fluid Handling 42

New Pig Corporation PIG Rapid Response Drainblocker Drain Cover Environmental Health 41

Prescolite MegaLum Lighting 46

Ramsay Corporation Maintenance Planner Test Productivity & Training 53

The Raymond Corporation iWAREHOUSE Productivity & Training 53

RIDGID RP 340 Maintenance Tools & Equipment 47

Rockwell Automation Allen-Bradley Kinetix 5500 Electric Motors & Drives 34

Rockwell Automation Allen-Bradley PowerFlex 525 Electric Motors & Drives 34

Rockwell Automation PlantPAx Automation & Controls 30

Schneider Electric Harmony XB5R Electrical Controls 36

Schneider Electric Lexium 32i Electric Motors & Drives 34

Schneider Electric Square D I-Line Combo Panelboard Power Transmission 51

Siemens Industry Inc. SIMATIC IFP1900 MT Automation & Controls 30

Siemens Industry Inc. SIMATIC S7-1500 Automation & Controls 30

Siemens Industry Inc. SIMATIC STEP 7 v12 Automation & Controls 31

Siemens Industry Inc. Simogear Electric Motors & Drives 34

Siemens Industry Inc. Sinamics V20 Electric Motors & Drives 35

Siemens Industry Inc. Sirius 3RM1 Automation & Controls 31

Siemens Industry Inc. Sirius 3SK1 Electrical Safety 39

SKF SKF Machine Condition Indicator Maintenance Tools & Equipment 47

Smartware Group Inc. Bigfoot OSH Productivity & Training 53

Spaulding Lighting Cimarron LED CL1S Lighting 46

Spirax Sarco MTI10/MTL10 Fluid Handling 42

Toyota Industrial Equipment Mfg. Inc. 8-Series (Diesel) Material Handling Systems 49

Toyota Industrial Equipment Mfg. Inc. 8-Series (Gasoline) Material Handling Systems 49

Toyota Industrial Equipment Mfg. Inc. 8-Series (Paper Roll) Material Handling Systems 49

UltraTech International Inc. Ultra-Ever Dry Safety 55

VibrAlign Fixturlaser NXA Pro Maintenance Tools & Equipment 48

Victaulic Style 171 Fluid Handling 42

Yale Materials Handling Corporation MO25 Material Handling Systems 50

SPECIAL ADVERTISING SECTION

You’ve met the finalists for the 2013 Product of the Year program.After you’ve completed the electronic ballot, you can learn more

about the finalists and the products they offer.Our special Product of the Year advertising section provides

a way to make plants run more efficiently, safely and productively.

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Companies interested in entering the 2014 Product of the Year competition may do so before the Sept. 5, 2014deadline. Details and entry forms will be available Apr. 1, 2014, at www.plantengineering.com/POY.

2013



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62 • November 2013 PLANT ENGINEERING

ISM report hits 12-month highofficials said their reporting members were mixed about its actual impact on themanufacturing sector.

“The panel’s comments are gener-ally positive about the current busi-ness climate; however, there are mixed responses on whether the government shutdown and potential default havehad any effect on October’s results,” said Bradley J. Holcomb, chair of the Institute for Supply ManagementManufacturing Business Survey Commit-tee.

Overall, the PMI grew for the fifth straight month. Since the index slipped to 49.0 in March, the PMI has risen 15% in the next five months. The New Orders Index and Production Index each finished above 60% for the third straight month, indicating strong demand.

Many of the monthly comments about the manufacturing sector focused on the government shutdown or the prospects for the holiday shopping season. Among the comments:

� “New business is booming.” (Textile Mills)

� “The government shutting down and threatening to go into a default posi-tion is causing all kinds of concerns in our markets.” (Fabricated MetalProducts)

� “The government shutdown has not had any impact on our business that I can determine, nor has it impacted any supplier shipments.” (ChemicalProducts)

� “Government spending continues to be slow in defense and military. The gov-ernment shutdown and debt ceiling crisis did not affect business.” (TransportationEquipment)

� “Telecom market — wireless and VOIP — appear to be spiking.We are very busy; busier than we have ever been.” (Computer & ElectronicProducts)

� “Seasonal demand has not decreased at the typical pace. Market showing resiliency in the residential market.”(Primary Metals)

� “ B u s i n e s s c o n t i n u e s t o improve every month for the pastnine months.” (Furniture & Related Prod-ucts). PE

One industry leader in the textile industry suggested that “new business is booming” and the October Institute for Supply Management PMI index shows the same trend.

The PMI jumped to a new 12-month high of 56.4% in Octo-ber, up two-tenths from September’s figure. The results came in the same month as the two-week federal gov-ernment shutdown, and while the PMI didn’t drop as a result, ISM

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plant engineering November 2013 • 63

Withstand current rating improves electrical systems

The automatic transfer switch (ATS) is a critical part of an electrical power system. Understanding its withstand current rating (WCR) is essential. If a transfer switch does not have a sufficient WCR, severe damage can occur, and a potential fire hazard can exist. On the other hand, selecting an ATS with a higher rating than what is required results in over-specification and unneces-sary expense.

Transfer switch considerationsA transfer switch is typically the last dis-

tribution device feeding the critical loads of a facility. As such, it has three crucial responsibilities:1. Close into high inrush currents, i.e.,

high inductive loads.2. Remain closed during faults, espe-

cially where very high fault current can result in significant voltage drop on affected phases. Failure here can result in arcing and heat damage that can lead to premature switch failure.3. Operate frequently, not only for power

system failures, but for standby system test-ing.

While undesirable, short-circuit faults are common. When faults occur, the fault impedance can be quite low, resulting in short-circuit currents of significant mag-nitude. High fault currents can create heat energy and thermal stress (measured in I2t), which can affect all electrical sys-tem components. Extended fault currents can result in destructive heating of cable and transformer insulation, breakers, and switch contacts. And it’s not just electri-cal stress problems: fault currents can cre-ate mechanical stress by producing high magnetic forces that bend bus structures, separate switch contacts, and cause power cables to pull out and energize surrounding structures.

Specifying a transfer switchProtective devices such as circuit break-

ers and fuses are used to isolate a fault from the power source if a fault occurs. A proper WCR rating ensures that a particu-lar transfer switch can withstand the fault current until the immediately upstream protective device opens. The appropriate

WCR also demonstrates that the switch will remain operational after the fault current passes.

To minimize fault risk, which is typi-cally caused by load-side cable failures, the transfer switch should be located as close as possible to the protected critical load it

serves. After a transfer switch is exposed to a short-circuit fault, it must still be oper-able to restore power from the alternative power source. PE

Steve Ennesser is an electrical project engineer and Allen Frederick is a senior staff engineer at Kohler Power Systems.

By Steve Ennesser and Allen Frederick

Kohler Power Systems


ELECTRICALSOLUTIONS

One of the main factors for obtaining long reliable service from any piece of equipment is maintenance. Any type of electrical or mechanical device is sub-

ject to wear and tear. This can be further aggra-vated by undesirable environmental conditions.

Heat, moisture, dust, dirt, poor electrical connections, and poor ground connections can cause premature failures. They can also cause the normal service life of the equip-ment to be shortened considerably. A piece of equipment employing the use of a motor controlled by a variable frequency drive (VFD) is no exception.

Many manufacturers of motors and VFDs as well as companies specializing in the ser-vice of these products, offer service related products such as preventative maintenance (PM) contracts to assist the user in maintain-ing the equipment.

Regardless of the type or brand of motor or VFD, there are some common areas that require attention during maintenance proce-dures. These can be categorized as electrical, mechanical, and environmental. Though these three areas can sometimes be quite interre-lated, we will address them individually.

MechanicalAs any mechanic will tell you, keeping

all moving parts aligned and lubricated will yield the most reliability and longest service life out of any piece of equipment.

Improper alignment of belts or shafts will result in undo stress or vibration. Shaft and pul-ley alignment should be checked periodically. Also, the condition of belts should be checked at the same time. Excessive wear of belts can sometimes indicate alignment problems.

Of course, maintaining the proper lubri-cation of all bearings is necessary. Lack of lubrication, or in some cases over lubri-cation can result in excessive wear on the bearing. Another area of concern here is using the proper lubricant. Sometimes the decision as to which type of oil or grease to use depends on the purchase price of that substance. It is important to remember that the wrong type of grease can be just as damaging as no grease at all. One should always follow the equipment manufacturers’ specification as to the type of lubricant and frequency of application.

ElectricalProbably the most common function in

the PM procedure for any piece of electri-cal equipment is to check that all electrical connections are tightened properly. Poor connections can cause a variety of problems ranging from instantaneous failure to exces-sive mechanical wear.

All screw type electrical connections should be checked at least annually to ensure that they are tightened to the proper torque.

One mistake often made by maintenance personnel is to tighten the terminal screw as tight as possible. That is almost never cor-rect. Every screw type electrical terminal has particular torque specification. Often these specified torque values will seem somewhat low for the size of the terminal screw.

VFDs: The path to prolonged lifeProper maintenance and attention todetail can stretch productivity.

By Gregory Finch

Danfoss

Figure 1: This is an example of a motor bearing lubrication fitting. All images courtesy: Danfoss

� There are common ele-ments and strategies to the proper maintenance of VFDs.� Align and lubricate all moving parts.� Make sure electrical connections are properly tightened.� Be sure to monitor such things as tempera-ture and environment.

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eLeCTRICALSOLUTIONS

Many people will see a large terminal screw and instinctively want to tighten it with a great deal of torque. Remember, the size of the terminal screw has more to do with the amount of current in that circuit than the physical strength requirement. Over tightening these screws can cause deforma-tion in the terminal or the wire resulting in a poor electrical connection.

If there is a considerable amount of dirt, oil, or other contaminants in the surrounding area, the exposed areas of the connection may also require periodic cleaning as well. This is especially true if the surfaces in the connection are oxidized or corroded.

Ground connections are of particular concern in any electrical installation. This is especially true when a motor is being controlled by a VFD. In addition to the amount of potential noise interference cre-ated anytime an ac motor is connected to an electrical power source, there is also the switching frequency from the VFD along with some common mode voltages associ-ated with using a VFD.

There are two main functions of a ground connection. One is to establish a ground level potential on the enclosure of a device to protect against electrical shock hazard for any personnel that may come in contact with the equipment. This is normally referred to as a low frequency ground.

The other function is to enable any struc-ture or enclosure to act as a shield to prevent

noise interference from entering or exiting the equipment. This is often referred to as a high frequency ground connection. With a high frequency ground, the integrity of the connection is much more critical.

Ground connections should be checked and cleaned periodically to ensure that the high frequency capability of the connection is maintained. A good high frequency ground connection on the motor can reduce the dam-age caused by bearing currents induced by common mode voltages, and eddy currents from asymmetrical coil windings in the motor.

EnvironmentalThere are several environmental factors

that can affect the life and reliability of a motor/VFD system.

One of the major factors is, of course, temperature. This can be caused by weather of the location where the system is installed or by the heat that is being produced by the equipment itself.

Heat can be considered the common enemy of any type of equipment whether it is electrical or mechanical. VFDs typically have efficiency ratings that range from 92% to 98%. This means that for every kilowatt of electrical power that is being used, 20 to 80 W are being dissipated in the form of heat.

By design, most manufacturers of motors and VFDs have included a method to remove excess heat. These normally consist of a cooling medium (either air or liquid) pass-ing along a heat exchanger or heatsink. The operative word is passing. This means that in order for the cooling medium to do its job effectively it must be moving along or through the heat exchanger.

A major maintenance function is to ensure that all cooling air or fluid passage-ways are free from clogs or obstruction that can reduce flow. Heatsinks and heat exchangers must be cleaned periodically to remove any dirt or material that would obstruct flow.

Ground connections should be checked and cleaned periodically to ensure that the high frequency capability of the connection is maintained.

Figure 2: This is an example of a power terminal block on a VFD showing fastener torque on the label.

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ELECTRICALSOLUTIONS

Quite often when the VFD is mounted in an enclosure with a NEMA type 12, 4 or 3R rating, an air filter is used to keep contaminants out. These filters must be cleaned or replaced periodically. The fre-quency depends upon the amount of dirt or contaminants present.

Of course, all fans and circulating pumps must be checked to ensure that they are in proper working order.

One major concern is cleanliness. While this has been alluded to a number of times in this article, it requires reiter-ating. Dust, dirt, and other contaminants can cause failures in every aspect of a motor/VFD system. Therefore a major function of anyone responsible for main-tenance is cleaning of the equipment andsurrounding area.

If the VFD or any other electrical equip-ment is mounted in a type 12, 4, 4X, or 3R enclosure, the cabinet door gaskets must also be checked to ensure that the integrity of the enclosure is maintained. It must also be emphasized that it is important to close and latch cabinet doors when work in that cabinet is complete.

It is not uncommon to find 4X enclo-sures with the door held closed by only one

insufficiently tightened door clamp. The rat-ing of an enclosure is only valid when the door is closed and latched properly.

The lack of regular maintenance can result in premature failures of either VFDs or motors. The extra expense of a regularly scheduled preventative maintenance pro-gram is considerably low compared to the cost of repairs or replacement of motors or VFD’s.

The primary reason for the use of VFD’s is to increase efficiency in processes and power consumption, and to save money. Proper maintenance will ensure you are able to continue on that path during the life of the system. PE

Gregory Finch is Service Training Manager for Danfoss VLT Drives.

Figure 3: This is an example of a common air inset/outlet filter assembly for a NEMA 12 rated panel.

Heatsinks and heat exchangers must be cleaned periodically to remove any dirt or material that would obstruct flow.

More on VFDsFind the following related articles at www.plantengineering.com, keyword “VFDs”:

� How to select a VFD

� The possibilities, limits of VFDs

� VFDs align energy consumption to power needs

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ELECTRICALSOLUTIONS

Arc flashes—the fiery explo-sions that can result from short circuits in high-power electrical devices— kill work-

ers in the U.S. every year and perma-nently injure many more.

Given the dangers they pose, arc flash events merit serious attention from engineering professionals. Here are six of the most effective strategies for reducing the frequency, severity, and harmfulness of arc flash incidents.

1Perform a hazard analysis.Every arc flash mitigation program

should begin with a hazard analysis aimed at calculating how much energy an arc flash could release at various points along the power chain. Accuracy is essential with such measurements, so plant managers who lack direct and extensive experience with arc flash incident energy assessment should always seek assistance from a qualified powersystems engineer.

To ensure employees are always aware of potential arc flash hazards, companies should place warning labels on any piece of electrical equipment that poses an arc flash risk. They should also mark arc flash hazard zones on the floor, so workers not wearing appropriate per-sonal protective equipment (PPE) can clearly see how far away from electrical equipment they must stand to avoid serious injury.

Note that the NFPA 70E standard explicitly requires employers to post signage notify-ing employees of potential arc flash dangers. Organizations that ignore this directive dra-matically increase their chances of paying serious fines and losing expensive lawsuits after arc flash incidents.

Figure 1: Arc flash remains a dangerous plant floor event, and strategies to mitigate such an event require constant attention. Courtesy: Eaton

Six strategies to mitigate arc flashincidentsFrom analysis to equipment, you canreduce the exposure to a dangerous event.

By David G. Loucks, PE

Eaton

2Reduce available fault current.Though not applicable to environments

protected by fuses and current-limiting break-ers, facilities using non-current limiting break-ers (NCLBs) can reduce the amount of incident energy released during arc flashes by reducing the amount of available fault current. The fol-lowing three strategies can help plants with NCLBs significantly reduce available fault current.

Operate with an open tie during main-tenance. When maintaining dual electrical sources, current limiting devices above cur-rent values can increase available fault cur-rent and reduce incident energy. Sometimes, however, opening the tie between dual power feeds during maintenance procedures reduces arc flash dangers by cutting available fault cur-rent in half.

Of course, opening ties during main-tenance also temporarily renders your power scheme less redundant, exposing equipment to heightened risk of failure.Given the devastating human and financial toll arc flashes can take, most organiza-tions consider that a trade-off well worthmaking.

� Arc flash incidents are deadly, dangerous, and still all too common in U.S. plants.� A hazard analysis is a crucial first step in arc flash mitigation.� Reducing current or having a shorter clearing time also can be impor-tant.� Reducing blast energy in the case of an arc flash incident is vital in any arc flash program.

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ELECTRICALSOLUTIONSEmploy high-resistance grounding. Dur-

ing ground faults, high-resistance grounding (HRG) systems provide a path for ground current via a resistance that limits cur-rent magnitude—dramatically reducing the size of line-to-ground faults and associatedarc flashes.

Use current limiting reactors. Current-lim-iting reactors act as a bottleneck on electrical flows, restricting current during faults. For example, low-voltage motor control centers can be supplied with three single-phase reactors that limit available short circuit current, resulting in smaller energy releases when faults occur.

3Shorten clearing time.Just as smaller arc flashes release less

energy, shorter ones do as well. To shorten arc flash events by decreasing fault clearance times, you can:

� Utilize zone selective interlocking. Zone selective interlocking (ZSI) is a protection scheme that uses an “inhibit” signal transmitted from downstream breakers that see a fault to the next breaker upstream. The upstream breaker sees both the fault current and the inhibit sig-nal and therefore delays tripping, allowing the downstream breaker to clear the fault. Should a fault occur between the downstream and upstream breaker, however, the downstream feeder doesn’t see the fault or send an inhibit signal to the upstream breaker. That causes the upstream breaker to bypass any intentional time delay settings, significantly reducing arc flash incident energy.

� Implement a bus differential scheme. These are coordinated zones of protection within an electrical system. When a fault occurs within a given zone of protection (i.e., between the main and feeder breakers), protective devices trip instantaneously, limiting arc flash dura-tions while also confining arc flash damage to specific portions of your infrastructure.

� Deploy an Arcflash Reduction Mainte-nance System (ARMS). An ARMS shortens faults by bypassing all time delays in the trip circuit any time current exceeds a preset maxi-mum. That enables faults to clear even faster than a circuit breaker’s “instantaneous” func-tion makes possible.

4Adopt remote operation.Executing potentially dangerous proce-

dures remotely can help protect personnel from injuries. Here are two ways to limit maintenance operations performed in range of arc flash events:

� Install remote monitoring, control, and diagnostics software. Today’s power manage-ment systems equip administrators with the ability to perform many administrative tasks remotely. They also equip companies to remote-ly de-energize electrical equipment before staff members come into contact with it.

� Employ remote racking devices. Tradi-tionally, technicians have had to stand close to equipment with live, electrical connections when racking and unracking breakers. Remote racking devices enable operators to perform these extremely dangerous tasks from a safe distance.

5Predict and prevent faults.One of the most effective ways to prevent

arc flashes is to anticipate and eliminate the conditions that cause them. The following three solutions help spot potential arc flash dangers before they have a chance to do harm and keep personnel safely away from live connections.

� Monitor insulation integrity. Deteriorating insulation is the leading cause of arc-producing electrical failures. Identifying and repairing compromised insulation before it fails can help avert arc flash explosions. Predictive mainte-nance systems provide early warning of insula-tion failure in medium-voltage switchgear, sub-stations, generators, transformers, and motors.

� Monitor pressure junctions. When cur-rent flows through a loosened connection, it can cause overheating and eventually produce an arc flash. Using non-contact thermal sen-sors called pyrometers, however, plants can monitor pressure junctions continuously and receive advance notification of loose connec-tions before they become so loose that they create an arc flash explosion.

� Use infrared (IR) windows. Using contact-less IR thermography technology, IR windows enable technicians to perform IR scans without removing switchgear side panels, lessening the likelihood of arc flash events caused by acci-dental contact with live bus.

6Redirect blast energy.When all else fails, arc-resistant switch-

gear offers vulnerable employees a critical last line of defense from the explosive power of arc flash incidents. However, its protective qualities are effective only when equipment doors are closed, so companies should train their technicians to fasten doors securely dur-ing normal operation. PE

David Loucks is manager of power solutions and advanced systems for Eaton.

The NFPA 70E

standard explicitly

requires employers

to post signage

notifying employees

of potential arc

flash dangers.

Organizations that

ignore this directive

dramatically

increase their

chances of paying

serious fines and

losing expensive

lawsuits after arc

flash incidents.

More on arc flashFind the following related content at www.plantengineering.com, keyword “arc flash”:

� Arc Flash University Webcast: Safe Use of Elec-trical Testing Devices

� Improving arc flash safety through design

� New solutions address arc flash energy reduction


DE-1 • November 2013 PLANT ENGINEERING www.plantengineering.com

DIGITALEXCLUSIVE

Understanding of resonance essential for solving vibration problems

It’s no secret that severe vibration can destroy bearings, ruin shafts and poten-tially disrupt production. What’s less well known is that resonant machine components and supporting structures can magnify even small vibration prob-

lems enough to damage connected equip-ment or cause catastrophic machine failure. To solve a vibration issue quickly and avoid such undesirable outcomes, an important first step is to determine if the source of the increased vibration is resonance in the rotating equipment or in a supportingstructure.

Resonant vibration in mechanical struc-tures such as pumps, turbines and motors occurs when a natural frequency is at or close to a forcing frequency such as rotor speed. When present, this condition can cause severe vibration levels by amplifying small vibratory forces from machine opera-tion. Such problems often develop after a

speed change has been implemented, as with retrofitting a machine with an adjustable-speed drive (ASD) or operating a 50 Hz motor on 60 Hz power. The solution fre-quently depends on the ability to distinguish between structural resonance and a rotor critical speed.

Structural resonance: Structural reso-nance refers to excessive vibrations of non-rotating components, usually machine parts or supporting structures. Due to the complexity of these components, it is the more common resonant condition and usu-ally occurs at or near the rotating speed of the machine. Even slight vibratory forces from residual unbalance and misalign-ment effects of the machine can excite the resonant base structure, resulting in severe vibration. A good example of this is the reed frequency vibration that often occurs with vertical turbine pumps that have a motor mounted on top of the discharge elbow.

Resonant machine components and supporting structures can magnify even small vibration problems enough to damage connected equipment or cause catastrophic machine failure.

By Eugene Vogel

Electrical Apparatus Service Association

Figure 1: Bode plot of resonance. All graphics courtesy: Electrical Apparatus Service Association

Amplitu

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Speed

Free space zone(inertia)

Ampli�cationzone

Resonance

Proportionalzone

(stiffness)

� Severe vibration can be caused by even the slightest forces from residual unbal-ance and misalignments.

� A rotor critical speed exists when a machine’s rotating element is the resonant com-ponent and its speed matches the natural frequency of the rotor.

KEYPOINTS

www.plantengineering.com plant engineering November 2013 • DE-2

Machine components can also be resonant; there are many examples of two-pole elec-tric motors where a resonant end bracket caused very high axial vibration at 1 x rpm or 2 x rpm.

Rotor critical speed: A rotor critical speed exists when a machine’s rotating element is the resonant component and its speed matches the natural frequency of the rotor. This is common with centrifugal pumps, gas and steam turbines, and large, two-pole electric motors. While the result is similar to structural resonance (high vibration at a certain operating speed), a rotor critical speed is a more complex phenomenon. When the operating speed reaches the resonant frequency of the rotating element, the rotat-ing element distorts and the vibratory forces increase significantly.

It is important to properly distinguish between structural resonance and rotor criti-cal speed. The term “critical speed” (without the word “rotor”) is somewhat ambiguous. Technically, a critical speed could be either a structural resonance or a rotor critical speed. For the sake of clarity it’s best to avoid using that term. The simple term “resonance” can be applied to both conditions to avoid con-fusion.

The characteristics of resonance As described above, the most notable char-

acteristic of resonance is increased vibration when a certain operating speed is reached. It will also be observed that as the operating speed is increased beyond the resonant fre-quency, the vibration amplitude will decrease somewhat. The Bode plot in Figure 1 shows the operating speed versus the amplitude. For the sake of illustration, assume that the exciting force is residual unbalance of the rotor at the rotating speed.

The formula for calculating the natural frequency is:

Where “K” is the stiffness of the reso-nant structure or component, and “W” is the weight (mass). Note that at the core of this formula is:

Increased stiffness will therefore raise the natural frequency, and increased mass will lower it. That’s logical since stiffness

creates a force that is always directed against motion, while mass has inertia, which is a force always directed with motion. Resonance is what happens when these two opposing forces are equal; they cancel each other out, allowing vibration to increase.

The damping factor A third force, damping, is at work

throughout the speed range. Damping absorbs vibratory energy, converting it to heat. In doing so, damping reduces the maxi-mum amplitude of the vibration at resonance and increases the width of the amplification zone (see Figure 2). A common example of damping is shock absorbers on a vehicle. Machines with sleeve bearings may have significant damping that can even mask criti-cal speeds. On machinery bases, concrete and grouting add significant damping to a base structure.

These forces (stiffness, mass and damp-ing) determine the characteristics of reso-nance and are important in the distinction between structural resonance and rotor criti-cal speeds.

With structural resonance, the machine is operating very close to a resonant fre-quency. It is most noticeable when damping is low, since very high vibration amplitude

Figure 2: The effect of damping on resonance.

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Understanding the difference between structural resonance and rotor critical speeds will help clarify the discussion for maintenance and service personnel.

DE-3 • November 2013 plant engineering www.plantengineering.com

DIGITALEXCLUSIVE

Rigid mode “bouncing” (�rst mode)

Rigid mode “rocking” (second mode)

First bending mode (third mode)

Second bending mode (fourth mode)

Third bending mode (�fth mode)

Figure 3: Examples of a series of bending modes.

r e s u l t s . T h e r e a r e t w o r i g i d modes which can be descr ibed as “ b o u n c i n g ” a n d “rocking”. Solu-tions include chang-ing the resonant frequency to move it away from the operating speed by modifying stiffness or mass and increas-ing damping to directly reduce the ampl i tude . (The var ious methods for implementing these cor rec t ive measures are topics for another article. The objective here i s a compar ison to ro tor c r i t i ca l speeds.)

Wi t h a r o t o r critical speed, the problem is quite d i f f e r en t . F i r s t , the stiffness, mass and damping of

rotors mounted on rolling element bearings can almost never be effectively changed, and damping is typically very low. (Note: Mounted rotor natural frequencies of large journal bearing machines typically can be changed to some degree by modifying the bearing dynamics.) Second, no rotor is ever intentionally designed to have a critical speed close to its operating speed. The problem in this case is not that the operating speed is close to resonance, but that at the rotor criti-cal speed the rotor distorts and non-linear effects cause excessive vibration. At that point it becomes a “flexible rotor” rather than a “rigid rotor.”

A rigid rotor operates below the first rotor critical speed and may have numerous unbal-ance forces distributed along its axis. The sum of these unbalance forces can be correct-ed in any two planes with common two-plane dynamic balancing methods. In these rigid modes the rotor may flex slightly, but the motions at the bearings accurately represent the unbalance condition. However, once the rotor becomes flexible, above the first rotor critical speed, the distribution of unbalance

forces will distort the rotor, causing an unbal-anced condition that was not present in the rigid modes. This flexible mode unbalance causes increased vibration that persists at higher speeds.

With structural resonance, the force is constant while the vibratory response of the structure changes with speed. With a rotor critical speed, the force changes as the rotor distorts to conform to unbalance forces distributed along the axis of the rotor. The solution to a rotor critical speed is to eliminate the unbalance forces in the various planes along the axis of the rotor. Usually it is not possible to detect where the unbal-ance forces are with the rotor in the rigid mode, so the rotor must be operated above the rotor critical speed (in the flex-ible mode) to detect the effects of the unbalance.

Bending modes As the speed of a rotor increases it will

go through a series of bending modes: first bending mode; second bending mode, third bending mode, and so forth.

Rotors for multistage pumps and gas and steam turbines may operate above the first or second rotor critical speed, and gen-erators sometimes operate above the third rotor critical speed. Rotors for large, two-pole electric motors may operate above the first rotor critical speed but seldom above the second. Rotors that are designed for such “flexible rotor” operation have pro-visions for additional balancing planes to accommodate dynamic balancing proce-dures that eliminate the residual unbalance forces that cause flexible rotor distortion. These dynamic balancing procedures require the rotor to spin at operating speed, which can only be done safely with spe-cially designed balancing machines in a spin pi t . Alternately, the individual components of f lexible rotors, such as impellers, can be balanced before assembly.

Understanding the difference between structural resonance and rotor critical speeds will help clarify the discussion for mainte-nance and service personnel, especially when the topic is multistage pumps, turbines or large, two-pole motors. PE

Eugene Vogel is a pump and vibration spe-cialist at the Electrical Apparatus Service Association, Inc. (EASA).

www.plantengineering.com PLANT ENGINEERING November 2013 • DE-4

DIGITALEXCLUSIVE

Maximizing the effectiveness of technical training

How many times have all of us attended training for a week or two, maybe longer, only to come away with ten pounds of manu-als, a hat emblazoned with the original equipment manufactuer’s

logo, and a screwdriver? Training is expensive—in tuition, travel, and time away from your shop. But embarking on a project involving an unfamiliar platform without training will cost a lot more. How can we maximize the return on our training investment? Sure, we’ll come away with some hands-on experience with a scripted training scenario in a classroom environment where you probably had to share a workstation with another student. How much knowledge will we have retained when the time comes to apply our training?

The latest trend in technical training is work-ing in virtualized environments. I have devel-oped and delivered several sessions using this method with very positive feedback and results. Students attend from their remote locations and access virtual training platforms via web browser or VPN. All the virtual platforms are hosted on a centralized server. The instructor delivers lectures and demonstration using web collabora-tion tools and can view and directly interact with each student’s desktop. The instructor can even display one or more student’s screens to the other attendees for group participation and discussion. While this environment might not be optimum for training that requires physical involvement with hardware components such as PLCs, drives, and physical I/O, most automation platforms have simulation utilities that can emulatePLCs, plant processes, and other hardware components.

Overall, virtualized training has several major advantages:

� Travel is eliminated.� There is no need to find, rent, or ship com-

puters.� Real time instructor monitoring of and

involvement with all students. In a classroom setting, the instructor can only monitor and sit with one student station at a time.

� Each student has his or her own station, no sharing required.

� Virtual stations can be made available for students to practice and experiment outside of class hours and beyond the last day of the course if needed. The effectiveness of training and knowledge retention are enhanced when the student can continue to experiment without risk.

Here are my suggestions for building value into training:

� Training delivery should be approximately one-third presentation, one-third demonstra-tion, and one-third lab exercise and discussion.

� Course material should be written at about a junior-high school reading level. By the way, reading level is not indicative of aptitude.

Use current technologies to reduce training costs and improvewhat your students retain.

By Ric Gibson

Maverick Technologies

Figure 1: Virtual stations can be made available for students to practice and experiment outside of class hours and beyond the last day of the course if needed. The effectiveness of training and knowledge retention are enhanced when the student can continue to experiment without risk. Courtesy: Maverick Technologies

� Advantages of virtualized training

� How to build value into training.

KEYPOINTS

n Don’t rush training development. For instructor-led training, allow two to three weeks of development per course delivery day. This may seem excessive but consider the cost and risk that comes with inadequately prepared and validated instruction.

n Choose your instructors carefully. An otherwise brilliant engineer may not have the delivery skills and patience necessary for knowledge transfer where there is a broad diversity of student experience and learning styles in the same classroom. Likewise, an instructor with exceptional public speaking and delivery skills may not have the real-world project experience to bring relevance to the learning. It’s imperative that you don’t lock your training people into boxes where they only do training delivery or training development. Instructors should also be involved in contem-porary real-world projects, spending equal time in development, delivery, and project work.

n If you’re going the train-the-trainer route, don’t go more than two generations. The person who receives the original train-ing should be the person doing the secondary delivery.

n Who are your learners? Consider factors such as: education, experience, language, cul-ture, work shift, and position within the com-pany. If you’re teaching a class in English to students for whom English is not their primary language, speak slowly, listen carefully, do not use contractions, and be careful what jokes you tell.

n What are the attitudes? Students usually fall into one of the three categories: explor-ers, hostages, or vacationers. I’ve taught many classes attended by senior engineers who found themselves having to implement a new and unfamiliar platform. They are proficient in the previous platform: they know how it works, they can fix it when it breaks, and often they’re not happy to be in my class. I make it a point to spend extra time with these students, and where possible, help them connect the dots between what they know and how it relates to what’s being taught.

If you want your engineers to develop new ways of thinking, give them the tools and envi-ronments that will lead them there. PE

Ric Gibson is a technology leader at Mav-erick Technologies.

DIGITALEXCLUSIVEVirtual stations can be made available for students to practice and experiment outside of class hours and beyond the last day of the course if needed.

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DIGITALEXCLUSIVE

When Perry Finco began as the maintenance manager at Pre-mier Silica’s Brady operation in spring 2012, he set a goal of bringing the 35-year-old facility up to 90% efficiency.

However, because he and his team had to deal with constant unplanned downtime, they didn’t have the time to get organized. Their task was made even more difficult because they had no idea what products were installed at the quarry, two wet plants, three dry plants, two bagging facilities, and two load out facilities.

Over the years, the Brady operation had been purchased and sold many times, and bills of material and other relevant historical product records had been lost by the time Premier Silica acquired the operation in April 2012.

“How can you put a preventive maintenance or inventory strategy in place when you don’t know what products you have running in your plant?” said Finco. “We didn’t even know what products were stocked in our warehouse. Not

having this information meant we were operat-ing by the seat of our pants, chasing down parts trying to keep the plant running.”

While Finco knew where he wanted to end up, he understood that without knowing what products he had running in the plant and sitting on the shelf, he had no way to get there. But Finco did have experience with plant surveys at previous facilities, and when he found an installed base evaluation (IBE) service offered by Baldor, he was very interested.

A team surveyed the electrical and mechani-cal products installed and inventoried at the Brady operation, capturing detailed nameplate information, application information, and plant location—all the information Finco was missing.

“Because of the fact that we are in such a remote area and a somewhat small project, I was worried about finding a firm to come in and conduct a survey,” said Finco. “The IBE team fit our needs perfectly.”

After the on-site survey was finished, the team went to work analyzing the data and

How Premier Silica’s Brady operation used evaluation to improve plant performance.

Figure 1 (above): Because an IBE provides a complete and detailed database of installed and spare com-ponents, plant officials can make informed choices that will impact reliability and the bottom line. At the Brady operation, the survey of inventoried parts in the warehouse supplied critical information for plant man-agement to determine its inventory strategy moving forward. All images cour-tesy: Baldor Electric

Case study

A road map to reliability


DIGITALEXCLUSIVE

preparing a report. When the results of the IBE were presented, Finco immediately saw product standardization opportunities, a critical step in his strategy to manage inventory better.

With the survey data uploaded to the Brady operation’s computerized maintenance manage-ment software (CMMS) system, the maintenance team has created its own database, which Finco said is now the framework for a preventive main-tenance strategy for both mechanical and motor products across the entire Premier Silica operation.

“We’re using some of the information from the IBE report to write the scope for our new preventive maintenance program,” said Finco. “Now that we know what we have, we are out-lining what’s needed for each product, setting up lubrication schedules, as well as other pre-ventive procedures. And because we are now better organized with all the correct parts on hand, we are prepared to support planned main-tenance shutdowns.”

The effort has already had a tremendous impact on preventing the constant bearing fail-ures that had been shutting down production.

Finco said by knowing exactly what kind of bearings were running in the plant, the team was able to upgrade product where necessary but also research the best way to maintain the bearings kept in service.

“What we found out is that we were using the wrong grease,” said Finco. “By conducting the right preventive maintenance with the cor-rect grease and the correct lubrication schedule, bearings are no longer causing shutdowns as they had in the past. And because we know what kind of bearings we have, we are also carrying the right quantity of bearings in the warehouse.”

With strategic plans in place and work well underway, Finco is happy to report that plant performance has improved tremendously since the time the IBE was conducted. He said his team has changed from being reactive to proactive and getting closer to the 90% efficiency goal.

“This tool helped us refocus our energies to work on all the strategies that will bring this plant back to the reliability levels we know are possible,” said Finco. “The IBE was just the beginning of our journey. Now we have to stay committed and follow through. However, we could not have begun this work without this survey to get us started.”

The Installed Base Evaluation team surveyed products at Premier Silica’s Brady operation quarry, two wet plants, three dry plants, two bagging facilities, and two load out facilities. The team not only provided an accurate count of electrical and power transmission equipment but also captured detailed nameplate information, as well as the application and plant location. PE

Information provided by Baldor Electric.

Figure 3: By getting the detailed information on all of the bearings running in the plant, the maintenance team was able to begin a preven-tive maintenance program using the correct grease and the correct lubrication schedule. The effort has had a tremendous impact on preventing the constant bearing failures that had been shutting down production.

Figure 2: Baldor’s Installed Base Evaluation team sur-veyed products at Premier Silica’s Brady operation quarry, two wet plants, three dry plants, two bagging facilities, and two load out facilities. The team not only provided an accurate count of electrical and power transmission equipment but also captured detailed nameplate information, as well as the application and plant location. (All equip-ment was properly locked and tagged out, according to Premier Silica safety pro-cedures during the survey.)


DIGITALEXCLUSIVE

Five reasons why aluminum piping makes sense for compressed air systems

Traditionally, engineers have speci-fied a variety of piping materials for compressed air systems, including black iron, galvanized steel, cop-per, stainless steel and even plastic. More recently, aluminum piping has

become an option considered by many contrac-tors, architects and engineering firms. Alumi-num piping makes sense for compressed air systems in many different applications.

Black iron and galvanized steel pipe are two common types of pipe used for compressed air systems. More than 60% to 70% of all com-pressed air systems installed today use black iron or galvanized pipe, due to a variety of factors:

n Contractors are familiar with these materials.n Material costs are low.n The pipe and compressed air system fittings

are readily available.

n Steel pipe is rated for high pressure.

There are, however, five key reasons why aluminum piping is a superior material to use for most compressed air installations today, each of which addresses a key disadvantage to traditional pipe systems.

1Lowering installation costsMore time is needed to install a compressed

air system when using steel pipe compared to installing a system using other materials.

One factor behind this is that steel pipe must be threaded in order to join pipes and install the proper fittings. To properly thread steel pipe, you need special threading equipment and skilled workers to operate it. These work-ers cost more than unskilled workers, and that also drives up installation costs.

Aluminum piping offers several key advantages to traditional pipe systems, including low installation costs and a lack of corrosion.

By Kyri McDonough

Transair

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DIGITALEXCLUSIVE

Also remember that threading pipes is dirty work. You need cutting fluids to get a good thread, and that must be cleaned from the pipe before you can start using the system. Thread-ing also creates a lot of debris.

Modifying and maintaining a compressed air system made with steel pipe is more difficult than modifying and maintaining systems built from other materials. One reason for this is that steel pipe is much heavier than other materi-als. Because steel pipe is so heavy, it requires more labor (read as higher labor costs) to handle the piping while making modifications than it would to make modifications to a system made with other piping materials.

2Minimizing system leaksAnother issue with threaded connections

is that they will inevitably leak. It’s been esti-

mated that eight to 10% of the compressed air in a system will leak through threaded connec-tions. This causes compressors to run harder and longer, driving up utility costs.

3 Aluminum piping doesn’t corrodeA common problem with using steel pipe

is that moisture inside the system will cause pipes to rust from the inside out. Even if your compressed air system has a moisture trap, there will be some moisture in the system and cor-rosion will occur. Even galvanized steel pipe will corrode, as not all pipes are galvanized both inside and out.

Corrosion causes several problems, begin-ning with air flow restricted by a rough inner surface caked with deposits caused by corrosion build up. Additionally, loose scale deposits col-lect over time and create pressure drops. This

Table 1: This table compares the advantages and disadvantages of compressed air pipe materials.


makes the air compressor work harder to maintain the pressure of the system. In extreme cases, loose scale can completely clog a line or damage equip-ment connected to a line. Of course, corrosion and loose scale affects air quality and makes it unsuitable for applications that require clean air.

4 Aluminum outperforms the copper alternative

Copper piping is another solution for com-pressed air systems and is attractive because it doesn’t corrode as much as steel pipe. While it can corrode, it doesn’t have pipe scaling like steel pipe. This means that a copper system will have fewer air flow problems and air cleanli-ness problems than steel pipe, but it can still experience flow restriction over time.

A copper solution comes with its own set of disadvantages, however; perhaps the biggest is the cost of copper material itself. In October 2011, the price of copper increased by 20%, and subsequently, so did the price of copper pipe. Even though prices have dropped since then, the fact remains that copper pipe continues to be considerably more expensive than steel pipe.

Another disadvantage is that fittings must be soldered, and this causes its own set of prob-lems. Soldering of course requires an open flame, making this a safety issue in some

environments. And, soldering requires some skill to accomplish, an increasing problem in an era when skilled labor is becoming harder to find. If a joint is not soldered properly, it will leak, and leaks increase energy costs.

Finally, not all types of copper piping are suit-able for use with high air pressures. So, if you’re planning to use copper, you have to make sure that you choose a pipe that can handle the pressure.

5PVC and stainless steel present obstacles in cost and durability

While steel pipe and copper pipe are the two most widely used materials for compressed air systems, you will also sometimes find systems that use PVC pipe and stainless steel pipe. In fact, it is against OSHA standards and highly danger-ous to use PVC pipe for compressed air systems. PVC becomes brittle over time and may explode when transporting air under high pressure.

Stainless steel is another option, especially when the compressed air system is to be installed in a corrosive environment. In some cases, stain-less steel is considered an option depending on the fluctuating cost of copper pipe.

As with other steel pipe systems, though, stainless steel systems can be costly to install. Threaded stainless steel pipe can be difficult

to seal, often requiring the use of lubricants to thread correctly. Welding stainless steel drives up installation costs and safety concerns through the need of a skilled welder, and the added risk of smoke inhalation, damage to eye sight, and fire.

The case for aluminum pipingIn recent years, aluminum piping has become

a solid alternative to other piping materials for compressed air systems. Compared to the materials described above, installing a compressed air system using aluminum piping offers many advantages:

n Aluminum pipe systems are much easier to install and to modify than steel or copper pipe systems. Labor savings of 50% can be achieved, since aluminum pipe is supplied ready for use. No particular preparations beyond cutting, deburring, and chamfering are required, nor are special tools needed. Aluminum pipe is calibrated, meaning that its diameter is strictly controlled. This means that associated quick connect components will fit securely, and each connection is automatically secured.

n Aluminum pipe is much lighter than steel pipe or copper pipe. This also reduces instal-lation and modification costs.

n Another factor that makes aluminum pipe systems easier to install and modify is that it doesn’t require threading or soldering.

n The compressed air provided by a system built with aluminum piping is much cleaner than air delivered by a steel pipe system. Alu-minum pipe systems can help meet the require-ments of ISO 8573-1: 2010 air quality stan-dards, should the application require it. Cleaner air also means lower maintenance costs.

n Aluminum pipe’s corrosion-resistant prop-erties mean optimal air flow, reduced energy costs, and better air quality.

n The fittings used with aluminum pipe systems fit securely and leak far less than the fittings used with threaded systems. This trans-lates directly into energy savings and improved plant productivity.

Naturally, there are some disadvantages. For example, material costs are higher for alumi-num pipe systems compared to steel pipe sys-tems. When compared to copper pipe systems, however, material costs for aluminum are about the same or even lower. And, the working pres-sure for aluminum is 232 PSI at 115 degrees. Overall, though, for many applications, alumi-num piping is a solid alternative for compressed air systems. PE

Kyri McDonough is the marketing services coordinator for Transair.

Modifying and maintaining a compressed air system made with steel pipe is more difficult than modifying and maintaining systems built from other materials.

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AUTOMATIONSOLUTIONS

The IT world started to standardize net-work infrastructures back in the 1990s, pursuing interoperability in everything from cabling and connectors to the

seven-layer Open System Interconnection model. Costs per connection plummeted and performance skyrocketed. But the industrial world sat on the sidelines for years, trapped in single vendor communities with proprietary Fieldbus systems as a result of a general belief that Ethernet was too fragile for manufactur-ing environments.

Eventually, however, the enormous cost dif-ferential between an “IT” network connection and an “industrial” connection led to a tipping point. Vendors started to provide ruggedized equipment, and Ethernet has become an inte-gral part of industrial automation.

We’re approaching another tipping point now. Like the early incarnations of wired Eth-ernet, wireless Ethernet was long perceived as being too unreliable for industrial applica-tions. A failure or interruption in the wireless connections at a local coffee shop is normally a mere inconvenience, but in the industrial world it can be a catastrophe. So, like wired Ethernet, wireless Ethernet had to make some

changes before it could be used for machine-to-machine (M2M) automation.

Reliable Wi-Fi connectionsWi-Fi’s interoperability and low-cost chip-

sets make it a natural choice for wireless IT applications. But the early Wi-Fi standards struggled with issues like multi-path propaga-tion, the phenomenon that occurs when radio waves are absorbed or reflected by obstacles in the local environment. The obstacles may be anything from ordinary building materi-als to vegetation, and each one interacts with radio in its own way.

The end result is that Wi-Fi signals arrived at the receiver at different times and out of sequence. A connection that worked at one moment might fail five minutes later because someone moved a forklift or relocated a stack of cartons.

The Wi-Fi 802.11n standard addresses that problem with multiple-input multiple-output (MIMO) technology. The standard employs multiple antennas at both the transmitting and receiving sides of the wireless connec-tion and splits the data into numerous spatial streams. The streams are transmitted through

Wireless M2M increases value of wired infrastructureNew technology overcomes limitations of previous systems to deliver value.

By Mike Fahrion

B&B Electronics

Figure 1: Vendors are now producing wireless rout-ers (left) and bridges that provide the serial-to-Wi-Fi conversion in a single box solution. An Ethernet port (below) lets you connect to the same wireless router or bridge. All images courtesy: B&B Electronics

� As when Ethernet first emerged in plants, wire-less Ethernet has gained acceptance as a stable platform.

� The new Wi-Fi 802.11n has helped address some of the lingering issues with wireless Ethernet.

� Several new router and bridge products provide a single-box solution for the wireless Ethernet environ-ment.

� Wired networks actually will be enhanced, and not replaced, by the new wire-less strategies.

KEYPOINTS


separate antennas and collected by corre-sponding antennas in the receiving devices, where onboard software uses signal process-ing algorithms to correct and interpret the incoming data.

MIMO 802.11n devices also employ pre-coding and postcoding techniques like spatial beamforming. Spatial beamforming modifies the phase and relative amplitude of the signal to create a pattern of constructive and destruc-tive interference in the wavefront, which sim-plifies interpretation on the receiving side. The 802.11n standard adds frame aggregation to the MAC layer, and makes it possible to specify management information less fre-quently by grouping several data frames into a single, larger frame.

The ratio of payload data to total data vol-ume is higher, allowing for better throughput. 802.11n also adds 40 MHz channels to the physical layer (PHY), twice the bandwidth

that was available under the older 20 MHz standard. Together, 802.11n’s many modifica-tions to the Wi-Fi standard have resulted in a wireless technology that is reliable enough for industrial applications.

Obsolescence isn’t an optionIf you buy a new desktop computer these

days it will come with multiple USB ports as standard equipment. But if you want a serial port you’ll probably have to install an expan-sion card. Serial communications have become irrelevant in the home/office world, where the inability to connect to some old dot matrix printer is hardly a cause for concern.

Things are a bit different in the industry. Companies and organizations all over the world still have enormous capital invest-ments in serial equipment. In fact, the low cost and rugged reliability of the serial pro-tocols continue to make serial installations

aUTOMaTIONSOLUTIONS

Together, 802.11n’s modifications to the Wi-Fi standard have resulted in a wireless technology that is reliable enough for industrial applications.

Figure 2: Connecting it to your serial device gives the serial device its own Wi-Fi hotspot, allowing technicians to communicate via laptops, tablets, or even smartphones.

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quite attractive, and the number of installed serial devices continues to grow. So how do you get those serial devices to communicate across modern networks, and how do you make them wireless?

Wired serial servers and media convert-ers have been around for a long time. So one option would be to Wi-Fi enable them by connecting them to an external wireless device. But there’s another way to go about it.

Vendors are now producing wireless rout-ers and bridges that provide the serial to Wi-Fi conversion in a single box solution.

You can use these devices to wirelessly network-enable either new or legacy seri-al equipment. There will normally be an

Ethernet port as well, which will let you connect local networks or stand-alone Ethernet devices to the same wirelessrouter or bridge.

Another option is the wireless access point. Connecting it to your serial device gives the serial device its own Wi-Fi hotspot, allowing technicians to communicate via laptops, tablets, or even smartphones. If you’re designing new serial equipment you can build in all of the same functionality by adding embedded modules that duplicate the features of the external routers/bridges/access points.

Wireless router/bridge/access points can also be used to network-enable mobile equipment like forklifts, which will con-nect to networks or handheld devices any time they are within range. Dual band Wi-Fi devices will let you choose between the 2.4 Ghz and 5 Ghz license free bands in environments where the airwaves are cluttered with transmissions fromcompeting equipment.

Long range communicationsThe 802.11n standard can provide for line-

of-sight ranges measured in kilometers, with throughputs of up to 150 Mbps. That’s very useful when you need to cross a barrier like a river or a superhighway. But as the network edge continues to expand, there is an increas-ing need for wireless connections in areas where there is no Ethernet infrastructure and where even the newest and most advanced Wi-Fi equipment would have insufficient range.

Cellular M2M data networking can solve the problem. Like some of the industrial Wi-Fi routers, today’s cellular routers will often include support for serial devices. A model with I/O ports, Ethernet ports, and Wi-Fi would let you connect a broad array of equipment to the Internet via the cellular telephone network while supporting the older serial protocols. Through virtual private net-working you can use the cellular networks as securely as if they were proprietary infra-structure.

This is just the beginning. The buildout of the 4G LTE networks is nearing comple-tion. Network designers will soon be able to combine 4G’s enormous bandwidth and low latency with enhanced Wi-Fi to give networks incredible wireless capabilities. And there will be no need to abandon your existing equipment or wired infrastructure. Wired networks aren’t going to go away—they’re only going to get better. PE

Mike Fahrion is director of product man-agement at B&B Electronics.

AUTOMATIONSOLUTIONSThrough virtual privatenetworking you can use thecellular networks as securelyas if they were proprietaryinfrastructure.

Figure 3: Today’s cellular routers will often include support for serial devices.

More on industrial EthernetFind the following related content at www.plantengineering.com, keyword “industrial Ethernet”:

� Industrial Ethernet Webcast, Part 1: Tech-nologies.

� Video: PINA General Assembly looks ahead to growing industrial Ethernet deployments

� Industrial Ethernet Best Practices eGuide

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MAINTENANCESOLUTIONS

Throughout industry we constantly hear statements like these:

“I do not have time to accomplish what needs to be done.”

“I can barely keep the plant running and you want me to validate the system hierarchy?”

“Who is going to maintain the equipment while I do this?”

“I just do not see the benefit of hierarchy validation—it’s a waste of time and money.”

Sound familiar? In most facilities the main-tenance staff has been so streamlined that it is almost impossible to accomplish everything that needs to be done each day. We look at every avenue to cut corners and still keep the plant up and running. Routine maintenance takes a back seat more regularly than we would like, while reactive maintenance often dictates the work load of the day.

No matter which computerized maintenance management software (CMMS) system is used to capture the information, an accurate system

asset hierarchy is of paramount importance in today’s plant environment. As we examine the importance and significance of an asset hierar-chy and the pitfalls of an asset hierarchy that is not current, it will become apparent that we are wasting both time and money if the hierarchy is not up to date.

If the hierarchy is not accurate, it is impos-sible to gain the reliability, maintainability, and required traceability of the assets. How can planners do their job if they are not aware of the plant’s assets and in particular how the assets relate to other assets? The planners’ only reference is the system asset hierarchy and the established parent-child relationships within the hierarchy.

There are several areas we consider when performing the hierarchy validation:

1. Current system hierarchy and establishing the parent-child relationship

2. Retired and or deleted assets 3. New assets not currently residing in the

hierarchy structure 4. Bill of materials to support the maintain-

able assets 5. Repair parts loading in the store room to

support the assets, and 6. Preventive maintenance assigned to the

assets.

Current system asset hierarchy Once developed, the asset hierarchy par-

ent-child relationship allows the end-user to easily identify which assets are maintain-able assets and which are considered bill of material assets. ISO 14224 illustrates how a parent-child relationship appears in apyramid taxonomy.

One benefit of establishing the parent-child relationship is scheduling preventive and pre-dictive maintenance activities. For example, if the planner is scheduling maintenance on a tank, then all assets associated with that tank (pumps, drive motors, loop instrumentation, pressure safety valves, associated piping, and

Finding the hidden value in asset hierarchy validationMake the effort now to save time and money down the line.

By Paul Langan

Life Cycle Engineering

� An accurate asset sys-tem hierarchy is essential in today’s plant environ-ment.

� The asset hierarchy parent-child relationship allows the end-user to classify assets.

� Follow a step-by-step process for asset valida-tion.

� If you asset system hier-archy in the CMMS system is out of date, you need to make time to bring it into order.

KEYPOINTS

Figure 1: The nine tier levels showing typical asset parent-child relationships, based on the ISO/DIS 14224 taxonomy. Courtesy: Life Cycle Engineering

(9)Parts

(8)Component/mantainable item

(7)Equipment subunit

(6)Equipment unit

(5)Section/system

(4)Plant unit

(3)installation

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(1)Industry

(Company name)

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isolation valves) can also be candidates for maintenance while the tank is offline.

This saves a lot of time and money because we can shut down a group once to do scheduled maintenance versus numerous shutdowns to do maintenance on individual assets.

Another benefit of establishing the asset hierarchy parent-child relationship is the abil-ity to charge costs to the lowest possible asset level, thereby providing a means to identify where maintenance dollars are actually being spent. Additionally, once the asset hierarchy parent-child relationship has been established, field technicians and engineers can write work notifications to the correct asset level and not to a general area. This helps develop historical data that can be used to identify the actual “bad actors” that create the maintenance burden.

When establishing the asset hierarchy parent-child relationship, the ISO/DIS 14224 Standard Taxonomy can be a useful guideline for estab-lishing the appropriate levels. The standard applies to the CMMS programs where asset hierarchies reside. Companies can customize the structure illustrated in the taxonomy to bet-ter manage their unique requirements.

Asset validation and optimization

Asset validation and optimization is a pro-cess that requires the involvement of subject matter experts (SMEs), process engineers, reli-ability engineers, planners, the maintenance department, instrumentation SMEs, and electri-cal SMEs, to name a few. The asset validation is a methodical process in which the most current process and instrumentation drawings (P&IDs), process flow diagrams, and electrical schemat-ics are used to identify the assets in relationship to the current system configuration.

The best way to approach asset validation is to first segment your plant into manageable areas or sections. The most expeditious way to do this is to form a committee utilizing sys-tem engineers, reliability engineers (REs), and planners from the various areas of the plant.

Once the areas have been identified and prioritized, this will be the best way to man-age a large project and provide a way to track progress as the asset validation moves forward plant-wide.

Once the plant has been segmented into man-ageable sectors, assemble a team of SMEs and REs that will be engaged in the asset validation. When the team has been identified, the next step is to gather all reference materials that will be required for the asset validation:

n Current revision of the P&IDs for the area where the asset validation will be conducted.

n Current process flow drawings for the area where the asset validation will be conducted.

n Current, active assets downloaded from the resident CMMS to be used as a reference in the asset validation. The CMMS download reflects what the current planning asset load is. Typically the CMMS asset population has an error rate of 35%-40%.

n Current electrical schematics for the area where the asset validation will be conducted.

n When all reference materials have been obtained, convene the asset hierarchy valida-tion and optimization team and brief them on the validation/optimization process and expec-tations for what the validation should yield. Major points to include in the briefing include:

n The reporting process of the actual asset validation.

n The methodology of marking up the P&IDs indicating assets that are no longer installed and indicating those assets that have been installed but were not reflected on the drawings.

n The methodology required when compar-ing the field validation data with the CMMS download data and making required corrections to validate the CMMS system to reflect the actual system configuration found during the field valuation phase.

n The methodology required to place the validated assets into a parent/child relationship prior to uploading back into the CMMS system.

At this time the field validation/optimiza-tion phase can be conducted using the down-loaded CMMS data, current P&IDs, and flow diagrams. The validation/optimization effort is a detailed and methodical comparison of all systems and assets that reside in the field

If the hierarchy is not accurate, it is impossible to gain the reliability, maintainability and required tracability of the assets.

mAINTENANCESOLUTIONS

A

with the asset listing that resides in the CMMS with those illustrated on the P&IDs and flow diagrams.

Retired assets and removed assetsRetired assets and assets that have been

removed from the plant but still appear as active assets in the CMMS system create a major problem. One of the major con-cerns is that typically there are preventa-tive maintenance (PM) tasks still assigned to the assets. If the MOC program is not functioning, the planners do not know the assets are not active. Therefore, the PM schedules have not been revised to eliminate unnecessary activities.

Looking at a plant where the asset load is 45,000 and calculating that 2% of those assets have been removed and/or retired from the plant over time, then we can assume that 900 assets are no longer active. If there were only two PMs assigned to each of those assets, we now have 1800 PMs that would be applied to those assets. Estimating one hour

is required to accomplish each PM and using a conservative, loaded man-hour rate of $55, the cost to perform the 1800 PMs would be $99,000 annually. But the assets requiring those PMs are no longer functioning.

New assetsDuring the asset hierarchy validation

and optimization effort, there will be numerous assets that will be identified that do not appear in the CMMS download or on system P&IDs or flow drawings. These assets typically were added during system upgrades and improvements. The

concern is that the new assets typically are not in the PM/predictive maintenance pro-gram or being properly supported by the spare parts in the store room. An effective MOC program would eliminate this issue.

If you work in an environment where the asset hierarchy in your CMMS is incomplete and out of date, chances are that it’s going to be difficult to find the time. You will need to make the time.

I’d recommend using some of the reasoning and examples I’ve provided to explain to your leadership team the importance of carving out some resourc-es to accomplish validating and opti-

mizing your asset hierarchy. The money and time you will save in the long run will more than justify an up-front investment. PE

A senior reliability technician with Life Cycle Engineering , Paul Langan specializes in executing best practices programs for asset management strategies supporting CMMS implementations.

More on asset managementFind the following related content at www.plantengineering.com, keyword “asset management”:

� Technology is an essential element of safety and asset management

� Machine safety and asset management

� Ask the right questions to create an asset man-agement financial plan



MAINTENANCESOLUTIONS

At the 2013 Association for Manufactur-ing Excellence Conference in Toronto in October, Michael Rackley, head of supply chain solutions for Ryder Sys-

tems, talked about the increasing demands by manufacturers and consumers on the supply chain. Rackley identified nine major trends affecting the supply chain today:1. Increasingly shorter lead time

(“Speed is worth more than cash these days,” he said.)

2. Impact of online and mobile informa-tion access

3. Acceleration of social media 4. Heightened susceptibility to natural

disasters5. Political and currency turmoil6. Shorter product lifecycles 7. Faster delivery8. More, lower cost competitors9. Demanding shareholders.

“We have to perform even more efficiently than ever before. What does that do to the supply chain? Our 12- to 14-week lead times have to get a lot smaller,” Rackley said. “Speed is driving the supply chain. Customers are defining the mark we have to hit and the speed we have to hit.”

The key to hitting these new marks, Rackley said, is collaboration. “We have to create a new network, a multi-tiered network of people working together, rather than individuals creat-ing plans for the supply chain,” he said.

The demand-driven supply chain, said Rack-ley, “has got to be around customer and con-sumer. We’ve got to listen to that customer. We now have to manage supply at the pull of the customer.”

It also changes the relationship between sales and manufacturing. “Manufacturing, distribu-tion, and sales all have to be working together,” he said. “Everyone has to have visibility to actual consumer demand. They need to know, what are consumers actually buying?”

The dynamic of such a system changes from a linear process to a wheel-and-spoke system. “Visibility is the key,” he said. “The most difficult part is building the net-work, but you’ve got to build the multi-tiered network, and then get that visibility.”Where that system has occurred, Rackley said, companies have seen increased sales, a 5% to 10% reduction in operating expense, and between 20% and 30% reduction in inventory costs.

He cited four main ingredients in a successful supply chain system:

� Product/package design: Rackley cited the example of two different grilles for a vehicle front—one with a V6 logo and one without. By making that logo a clip-on rather than a molded change, they were able to produce one grille and reduce inventory.

� Network: “You need to look at best-cost areas vs. simply the low-cost areas,” he said. By localizing the finished goods and spares, delivery times can be reduced, which can offset any piece pricedifferences from a lower cost supplier with higher transportation costs or longer lead times to delivery.

� Visibility and collaboration: Rackley noted the manufacturer who re-examined his logistical system for inbound supplies. The manufacturer created a material flow center strategically located to support the assembly plant, with material flow center sequenc-ing parts to each assembly line. “It’s get-ting the parts to the right place at the right time,” Rackley said. “Sequencing is very important. It’s getting visibility to all thatinbound material.”

� Lean execution: That would include not just working internally, but with all parts of the supplier base. “You’ve got to take it out from the four walls (of the plant) and move it across the entire supply chain,”Rackley said. PE

4 keys to

By Bob Vavra

Content Manager

“Speed is

worth more than

cash these days.”Michael Rackley, Ryder Systems

a successful supply chain

PRODUCTMART

PLANT ENGINEERING November 2013 • 85




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November 2013

86 • November 2013 plant engineering

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Got a wish list? You’ve come to the right place

The generational gap is something I write a great deal about, and it’s a continuing issue for manufactur-ing. The ease with which the younger engineers have comfort with the

technology and the visual readings avail-able on most systems today is offset by their relative lack of experience. The more mature manufacturing professionals (did you like how I avoided the use of “old” there?) grew up with clipboards and pencils and have evolved to the new data explosion on the plant floor, but it all must feel a tad intimidating at times.

What has changed is the level of products available to help engineers on the plant floor. When Plant Engineering held its first Product of the Year recognition 26 years ago, it was a very different world. Today, because of our advancements in database management and searchable products, Product of the Year is like an Amazon.com for new products. When we began 26 years ago, the first Product of the Year entries were like the Sears Wish Book for new manufacturing products.

Ah, the Sears Wish Book. (Cue nostal-gic music.) Every October, the Wish Book would arrive in the mail—a thick slab of paper wrapped in a slice of brown paper, heralding the start of the Christmas shopping season and trumpeting the arrival of all the cool new toys—or at least new versions of the old ones.

For me, it was the electric football game. As a kid, I would be drawn to what the new electric football game would look like that year—new stadiums, new uniforms for the players, same old stupid felt football that never seemed to stay on the player base. It didn’t matter. I wanted the new game.

It also didn’t matter that the previous year’s game had been similarly examined, sought, and pleaded for and was found waiting, neatly wrapped under the tree. It was then opened, played with for a few days, shoved under the bed to collect dust, and ultimately turned to the garbage heap by June. And the whole pro-cess would begin again when the next Wish Book arrived.

Today, we refer to this concept as “lifecycle management.”

As we begin the process of celebrating this year’s great new innovations in manufactur-ing, it might be useful to remember that the

root of “productivity” is “product.” That can mean both what we are manufacturing and the tools we use to manufacture. We are more productive today because we have more pro-ductive machines and information on our plant floor. It is this constant reach for improve-ment that we celebrate in this year’s edition of Product of the Year.

We know you don’t need all 106 products tomorrow. That’s why I like the concept of the Sears Wish Book. This edition should stay on your desk throughout the year. It’s a great resource to identify and understand how well product managers have been listening to their customers all year long. What drives new products in manufacturing, as in most fields, is constant feedback from you, the customers.

This issue begins each year with a lot of plant managers, engineers, and line workers asking a simple question: “Can you make a product that does this?” We seldom see whole new product categories created out of thin air.

The latest example of this was the tablet industry, which grew from non-existent to pervasive in five years. Now there are apps for your tablet on your plant floor—and last year, we added an Apps for Engineers category to Product of the Year.

The speed of change reflects the speed with which we are asked to improve today. In our evolving world, with new uses for old technol-ogy and greater need for data management and visibility, we see new ideas popping up each year. And yet we still must do the basics—light the plant, keep it a safe and comfortable place to work, and maintain the plant’s equipment. You’ve got to safely deliver electricity, com-press the air, and monitor the operation. And unlike the little boy who had the luxury of shoving an electric football game under the bed, you also must also justify the cost.

The Sears Wish Book is a relic of a sim-pler time, but new products are the continuing effort to make life simpler. There are times when we’d all like to climb into the Wayback Machine (I’m not going to explain all the cul-tural references—that’s what Google is for. Look it up.), but mostly we find ourselves moving forward, looking to the future.

That future begins today with the introduc-tion of the 2013 Product of the Year finalists. I hope you find what you’ve been wishing for. PE

Bob VavraContent Manager

We are more productive today because we have more productive machines and information on our plant floor. It is this constant reach for improvement that we celebrate in this year’s edition of Product of the Year.

INCONCLUSION

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1990

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Documents

Plant Engineering November 2013