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Now you can expect more

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MORE LOGIC

The C-more EA9 HMI software (just $99)


now delivers more functionality, usability
and value to our popular C-more touch
panels. Dozen of new features and
upgrades give you MORE for LESS!

New tag combinations allow simple


logic with multiple events
Combine up to four different tags to
trigger actions based on logical results

MORE MATH

New math functions let you create


custom formulas with constants or tag
values
The Math Keypad provides both simple
and complex operations including log, sine,
and square root

MORE ACCESSIBILITY

The new Object Layer List Window shows


all the objects on the active screen and
lets you lock/unlock, hide/unhide objects
or quickly select them for editing
The Object Layer List allows access to
individual objects in a group; additional lists
for hidden, locked or overlapping objects
Recipe database supports 99 recipe
sheets, each with 1000 recipes of 256
possible tags or values; operator can now
modify and save while the process is active
New menu options, customizable toolbars
and updated graphics for improved ease
of use

MORE ALARMING OPTIONS

Enhanced Alarm List offers more options


for alarm customization
New alarm lters allow for dedicated
alarm summaries

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* EA9-PGMSW for use with EA9 series panels only;


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Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.

1-800-633-0405

input #1 at www.plantengineering.com/information

the #1 value in automation

kaeser.com

COMPRESSORS

2014

Gold Award

Facts are
stubborn things.
John Adams

As our second president, John Adams focused


on the facts when facing our young nations
challenges. At Kaeser, thats our approach, too.

Its a fact: Compressed air is inherently inefficient.


It takes 8 kW of electricity to deliver 1 kW of power in
compressed air and almost all of the remaining 7 kW is
lost as heat. At Kaeser, we design efficient compressors
with smarter controls and more effective heat recovery,
so you can have more efficient plant air.
Heres another fact: If you operate a compressor,
you cant afford to do business without it. Downtime
is expensive and disruptive. Thats why we build our
products for maximum reliability and easy serviceability.
So when service is needed, it takes less time.
Learn the facts. They point to Kaeser.

Our 25-125 hp compressors feature true direct drive design,


a thermal management system plus built-in heat recovery
options for the ultimate in operational efficiency.

input #2 at www.plantengineering.com/information

Kaeser Compressors, Inc. 866-516-6888 kaeser.com/PE


Built for a lifetime is a trademark of Kaeser Compressors, Inc.

2015 Kaeser Compressors, Inc.

customer.us@kaeser.com

Clean air. Its what we do.

From power gen to pigment, no matter the application, BHA from


CLARCOR Industrial Air has a solution. Backed by nearly 50 years of
experience, we are experts at improving operational performance and
reducing emissions. We deliver unparalleled support, from installation
to inspection to maintenance. We are a one-stop shop now offering
equipment solutions from United Air Specialists. With BHA from
CLARCOR Industrial Air, we provide answers, not just filters.
Get a free copy of our money-saving baghouse
troubleshooting guide at BHA.com

2015 BHA Altair, LLC. All Rights Reserved.

input #3 at www.plantengineering.com/information

June 2015
Volume 69, No.5

Cover image courtesy: Trelleborg Sealing Solutions

25 Lubrication Guide
A sound lubrication strategy requires finding the right product in the right formulation
for the specific use. Great strategic lubrication doesnt end there. A great plan includes
understanding when and why to look at your lubricant. Its also about understanding when
and why to lubricate and maintain your systems. A plan that lubricates too often wastes
time and money; a plan that lubricates too seldom risks equipment damage and downtime.

26 Green and gold in lubrication


While replacing all traditional hydraulic fluids with bio-fluids is not possible,
there is an increase in the use of such fluids. Care must be given in selecting
the right product for a specific application and to ensure that those products can
meet the same performance standard as traditional fluids.

30 The culture of lubrication


Lubrication is so integral to the success of so many plant processes that it is difficult to imagine it being overlooked, but the reality is that many have developed
the habit of not placing this valuable process on their priority list for scheduled
maintenance.

36 Unusual flush plans for mechanical seals


There are many manufacturers of mechanical seals and their overall strategies
appear similar: each desires to deliver safe products at reasonable cost. However, the business objectives of the very best mechanical seal manufacturers go
beyond the obvious. Their objectives are expressed in marketing approaches
which consistently represent value.

46 Plant Engineering Lubrication Guide


PLANT ENGINEERING (ISSN 0032-082X, Vol. 69, No. 5, 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 2015 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 additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@
cfemedia.com. 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: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST,
GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 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.

www.plantengineering.com

PLANT ENGINEERING

June 2015 3

LASER & PLASMA CUTTING

SHOT BLASTING

WELDING
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AND MORE

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input #4 at www.plantengineering.com/information

OO S LIKE A SAFE BECAUSE ITS


TM

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Automation Solutions

51 Lean production and automation


PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph 630-571-4070, Fax 630-214-4504

CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
630-571-4070 x2212, BVavra@CFEMedia.com
AMANDA PELLICCIONE, Director of Research
978-302-3463, APelliccione@CFEMedia.com

Is it possible to use automation and still be Lean? Newly


emerging manufacturing platforms that
utilize mechatronics concepts; powerful, intelligent, connected controls; and
even wireless technologies are changing
the equation by creating an entirely new
range of capabilities.

ANISA SAMARXHIU, Production Coordinator


630-571-4070 x2220, ASamarxhiu@CFEMedia.com

PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder & Publisher
630-571-4070 x2203, JLanghenry@CFEMedia.com
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630-571-4070 x2204, SRourke@CFEMedia.com
TRUDY KELLY, Executive Assistant
630-571-4070 x2205, TKelly@CFEMedia.com
ELENA MOELLER-YOUNGER, Marketing Manager
773-815-3795, EMYounger@CFEMedia.com
KRISTEN NIMMO, Marketing Manager
630-571-4070 x2215, KNimmo@CFEMedia.com
MICHAEL SMITH, Creative Director
630-779-8910, MSmith@CFEMedia.com
KATIE SPAIN, Associate Art Director
630-571-4070 x2218, KSpain@CFEMedia.com
PAUL BROUCH, Director of Operations
630-571-4070 x2208, PBrouch@CFEMedia.com
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
RICK ELLIS, Audience Management Director
303-246-1250, REllis@CFEMedia.com
LETTERS TO THE EDITOR
Please e-mail your opinions to BVavra@CFEMedia.com.
INFORMATION
For a Media Kit or Editorial Calendar,
e-mail Trudy Kelly at TKelly@CFEMedia.com.
REPRINTS
For custom reprints or electronic usage, contact:
Brett Petillo, Wrights Media
281-419-5725, bpetillo@wrightsmedia.com

Mechanical Solutions

57 VFD trends and solutions


for drive systems
The increase in variable frequency drive (VFD) installations
across the globe has meant that
drives are being applied in more
challenging system environments. Not only is the environment challenging, but drives also
have a few inherited issues that
can limit the overall system performance.

60 Dust collection
projects: 8 tips to ensure success
The implementation of a dust collection system offers many
benefits to a production facility including increased manufacturing effectiveness and a generally cleaner and safer work environment for employees. Given the positive impacts a quality
dust collection system affords, it would be nice if its installation
could go smoothly.

PUBLICATION SALES
Tom Corcoran, West, TX, OK
1111 W. 22nd St., Suite 250,
Oak Brook, IL 60523
Karen Cira, Southeast
879 Autumn Rain Ln.
Charlotte, NC 28209
Patrick Lynch, AL, FL
1111 W. 22nd St., Suite 250,
Oak Brook, IL 60523

TCorcoran@CFEMedia.com
Tel. 215-275-6420
Fax 484-631-0598
KCira@CFEMedia.com
Tel. 704-523-5466
Fax 630-214-4504
PLynch@CFEMedia.com
Tel. 630-571-4070 x2210
Fax 630-214-4504

Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com


246 South Franklin St.
Tel. 216-409-8314
Chagrin Falls, OH 44022
Fax 440-348-1980
Richard A. Groth Jr., NJ/ E. PA
12 Pine St.
Franklin, MA 02038

RGroth@CFEMedia.com
Tel. 774-277-7266
Fax 508-590-0432

Jerry Preston, West Coast


6746 E. Tyndall Circle
Mesa, AZ 85215

JPreston@CFEMedia.com
Tel. 602-369-3037

Stuart Smith, International


SSM Global Media Ltd.

stuart.smith@ssm.co.uk
Tel. +44 208 464 5577
Fax +44 208 464 5588

Electrical Solutions

64 Arc flash relays meet code compliance


In 2014, the National Electric Code was revised in multiple
areas. Changes to Paragraph 240.87 have made compliance simpler and less expensive.
One easy-to-apply device
can simplify meeting the
new requirements while
providing important
additional safeguards for
people and equipment.

PLANT ENGINEERING

June 2015 5

JUNE

www.plantengineering.com

Trending

New Products

Maintenance

Electrical

Mechanical

Energy Management

Arc Flash University Webcast:


Whats new with NFPA 70E?

As the NFPA 70E guidelines continue to be revised, it can be challenging for plant managers to
understand how the new requirements will affect their goal of operating a safe facility that also is
efficient. In the next session of Arc Flash University on June 18 at 1 p.m. CST, Plant Engineering
will explore the special questions that come up when manufacturers look to
implement or revise their NFPA 70E program to meet the new 2015 version
of the standard.
Among the topic areas are:
An overview of NFPA 70E changes for 2015
PPE and how to meet new requirements for personal protective
equipment
Practical equipment labeling approaches
The challenges faced in safety audits.
The presenter is Hugh Hoagland, senior consultant for ArcWear.
All Webcasts in the Plant Engineering series over the last year are available
on the Plant Engineering Webcast, www.plantengineering.com/Webcasts.

Top 10 articles at www.plantengineering.com

Our 10 most popular new stories from May can be found at www.plantengineering.com:
1.10 steps to achieve world-class manufacturing
2. Top safety concerns in the manufacturing industry
3. Preventing compressed air leaks: Taking a proactive approach
4. Study identifies 10 ways to improve supply chain efficiency
5. The promise and risks of IIoT and Industry 4.0
6. 12 ways to find time for maintenance
7. Pneumatic systems: 10 ways to save energy
8. Self-priming centrifugal pumps; What you need to know
9. The age of the control engineer is just dawning
10. Use your sense to build a proactive approach to maintenance

Apps for Engineers: General Engineering

Download these and many other Apps at: www.plantengineering.com/appsforengineers


CONVERT ANY UNIT FREE
A conversion application which intelligently helps users select the most likely units as they
import their data.
CONVERTER
This app allows the user to convert frequently-used units and currencies in an easy way. The
conversions are based on ISO and ASTM standards.
COOPER BUSSMANN FAULT CURRENT CALCULATOR
The Fault Current Calculator (FC2) app is designed for calculating available fault current levels
in single- or three-phase electrical systems.

6 June 2015

PLANT ENGINEERING

Plant Automation

Safety

People and Training

Engineering eNewsletters
Stay in touch with
changes in the
industry, including
news, articles, and
product updates.
eNewsletters include:
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Connection, PlantMail,
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Safety & Security, Product & Media
Showcase, and Whitepaper Connection.
Subscribe to one or more eNewsletters at:
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Read this on your tablet


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include interactive tools
such as videos, Web
links, and other items.
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and receive the digital
edition in your e-mail in-box:

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Upcoming webcasts
Register for educational webcasts at
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July 14: Integrated Drive Systems Ensures
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Predictive. Preventive. Productive.


Introducing an integrated team of tools that work
together to check, detect, isolate and report.
See MORE with the Fine Resolution capability
of the TrueIR Thermal Imager. Do MORE with
the durable Insulation Resistance Testers and
reach MORE with the Remote Link Solution
powered by the Bluetooth adapter and
remote logging display. Keep things running
faster and more efciently than ever before.
Find insights with this predictive and
preventive maintenance solution.

Keysight U5855A
TrueIR Thermal Imager

Keysight U1450A/60A Series


Insulation Resistance Testers

Keysight Remote
Link Solution

320x240 Fine Resolution, from


160x120 pixels detector resolution

Wireless testing and


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Measurement distance:
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4x digital zoom

Insulation resistance:
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Supports up to 20 models of
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View objects as close as


10 cm away

Adjustable test voltages:


10 V to 1.1 kV

Supports iOS and Android


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Thermal sensitivity:
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4.5-digit full-featured OLED


digital multimeter

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monitoring and logging

Find out more. Video available here:


www.keysight.com/find/PMinsight
USA: 800 829 4444

CAN: 877 894 4414

Keysight Technologies, Inc. 2014


Bluetooth and Bluetooth logos are trademarks owned by Bluetooth
SIG, Inc., USA and licensed to Keysight Technologies, Inc.

input #5 at www.plantengineering.com/information

CONVEY

DUMP
FLEXICON Manual
Dumping Stations allow
dust-free dumping of bulk
material from bags and other
containers. Automatic reversepulse filter cleaning allows
continuous, efficient
operation. Available
with integral bag
compactors for
total dust
containment.

FLEXI-DISC Tubular Cable


Conveyors gently slide fragile
foods and non-foods through
smooth stainless steel tubing
routed horizontally, vertically
or at any angle, over short
or long distances, dust-free.
Single or multiple
inlets and
outlets.

CONDITION

FILL

BLOCK-BUSTER Bulk Bag Conditioners


loosen bulk materials that have solidified
during storage and shipment. Variable height
turntable positions bag for hydraulic rams
with contoured conditioning plates to press
bag on all sides at all heights.

SWING-DOWN , REAR-POST
and TWIN-CENTERPOST
Bulk Bag Fillers can fill
one bulk bag per week or
20 per hour at the lowest
cost per bag. Numerous
performance options.
Available to industrial
or sanitary
standards.

CONVEY

DUMP

PNEUMATI-CON
Pneumatic Conveying
Systems move a broad
range of bulk materials
over short or long
distances, between single
or multiple inlet and
discharge points in low
to high capacities.
Available as dilute-phase
vacuum or positive
pressure systems, fully
integrated with your
process.

USA
sales@flexicon.com
1 888 FLEXICON

TIP-TITE Container Dumpers


dump bulk material from drums
(shown), boxes or other containers
into vessels up to 10 ft (3m) high.
Dust-tight (shown) or open chute
models improve
efficiency and
safety of an
age-old task.

CHILE
UK
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SINGAPORE
SOUTH AFRICA

UNLOAD
BULK-OUT Bulk
Bag Dischargers
unload free- and
non-free-flowing
solids from bulk
bags automatically.
Allows untying,
discharging, retying
and collapsing of
bulk bagsall
dust-free. Available
with weigh
batching controls.

CONVEY
FLEXICON Flexible Screw
Conveyors transport free- and
non-free-flowing bulk solid materials
from large pellets to sub-micron
powders, including products that
pack, cake or smear, with no
separation of blends, dust-free
at low cost. No bearings contact
material. Easy to clean
quickly, thoroughly.

SUCCEED
The FLEXICON Lifetime Performance
Guarantee* assures you of a successful
result, whether you purchase one piece of
equipment or an engineered, automated
plant-wide system. From initial testing in
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after-sale support by a
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factory experts, you
can trust your process
and your reputation
to Flexicon.

+56 2 2415 1286


+44 (0)1227 374710
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+61 (0)7 3879 4180
+65 6778 9225
+27 (0)41 453 1871

input #6 at www.plantengineering.com/information

DD-0633

2015 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
*See full Lifetime Performance Guarantee for details.

IN FOCUS

5 tips to make HVAC


maintenance more effective
By Timothy Robb
Goodway Industries

When it comes to plants and facilities,


HVAC systems play an important role in
making sure the building stays at the right
temperature and humidity levels. But, like
any equipment, they can also become a
major headache if something goes wrong.
Preventive maintenance is key to keeping HVAC systems running effectively
and efficiently.
Although many facility managers find
themselves implementing reactive maintenance rather than proactive due to time
and costs, a variety of tools and products
can lighten the burden and make routine
maintenance a quick and easy task that
saves money in the long run.
Here are five tips to help ensure
the success and effectiveness of your
facilitys HVAC maintenance plan:

1. Make sure that you have the right prod-

standing how to use maintenance equipment correctly will save a company time,
since the job can be done correctly the
first time. Just as important, it can reduce
the risk of injuries due to operator error,
thereby saving the company money as
well. When purchasing new equipment,
many vendors will provide on-site training
as part of the purchase if it is requested.

3. Have a maintenance plan for each


HVAC system. Spending a little on regular
HVAC maintenance will save you a lot on
repairs and life of the equipment in the long
run. First, make sure your facility has a plan
that includes and schedules time for HVAC
maintenance at least annually, if not twice
a year, between heavy-use seasons. Having
a maintenance plan in placeand sticking to ithelps prevent unexpected and
costly breakdowns, outages, and repairs.
Also known as a preventive maintenance
plan for the abovereasonsabove reasons,
cleaning and maintaining the systems
also results in better energy efficiency.

ucts for each maintenance need. When the


proper tools arent used to complete maintenance tasks, they end up doing more harm
than good. For example, you wouldnt use
a saw to hammer in a nail, so why use a
pressure washer to clean coils? Pressure
washers risk damaging delicate coil fins,
potentially causing the need for repairs that
would cost more time and money than if
you used a coil-cleaning machine, which is
specifically designed to clean coils. Some
tools even allow clean-in-place maintenance to enable less downtime. Facility
managers want to make sure their time
spent maintaining equipment is effective
and productive. Its important to invest in
the right products to save time and money
and reduce the risk of damage and waste.

4. Maintain an operating log. A neglected


tool in the plant maintenance toolkit is an
operating log. These logs help track information related to the systems operation.
Most commonly used for
chillers, operating logs
should help you monitor
temperature, pressure, and
fluid level. When readings
outside the norm occur,
maintenance or repairs
may be needed. Operating
logs are also a helpful way
to track trends, measure
improvements, and compare data year-over-year.

2. Ensure employees receive proper


training on the maintenance equipment.
Training on how to properly conduct
maintenance and clean HVAC equipment should be included in any new
employees onboarding process. Under-

5. Measure efficiency
gains. Measurement is
an often overlooked or
skipped task, because
it takes extra time and
determining what and how

www.plantengineering.com

to measure may be hard to figure out if


you dont have a plan in place. In fact,
a recent survey conducted by Goodway
Technologies revealed that only 39% of
the 255 respondents measure the efficiency
gains resulting from chiller cleaning. However, HVAC systems make up some of the
plants largest operational expenses. Measuring the gains in energy efficiency as a
result of regular maintenance shows the
impact of the facility managers work in a
way thats meaningful to upper management: cost savings.
When you make sure your facility management team has purchased and been
trained to use proper equipment, uses an
operating log, and performs maintenance
on schedule, your plants HVAC systems
will show positive returns. PE
Timothy Robb is director of marketing at Goodway Technologies, a global
manufacturer of industrial maintenance
solutions used by facilities and plant
maintenance personnel.
Preventive maintenance is key to keeping HVAC systems running effectively
and efficiently. Image courtesy: CFE
Media

PLANT ENGINEERING

June 2015 9

IN fOCUS

Use your senses to build a proactive


approach to maintenance
When touring your plant floor, make sure to get close to your equipment.
By Scott Hoff
Life Cycle Engineering

My former boss liked to say, If you keep doing the


same thing but expect different results, thats insanity. Doing firefighting maintenance and hoping for
a different outcome, thats insane. The issue might be
financial: Theres no money in the budget to buy a vibration analyzer (or some other predictive tool). Another
common roadblock is: I dont have enough manpower
to do proactive maintenance.
Dont let budget woes or limited manpower drive total
insanity in your workplace. You can uncover a lot of
problems or potential problems just by using your senses.
Start by doingwith the basics: look, listen, touch, and
smell. Here are some examples from a recent visits to
a
client site.
EIG-020 Power & Consult 6/1/15 4:05 PM Page 1

Power Quality Metering


& Energy Management

Nexus
1500+

Power Quality
Metering
Measure and record harmful
power quality events
Conduct harmonic studies
Understand feeder
efficiency & load balance
Create automated power quality reports

Energy
Management

Low energy usage at each circuit


Calculate coast allocation
to different processes
Control loads to reduce demand
Generate automated
energy reports for executives

1- 877-EIMETER | www.electroind.com

input #7 at www.plantengineering.com/information

A proactive maintenance approach begins by using your


basic senseslook, listen, smell and touch. Image courtesy:
CFE Media

Standing next to a furnace, I just happened to lay


my hand on the control panel and I felt a vibration. I
asked, Do you know this piece of equipment has some
vibration that doesnt feel right? The reply: No, but
Ill have my guys check it out. The guys discovered
the fan cage had moved on the shaft, and the support
bearings were not supporting much.
While walking around, I asked about a leaking gearbox. What gearbox are you talking about? the supervisor asked. We walked out to the line and I showed
him. It felt a little warm, too. They took a temperature
check and compared it to a similar gearbox on a very
similar conveyor. The original gearbox temperature
was almost 30 degrees F higher.
We looked at an assembly station, and I asked about
the pile of dusty stuff on the base of a machine. The
reply: Im not sure where its from. I didnt know
either, but I would have someone look into it before
it becomes an issue that relates to some unplanned
downtime.
The site had installed some nice digital temperature
and level indicators on a hydraulic unit because of an
issue they had experienced. I asked what the temperature
range should be. Im not sure, was the response. We

10 June 2015

plant engineering

input #8 at www.plantengineering.com/information

IN FOCUS
asked the line tech and he wasnt sure either. At the same
time, I inquired about the level indicator reading. The
answer was the same. Someone had recently filled the
unit, because the oil level was so high you couldnt see
it in the sight glass. Plus, the hydraulic unit was running.
This might present an opportunity to improve training.
Walking the maintenance area, we observed at least
seven large workpiece carriers lying in a pile on a cart.
Do you think the line needs these? I asked. It turns
out, the line was ordered with 30 workpiece carriers.
Those carriers in the pile accounted for almost 25% of
the carriers from the line. I was sure it had an impact on
the output of the assembly line. The response: Well
get someone on it.
You can begin a proactive maintenance approach by
using your basic senseslook, listen, smell and touch.
Act on what you discover, and improve what needs fixing. Small things can make a huge difference. PE
Scott Hoff is an asset management services technician with Life Cycle Engineering. He has more than
35 years of experience in roles including maintenance
mechanic, engineering technician, and maintenance
supervisor/planner. You can reach him via his email at
shoff@LCE.com.

PMI rebounds to 52.8% in May


By Bob Vavra, Content Manager, CFE Media

Reversing a two-month decline, the Institute for Supply Managements PMI Index for May climbed 1.3 percentage points
to 52.8%, as industry experts saw signs of strengthening in the
manufacturing sector.
The index had fallen to a 12-month low of 51.5% in both March
and April, but members of the ISMs Manufacturing Business
Survey Committee saw a stronger overall economy emerging in
May. Comments from the panel carry a positive tone in terms
of an improving economy, increasing demand, and improving
flow of goods through the West Coast ports, said committee
chairman Bradley Holcomb. Also noted, however, are continuing concerns over the price of the U.S. dollar and challenges
affecting markets related to oil and gas industries.
All the indices supporting the PMI Index were up significantly
in May. The New Orders Index rose 2.3 percentage points to
55.8%, the Production Index climbed 1.5 percentage points to
54.5% and the Employment Index climbed back above the 50%
growth barrier, rising 3.4 percentage points to 51.7%.
Committee members expressed concern over the strong U.S.
dollar and its impact on global trade. Among the comments:
Economy is showing signs of improvement. (Food, Beverage & Tobacco Products)
Automotive is still strong. However, steel prices have
dropped due to overcapacity and the strong U.S. dollar.
(Fabricated Metal Products)
Overall business is steady. Employment in this area is up,
a good sign. (Transportation Equipment)
The exchange rate on the dollar is hurting our sales in Asia.
The conversion rate is lowering our profit in Europe where
we sell in Euros. (Computer & Electronic Products)
Continued challenges in markets related to oil and gas industries. (Miscellaneous Manufacturing)
Oversupply is continuing to tighten profit margins. (Wood
Products)
West Coast port issues have eased up and our incoming
imports are flowing again. (Machinery)
The PMI reached a milestone in May as well. The Index
marked six consecutive years above the economic growth level
of 43.1%. The overall manufacturing sector growth level of 50%
was reached for the 29th straight month.

PMI on the rebound


Here are the last six months of PMI Index figures:

input #9 at www.plantengineering.com/information

December 2014

55.1%

January 2015

53.5%

February 2015

52.9%

March 2015

51.5%

April 2015

51.5%

May 2015

52.8%

12 June 2015

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input #10 at www.plantengineering.com/information

IN fOCUS
Become an employer of choice
Strategies to attract and retain manufacturing employees
By Traci L. Fiatte, Randstad Staffing

As manufacturers map their 2015


workforce plans, a key activity will be
assessing the mechanisms they use to
attract new talent and retain key players.
An effective talent acquisition and retention program helps organizations shore
up the skills gap and minimize the negative effects of employee turnover, such as
increased overtime costs, expanded cycle
times, more frequent downtime, and other
related soft costs.
In todays hiring atmosphere that
increasingly favors candidates, employers who can quickly appeal to and hire
new workers will be better positioned
to maintain productivity as their teams
respond to staffing vacancies. The ideas
presented below can help hiring managers
improve workforce stability and impact
the organizations bottom line.

Know the hiring landscape

The Society for Human Resource


Managements February 2015 LINE
Employment Report confirms that manufacturers continue to fuel a strong hiring landscape, with about half (50.5%)
saying they plan to add staff. This
optimistic hiring projection followed
January 2015s 17.2-point increase in
recruiting difficulty when compared to
the same month in the previous year.
Additionally, Randstads Manufacturing & Logistics Employee Confidence
Index (a measure of U.S. manufacturing workers overall confidence in the
economy, job market, and their personal
employment situations) hit a historic high
in the fourth quarter of 2014. Workers
also showed growing confidence in their
ability to find a new job, another indication of the candidate-driven job market
and the potential for growing competition
among employers for top talent.

Know the hot jobs

Knowing the industrys most in-demand


and hardest-to-find skillsets is knowledge
that helps inform what strategies and
company offerings will best secure scarce
talent resources.

14 June 2015

plant engineering

For example, Randstad expects expanded


opportunities for forklift operators, production supervisors, and quality-control
technicians over the next 12 months. By
anticipating higher competition for these
roles, employers can better position both
their offers and employer brands for highest appeal to potential employees.

The money strategy

Although increased pay remains a highly


persuasive recruiting tool, its not realistic
for most organizations to raise salaries
across the board. However, the strategic use of financial incentives can be
extremely effective when recruiting for
hard-to-fill positions.
For example, weve seen manufacturers increase starting pay by $1.50/hour to
bring on an experienced forklift operator.
Pay increases also help managers retain
top staff members who are already trained
and producing.
According to recent Randstad research,
manufacturing and logistics employers
clearly indicate that salary increases are
the most effective tool to decrease turnover
rates. Of the 10 industry segments that participated in the Randstad study, manufacturers felt strongest that bonuses are highly
effective at heightening employee retention.

Motivations beyond money

To successfully contend for top candidates, manufacturers will not only need to
assess the competitiveness of their compensation packages, but also the strength
of their employer brand and overall workplace environment.
A recent Randstad employer branding
study found that when rating the criteria
that influence their choice of an employer,
respondents first selected salary and benefits, followed by long-term job security
and a pleasant work atmosphere. Both of
the latter components are slightly more
important to candidates over the age of 35
and those without a college degree.

Keep experts on board longer

Retiring baby boomers combined with


a looming skills gap presents significant
challenges to manufacturing employ-

ers. Because an organizations tenured


employees are often involved in training
less experienced staff, retaining those
experts past eligible retirement age can
help assure that appropriate knowledge
transfer occurs as employees transition
through their careers.
When Randstad recently asked companies if they tailor their retention programs
to generational preferences, 51% of manufacturing hiring managers replied in the
affirmative. This indicates an opportunity
for many organizations to finesse this piece
of their retention strategy.
For example, our employer branding
research shows that a more relaxed work
schedule and friendly work atmosphere are
two top conditions motivating employees
to work beyond their anticipated retirement
schedules. Investigating tenured employees desires around company flexibility and
discussing options with those approaching
retirement may be a worthwhile effort for
organizations looking to shore up current
and future workforce needs.

Wooing the younger generation

Refining workforce strategy along generational lines is particularly important to


attract the youngest generation of workers
(Generation Z), who have distinct inclinations related to topics such as workplace
environment, employee benefits, and
means of communication.
Randstad recently conducted a worldwide study on the workplace preferences of
Gen Z (16- to 20-year-olds), which reveals
a number of interesting trends of the incoming workforce. For example, Gen Zs say
the opportunity for advancement is the No.
1 factor motivating them to work hard and
remain with their employers. Like many
generations before them, medical coverage
is the top benefit they expect to receive as
employees.
Gen Zs also prefer to talk to their managers in person (versus email, for example),
and they are very interested in connecting
with a workplace mentor, which reinforces
the notion of retaining tenured talent. PE
Traci L. Fiatte is group president of
Randstad Staffing.
www.plantengineering.com

input #11 at www.plantengineering.com/information

IN fOCUS

The promise and the risks


of IIoT and Industry 4.0
Ubisense VP discusses the need to go slow in moving manufacturing
away from manual systems to an integrated production system.
The concept of the Industrial Internet of Things (IIoT) and its European
equivalent, Industry 4.0, continues to
grow. The promise of these strategies
is to bring data together to deliver
actionable results and improve productivity, but the reality of plants
today is that there is widely disparate
use of sensors and monitors. Many
other plants simply arent that far
along in the manufacturing process.
A recent study by Ubisense, a global
enterprise software solutions company, found there is a continued use of
manual systems in plants. Among the
findings of the study:
40% have no visibility into the
real-time status of their companys
manufacturing process.
More than 80% rely on human
observation to support process
improvement initiatives.
85% of quality issues are caused
by worker errors.
Nearly 10% of manufacturers
spend half their day looking for
equipment and products.

Almost 15% of manufacturers


dont prioritize product repairs.
Adrian Jennings, vice president of
manufacturing industry strategy for
Ubisense, discussed the studys findings and its implications for discrete
manufacturing with CFE Media:

CFE MEdia: You work with a lot

of customers in all areas of manufacturing. Were there any surprises


from the results of the study?

JEnnings: On the face of it, the


survey was somewhat surprising:
10% of respondents waste at least
half of their day searching for lost
items; 40% have no real-time process visibility; and 50% dont keep
fastener tightening records.However,
the reality is that this reflects my
experience when visiting all kinds
of assembly plants globally.
I think people have a general
belief that assembly plants are rather
advanced technologically, and thats
just not the case. The picture people
imaginetypically involves legions of
robots happily welding and spraying
in high-volume car
plants. But out there
on the assembly line,
and in other, lower
A recent study found
40% of manufacturers
have no visibility into
the real-time status
of their companys
manufacturing process
and that 85% of quality
issues are caused by
worker errors. Image
courtesy: CFE Media

16 June 2015

plant engineering

volume plants (tractors, backhoes,


street sweepers, Dreamliners) the
scene is quite different. The reality
is that manufacturing plants are still
dominated by manual processes and
in that light, the survey results are
not surprising at all.

CFE: What are the biggest barriers for manufacturers to implement


Industry 4.0? How many of those
barriers are human and how many
are financial?
JEnnings: I should preface my
answer by saying that I dont think
anybody in the automotive vertical is implementing Industry 4.0
today, and precisely because there
are some formidable barriers. Its
tempting to think of any kind of computer controlled process as Industry
4.0 since weve been persuaded to
believe that 4.0 is all about cyberphysical systems. But we are also
told that Industry 3.0 refers to the
introduction of microprocessors and
computerized controland what is
that if not a localized cyber-physical
system?
I think its critically important to
understand that Industry 4.0 is about
scale of integration, which is why it
is wrapped up with the Internet of
Things. The underlying paradigm
shift is that people will have realtime, detailed knowledge of the status
of the entire value chainfrom order
to fulfillmentso that production
can be agile and reactive to different issues and drivers.
With that definition, I think there
are four critical barriers to Industry
4.0 adoption: networks, security,
skills and culture. Perhaps networks
and security go hand in hand since
www.plantengineering.com

input #12 at www.plantengineering.com/information

IN fOCUS
they are closely related. In terms of networks, in order
to crunch data based on widely distributed process sensors, you need the network infrastructure to get all that
data to one location.
The first problem is getting it from line side to a
server, and thats no small task. Wireless networks today
are not widely used in mission-critical applications since
they are not robust enough, and wired networks are costly
to install. Many plants just dont have the infrastructure
to distribute data inside the plant, let alone between
plants and suppliers on a global basis.

I think people have a general belief


that assembly plants are rather
advanced technologically, and
thats just not the case.

Its at that level that security concerns become an


issue too: Industry 4.0 requires high-bandwidth, lowlatency, mission-critical reliability over global, secure
networksnetworks built and managed by Telecom
operators outside of the control of automotive OEMs.

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CFE: For your customers already implementing


Industry 4.0, where have they seen the biggest benefits?

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The IT challenge is critical, and its not simply financial. The vast majority of plants are shop-floor driven
with strategic direction on control systems driven by
process engineers on the line. IT is a supporting function and is rarely seen as an area for investment in its
own right.
Industry 4.0 is a seismic shift; it is without question
the IT-ification of manufacturing. If the production
process is truly to be driven by real-time intelligence
from sensors throughout the supply chain, then IT will
take on a central, leading role all the way to the devices
on the line. Thats a big shift in thinking for most people
and requires a long-term view of IT infrastructure as a
strategic investment rather than the incremental cost of
any controls project.
The other cultural issue is about willingness to change.
Industry 4.0 is truly a revolutionary idea and it will
open up huge opportunities for people ready to embrace
it. Lets remember though that it is not about technology adoption; the technology is simply a tool. Rather,
Industry 4.0 is about a whole new way to approach
production, and the automotive industry is rightly cautious about big new ideas.
When you are pushing out 400 cars in a single shift
or bolting wings on an airliner, theres no room for
risk-taking, and that breeds a healthy level of caution.
Industry 4.0 will shatter long-held notions about how
to control processes and create a level of flexibility
that goes against generations of experience. Technology
adoption alone cannot change the bottom line unless
the potential for change is embraced throughout the
organization

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JEnnings: I mentioned that I dont think anyone in


automotive manufacturing is fully adopting Industry 4.0
yet, but many are on the path. I want to make a distinction between the end-to-end cyber-physical systems of
Industry 4.0, and local cyber-physical systemsthat are
adding value to a single process or physically close set
of related processes. Lets call these cyber-physical
islands and frame them either as advanced Industry 3.0,
or embryonic Industry 4.0 depending on your preference.
Ubisense is certainly in the business of enabling cyberphysical islands and our customers are seeing big benefits as a result. There are many examples, so Ill just
pick two to illustrate the point:
One of our solutions virtualizes the product identification processa common function required at many
locations along an assembly line. Traditionally, this is
performed either manually, using barcode scanners, or
automatically, using RFID or other fixed infrastructure.
Continued on page 20

.com

input #13 at www.plantengineering.com/information

18 June 2015

plant engineering

Smart factories need


smarter supply chains
Automated manufacturing facilities will require
higher levels of logistics integration
By Charlie Chung, UPS

Its been just three years since Germanys Federal Ministry of Education and
Research coined the term Industry 4.0
to describe a manufacturing and assembly
process closely aligned through interconnected machines. Also known as the Fourth
Industrial Revolution, the next evolution of
manufacturing has arrived with the promise of increased efficiency, productivity,
and quality control achieved by synchronizing industrial automation equipment to
perform at levels seldom seen today.
Everything from fixtures and assemblies
to complex finished goods production can
benefit from Industry 4.0. Business size
and complexity is no longer a barrier to
using industrial automation equipment that
speeds production and improves quality
control.
According to the Robotic Industries
Association (RIA), the number of robot
units ordered from North American companies increased 28% from 2013 to 2014.
The number of robots shipped to North
American companies increased 13% in
the same period.
When that time comes, the visibility of
inbound and outbound supply chains will
be put to the test. Factories will need higher
levels of visibility for inbound raw materials and parts to protect against materials
shortages. Outbound order-tracking will
become more important as production
schedules are further refined to align the
assembly process, manage multiple production and distribution locations, meet
customer deadlines and just-in-time delivery, and minimize overproduction.

The industrial Internet of Things

Wholesalers, retailers, and consumers


also will be impacted by these technological advancements. Data currently available through smart labels, for example,
will continue to be captured and tracked.
Their role will become increasingly
important at every phase of the manufacturing and distribution process.
www.plantengineering.com

Custom approaches come standard

Automating production lines will require


a more complex system of sensors and
control software that synchronize the
facilitys machinery. In addition to a
single machines ability to detect small
reductions in performance, the adjoining
machines also would be able to detect
variations in production or assembly
performance, based on the speed that
items are dispatched from one machine to
another in the assembly line.
This machine-to-machine, or networked,
communication makes the fully automated
system substantially more powerful than
the individual machines.
The higher level of efficiency should
require additional emphasis on the facilitys
preventive maintenance and service programs. Service agreements will no doubt
evolve with more stringent requirements for
responsiveness and reduced unplanned service outages. In turn, increased importance
will be placed on field stocking locations
and ready access to skilled technicians who
are well-equipped to keep production online. As part of this, when the automation
sensors and control software detect reductions in machine performance, they would
alert the system manager of unplanned
maintenance before an issue arises.
In many places where preventive maintenance is critical to operational efficiency,
including UPS, these technologies and
processes are already in use. The experience of these industry pioneers will help
incorporate Industry 4.0 technologies and
practices into the marketplace.
The flexibility and operational efficiencies promised by smart manufacturing will
revolutionize manufacturing and distribution processes as we know it. As the speed of
business continues to accelerate, it will most
likely be sooner than many people expect. PE
Charlie Chung is the industrial assemblies and machinery marketing manager
for the Industrial Manufacturing and
Distribution segment at UPS.
PLANT ENGINEERING

June 2015 19

input #14 at www.plantengineering.com/information

IN fOCUS
When you are pushing out 400 cars in a single

Continued from page 18


By removing barcode scanners, our
customers have eliminated a significant amount of process waste, enough
to actually reduce the number of
workstations on the line.
By doing away with fixed ID infrastructure, other customers have been
able to significantly reduce the cost
of line rebalancingthe continual
process-shuffling burden that always
has engineers working the weekends.
Another solution completely virtualizes the entire workstation, creating process control zones in software
that attach themselves to the product
and entirely replace the traditional
fixed workstation. Once virtualized,
the workstation can vary in real time
in reaction to product variation,
task overrun and many more of the
increasing number of variables in
plants.
One customer has benefited from
the ability to give workers a few extra

shift or bolting wings on an airliner, theres


no room for risk-taking, and that breeds a
healthy level of caution.

seconds of process time when needed,


avoiding a large number of short line
stops throughout the day. Another has
used the idea of a virtual workstation
to create overlapping processes, with
one new third-row seat process riding
on top of three existing processes.

CFE: Talk about the challenges for


manufacturers trying to deal with
the issues of Big Data. How can they
do a better job of managing data
to better understand the metrics?
JEnnings: Big data analytics is
a skill set that simply doesnt have a
foothold in most plants. Until now,

data analysis has been at the local


level, often constrained to single
processes or a small set of related
processes. The data analytics tools
are also non-specialized you only
have to look at the printouts on
most plant notice boards to realize
that Microsoft Excel is the leading
analysis tool. Finding trends and
triggers in a mountain of seemingly
unconnected data is a very different
challenge, more in the domain of the
NSA than manufacturing.
Manufacturers will have to decide
whether to outsource their analytics
(creating another layer of cybersecurity issues) or hire a whole new
skillset from other industries. Both

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input #15 at www.plantengineering.com/information

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options have their challenges, but


probably outsourcing is the farther
reach: software-as-a-service and
analytics-as-a-service sound reasonable, but if Industry 4.0 is to
be embraced in all its end-to-end,
real-time connectedness, then production-planning-as-a-service and
process-control-as-a-service will
have to be considered, too. The implications for cybersecurity and performance SLAs under such a model are
immense.

CFE: If a manufacturer is looking


to implement 4.0, whats the first
thing he should do?

JEnnings: Stop! I joke, but only


partly. Industry 4.0 comes with a
warning: choking hazard. It is a very
big thing with potentially huge benefits and my advice is to try to swallow
it in bite-sized chunks. I talked about
cyber-physical islands and, whether
you consider those to be late-stage
Industry 3.0 (like I do) or early-stage
Industry 4.0, they are absolutely the
correct stepping stones that people
should be considering today.
You dont need real-time process
data from your Tier 2 supply base in
order to make great strides in quality and throughput in the plant. A
growing number of available solutions apply sensors to islands within

the plant and deliver a strong ROI


through process visibility and smart
controls. These solutions can be
fairly large projects with similarly
large ROIs, but they can be managed
locally and with no dependence on
third parties for networking, cybersecurity and data analytics.
My advice is this: build your
cyber-physical islands today, and
connect them all tomorrow. Once
these islands are running and creating
value, the impetus to connect them
together will be strong, and the ROI
obvious. Before then, the end-to-endconnectedness-of-all-things simply
holds great promise and high risk. PE

Manufacturers will have to decide whether to outsource their

analytics (creating another layer of cybersecurity issues) or hire a whole


new skillset from other industries.

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Shutdown frequency to maintain


standard machinery

research

Dont know
23%

Yearly
26%

Quarterly
14%

2014 SAFETY STUDY:

Every other
month
20%

6 safety findings from


smaller facilities

f the respondents to the Plant


Engineering 2014 Safety
Study, 56% work at a manufacturing facility with fewer
than 250 employees. Here are six highlevel findings from this data segment:

1. Safety commitment: More than


half of respondents confidently report
that their plant workersline workers,
line supervisors, operations management, and senior managementare
very committed to safety within their
facility.
2. Work group safety: 80 precent of
respondents believe their plant management and corporate executives feel
very safe on a daily basis, yet only 54%
think their line workers feel just as safe.
3. Safety program benefits: As direct
results of their plants safety programs,
the vast majority of respondents said
their employees feel safe on the job
(96%) and feel respected by management (80%), cost of injuries has
decreased (84%), cost of insurance
claims has decreased (75%), and productivity has increased (83%).

4. Enforcing safety: Seven in 10

respondents facilities host regular


safety meetings, have an appointed
safety committee, perform safety
audits, and/or reprimand safety violations with suspension, termination, or
other forms of discipline.

5. Safety meetings: 48 precent of

facilities hold monthly safety meetings, compared to 22% weekly, and


19% as needed. The most heard
voices during these meetings are
operations (65%), safety executives/
managers (65%), maintenance (62%),
and plant management/corporate
managers (60%).

6. Measuring success: The top methods respondents plants measure safety


success are recognizing a decrease in
OSHA recordables/time-lost accidents
(84%), being able to lower workers
compensation costs (58%), and lowering insurance premiums (42%).
View additional findings at
www.plantengineering.com/2014Safety.
Amanda Pelliccione is research director for Plant Engineering, CFE Media.

Twice a year
17%

27%

of plant workers agree


that having employees understand the goals and objectives
is a serious challenge with their
energy management program.
Source: Plant Engineering 2014
Energy Management Study

6% of plant engineers report


their current workforce shortage is directly related to the
expansion of manufacturing and
lack of financial resources to fill
positions. Source: Plant Engineering 2014 Workforce Development Study

3 in 5 facilities have one


safety executive or manager in
charge of implementing safety
strategies. Source: Plant Engineering 2014 Safety Study

Plant employees yearly safety training


Facilities with <250 employees

None
Job-related safety

21- 40 hours

74%

MORE RESEARCH

Dont know

68%

19%

6%

> 40 hours
19%

61%

4%

Ergonomics

First-aid/personal safety

1- 20 hours

12%

14%

2%

7% 4%

2%

5%

3%

Plant Engineering surveys its


audience on five topics each
year: salary survey, maintenance, energy management,
safety, and workforce development. All reports are available at
www.plantengineering.com/research.

Source: Plant Engineering, CFE Media

22 June 2015

PLANT ENGINEERING

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input #18 at www.plantengineering.com/information

2015 Lubrication Guide


A sound lubrication strategy requires finding the right product in the right formulation for the
specific use. Great strategic lubrication doesnt end there.
A great plan includes understanding when and why to look at your lubricant. Its also about
understanding when and why to lubricate and maintain your systems. A plan that lubricates
t often
ft wastes
t time
ti andd money; a plan
l that
th t lubricates
l b i t too
t seldom
ld risks
i k equipment
i
t damage
d
too
a d downtime.
do
e
and
0 5 Pl
i
i g Lubrication G
Thee 2015
Plant EEngineering
Guide will provide you with a comprehensive look at
h available
il bl lubricants,
l bi
h list
li begins
b i on Page
P
B this
hi years
guide
id also
l considers
id
the
andd that
46. But
the important issues off environmental impact off oils, greases and ffluids, the need ffor a
sstrong culture off lubrication excellence, and an in-depth look at some of the new stand
dards
in bearings
g and seals..

26
30
36

46

G
Green
and gold
g
in lubrication
n
T e culture
The
cu u e of
o lubrication
ub ca o
Unusual fflush plans ffor mechanical seals
Plant Engineering
g
g Lubrication
ub ca o Guide
Gu de

LUBRICATIONGUIDE

Green and gold


in lubrication
Environmentally friendly fluids and sealing systems offer a new perspective.
By Joe Savina
Trelleborg Sealing Solutions

he development of biodegradable
engine oils, hydraulic fluids, and
other lubricants provides a safer
alternative to traditional fuels,
especially in environmentallysensitive areas.
For example, in order to mitigate the
costs associated with petroleum spills,
many offshore operators are using or considering environmentally safer products.
These types of fluids can protect the users
against cleanup costs, downtime and potential fines.
While replacing all traditional hydraulic
fluids with bio-fluids is not possible, there
is an increase in the use of such fluids. Care
must be given in selecting the right product
for a specific application and to ensure that
those products can meet the same performance standard as traditional fluids.
Equipment operators may prefer biodegradable hydraulic fluids, and fluid manufacturers are meeting these demands as they
add new fluids and formulations based on
low toxicity. While this is important, it is
also crucial that the hydraulic component

and system manufacturers are able to ensure


that the products they provide are useful
and compatible with fluids and account for
the end users requirements.
Education for system designers combined
with the cooperation between seal and fluid
manufacturers is really crucial to successfully navigate such a complicated web of
chemistry interactions.

Complex formulas

Hydraulic fluids and seal materials are


similar in that both are extremely complex
and variable in regards to their formulation. You will never hear a manufacturer
of either say that their formulation is
identical to another supplier, and it should
never be taken for granted by the equipment supplier that they are.
Inside the very familiar group of materials called NBR (nitrile butadiene rubber)
are thousands of different formulations
that have been compounded differently for
a multitude of reasons. Those reasons can
relate to desired material capabilities such
as temperature or chemical resistance, they

Education for system designers combined with the cooperation between seal and fluid manufacturers is really crucial to successfully navigate such a complicated web of
chemistry interactions.
26 June 2015

PLANT ENGINEERING

www.plantengineering.com

might be related to manufacturing concerns such as mold flow and cure time, and
they are most certainly affected by cost.
To pick up any 70 Shore A NBR from
one company and assume it will function
the same as the 70 Shore A NBR from
another company is a mistake that can lead
to serious consequences in your application. The same holds true for hydraulic
fluids.
Environmentally friendly hydraulic
fluids, as with all hydraulic fluids, have
considerable variation in their formulations not only in the selection and blending
of the base stocks but also in the variety
of additives that can be chosen to get the
necessary properties.
The dozen or so additives are considered
proprietary and for the most part are going
to be kept secret as long as required regulatory tests are passed and performance
requirements are met.

Collaboration is key

Customers who turn to their suppliers


with an application in which they require
a biodegradable fluid find that it is usually because the end customer has specified the fluid. It is in this scenario that
suppliers need to collaborate with their
customers in trying to determine seal
material depending on the fluid type. In
addition to working with the customer,
suppliers should also be working with
fluid manufacturers to develop a mutual
understanding of how seals behave in
their fluids and vice versa. This proactive
approach solves challenges on both ends
of the supply chain.
It is very important that hydraulic fluid
transfer power efficiently and economically. Fluids with poor lubricity characteristics can usually be used if the appropriate
seal material selections are made. Excessive heat build-up due to poor lubrication
will result in seal wear and hardware damage otherwise.

Lubricant systems within


marine environment

As demands on lubricant systems increase,


the likelihood of accidental release of
fluids increases. Increased operating temperatures, pressures and working cycles
shorten the life of circuit components.
The single best approach to protecting the
environment, the equipment and the operwww.plantengineering.com

Suppliers should also be


working with fluid

manufacturers to develop a
mutual understanding of
how seals behave in their
fluids and vice versa.
This proactive approach
solves challenges on both

ends of the supply chain.

ation is to deploy the best sealing solution


tailored specifically for the application in
order to prevent leaks and spills.
Routine maintenance is also key. A good
preventative maintenance program will
increase productivity since equipment
is utilized more. It will keep down costs
by allowing more in-shop maintenance
since there will be less emergency work.
Additionally it will decrease equipment
downtime, reduce safety hazards, increase
equipment life, and minimize fines and
cleanup costs.

Oil and gas exploration and production

One of the biggest applications for biodegradable fluids is in oil and gas exploration and production. Fluid suppliers
have responded by introducing new, ecofriendly biodegradable and non-toxic fluids based on a variety of different chemistries. What is needed is not only a sealing
solution that can handle the fluid, but
also all the other demanding parts of that
application, such as salt water, storms,
various tidal and freezing conditions.
In critical operations, these systems
need to be in continuous operation. Any
downtime is very costly. Seal manufacturers have responded to this trend by ensuring their seals are able to interact appropriately with these new greener fluids,
which many times do not have the best
lubricating properties.
Oil and gas exploration applications
continue to be complicated due to ecoplant engineering

June 2015 27

LUBRICATIONGUIDE
Oil and gas exploration applications continue to be

complicated due to economic pressures that are


moving the industry toward higher operating pressures,
temperatures, and working cyclesall of which
are more efficient but also increase the
stress on components such as seals and lubricants.

nomic pressures that are moving the industry toward higher operating pressures,
temperatures, and working cyclesall of
which are more efficient but also increase
the stress on components such as seals
andd lubricants.
ub c s.
Additionally,
y ggovernment regulations
g
aimed at protectingg the environment mustt
be considered for those who design,
g build,
or
systems.
With this in
o use hydraulic
y
y
mind,
it is important
to understand the
m
p
entire sealingg system,
gather
all customerr
y
g
requirements,
and evaluate the applicar q
pp
ttion. Specifically,
y a shoulder-to-shoulder
design
g engineering
g
g approach where
ccollaboration between the seal supp
pplier and the customers application
pp
engineers
makes a difference in
g
deliveringg substantial addedvalue
vvalue
ue and
d a total
o
v ue of
o
oownership
p advantage.
g

Going green with better sealing systems

There are a number of advantages to using


biodegradable hydraulic fluid, but the
most important factor is that it can prevent pollutants from contaminating the
soil
and ground
water.
s
g
Seal suppliers and hydraulic
equipmentt
y
manufacturers
must be knowledgeable
of
m
g
chemical
compatibility
c
y requirements and
d
test
methods. Workingg with material supt
pliers that understand these challenges
g and
d
that
are able to perform the proper testingg
t
to
t ensure compatibilityy is imperative for
a smooth
s oo transition.
s o .
IIn addition to compatibility,
y suppliers
should
s ou d also
so know
ow how
ow too extend
e e d advandv tages
t g received with standard hydrocary
bon-based fluids such as a longer
g oper-atingg life of the seal, lower friction and
reduced
energy
r
gy consumption, enhanced
sealing
and the deliveryy of a
s
g techniques
q
total
value of ownership.
t
p PE
J Savina is ffluid power application
Joe
engineer
for
g
f Trelleborgg Sealingg Solutions.
(www.tss.trelleborg.com)
g

28 June 2015

PLANT ENGINEERING

www.plantengineering.com

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input #19 at www.plantengineering.com/information

LUBRICATIONGUIDE

The culture of lubrication


Critical process often goes overlooked and underappreciated.
By Kevin Smay
Valin Corporation

lant engineers often fail to incorporate correct lubrication into


system processes and do not realize its critical importance until
something goes wrong. Lubrication is frequently one of the
last things considered for project budgets
when, in reality, it is one of the most crucial
aspects to a systems lasting functionality
and integrity. Despite this fact, the lubrication process is commonly regarded as less
important and overlooked when designing
a system.
While this may seem like a simple oversight on the part of many plant engineering
professionals, it is in actuality a widespread
cultural norm to neglect and look down
upon the lubrication process. This unfortunate situation often results in malfunctions that could have been avoided given
a regular maintenance schedule and the
willingness of plant managers to address
the lubrication process correctly and to
value the stability and reliability it brings
to a system.
Lubrication is so integral to the success
of so many plant processes that it is difficult to imagine it being overlooked, but
the reality is that many have developed the
habit of not placing this valuable process
on their priority list for scheduled maintenance.
Below are several issues that negatively
impact this culture of lubrication in indus-

trial applications. These issues concern the


industrial field as a whole as well as individual plant employees and managers. If
improvements are made in each of these
areas, plant managers can expect their process failure rate to drop significantly, their
employees to have higher job satisfaction
and their budget projections to be more
accurate due to a lack of unforeseen maintenance requirements caused by inadequate
lubrication.

Complacency

Lubrication has been referred to as a guerilla tradeit is sometimes perceived as


mysterious, can conjure unpleasant sights
and smells in the imagination, and is not a
welcome topic of conversation for some.
This is one reason that it is not properly
addressed on a regular basis. This attitude of complacency has been adopted
by many and has caused a lack of knowledge among industry professionals regarding the importance of lubrication, proper
methods, procedures and having dedicated
personnel.
A common result of this widespread attitude of complacency is the lubrication system often being the first thing to be blamed
when a system malfunctions. Because many
do not understand the workings of the lubrication system, they are not educated enough
to make an informed judgement on what
may have actually gone wrong with the

Lubrication is so integral to the success of so many


plant processes that it is difficult to imagine it being overlooked, but the reality is that many have developed the
habit of not placing this valuable process on their priority
list for scheduled maintenance.
30 June 2015

PLANT ENGINEERING

www.plantengineering.com

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Lubricationguide

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system components. Their inclination is


to blame the aspect of the process that is
the most undesirable or about which the
least is known; which in most cases is the
lubrication system.
Additionally, in terms of regular maintenance, lubrication is often one of the lowest
priorities despite playing what is arguably
the biggest role in terms of overall system
functionality. This, again, is due to this
culture of complacency that exists toward
lubrication.

Lubrication has been referred to as a guerilla

tradeit is sometimes perceived as


mysterious, can conjure unpleasant sights and
smells in the imagination, and is not a welcome
topic of conversation for some.

32 June 2015

plant engineering

Take for instance the hydroelectric dam


in Folsom, Cal. that utilizes large, bearingoperated spill gates to maintain its reservoir.
On July 17, 1995, the hydroelectric plant
was temporarily shut down so the flow of
the nearby American River could be maintained using a spill gate on the dam. As the
gate was being opened, the axis point seized
due to excessive friction, causing the load
to be redistributed and the entire spill gate
to buckle under the stress. As a result of this
failure, nearly 40% of Folsom Lake was
released towards San Francisco Bay, even
causing some salmon and striped bass to
incorrectly change their migration patterns.
An investigation later revealed a number of ways that the dams engineers had
ignored their responsibility to properly
lubricate the bearings prior to the failure.
First, the maintenance staff had considered
implementing a new lubrication system five
years before the failure but later decided
against it. Had they put this new system
in place, the spill gate failure most likely
would not have occurred.
www.plantengineering.com

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input #21 at www.plantengineering.com/information

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Lubricationguide
Providing insight and advice is an important
aspect of a lubrication technicians services for a
plant, as companies often have false information
on lubrication applications and the
technician may be the only one with the
training to provide the correct solution.
Records also uncovered after the incident
showed that the regular maintenance and
lubrication schedule was steadily decreased
throughout the life of the dam due to budget
limitations, causing the bearings to slowly
fall out of repair. Finally, the plant maintenance team did not use the correct lubricant
in the first place, choosing to use a lubricant
that was insufficiently water-resistant and
that allowed water to enter the bearings and
cause corrosion which eventually led to the
spill gate failure.
Several conclusions about dam maintenance in general can be drawn from this
example, but in terms of the culture of lubrication, the message is clear. The engineers
responsible for the operation of this dam did
not consider lubrication to be an important
part of the spill gates ability to function.
They were complacent in implementing a
regular schedule of maintenance and lubrication and were ignorant of the correct type
of lubrication to use, a combination which
resulted in a massive system failure.

Lack of employee appreciation

Lubrication technicians are tasked with


climbing into the dark, dirty places within
plants that must be accessed and lubricated
in order to keep all of the systems properly
functioning. Their job, essentially, is to keep
the machines going using a combination of
knowledge, expertise and resources provided to them by their employers. In turn,
employers are tasked with respecting the
opinions of the technicians when it comes to
lubrication requirements and not disregarding or ignoring their recommendations.
Providing insight and advice is an important aspect of a lubrication technicians services for a plant, as companies often have

34 June 2015

plant engineering

false information on lubrication applications


and the technician may be the only one with
the training to provide the correct solution.
The previous paragraph is a depiction of
a healthy relationship between an employer
and a lubrication technicianone that is
unfortunately not always realistic. What
lubrication professionals often experience
is a lack of respect and appreciation. This
lack of employee appreciation towards lubrication technicians has negatively impacted
the culture of lubrication throughout the
industrial world for some time.

Exclusion from budget

As an extension of their attitude of complacency, plant managers will often completely


overlook lubrication requirements when
planning their budgets. Despite owning
multi-million dollar machines that rely on
regular lubrication to function, there are
companies that do not even consider this
requirement in their list of necessities for
plant operation. This can lead to catastrophic results including the loss of millions of
dollars in equipment, time and plant output.
When considering lubrication, plant engineers need to recognize the importance of
the process and place it just as high on their
list of priorities as other essential system
processes. The cultural perception of lubrication as dirty and unnecessary needs to
change, starting with the individual, in order
for plants to ultimately operate at a higher
level of efficiency and productivity. PE
Kevin Smay serves as technical specialist, lubrication applications & systems for
Valin Corporation. He has more than 25
years of experience in the lubrication system application industry.
www.plantengineering.com

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input #22 at www.plantengineering.com/information

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LUBRICATIONGUIDE

Unusual flush plans


for mechanical seals
API-682 edition highlights five plans that can be of benefit.
By Heinz Bloch, P.E.

Figure 1: API Flush Plan 03


recognizing tapered stuffing
box environment. Note also
the bearing housing protector seal with large O-ring
moving in axial direction.
Please note: As a drawing
convenience, these illustrations may show certain
porting arrangements above
the centerline; on actual
seals a particular port may
be located near the bottom.
All images courtesy: AESSEAL, Inc.

echanical seals are used in


millions of process pumps;
the many available seal configurations are described in
the standards of the American
Petroleum Institute (API-682).
These standards also describe the many flush
plans (piping plans) used by modern industry. Except for automotive, home appliance
and similar applications where the pumpage
fully envelops the sealing components, a flush
liquid stream and associated piping plans are
used to remove heat from the seal faces.
There are many manufacturers of mechanical seals and their overall strategies appear
similar: each desires to deliver safe products at reasonable cost. However, the business objectives of the very best mechanical
seal manufacturers go beyond the obvious.
Their objectives are expressed in marketing
approaches which consistently represent
value.

Superior service and high customer satisfaction are among the discernibly beneficial
aspects of good marketing. Additional benefits accrue if the seals service and asset
provider conveys educational or training
updates to the ultimate seal user.
All of the objectives endorsed by client
and provider can be summarized in the
three Cscommunication, cooperation,
and consideration. The content of this article
is rather typical of the communications
aspect of a rewarding relationship between
the parties. The manufacturer should make it
their goal to alert user-clients to new opportunities.
Such opportunities exist based on new
flush plans found in the 4th edition of API682; they are Plans 03, 55, 65A and B, also
Plans 66 and 99. Although these five flush
plans and their derivatives are little known,
they can be of great advantage in certain
services.

1. API Plan
Pl 033

The new API Plan 03 (Figure


T
gure 1) is a great
addition; it relates to a taper-bore seal
chamber
for an API pump.
c
p p. For decades API
pumps have been using
g closed
osed (cylindrical)
seal
chambers and have relied on piping
s
plans
to maintain a chosen
p
sen seal environment.
However, because taper-bore stuffm
ing boxes are now
very well proven in
American National
Standards Institute
(ANSI) pumps in
contaminated services, we also now
can specify tapered
bores for
API-compliant pumps.

36 June 2015

PLANT ENGINEERING

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input #23 at www.plantengineering.com/information

LUBRICATIONGUIDE

Figure 2: Plan 55 and a bidirectional tapered pumping


ring in an unpressurized
buffer fluid loop.

38 June 2015

In Plan 03 the flush fluid flows into the


pumpage. Circulation between the seal
chamber and the pump is facilitated by the
tapered geometry. Solids accumulation risk
is greatly reduced by the tapering and the
former stuffing box is now part of the back
pull-out cover of this pump. New pumps
can accommodate the tapered design, as
will pre-existing pumps through a modification or upgrading process. It should
be noted that the taper should be relatively steep; 30 to 45 degree inclination has
worked well. Very shallow taper angles
should be avoided.
This seal chamber geometry promotes
circulation which, in turn, provides cooling
for the seal and vents air or vapors from the
seal chamber. Flush Plan 03 is most often

PLANT ENGINEERING

used in applications where the seal faces


generate relatively small amounts of heat.
Plan 03 is also used in applications where
the old-style cylindrical chamber would
have allowed solids to collect. Occasionally, the tapered bore is fitted with anti-swirl
vanes (sometimes called swirl interrupting
ribs) for even greater assurance against
solids accumulation.
Note also the floating outboard throttle
bushing in Figure 1. This provision allows
leakage monitoring, assuming the outlet
port is located at the bottom.

2. Standard Seal Flush Plan 55

In Plan 55 (Figure 2), there is an unpressurized external buffer fluid system supplying clean liquid to the buffer fluid seal
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input #24 at www.plantengineering.com/information

LUBRICATIONGUIDE
Mechanical seals are used in millions of process
pumps; the many available seal configurations
are described in the standards of the American Petroleum
Institute (API-682).

Figure 4: In Plan 65A, minor


leakage flows away through
an orifice; major leakage is
noted by a level indicatortransmitter (LIT).

chamber. Plan 55 is used with dual (double, tandem) liquid seal arrangements.
The buffer liquid is typically maintained
at a pressure less than seal chamber pressure and less than 0.28 MPa (2.8 bar or
40 psi).
Plan 55 is similar to Plan 54 except the
buffer liquid is unpressurized. The Plan 55
representation in Figure 2 shows an efficient bi-directional tapered pumping ring.
This particular ring greatly assists in moving the buffer fluid to and from an external
reservoir and/or through an external heat
exchanger (cooler). Also, the potential
advantages of using a tapered pumping ring
can be significant. One such model, as seen
in Figure 2, is offered with bi-directional
functionality and a wide clearance between
its vane tips and the opposing stationary

parts. In the event of pump bearing distress,


this wide clearance gap protects against
scraping and extreme heat generation.
The outboard seal in Figure 2 is a wet
containment seal (API calls it configuration 2CW-CWdual contact wet seal)
and is normally used in services where
process fluid leakage to atmosphere must
be avoided, which is to say minimized
and contained. Many users found Plan 55
advantageous in applications where the
process was prone to solidify in contact
with atmosphere or in applications where
additional heat removal from the inner seal
was required.
Examining major seal manufacturer Websites allows users to see how Plan 55 differs
from Plan 52. In Plan 52 the buffer liquid is
not necessarily self-contained; with Plan 52
buffer liquid circulation is created by
an external pump or pressure system.
Iff Plan 55 is specified, carefully consider
ider the reliability of the buffer liquid
source
ource and the possible contamination
of the buffer flow with process liquid
or vapor.
H o w e v e r, s u i t a b l e s u p e r v i s o r y
instrumentation may give ample warning of a compromised primary seal.

3. API Plans 65A and 65B

In Plan 65A/B there is an atmospheric


leakage collection and detection system for condensing leakage. Failure of the seal will be detected by
an excessive rate of flow into the
leakage collection system. Figure 3A
and Figure 3B is intended to convey
that many different seal configurations are allowed; the emphasis is
largely on leakage monitoring. The
central port is equipped with one of
many feasible instruments. In any
event, Figure 3 depicts a standard
setup
etup when pumped fluid condenses

40 June 2015

PLANT ENGINEERING

www.plantengineering.com

input #25 at www.plantengineering.com/information

LUBRICATIONGUIDE

Figures 3A and 3B: Piping


Plan 65A/B is generally
used for standard leak
detection.

42 June 2015

PLANT ENGINEERING

www.plantengineering.com

at ambient temperatures.
Plan 65A/B differ only in that A
is using a throttle bushing whereas
B uses an orifice arrangement in
the leakage collection setup.
Plan 65A/B is normally used with
single seals in services where the
anticipated seal leakage is mostly
liquid, not gas. Piping is connected
to the drain connection in the gland
plate and directs any primary seal
leakage to an exterior collecting volume or system.
The exterior collecting reservoir
(the volume) is not usually provided by the seal manufacturer; the
volume could be an oily water
sewer or some other environmentally
acceptable liquid collection system
in the plant. Within the seal, excessive flowrates would be restricted
by the orifice located downstream
of the reservoir and are redirected to
it, causing the level transmitter to activate
an alarm.
The orifice shown with Plan 65A (Figure
4) is typically 5 mm (about 0.25 in.); it
should be located in a vertical piping leg
to avoid accumulation of fluid in the drain
piping. The piping allows bypassing the orifice so as to effectively self-drain excessive
leakage amounts. A pressure transmitter
can be provided as a monitoring alternative to the level indicator-transmitter (LIT)
as shown.
Plan 65B is very similar, as seen in Figure 5. A needle valve can be trimmed to suit
the users needs. Major leakage bypasses
this valve and flows away. The rate of leakage can be safely tracked by the LIT. The
leakage collecting reservoir again has to
be mounted below the seal gland to allow
gravity flow from seal to reservoir. A valve
is usually located between seal and reservoir; it has to remain open during operation and should be closed during controlled
maintenance events only.

4. How Plan 66 fine-tunes leakage detection

Plan 66 (Figure 6) is a leakage detection


plan often used by the pipeline industry
sector for duty in remote applications.
Here, high leakage flow is of prime interest. Note how a suitably orificed (or valveequipped) pressure transmitter would be
connected to the central port of this cartridge seal. Under conditions of high leakage flow, the resulting pressure rise would
trigger an alarm.
This approach will probably be similarly
effective with more viscous fluids. Indeed,
alternative versions have appeared in production areas with a closed valve on the
outlet rather than the orifice. The valve will
require periodic opening to drain off the
normal or reasonably expected seal leakage. By trending the time interval between
drain-downs users obtain accurate data on
the condition (or even failure trend) of a
single seal.
Bearing protection takes on a special
significance in remote pipeline pumping.

Figure 5: Plan 65B, a needle


valve can be finely adjusted, to suit. Major leakage
bypasses this valve and is
led away. The rate of minor
leakage can be tracked by
the LIT device.

There are many manufacturers of mechanical seals and


their overall strategies appear similar: each desires to deliver

safe products at reasonable cost.


www.plantengineering.com

PLANT ENGINEERING

June 2015 43

LUBRICATIONGUIDE

Figure 6: API Plan 66 is


often used in remote pipeline services.

Figure 6 prompts the author to bring this to


the readers attention. An advanced bearing housing protector seal is illustrated, as
in several of the preceding figures.

5. API Plan 99the Catch-All Plan

There could also be an engineered piping


plan not covered by present API standardsa plan executed to the customers
orders. A knowledgeable customer still
wants to listen to manufacturers advice
and experience.
To recap and summarize our opening
paragraphs: There are many manufacturers of mechanical seals and their overall
strategies seem similar. Special seals and
special applications are of interest to reliability-focused users. Such users often seek
out seal manufacturers whose overarching
desire it is to go beyond delivering safe
products at reasonable cost.

44 June 2015

PLANT ENGINEERING

These may be companies other than your


traditional alliance partners; they will, by
definition, be manufacturers whose marketing
approaches consistently represent value. They
must be able to point to superior service and
high customer satisfaction. And they must
have the desire to teach. We consider them
seal service and asset providers who willingly
convey educational and training updates to
the ultimate seal user. PE
Heinz P. Bloch resides in Westminster, Colorado. His professional career commenced in
1962 and included long-term assignments as
Exxon Chemicals regional machinery specialist for the US. He has authored over 600
publications, among them 19 comprehensive
books on practical machinery management,
failure analysis, failure avoidance, compressors, steam turbines, pumps, oil-mist lubrication and practical lubrication for industry.
www.plantengineering.com

Because downtime is not an option.


SINAMICS PERFECT HARMONY delivers uptime, all the time.
usa.siemens.com/perfectharmony
Operating conditions will never be perfect, but at least your drives can be. Siemens equipped the
SINAMICS PERFECT HARMONY drive with 50+ patented technologies proven to increase reliability.
Its the No. 1 selling drive because its the most trusted.
input #26 at www.plantengineering.com/information

2015

Energy Management

Turning research into insights makes for better business decisions


The 2015 Energy Management study asked key questions on energy
management practices, including continuous energy monitoring,
challenges to energy management, energy reduction goals, and
alternative energy sources.
According to the study top challenges to energy management
programs continue to be acquiring resources from corporate
or management (34%), calculating return on investment
(27%), and educating workers on the goals and
objectives (26%).
Access the full Plant Engineering 2015 Energy
Management report with additional findings and insights.

www.plantengineering.com/2015EnergyManagement

Lubrication Guide
Lubriplate Lubricants Co.
Newark, N.J.
www.lubriplate.com

AMSOIL Inc.

Baums Castorine Co. Inc.

Superior, Wis.
www.amsoil.com

Rome, N.Y.
http://baumscastorine.com

RCH Gear & Bearing lube

Tena-Film 150 TH

General Purpose Lubricant


ISO Viscosity Grade

Viscosity,
SUS at 100 F

32

135-165

H0-0 or Syn Lube 32

46

194-236

H0-1 or Syn Lube 46

RCI Gear & Bearing lube

Tena-Film 300 LTH

68

284-346

H0-2 or Syn Lube 68

RCJ Gear & Bearing lube

Tena-Film 300 MTH

150

630-770

H0-3 or Syn Lube 150

RCL Gear & Bearing lube

Tena-Film 400 TH

220

900-1100

H0-4 or Syn Lube 220

RCM Gear & Bearing lube

Tena-Film 500 TH

460

1935-2365

H0-6 or Syn Lube 460

RCO Gear & Bearing lube

Tena-Film 2500 TH

32

135-165

H0-0 or Syn Lube 32

HVH Antiwear Hydraulic Oil

Tena-Film 150 TH

46

194-236

H0-1 or Syn Lube 46

HVI Antiwear Hydraulic Oil

Tena-Film 300 LTH

68

284-346

H0-2 or Syn Lube 68

HVJ Antiwear Hydraulic Oil

Tena-Film 300 MTH

135-165

GG Oil

10

194-236

No. 0 or SFGO ULTRA-7

Tena-Film 75 TH

22

284-346

No. 1 or Syn Lube 22

Tena-Film 100 TH

32

135-165

10-R

Tena-Film EP 150 ST

68

284-346

Way Lube 68

Tena-Film EP 300 ST

220

900-1100

SPO-255

Tena-Film 1000 ST

284-346

APG-80

Tena-Film EP 300

Antiwear Hydraulic Oil

Spindle Oil

Way Oil

Extreme Pressure Gear Oil


68
150

630-770

APG-90 or Syn Lube HD150

SGL EP Gear Lube

Tena-Film EP 700

350

135-1650

APG80W-140 or Syn Lube HD320

SGN EP Gear Lube

Tena-Film EP 1400

460

1935-2365

SPO-277 or PGO-460

Cylinder Compound 180

Cling Type Gear Shield

Gear Shield Extra Heavy

Tena-Film Moly Compound O-9477

General Purpose Extreme Pressure


Lithium Base Grease

NLGI 2

No. 1200-2 or Syn 1602

GLC Multi Purpose Grease

Tena-Film EP 2

Molybdenum Disulfide Extreme


Pressure Grease

NLGI 2

No. 3000 or Syn 3002

GPOR2 Synthetic Polymeric OffRoad Grease

Tena-Film Moly Compound O 23

HI Grease

FGL-2 or SFL-2

GXC X-Treme Synthetic Food


Grease

H1 Fluid

FMO-AW Fluids or SFGO ULTRA

General Purpose Synthetic Fluid

Syn Lube 68

Tena-Film Synthetic CL 46 AW

Worm Gear Oil

46 June 2015

PLANT ENGINEERING

www.plantengineering.com

Chain Guard
industrial Lubricants

Chemtool Inc.

Chevron Lubricants

Motion Industries Inc.

Rockton, Ill.
www.chemtool.com

Richmond, Calif.
www.chevronlubricants.com

Birmingham, Ala.
www.motionindustries.com

CT R & O Oil ISO 32

Rando HD, Clarity Hydraulic Oil AW and others

Lubriplate L0881-057

CT R & O Oil ISO 46

Rando HD, Clarity Hydraulic Oil AW and others

Lubriplate LO882-062

CT R & O Oil ISO 68

Rando HD, Clarity Hydraulic Oil AW and others

Lubriplate LO884-057

CT R & O Oil ISO 150

Rando HD, Clarity Hydraulic Oil AW and others

Lubriplate L0975-057

CG-FS-220-H1 - Chain Guard Food


Grade 220

CT R & O Oil ISO 220

Rando HD, Clarity Hydraulic Oil AW and others

Lubriplate L0735-057

CT R & O Oil ISO 460

Rando HD, Clarity Hydraulic Oil AW and others

Lubri-Loy 03260292

CG-FS-HY-32-H1

CT AW Hydraulic Oil ISO 32 NZ

Rando HD, Clarity Hydraulic Oil AW, Clarity Synthetic HO AW, Rando HDZ

Lubri-Loy 03260293

CG-FS-HY-46-H1

CT AW Hydraulic Oil ISO 46 NZ

Rando HD, Clarity Hydraulic Oil AW, Clarity Synthetic HO AW, Rando HDZ

Lubri-Loy 03260294

CG-FS-HY-68-H1

CT AW Hydraulic Oil ISO 68 NZ

Rando HD, Clarity Hydraulic Oil AW, Clarity Synthetic HO AW, Rando HDZ

CT Spindle Oil ISO 2

CT Spindle Oil ISO 10

Rando HD

CT Spindle Oil ISO 22

Rando HD

Bel-Ray 05094675

CT Waylube NZ ISO 32

Way Lubricant

Bel-Ray 05094678

CT Waylube NZ ISO 68

Way Lubricant

Bel-Ray 04801543

CT Waylube NZ ISO 220

Way Lubricant

Lubriplate

EP Ind. Gear Oil ISO 68

Meropa, Meropa XL, Meropa Synthetic EP

Lubriplate

EP Ind. Gear Oil ISO 150

Meropa, Meropa XL, Meropa Synthetic EP

Lubriplate

EP Ind. Gear Oil ISO 320

Meropa, Meropa XL, Meropa Synthetic EP

Lubriplate

CT SHC 460

Cylinder Oil W

Boston Gear (Altra)

SLC HV 00 Purple

Ultra Duty Grease

Lubriplate

Duralube EP -2 RED HV

Delo Grease, Ultra Duty Grease

Sprayon

Alpha 2000 HD with Moly Graphite

Moly Grease EP

Sprayon

Alpha 2000 Green

FM CSC EP

Loctite

CT PURE-FLOW

Chevron Lubricating Oil FM

Lubriplate

CT EP Syn Gear Oil

Clarity Synthetic Hydraulic Oil AW, Clarity Synthetic


Machine Oil, Cetus PAO

Markham, Ontario
www.chainguardlubricants.com

www.plantengineering.com

PLANT ENGINEERING

June 2015 47

Lubrication Guide
Oil Service Inc.

OPCO Lubrication Systems Inc.

Petron Plus Global Inc.

Pittsburgh, Pa.
www.oilservice.com

Hutchinson, Kan.
www.petronplusglobal.com

Hutchinson, Kan.
www.petronplusglobalcom

General Purpose Lubricant


ISO Viscosity Grade

Viscosity,
SUS at 100 F

32

135-165

Prestige R & O Oil 32

Petron Plus Formula 7 General Purpose


Lube 52070

46

194-236

Prestige R & O Oil 46

Petron Plus Formula 7 General Purpose


Lube 52072

68

284-346

Prestige R & O Oil 68

WearMaster KF-100

Petron Plus Formula 7 General Purpose


Lube 52074

150

630-770

Prestige R & O Oil 150

Petron Plus Formula 7 General Purpose


Lube 52078

220

900-1100

Prestige R & O Oil 220

WearMaster KF-101/220

Petron Plus Formula 7 General Purpose


Lube 52080

460

1935-2365

Prestige R & O Oil 460

Petron Plus Formula 7 General Purpose


Lube 52084

32

135-165

Prestige AW 32 Hydraulic Oil

Petron Plus Formula 7 AW Hydraulic


Fluid 52142

46

194-236

Prestige AW 46 Hydraulic Oil

Petron Plus Formula 7 AW Hydraulic


Fluid 52144

68

284-346

Prestige AW 68 Hydraulic Oil

Petron Plus Formula 7 AW Hydraulic


Fluid 52146

135-165

Prestige Spindle Oil 2

Petron Plus Formula 7 Spindle Oil


51506

10

194-236

Prestige Spindle Oil 10

Petron Plus Formula 7 Spindle Oil


51508

22

284-346

Prestige Spindle Oil 22

Petron Plus Formula 7 Spindle Oil


51511

32

135-165

Prestige Way Lube 32

Petron Plus Formula 7 Way Oil 58140

68

284-346

Prestige Way Lube 68

WearMaster KF-310-68

Petron Plus Formula 7 Way Oil 58144

220

900-1100

Prestige Way Lube 220

WearMaster KF-310-220

Petron Plus Formula 7 Way Oil 58150

68

284-346

Prestige EP Gear Oil 68

WearMaster KF-330-68

Petron Plus Formula 7 Industrial Gear


Oil 52070

150

630-770

Prestige EP Gear Oil 150

WearMaster KF-330-150

Petron Plus Formula 7 Industrial Gear


Oil 52074

320

135-1650

Prestige EP Gear Oil 320

Petron Plus Formula 7 Industrial Gear


Oil 52078

460

1935-2365

Prestige SCO 460

Petron Plus Formula 7 Worm Gear Oil


55140

Cling Type Gear Shield

Petron Plus Formula 7 Heavy-Duty Open


Gear Lube 53900

General Purpose Extreme Pressure


Lithium Base Grease

NLGI 2

Petron Plus Formula 7 Hi-Temp, E.P., M-P,


Lithium Complex Grease 00880

Molybdenum Disulfide Extreme Pressure Grease

NLGI 2

Petron Plus Formula 7 Hi-Temp, E.P., M-P,


Lithium Complex Grease w/Moly 00800

HI Grease

Petron Plus Formula 7 Hi-Temp, HeavyDuty Fleet & Industrial Grease 00550

H1 Fluid

Petron Plus Formula 7 Hi-Temp, Food


Grade Grease 51800

General Purpose
Synthetic Fluid

Petron Plus Formula 7 General Purpose


Synthetic Lube 51070

Antiwear Hydraulic Oil

Spindle Oil

Way Oil

Extreme Pressure Gear Oil

Worm Gear Oil

48 June 2015

PLANT ENGINEERING

www.plantengineering.com

Schaeffer Manufacturing Co.


St. Louis, Mo.
www.schaefferoil.com

Sentinel Lubricants

Miami, Fla.
www.sentinelsynthetic.com

SYNCO Chemical Corp.


Bohemia, N.Y.
www.super-lube.com

New Castle, Del.


www.ultracheminc.com

112 HTC ISO 32 or 254 HTC Supreme


ISO 32

S-MPO 10

Extra Lightweight Oil

Chemlube R&O 32

112 HTC ISO 46 or HTC Supreme ISO 46

S-MPO 10/20

Chemlube R&O 46

112 HTC ISO 68 or 254 HTC Supreme


ISO 68

S-MPO 20

Light Weight Oil

Chemlube R&O 68

112 HTC ISO 150 or 254 HTC Supreme


ISO 150

S-MPO 30

Oil with PTFE

112 HTC ISO 320 or 254 HTC Supreme


ISO 220

S-MPO 40

Gear Oil ISO 220

S-MPO 50

Gear Oil ISO 460

112 HTC ISO 32, 254 HTC Supreme ISO


32, 288 HTC Supreme Extreme Performance ISO 32

SH 10

Chemlube AW 32

112 HTC ISO 46; 254 HTC Supreme ISO


46; 288 HTC Supreme Extreme Performance ISO 46

SH 10/20

Chemlube AW 46

112 HTC ISO 68; 254 HTC Supreme


ISO 68

SH 20

Chemlube AW 68

Spindle Oil L

324 Moly Spindle Oil ISO 10

Spindle Oil LM

324 Moly Spindle Oil ISO 22; 112 HTC


ISO 32

Spindle Oil M

Omnilube FGH 22

160 Moly Slide & Way Lube ISO 32

S-Way Oil 10

160 Moly Slide & Way Lube ISO 68

S-Way Oil 20

160 Moly Slide & Way Lube ISO 220

S-Way Oil 50

Omnilube FGG 220

203B EP Industrial Machine Lube


ISO 68

S-75/80

Light Weight Oil

Omnigear EP 68

293 Supreme Gear Lube ISO 150

S-80/90

Gear Oil ISO 150

Omnigear EP 150

294 Supreme Gear Oil ISO 320

S-90/140

Gear Oil ISO 320

Omnigear EP 320

147 Steam Cylinder Oil

S-WGO 460

PGWS 460

200S Silver Streak Open Gear Lube

SLOG

221 Moly Ultra EP #2; 238 Ultra Supreme


#2; 229 Ultra Red #2; 274 Moly E.P. Semi
Synthetic #2

SL 123R

221 Moly Ultra EP #2; 238 Ultra Supreme


#2; 229 Ultra Red #2; 274 Moly E.P. Semi
Synthetic #2

SL M2

271 Synthetic Food Grade Grease H-1; 195


Supertac Food Grade Grease H-1

SL NT AAI

280 Food Grade HTC; 269 Hydraulic Oil


H-1; 276 Synthetic Food Grade Gear
Lube H-1

S NT

Omnilube Series

264 Moly Full Synthetic Hydraulic Oil

S-MPO

Chemlube 600 Series

www.plantengineering.com

Ultrachem Inc.

PLANT ENGINEERING

June 2015 49

Brands YOU Count on,


People YOU Trust

With more than 5 million industrial products, supplies and services,


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2015 Motion Industries, Inc.


input #27 at www.plantengineering.com/information

AUTOMATIONSOLUTIONS
Lean production and automation
Select the best production platform to maximize your Lean operation.
By Kevin Gingerich
Bosch Rexroth

Figure 1: The intelligence,


flexibility, and efficiency
of todays production
platformsfrom manual
production cells to full automation solutionsoffer new
options for companies that
want to use technology to
become Lean. All images
courtesy: Bosch Rexroth

www.plantengineering.com

odays competitive global markets challenge manufacturers in


all industries to constantly seek
efficiencies to stay competitive.
Factors such as mass-customization, small lot sizes, and demands
for extremely rapid turnaround drive manufacturers to become much more flexible.The
need to maximize manufacturing return on
investment (ROI) has never been stronger;
you need to get the most out of your processes, your systems, your equipment, and
your people.
Lean manufacturing has proven to be a
powerful, fundamental way to achieve these
goals. By providing a systematic way to identify waste and remove it, Lean manufacturing is more than just an extra tool in your
manufacturing toolbox. Its a way of life. To
be good at Lean, companies must commit to
it and pursue Lean techniques vigorously.
That includes making intelligent decisions
about how and when to use automation technology to becomeand to stayLean. At
its most elemental level, Lean manufacturing is pull production, driven by customer

or marketplace demand. Lean production


optimizes all of your enterprises flow in
response to that demand: material flow,
people flow, and information flow.
Is it possible to use automation and still
be Lean? Newly emerging manufacturing
platforms that utilize mechatronics concepts;
powerful, intelligent, connected controls; and
even wireless technologies are changing the
equation by creating an entirely new range
of capabilities.
These new capabilities add truly demanddriven flexibility to the traditional automation advantages of precision and speed,
whether in semi-automated or fully automated production environments, and can
even help to eliminate wasteful processes in
assembly operations that are mostly manual.
Finding the right level of automation can
enhance your Lean initiatives in previously
unconsidered ways, giving you new ways
to reduce wasted time, wasted energy, and
wasted effort when used in the right applications.

Identifying waste to optimize flow

It takes more than tying together a few


U-shaped or L-shaped work cells to become
Lean. Lean is a philosophy that drives efforts
to reduce waste throughout the manufacturing
process. Its a guide for decision-making
and to make the right decisions about eliminating waste, its crucial that you step back
and consider how materials flow through the
manufacturing process.
Optimizing the flow of material will guide
the decisions you make about how best to
eliminate waste. To get an idea of how much
optimization might be needed, take a quick
waste walk and think about addressing the
seven types of waste normally identified by
Lean practitioners:
Overproduction
Waiting
Defects and errors
Excess motion and movement
Excess inventory
Inefficient processes
Excess transportation.
PLANT ENGINEERING

June 2015 51

aUTOMaTIONSOLUTIONS
Lean production system matrix

Lean production provides the


optimum framework for efficient
competitive production, based on
a philosophy of comprehensive
waste avoidance. To become Lean,
manufacturers need to attack waste
everywhere by establishing processesand using the right kind
of production systemsthat enable
you to:
Reduce inventory
Eliminate downtime
Reduce space requirements
Avoid errors and inefficient
processes
Intelligently monitor and track
production
Avoid overproduction
Shorten transport routes.
Figure 2: This decision
matrix demonstrates how
to choose the right Lean
production technologies by
assessing workflow in terms
of production volume and
product mix, and to chart
these factors against different types of production
solutions.

52 June 2015

These classic types of waste can be seen


on a daily basis in many production environmentsincluding those with a high degree
of manual production. Further analysis has
identified two other types of systemic waste
that Lean can address:
Talent: This can be a consequence of poor
or inadequate training, or an operator interface that is poorly designed and creates an
opportunity for operator error.
Energy: Many production platforms are
not designed to be as energy-efficient as
they could be; Rexroths 4EE for energy
efficiency, an internal systematic approach,
identifies four leversenergy system
design, efficient components, energy on
demand, and energy recoverythat can be
used to eliminate wasteful use of energy in
manufacturing.
A very effective Lean tool to help you get
to the root of waste within your manufacturing systems is a value stream map. Create a value stream map and identify waste
wherever it occurs in your system. (A simple
Internet search can help you find templates
and resources for value stream mapping.)
And if you dont want to get this involved,
ask your operators about wasteful processes.
Because theyre close to the process, they
often know right where to start fixing things.
With this information, you can begin making effective, intelligent decisions about
how to eliminate the waste you find, including determining the right level of automation
to use to help accomplish that goal.

plant engineering

A helpful approach to choosing


the right production systems is to think in
terms of production volume and product
mix, and to chart these factors in a matrix.
One matrix that Bosch Rexroth has created
plots the four broad types of most commonly
used production systems: manual production
systems, modular production systems with
some automation, standalone automated
production cells, and fully automated production lines.
This useful decision matrix can help you
choose the right Lean production technologies, by assessing your flow in terms of
production volume and product mix, and
charting these factors against different types
of production solutions.
Depending on where your situation falls
on the Lean production matrix, the level of
automation you need may range from no
automation at all (manual production) to
fully automated production.
In the most unpredictable assembly environmentlow volumes, high product mix
manual assembly is usually the reasonable
choice because youd never recoup your
investment in automated equipment. Its a
dynamic set of considerations, with no one
right answer.
In some assembly operations, manual
production is augmented by automated
intelligence: A new generation of cordless
nut runners for assembly operations has an
integrated controller that temporarily stores
the results of every nut tightened, and then
transmits that data via Wi-Fi to a receivwww.plantengineering.com

ing station and the production platforms


quality-tracking system.
This ensures, through automated data capture, total tracking of the quality of manual
production through integrated intelligence,
while at the same time eliminating the need
for redundant, manual, post-operation
checking.

Effective use of new technology

The level of machine intelligence and


sophistication now available has indeed
begun to change the calculation for when
automation makes sense. Automated production cells, which often combine skilled
manual operator activities with automated
conveyors and/or standalone handling solutions, enable relatively high volumes of
production.
The use of conveyor systems in Lean production environments is often disregarded
too quickly, most likely because they are
thought of as simply moving parts from
place to place. Todays flexible conveyor
systems go far beyond that, and are instrumental in minimizing waste in low-mix,
medium-to-high-volume production. Yes,
they quickly move products among operations. But with integrated parts tracking,
precision work piece holding, and ergonomically correct work positioning, wellimplemented conveyor systems are key in
the Lean factory of tomorrow, especially
when coupled with the latest mobile-enabled
controls technologies.
Indeed, new ways of identifying, tracking,
and eliminating waste are becoming more
apparent as the world of automation control

www.plantengineering.com

K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD: LEAN
AUTOMATION that further discuss this topic:

GAIN PRODUCTIVITY WITH LEAN AUTOMATION, CONNECTIVITY


Machinery original equipment manufacturers, panel builders, and others
can more easily see the productivity, reliability, and economic advantages of
using a smart-module-type device-level wiring system when compared to a
conventionally wired control panel.
AUTOMATION, LEAN JOIN FORCES TO KEEP PRODUCTS MOVING
Ever since Henry Ford perfected what has become the modern-day assembly line, manufacturers have attempted to improve the concept. It continues
today as companies demand their plant personnel to continually do more
with less. Whether its through installing new machines to increase throughput, incorporating new controls and components to make those machines
run more efficiently or reconfiguring the line to improve the flow of product,
manufacturers are faced with tough decisions every day on how to get the
most out of their operations.
LEAN AUTOMATION ARCHITECTURES
Technical advances in processing and communications are yielding new
capabilities for machine automation. These communications advances are
at both the device and enterprise level and are enabling a streamlined automation architecture.
meets the world of modern information technology. Supervisory control systems play
a part, of course, but so does a movement
toward more open engineering standards,
which enable communication between more
traditional PLC platforms and higher-level
systems and languages.
As well as allowing the use of modern
devicessuch as tablets using standard
operating systems this new level of communication allows manufacturers to bring
together previously unconnected systems.
This move toward connected industry

Figure 3: Costs per Transfer Cycle: As cycle time


goes down and products
are manufactured faster,
automated transfer makes
greater sense, even in lowwage scenarios.

PLANT ENGINEERING

June 2015 53

aUTOMaTIONSOLUTIONS
allows unlinked automated cells even Leaner , through faster, real-time
frequently used in packaging, inspec- communication. If theres a problem
tion, and other post-assembly opera- in your system that results in waiting
tionsto be connected to overall or other forms of waste, youll know
production system diagnostics and instantly.
other control and monitoring apps.
And as volumes increase, as the
Such smarter and Leaner production matrix shows, automationespecialsystems
willAdmake
Lean1 practices
lyAM
if helped
New
Hydraulic
PE_Layout
6/2/2015 11:11
Page 1 along by the latest auto-

Reliable

Hydraulic

mation controls and energy-saving


technologiescan help to increase
efficiency and quality even further;
thus reducing waste to a bare minimum. When you have long product
lifecycles and high production runs,
a fully automated production system
makes Lean sense by allowing you to
take full advantage of your investment
in equipment and skilled personnel for
the most efficient, and least wasteful,
Lean production solution.

Lean manufacturing has


proven to be a powerful, fundamental way to
achieve these goals.

Lubricants

Reduce excessive
wear, sludge, rust,
overheating, and
oxidation

Local production offers


Lean advantages

NSF H1
lubricants
available
You can reduce your hydraulic problems by increasing equipment
reliability with lubricants from Summit Industrial Products. Summit
offers a variety of hydraulic fluids including 100% synthetic, NSF
H1 registered, mineral oil food grade, fire resistant and bio-based
formulations.
Summit provides a wide range of viscosities to insure optimal
volumetric and mechanical pump efficiency, which prevents
over-heating. Each Summit hydraulic lubricant series is
formulated to enhance product efficiency and meet or exceed
OEM standards.

Summit

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800.749.5823
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input #28 at www.plantengineering.com/information

In the recent past, one of the choices


many companies made to improve
productivity and reduce costs was to
outsource their assembly operations
to countries with low-cost manual
labor. The calculation underlying
this approach is that its easier and
less costly to add workers to increase
production as needed, instead of
investing in potentially higher-cost
local personnel and equipment.
There appears to be a significant
change in this thinking: Moving
production closer to the end-user
customers and markets is occurring with greater frequency in many
industries. Its driven in part by the
realization that there are many costs
that are initially difficult to quantify
in outsourcing arrangements, including quality control and the ability to
quickly respond to changing customer desires and requirements.
In addition, our Cost per Transfer
Cycle chart (Figure 2) compares the
costs per transfer cycle of manual
transfer, a pick-and-place solution, and an automated system. As
cycle time goes down (i.e., speed of
manufacture increases), automated
transfer begins to make greater eco-

54 June 2015

plant engineering

nomic senseeven when compared


to manual assembly in low-wage
countries.
When thinking about Lean, its
worth remembering that travel distance is a kind of waste. Thats why
companies that practice Lean as a
culture try to manufacture as close
to their customers as possible, and
insist that their suppliers do the same.

at the best way to optimize material


flow, people flow, and information
flowincluding selecting the right
level of automation that consistently, demonstrably removes waste from
your manufacturing processesits
possible to get and stay Lean, and
more important, to build a sustain-

able competitive advantage in your


market. PE
Kevin Gingerich is responsible for communications and electronic marketing at
Bosch Rexroth, and has worked for the
Bosch organization in various marketing
and communications functions for 24 years.

The right automation mix

In todays economy, manufacturers must seize every opportunity to


increase productivity and throughput, reduce costs, eliminate waste,
and improve product quality and
reliability while managing change
on an almost daily basis.
Lean manufacturing principles,
when effectively applied, can make
all these benefits an ongoing reality.
Whats important to remember is that
the technology you use to become
Lean depends very much on your
assembly requirements. By looking

The BoTTom Line:


Lean is a guide for decision-makingand to make the right decisions about eliminating waste, its
crucial that you step back and consider how materials flow through
the manufacturing process.
Depending on where your situation
falls on the Lean production matrix,
the level of automation you need
may range from no automation at all
(manual production) to fully automated production. Its a dynamic set
of considerations, with no one right
answer.
New ways of identifying, tracking,
and eliminating waste are becoming
more apparent as the world of automation control meets the world of
modern information technology.
As cycle time goes down, automated transfer begins to make greater
economic senseeven when compared to manual assembly in lowwage countries.
plant engineering

June 2015 55

Experience the Ultimate in Pneumatic Conveying


and Industrial Vacuum Cleaning Solutions.

input #29 at www.plantengineering.com/information

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CALLING ALL SYSTEM INTEGRATORS...

2016

SYSTEM INTEGRATOR
OF THE YEAR

CALL FOR ENTRIES


ENTRIES ARE DUE AUGUST 7, 2015

Control Engineering and Plant Engineerings annual

System Integrator
of the Year Awards

WHO SHOULD ENTER?

GLOBAL
SYSTEM INTEGRATOR
REPORT

www.cfemedia.com

If youre part of a contract engineering firm or an engineering division of a larger


company that can design and implement computerized control systems for industrial
machinery, manufacturing lines, or other automated facilities that produce either a
commodity or a finished product, Control Engineering and Plant Engineering urge you
to enter the 2016 System Integrator of the Year competition.

2015

WHATS IN IT FOR THE WINNERS?

System Integrator of the Year Winners

The chosen System Integrator of the Year winners will receive worldwide recognition
from Control Engineering. The winners also will be featured as the cover story of the
2016 Global System Integrator Report, distributed in December 2015.

GSIR 5

Paul Galeski of MAVERICK Technologies GSIR 6


Charlie Jager of Polytron GSIR 8
Stephen Malyszko of Malisko Engineering GSIR 10
Supplement to

www.controleng.com | www.plantengineering.com

CTL_2014_Supplement_Cov_REPORT_V3.indd 1

HOW WILL THE COMPETITION BE JUDGED?

Control Engineering and Plant Engineerings panel of judges will conscientiously


evaluate all entries. Three general criteria will be considered for the selection of
Control Engineering and Plant Engineerings System Integrator of the Year:
Business skills
Technical competence
Customer satisfaction

11/26/2014 12:53:55 PM

QUESTIONS? Contact Bailey Rice


Director of Business
and Market Development
CFE Media
brice@cfemedia.com
(630) 571-4070 x 2206

Tell us how you measure up in these three areas.

Get the application: www.plantengineering.com/SIYApplication

MECHANICALSOLUTIONS

VFD trends and solutions


for drive systems
Harmonics mitigation, filtering voltage spikes are two key issues.
By Alex Ward
REO-USA

Figure 1: A chart comparing


harmonics. All images courtesy: REO-USA

www.plantengineering.com

he increase in variable frequency


drive (VFD) installations across
the globe has meant that drives are
being applied in more challenging
system environments.Not only is
the environment challenging, but
drives also have a few inherited issues that
can limit the overall system performance.
International standards have helped guide
system integrators to make the correct choices for equipment inside their systems. These
choices help to eliminate problems such as
electromechanical interference and harmonic
noise at the input of the drive; as well as voltage spikes and short-circuit and interference
currents at the output. Each of these issues
should be taken into consideration during
the design phase to increase overall system
efficiency during operation.
When many electrical systems are installed
in the same area, the equipment in the network begins to interfere with each other.

This is often referred to as electromechanical interference, or EMI. This can lead to


many problems within the network, including
eventual equipment damage. These are risks
that many applications such as datasystems,
hospitals, and schools cannot afford.
Many integrators are turning to the simplest and cheapest solution, an EMI filter.
These filters have a small footprint and are
easy to install. They are installed on the line
side of the drive system to help suppress the
unwanted high frequencies associated with
crowded networks. International standards
such as International Electrotechnical Commission (IEC) 61000-6-4 have set guidelines
for the acceptable levels of EMI in industrial systems. Integrators need to be aware
of these guidelines and select components
appropriately.

The problem of harmonics

Harmonics are present in every drives


application. Harmonics are created by nonlinear
loads like VFDs.
The non sinusoidal
currents present
in all drives using
diodes or switching devices on the
input may lead to
harmonic currents
in the system. Harmonic currents can
cause a number of
issues in systems
such as component overheating,
reduced power factor, and equipment
malfunction.
There are several
different component
solutions that sysPLANT ENGINEERING

June 2015 57

MECHANICALSOLUTIONS
K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD: HARMONICS that further discuss this topic:

MITIGATING HARMONICS IN ELECTRICAL SYSTEMS


The critical question is: When do harmonics in electrical systems become
a significant enough problem that they must be mitigated? Operational
problems from electrical harmonics tend to manifest themselves when two
conditions are met: Generally, facilities with the fraction of nonlinear loads to
total electrical capacity that exceeds 15%, and a finite power source at the
service or within the facility power distribution system with relatively high
source impedance, resulting in greater voltage distortion resulting from the
harmonic current flow.
UNDERSTANDING HARMONICS
We care about harmonics for several reasons. Harmonic current generates
heat in all the current carrying components of the electrical distribution system: switchgear, breakers, fuses, cabling, capacitors, busduct, busbar and
transformers. Harmonic current generates more heat on a per-Amp basis
than current at the fundamental frequency (60 Hz).
MOVING HARMONICS OUT OF HARMS WAY
Are harmonics refusing to jibe with the harmony of a facilitys power flow?
In the old days of predominantly linear loads, harmonics were a natural
occurrence that didnt cause problems because with normally balanced,
three-phase AC systems that have non-distorted waveforms, the harmonic
currents got cancelled out.
tem integrators use to mitigate harmonic
current content in todays installations. One
of the most common methods is a line reactor. As the name implies, line reactors are
installed on the line side of the drive system.
A simple 3% impedance line reactor can
decrease system harmonic current content
by more than 30%.
The reactor itself is just a simple inductor
with a specific amount of impedance. Adding impedance to any system will help to
mitigate harmonics in every situation. International standards such asthe IEEE 519 and
IEC 610003-2 should be referenced before
installing any industrial or commercial VFD
system. The simple addition of a line reactor
will improve the overall system efficiency,
decrease component maintenance cost, and
increase the system equipment lifetime.

The output of VFDs sometimes causes


issues that can lead to increased motor stress
and increases in system downtime. A common problem at the output is voltage spikes.
The switching devices inside the drive turn
on and off very quickly, causing resultant
voltage spikes greater than the rated voltage
of the motor.
Depending on the cable length between the
drive and motor, the peak voltage can often
be greater than 1,200 V in a 480 Vsystem.
The longer the cable length, the higher the
voltage spikes. These spikes will eventually
cause deterioration of the motor insulation
and motor winding failures. Certain applications require long cable lengths due to the
environment of the system installation.

Filtering voltage spikes

The formula dV/dt represents the instantaneous rate of voltage change. System
integrators are turning to dV/dt filters to
help mitigate voltage spikes in their VFD
systems. These filters are installed at the
output of the VFD, in front of the motor in
the system. The dV/dt filters suppress the
voltage spikes to limits that the motor can
better manage. The increased motor protection will lead to an increase in overall
motor lifetime, and a decrease in equipment
downtime caused by the damage from the
voltage spikes.
Like the line reactor and EMI filters
on the line side, dV/dt filters are simple
to install and are inexpensive, especially
when compared to the cost of replacing
damaged motors. Most commonly, these
filters are used in applications with harsher
environments such as oil and gas, mining,
and marine.
Another common problem found at the
output of the VFD system is the presence
of differential-mode and common-mode
currents. These are distortions in the output current of the VFD, often referred to as
asymmetric and symmetric, respectively.

International standards such as International


Electrotechnical Commission (IEC) 61000-6-4

have set guidelines for the acceptable levels of


EMI in industrial systems.
58 June 2015

PLANT ENGINEERING

www.plantengineering.com

Like voltage
spikes, the current distortions
exist because of
the fast switching devices in
the VFD. Current distortion
has a negative
e ff e c t o n t h e
motor, causing
audible noise,
higher losses in heat, as well as overheating when it is ignored.

International standards
have helped guide
system integrators to
make the correct
choices for equipment
inside their systems.
These choices help to
eliminate problems.

Solutions for harmonic distortion

There are several common solutions to mitigating these current distortions. Focusing
on the simplest and the most cost-effective
options, the load reactor is a formidable
solution. Load reactors are installed at the
output of the VFD, before the motor in the
system topology. A load reactor acts in the
same manner as a line reactor; in fact, many
reactor manufacturers produce the same
unit as interchangeable between the line and
load. The reactor inductance acts to smooth
the current distortion from the output of the
drive, while also helping to suppress the
voltage spikes caused from the drive switching devices. Consequently, motor noise and
losses are significantly reduced.
For systems with longer cable lengths
between the VFD and motor, such as those
greater than 100 m, both voltage spikes and
current distortion will be present. In these
applications, sinewave filters can be utilized. These filters use an inductor-capacitor
topology to achieve a sinus waveform. Comwww.plantengineering.com

Figure 2: A load reactor


chart.

bining the benefits of the dV/dt and load


reactor, the sinewave filter increases motor
lifetime, while decreasing noise, losses, and
voltage spikes.
The benefits of all of these component
solutions need to be taken into consideration when designing a drive system. Careful preparation during the design phase will
reduce the likelihood of future costly system repairs and possible retrofits. Applying
any of these five common solutions at the
input or output of the VFD will increase the
overall system efficiency and the lifetime
of system components. Many manufacturers
provide these solutions. It is the responsibility of the system integrators to make sure
that the proper components are installed. PE
Alex Ward is a technical sales engineer for
Indianapolis-based REO-USA, which engineers and manufactures power conversion
components for the VFD industry. His email
is award@reo-usa.com.

THE BOTTOM LINE:


When many electrical systems are
installed in the same area, the equipment
in the network begins to interfere with
each other. This is often referred to as
electromechanical interference, or EMI.
This can lead to many problems within the
network.
There are several different component
solutions that system integrators use
to mitigate harmonic current content in
todays installations.
The formula dV/dt represents the instantaneous rate of voltage change. System
integrators are turning to dV/dt filters to
help mitigate voltage spikes in their VFD
systems.
PLANT ENGINEERING

June 2015 59

mechanicalSOLUTIONS

Dust collection projects:


8 tips to ensure success
Review the project plans and make sure to get all departments involved.
By John Staskiewicz
Donaldson Torit

he implementation of a dust collection system offers many benefits


to a production facility including
increased manufacturing effectiveness and a generally cleaner
and safer work environment for
employees. Given the positive impacts a
quality dust collection system affords, it
would be nice if its installation could go
smoothly so the system can start delivering
those benefits quickly.
Once the budget has been submitted and
capital has been approved, there are a few
key things to consider to help the project go
smoothly. Consider the following eight tips
to help ensure your project does just that with
the right equipment delivered, installed, and
started-up on time.

1. Ensure project requirements have

not changed since the budget was


submitted.
In many cases, the budget that was originally submitted may no longer reflect the
current project requirements. Scope changes along the way
including even small
changescan affect
system performance
Given the positive
in very big ways.
For example: A
impacts a quality dust
minor change in
location of the
collectionsystem affords, the
dust collector may
require changes in
it would be nice if its
duct layout. This
means duct system
installation could go
calculations need to
be checked to ensure
the fan selection will
smoothly so the system
still be sufficient.
can start delivering those Other changes could
include: increases or
decreases in system
benefits quickly.
air volume requirements due to added

60 June 2015

plant engineering

or shifted production layouts on the floor.


In todays markets, plants often adjust
processes or they change the materials they
work with, or their production rates shift.
Each of these events changes the amount of
dust the collection systems have to handle.
In addition, reviews of the potential hazards
for materials being collected are critical.
Many materials may require considerations on collector location or possible
hazard mitigation strategies, and these are
often easier to address before you order
equipment. Materials you collect may also
require process monitoring devices or material handling system features, which must
be added to the collector. These changes
may also require adjustments in the utilities
provided to the collection system.
No matter how insignificant the changes
might seem at the surface, invite a knowledgeable dust collector supplier in to review
your project requirements before you write
a purchase order. The supplier can help confirm the dust collection equipment originally
selected fits the current project needs and
scope. If the original collection equipment
cannot meet the current needs, the supplier
can help explore options to meet the revised
requirements.

2. Ensure your company has standard

component requirements established.


Standard components include anything
from motors and gearboxes, rotary airlock
valves, or electrical items such as motor
starters and PLCs. If your company has
standardized on a set of components based
on your prior successes with them, be sure
to let the dust collection system provider
know.
Incorporating your established components into a new dust collection system
makes it easier for your personnel to perform maintenance on items and increase
their confidence in the total system.

www.plantengineering.com

3. Consider involving resources beyond a

design/build contractor or engineering


company in the project.
Design/build contractors or engineering
firms sometimes provide layouts for space
without taking into consideration key industrial ventilation engineering principles and
practices. As an example, the influence of inlet
and outlet duct requirements on the performance of dust collection equipment is well
understood by quality dust collector suppliers,
but may not be evident to the engineering firm.
To ensure overall system performance,
include a knowledgeable dust collector supplier along with the contractor or engineering firm in a thorough review of your project
drawings. The dust collector supplier should
be able to make recommendations on good
industrial ventilation practices based on their
experience with dust collection systems.
Beyond just how the ducts are connected to
their collector, a good collector supplier may
be able to offer recommendations on subtle
adjustments in ducts or hood design, which
could improve overall system performance.
And those types of recommendations represent
changes that are much less expensive on paper
than trying to optimize the system once it is
all already installed.
Never forget that good inlet and outlet duct
designs will improve long-term collector filter performance by increasing filter life and
reducing filter maintenance requirements.

4. Host a kick-off meeting and ensure all

K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD: DUST
COLLECTION that further discuss this topic:

RECIRCULATING AIR FROM DUST COLLECTORS


Whether dust collectors are used in a plant to control indoor air quality
(IAQ), keep equipment clean, and/or recover high-value process dusts, many
plants are considering recirculating the air back into the plant downstream
of collectors instead of exhausting it outdoors. When using recirculating
dust collection systems, special safety and performance concerns must be
addressed.
IMPROVING DUST COLLECTION
When it comes to dust collection, the first consideration is what type of
collector best fits the application. The choice comes down to the baghouse
collectorwhich some refer to as the grand daddy of filtration technologiesor its offspring, the cartridge dust collector. For some filtration projects, there really is a choice.
PRESSURIZING WITH DUST COLLECTORS: MAKING THE RIGHT DECISION
Pressurizing with dust collectors is applicable to many industries, including
cement and lime production, metal and coal mining, pharmaceutical processing, grain processing, or potentially anywhere that high volumes of dust
are generated.
ask the manufacturer when you place the
order to pre-assemble key sub-sections at
their factory to ensure fit. Having a factory
pre-assemble parts of the equipment can
eliminate many assembly concerns once
the equipment is in the field, allowing you
a smoother installation. Some of the challenges of fit can be reduced if you work
with manufacturers that build their products
in-house rather than through subcontractors.

parties are involved.


To ensure all stakeholders are involved
and understand the scope of the project,
invite everyone to a pre-installation meeting.
Inclusion of plant management and production and/or maintenance staff allows them
to voice their concerns before they have
to live with the disruptions an installation
could have on their facility. This step can
often reduce or eliminate some downtime.
The engineering company overseeing
the project and the outside contractors and
equipment providers, including the dust
collector expert, should attend to ensure
effective communication between parties
throughout the project.

ment on-site during installation.


Make sure to schedule representatives
from each of the equipment suppliers onsite when their products are in assembly
and installation. As an example, a qualified dust collector representative can
quickly eliminate confusion by clarifying
collector assembly drawings or assembly
instructions, and they can then interface
with plant staff if any detail interpretations are required, such as the identification of parts for proper location. They can
also answer questions on how to simplify
installation.

5. If the equipment is custom or configured,

7. Consider ordering spare parts for use

have the manufacturer preassemble sections at their factory.


If your dust collection project includes
special order equipment with custom items,
www.plantengineering.com

6. Have a factory representative for equip-

during installation.
Most contractors take great care when
installing collection systems, however, the
risk of components getting bumped, ripped

PLANT ENGINEERING

June 2015 61

mechanicalSOLUTIONS
or torn during installation is a reality.
Some items can be reworked on-site,
but there may be some items that need
to be replaced, and a purchased part
such as an explosion vents or filter
may not be in stock.
Standard items usually are and can
be shipped to the site quickly, but special items may have long lead times
for replacement, and it might be best
to order spares up-front to reduce the
risk of project delays.

8. Make sure suppliers of equipment

provide both start-up assistance


and product training.
Once all of the mechanical and electrical equipment has been installed
and contractors are in the final phases
of proving or commissioning equipment, schedule the dust collector
expert back in for additional startup and commissioning assistance too.
Having this resource on-site ensures
the collector start-up process includes
support for troubleshooting.

Once the system is operating, the


experts can inspect the system, measure airflows and verify static pressure, often adjusting the system to
ensure design airflow parameters are
matched. They can also check the
overall operation of the filter cleaning
system and, once the dust collector
is successfully running, the collector
expert can offer operator and maintenance training to plant staff.
Dust collection systems require
close integration into production processes and often require modifications
to production equipment, rerouting
of plant services such as power and
compressed air, and, of course, the
installation of new capital equipment. The potential for delays and
challenges from even moderate-sized
projects can be enormous, but proactive planning and the tips above can
help you reduce or eliminate many of
the delays and challenges associated
with installing a dust collection system in your facility. Your investment

on the front end of any project helps


ensure its ultimate success. PE
John Staskiewic is a regional sales
engineer for Donaldson Torit.

The BoTTom line:


The benefits of implementing a dust
collection system are enhanced
when the installation goes smoothly
so the system can start delivering
benefits.
A pre-installation meeting gets
everyone on the same page for the
project before it begins. Including
plant management and production
and/or maintenance staff are crucial
to its success.
Make sure to schedule representatives from each of the equipment
suppliers on-site when their products are in assembly and installation.

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input #30 at www.plantengineering.com/information

The Industrial Internet of Things (IIoT), is about connecting machinesto each


other, to expert systems, and to management execution systems. This revolutionary
strategy delivers actionable information to intelligent devices and systems at all
levels of the manufacturing enterprise--from the plant floor to the corner office.
Control Engineering, Oil & Gas Engineering and Plant Engineering are joining
forces to launch a webcast series covering critical IIoT topics.
*This series is RCEP-certified and attendees qualify for ACEC Certified Professional Development Hour(s).

THE 2015 INDUSTRIAL INTERNET OF


THINGS (IIoT) WEBCAST SERIES:
WEBCAST ONE: Design considerations
Tuesday, July 21, 2015
Industrial Internet of Things (IIoT) concepts include
Big Data and designing in manufacturing intelligence.

WEBCAST TWO: Operations


Thursday, September 17, 2015
Industrial Internet of Things (IIoT) can help manufacturers make
their right decisions with the right information at the right time.

WEBCAST THREE: Integration considerations


Tuesday, November 3, 2015
Industrial Internet of Things (IIoT) promotes intelligent devices
and systems, sharing information and awareness among
all systems and the humans that use them.
For more information and to register visit:
www.plantengineering.com/IIoTWebcastSeries

ELECTRICALSOLUTIONS
Arch flash relays
meet code compliance
Revised NEC 240.87 requirements make mitigation easier to achieve.
By Jeff Glenney, P.E.
Littelfuse

Arc flash relays use either


point or fiber-optic light sensors to detect an arc and
send a trip signal to the circuit breaker in <1 ms. Image
courtesy: Littelfuse

ts not easy to keep up with changing standards. Consider the case of a


company in Denver that was building
switchgear for a manufacturing plant.
The electrical inspector for their jurisdiction told them that the design was not
compliant with a recently updated provision
in the National Electric Code (NEC). Colorado is among 36 states that have adopted
the 2014 edition.
Besides wanting to comply with state
regulations, managers knew that insurance
providers expect equipment to meet minimum
design standards, which the NEC provides.
They discovered that the code change makes
it easier to protect workers and equipment
from arc flash hazards.
In 2014, the NEC was revised in multiple
areas. Changes to Paragraph 240.87 have
made compliance simpler and less expensive.
One easy-to-apply device can simplify meeting the new requirements while providing
important additional safeguards for people
and equipment.

The previous version of the Code

Paragraph 240.87 of the 2011 edition of the


NEC, which was titled Non-instantaneous
Trip, said that whenever using a circuit breakerwith a rating of 1,200 A or higher (or one
that could be adjusted to 1,200 A or higher)
that did not have an instantaneous trip function, one of the following was required:
1. Zone-selective interlocking
2. Differential relaying
3. An energy-reducing maintenance
switch with local status indicator.
Zone-selective interlocking addresses a
shortcoming of selective coordination. It
involves interconnecting downstream and
upstream circuit breakers: If a short circuit
or ground fault occurs on a branch circuit,
the breaker feeding it will trip instantaneously, and simultaneously send a signal
to the breaker just upstream, telling it to use
its time-delay function instead of tripping
instantaneously.
This is important because, otherwise, a
downstream short or
ground fault could draw
enough current to cause
both breakers to trip
instantaneously, killing
power to branch circuits
other than the one with
the fault.
An unfortunate drawback is that an arc flash
may not immediately
draw enough current to
trip either breaker, resulting in personal injury and
damage or destruction of
equipment.
Differential relaying
uses current transformers at the inputs and
outputs of the electrical

64 June 2015 PLANT ENGINEERING

www.plantengineering.com

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seweurodrive.com / 864-439-7537
input #31 at www.plantengineering.com/information

ELECTRICALSOLUTIONS
K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD: ARC

FLASH that further discuss this topic:

SIX STRATEGIES TO MITIGATE ARC FLASH INCIDENTS


Arc flashes can also wreak financial havoc in the form of fines, lawsuits,
and damage to expensive equipment. Given the dangers they pose, arc flash
events merit serious attention from engineering professionals.
NEW SOLUTIONS ADDRESS ARC FLASH ENERGY REDUCTION
In order to maintain selective coordination in some applications, an
upstream main circuit breaker may be chosen that does not have an instantaneous trip function. In these cases, if the main circuit breaker were to
experience a short-circuit condition, it would remain closed for its preset
delay time. And the longer it takes to trip, the higher the arc flash risk.
EXPLODING THE MISCONCEPTIONS AND MYTHS ABOUT ARC FLASH ISSUES
Large arc flashes are rare, but when they happen, they are life-changing
events. Your life is forever changed in a split secondless than 1/10 of a
second actuallyand and it can never be the way it used to be. The way
you feel about your self-worth, the way you interact with your wife (or husband) and family may never be the same again.
equipment being protected (zones). When a
fault occurs, the zone in which the input and
output currents do not match is the location
of the fault, and the appropriate breaker is
tripped. This is complicated and expensive
and takes up a fair amount of space.
An energy-reducing maintenance switch
manually sets the current pickup lower and
the time delay faster, to trip the breaker feeding a panel as fast as possible while someone
is working on it. If there is an arc flash, the
breaker should trip instantaneously and limit
the energy delivered. This reduces the level
of PPE required for the panel. The switch
must be activated manually before beginning
the maintenance activity to provide protection, and deactivated afterward to prevent
future nuisance tripping or miscoordination.

The current version of the Code

The 2014 edition of the NEC changed the


name of paragraph 240.87 to Arc Energy
Reduction and focused more on personnel

Changes to Paragraph
240.87 have made

compliance simpler
and less expensive.
66 June 2015 PLANT ENGINEERING

protection. As explained in the 2014 NEC


Handbook, the change to this section
removes the mention of instantaneous tripsetting from the criteria for applying this
requirement.
Instead, it is now required where the highest continuous current trip setting in a circuit
breaker is rated or can be adjusted to 1,200
A or higher. It allows for two new methods
that can make the job of compliance a good
deal easier:
An energy-reducing active arc flash mitigation system
An approved equivalent means.
An arc flash relay fulfills the mitigation
requirement. Using light sensors, it directly
detects the light emitted as an arc flash begins
and, in as little as 1 ms, sends an instantaneous trip signal to the breaker feeding
the affected panel or enclosure. This stops
the arc and minimizes the danger by helping
reduce the amount of energy released. This
can greatly reduce the potential for arc flash
injury to personnel and damage to equipment.
It may also reduce the level of PPE required
to work on the panel.
This Denver-based company discovered
that arc flash relays are easy to incorporate
into switchgear designs, and easy to retrofit.
The biggest challenge has been minor: deciding where in the cabinet to place the light
sensors. Managers are happy that installing
a relatively inexpensive arc flash relay not
only protects people and equipment directly,
but also helps bring the facility into compliance with the new revision of NEC 240.87. PE
Jeff Glenney is a sales engineering manager
for Littelfuse.

THE BOTTOM LINE:


Zone-selective interlocking addresses a
shortcoming of selective coordination. It
involves interconnecting downstream and
upstream circuit breakers.
In differential relaying, when a fault
occurs, the zone in which the input and
output currents do not match is the location of the fault, and the appropriate
breaker is tripped.
An arc flash relay fulfills the mitigation
requirement cited in NEC 240.87.
www.plantengineering.com

We proudly salute manufacturing innovation and


invite you to explore and celebrate the success stories
of these participating manufacturing innovators:
Allied Electronics
AutomationDirect
AVO Training Institute
Baldor
Camfil Air Pollution Control
Electro Static Technology Inc.
ErectAStep
Flexicon
FS-Elliott Co. LLC
Kaeser Compressors
Lubriplate
Meggitt Sensing Systems
Motion Industries
Paratherm
Prosoft Technology Inc.
SEW Eurodrive Inc.
SPM Instrument
Vac-U-Max
Yaskawa America Inc.

Look for the special Innovations videos at:

www.plantengineering.com/innovations

A DV E R T I S E M E N T

Quick, Easy, and Error-Free Product Design


In todays fast-paced world, improving efficiency, saving time, and reducing
errors is critically important. Thats why Allied Electronics has created the
Schneider Electric Visual Product Configurator.

Using this advanced and intuitive tool, designers, buyers, and MROs can quickly
and easily order custom configurations of important products, including:
Pushbuttons (16mm, 22mm, and 30mm)

Control Stations

Drives
Tower Lights

Parts created exactly to your specifications

The Schneider Electric Visual Product Configurator walks you through the
construction and ordering of a particular system. This ensures that all necessary
parts are ordered, and all options are considered. For example, if youre interested
in a variable torque drive, you would choose the selection type (or ask the
Configurator for help), the input voltage, the input phase, the motor power, the
power rating, and the functionality. Next, add any needed accessories, including
configuration tools, I/O adapters, keypads, mounting, and option cards. Using this
simple process, such parts are created exactly to your specifications, ensuring
the best possible fit for your application.
Finally, when the product is configured to your satisfaction, all the parts are added
to a Bill of Materials (BOM), complete with description, catalog number, and
quantity, which can then be exported as a PDF for later ordering, or added to your
cart for easy purchasing.
By approaching system design in a holistic way through the Schneider Electric
Visual Product Configurator, rather than simply ordering discrete parts, youre
assured youre getting everything you need in a single order, saving both time and
money and boosting efficiency.
Ordering custom-configured products has never been easier. With just a few
mouse clicks at thinkallied.com/schneidervpc, you can have the products you
need configured to your exact specifications built and ready to ship to you.
No more time spent combing the web trying to find what you need, now you can
build what you need easily and efficiently. Its one more way that Allied provides
your total solutions.

Allied Electronics | 800.433.5700 | ThinkAllied.com


input #32 at www.plantengineering.com/information

A DV E R T I S E M E N T

Award-winning services satisfy customers


AutomationDirect has always maintained a huge
inventory, allowing us to ship 99.7% of orders complete
the same day. We were among the first to offer free
2-day shipping, available for any order over just $49.
Shipment confirmations and any backorder status
and estimated delivery information is communicated
electronically to keep you informed.

AutomationDirect Headquarters, Cumming, GA

Our online store is one of the most exhaustive in the


industry all technical documentation can be downloaded free of charge, as well as software and firmware
updates. Hundreds of instructional videos are available
for viewing without registration.

AutomationDirect takes the best ideas from


the consumer world to serve industrial market
As a direct seller of industrial automation products for
over 20 years, AutomationDirect has led the industry in
offering many customer services not typical with
traditional distributors. We created a print catalog, and
later an online store, that provides complete product
information and pricing so that customers can make
informed decisions on their automation purchases
quickly and independently.
AutomationDirects standard for products is that they
are practical, easy to use, and offer a low cost of
ownership. We offer quality products at prices up to
50% lower than those of more traditional distributors.
Most of our products programming software is free,
requiring no initial or upgrade costs, and no software
maintenance contracts.

99.7% orders shipped complete the same day

Online access to your account includes viewing and


changing account information, viewing order history
and making payments. Customers can also obtain return
authorizations online for quick and easy product returns
or exchanges.
Our phone technical support staff has garnered top
honors in service from industry magazine readers 14
years in a row. And with tens of thousands of active
customers, our online technical forum taps into that
knowledge base by encouraging peers to help each
other with applications and other questions.
Other online help includes frequently asked questions,
application examples, and product selection guides.

Practical automation products, including


programmable controllers

www.automationdirect.com | Email: sales@automationdirect.com | Phone: 1-800-633-0405


input #33 at www.plantengineering.com/information

A DV E R T I S E M E N T

Baldor Electric Company


Leading the Way in Design and Manufacturing
Lower Cost, High Efficiency Solutions
from Baldor

Baldors newest addition to our gear reducer product


offering the BaldorDodge Vertical Gearmotor
(VGM) offers a cost effective alternative to the
common low speed vertical pump drive technologies,
which utilize large, high pole count vertical motors or
a combination of horizontal motor with a right angle
gear reducer. The VGM is built on a standard low
pole count induction motor platform utilizing proven,
highly efficient BaldorDodge planetary gearing.
Vertical Gearmotors in production at the Baldor plant in Stratford

Baldor Electric Company, headquartered in Fort


Smith, Arkansas, is a leading marketer, designer and
manufacturer of energy-saving industrial electric
motors, drives and mechanical power transmission
products. The company was founded in 1920 on the
premise that a better motor is one that uses less
electricity, and that belief holds true today.

Providing a
Wealth of Solutions
and Support

Baldor offers strong


support and product
solutions for the water,
power generation, oil &
gas, mining, food &
beverage, paper & forest,
aggregate& cement, unit
and air handling industries.
The company provides
reliable, applicationspecific products and
expert knowledge for each
of these markets. Installed
Base Evaluations are also available to aid end users
in reducing energy consumption with the right mix
of industrial motors, drives and gearing in a single
application or throughout an entire facility.

By utilizing low pole count


induction motors, the
VGM provides better
power factor for reduced
utility rates, higher
efficiency, better
availability and reduced
maintenance costs. The
smaller physical size
reduces facility requirements, handling and
support structure costs.
Using a standard motor
design can also lower
capital costs. It all results
in a smaller, lighter, highly
efficient drive package.
Baldor-Dodge Vertical Gearmotor
The BaldorDodge
Vertical Gearmotor product
line is available in six sizes, for vertical pump
speeds from approximately 100 to 500 RPM.
The VGM has torque ratings from 550,000 in-lbs
through 7,000,000 in-lbs and approximate power
ratings from 750 HP to over 25,000 HP, depending
on output RPM. The VGM is ideal for a wide range
of applications, including pumping stations for flood
control and wastewater, circulating water in power
plants, desalination plants, irrigation systems, and
pumping systems for residential and commercial
water supplies.

Baldor Electric Company | Tel: 479-646-4711 | www.baldor.com


input #34 at www.plantengineering.com/information

A DV E R T I S E M E N T

StingerTM Explosion Isolation Valve


Protects Against Dust Collector Explosions
During normal operation, the airflow holds the
blade open. If a deflagration occurs, a pressure
wave will travel through the pipe faster than
the flame front and close the flap valve,
protecting downstream personnel and equipment.
When the valve is fully closed, a latching
mechanism keeps it shut. The closed valve
prevents transmission of flame and keeps smoke,
dust and burning debris from traveling through
the inlet pipe into the factory.

The Stinger explosion isolation valve prevents a


dust collector explosion from traveling back through the
inlet pipe into the workspace.

The Stinger explosion isolation valve isolates


dust collector explosions to prevent a deflagration
from traveling back through the inlet pipe of the
collector into the workspace. Following extensive
testing, Camfil APC reports that the Stinger is the
first U.S.-made explosion flap valve to be certified
by an independent testing agency to comply with
NFPA standards. It may be retrofitted onto most
dust collection systems and used with new or
existing Farr Gold Series dust collectors where
a combustible dust explosion risk exists.

The blade is easily replaceable, eliminating the


need to replace the entire valve after an explosion
event. A wear-resistant liner that doubles as a
wear indicator will show when the blade needs to
be replaced.
These advantages have earned the Stinger
explosion valve a Bronze award in the Safety
category of the 2014 Plant Engineering Product of
the Year competition. View product
information and a video at
www.camfilapc.com/stinger.

A key feature is a lightweight, patent-pending


composite blade that reacts with the highest
possible speed in an explosion, closing faster
than heavier steel blades typically used for dust
collector inlet protection. Because of its light
weight, less pressure drop is needed to hold
the blade open during normal flow, saving on
energy use. Also, the composite material has a
smooth surface and does not use stiffeners
which can allow dust to build up on the blade to
compromise performance.

2014

The Stinger valve


has been explosion
tested and certified
to comply with
NFPA standards

Camfil Air Pollution Control Tel: 800-479-6801 or 870-933-8048 filterman@camfil.com www.camfilapc.com


input #35 at www.plantengineering.com/information

A DV E R T I S E M E N T

New AEGIS High-Frequency Ground Straps Complete


the Path to Ground for Damaging Shaft Currents
recognized as the most efficient path to ground for
high-frequency currents, high-frequency grounding
straps are recommended by major motor and
drive manufacturers.

AEGIS Bearing Protection Rings /AEGIS HF Ground Strap

AEGIS High-Frequency Ground Straps ensure a


very low-impedance path to ground for the highfrequency currents generated by VFD-driven
motors and systems. Used in conjunction with
AEGIS Rings, which
provide a path for
damaging VFDinduced currents from
motor shaft safely
away from bearings to
motor frame, AEGIS
HF Ground Straps
complete the path from
motor frame to ground.
These 12-inch long
flat-braided, tinned
copper straps are
specially engineered
for the lowest possible impedance to the
high-frequency currents generated by VFDs.
Designed with a circular hole on one end for
easy installation around the foot mounting
screw of NEMA- or IEC-frame motors, they
are equipped with a ring terminal on the
opposite end. Custom lengths and terminations
are also available upon request. Generally

Variable frequency drives (also known as VFDs,


variable speed drives, or inverters) can save 30%
or more in energy costs, but they can also
damage motors. VFDs induce high-frequency
voltages on the shafts of the motors they
control voltages that can discharge through
motor bearings, destroying them in as little as
3 months and damaging coupled equipment.
AEGIS Shaft Grounding Rings provide effective
long-term protection of bearings against
damaging VFD-induced currents. By channeling
these currents away from bearings and safely to
ground through the motor frame, they mitigate
frosting and fluting damage, premature bearing
failure, and costly motor system downtime.

AEGIS Shaft Grounding Ring channels damaging shaft currents around


motor bearings safely to the motor frame. The AEGIS HF Ground Strap
completes the path to ground by effectively grounding the motor frame.

Together, AEGIS Shaft Grounding Rings and


AEGIS HF Ground Straps provide total system
protection against damaging high-frequency
currents from motor shaft to earth ground.

Tel: 1-866-738-1857 | E-mail: sales@est-aegis.com | www.est-aegis.com


input #36 at www.plantengineering.com/information

A DV E R T I S E M E N T

ErectaStep & PerfectaStep. Safety Meets Simplicity


ErectaSteps goal is to keep industry moving safely
and efficiently. A 2011 Plant Engineering Product of
the Year Finalist, we strive to bring speed, simplicity
and convenience to safety.
PerfectaStep, our newest customizable solution,
tailors the same modular, bolt-together components
to fit any installation scenario.

Our philosophy: configure dont fabricate


We built ErectaStep and PerfectaStep by answering
a question: Why do fall protection and safe access
take so long and cost so much? The answer: they
shouldnt. That led to our next question: What if we
could modularize safety and compliance? Thats
what we did using the classic ERECTOR set as our
model few components, unlimited possibilities.
ErectaStep includes five universal components:
1.
2.
3.
4.
5.

Industrial handrails
Work platforms
Aluminum stairs
Tower platform supports
Platform ladders

PerfectaStep adds precision modifications to the


versatile modular components. Custom platforms,
variable-width stairs, and unique railing solutions
make PerfectaStep the perfect solution for any challenging application. All components are preconfigured to meet OSHA fall protection requirements.

Our goal: make fall protection easy


to obtain and install.
EHS leaders told us that safety cant wait. Thats
why we stock the five universal components, and in most cases, ship the same day. Patent-pending technology
and precision manufacturing techniques make ErectaStep easy to assemble just like an ERECTOR set.
Case Study: ErectaStep Lightens the Load for a Major National Contractor
When youre a major national builder of home and commercial real estate, you know a thing or two about
load bearing. Thats exactly why their project manager selected the lightweight aluminum ErectaStep brand
mezzanine stairs and platform over a custom fabricated solution.
We wanted to limit additional load on the roof, so we chose the ErectaStep platform because of its light weight,
said the project manager. He explained that the company had recently installed a large dehumidifier on an
elevated stand atop the roof of its production warehouse. ErectaStep enabled workers to safely conduct quarterly
maintenance on the dehumidifier. Thanks to ErectaSteps modular design, the installers had it assembled in just
a few days.

Call +1 888 878-1839 | input #44 at www.plantengineering.com/information


input #37 at www.plantengineering.com/information

A DV E R T I S E M E N T

Flexicon stand-alone bulk handling equipment


to engineered, plant-wide systems
Flexicon is an international organization with
administrative, engineering and manufacturing capabilities on four continents, and an extensive worldwide
network of applications engineers, authorized representatives and field support technicians to serve you
a unique consolidation of bulk handling specialists with
hundreds of years of combined experience.

Equipment overview
Flexicon Corporation is a world leader in the design and
manufacture of bulk handling equipment and customengineered and integrated plant-wide systems that
transport, discharge, fill, weigh, blend, deliver and/or feed a
broad range of powder and bulk solid materials.
Flexicon products range from individual equipment to automated systems that source bulk material from interior and exterior plant locations, transport it between process equipment
and storage vessels, weigh it, blend it, feed it to packaging
lines, extruders, molding machines and storage vessels, and
load it into railcars and trailers.

An extensive research and development program


continually sets new standards for bulk handling equipment performance with entirely new designs, product
improvements and equipment that complies with
certifications required by governmental and industry
associations for chemical, food, dairy and pharmaceutical applicationsboth nationally and internationally.
Flexicons design engineering staff devises efficient
solutions to the most unusual problems with highly
custom equipment, basing solutions on unique
customer requirements, not merely on existing product

Choose from a broad range of reliable, high performance


equipment in carbon steel with durable industrial finishes, or
in stainless steel designed and constructed to industrial, food,
dairy or pharmaceutical standards:

Flexible Screw Conveyors


Volumetric Feeding Conveyors
Tubular Cable Conveyors
Pneumatic Conveying Systems
Bulk Bag Fillers

Bulk Bag Dischargers


Bulk Bag Conditioners
Weigh Batching Systems
Manual Dumping Stations
Drum/Box/Container Dumpers

Flexicon can also custom-engineer automated, plant-wide


bulk handling and processing systems that integrate Flexicon
equipment with bulk handling and process equipment of other
manufacturers including:
Gravimetric/Volumetric
Feeders
Silos and other storage
vessels
Dryers/Coolers
Mixers/Blenders
Screeners
Crushers/Grinders
Packaging Machines
Other bulk processing
equipment

line offerings. This approach provides each customer


with the most efficient solution to his or her individual
problem, and endows Flexicon with a depth and
breadth of bulk handling experience unequalled by
any other comparable manufacturer in the world.

Flexicon Corporation | Tel: +1 610 814 2400


sales@flexicon.com | www.flexicon.com

input #38 at www.plantengineering.com/information

A DV E R T I S E M E N T

Choose FS-Elliott to lower your compressed air energy costs.


For over 50 years, FS-Elliott has been at the
forefront of centrifugal compressor design and
engineering, incorporating the latest aerodynamic
and control system technologies to ensure optimum
performance. This experience allows us to deliver
reliable, energy-efficient air compressors with the
lowest cost of ownership of any compressor on the
market today.

Increase energy efficiency, improve


your bottom line.

Energy costs can account for up to 75% of the


total life cycle cost of an air compressor.
To reduce power requirements, FS-Elliott
compressors combine optimized aerodynamic
stage matching with intercooler efficiencies. By
controlling the amount of air being compressed,
and consequently the power consumed, our inlet
guide vanes adjust to plant conditions and load
variations to conserve energy.
FS-Elliotts R1000 Control System efficiently
manages plant load while maximizing energy
savings. Advanced control modes enable
operators to reduce waste and decrease their
facilities energy consumption while the 9-inch
full touch screen display makes managing the
compressor an intuitive, user-friendly experience.
These features that serve to improve plant
operation have earned the product a 2014
Plant Engineering
Product of the Year
award.
The R1000, part of
FS-Elliotts Regulus line
of control systems, offers
flexible control options and
proactive service notifications
to make managing your
compressor a simple, stressfree experience.

FS-Elliotts Polaris+ industrial air compressors deliver the


highest quality, efficiency, and ease of operation that make any job
more successful.

Minimal maintenance keeps your


operations up and running.

Designed to operate reliably for extended periods,


FS-Elliotts centrifugal compressors feature no
wearing parts that would require regular replacement. The horizontally split gear case and internal
components provide the only truly field serviceable
gear box in the industry, avoiding costly production
shutdowns as a result of sending the airend out
for maintenance.
Offering customers maintenance savings along
with across product energy efficiencies, FS-Elliott
compressors lead the industry in delivering troublefree operation with the lowest cost of ownership.
To learn more about the benefits of employing an
FS-Elliott compressor in your operation, visit
www.fs-ellliott.com.

FS-Elliott Co., LLC | 724-387-3200 | info@fs-elliott.com | www.fs-elliott.com


input #39 at www.plantengineering.com/information

A DV E R T I S E M E N T

Custom Solutions from a Heritage of Innovation


performance without compromising pressure/flow
requirements or system reliability. We can also
produce 2D and 3D CAD drawings of the proposed
system to facilitate installation planning.

Our containerized compressed air systems are ideal for


installations where floor space is limited.

Our turnkey, all-weather compressed air packages


integrate our high quality compressed air systems
with rugged, weather-proof containers. These are
built to specification for any climate or location
and feature our superior quality air compressors,
blowers, dryers, filters, SmartPipe, and other system
accessories. Remote operations are supported by
our Sigma Air Manager, which controls air production
and offers a variety of industrial communications
interfaces for seamless integration into remote
monitoring and control systems.

With a heritage that extends back to 1919,


Kaeser Compressors, Inc. is an industry leader in
manufacturing industrial compressed air equipment.
With a cutting edge research and development team
committed to building industry-leading products, innovation is our lifeblood. Kaesers custom, containerized
compressed air systems are yet one more way we
are delivering better solutions to meet our customers
compressed air needs.

Our world-renowned
energy efficient industrial
compressed air equipment is
in each of our custom-built
containerized solutions.

There is nothing
cookie-cutter about
our containerized
compressed air systems.
Our team of engineers
works with you to determine your system needs.
Using our Air Demand
Analysis (ADA) and
Kaeser Energy Saving
System (KESS), we
can evaluate your
existing installation
and demonstrate how
proposed changes will
improve your system

Our turnkey, all-weather compressed air packages integrate our high


quality compressed air systems with rugged, weather-proof containers.

Each and every component is selected for optimal


efficiency and is backed by the built-for-a-lifetime
reliability you expect from the Kaeser name.
Kaeser isnt intimidated by demanding applications.
Our commitment to designing the best engineered
solutions results in compressed air systems that
remain reliable even in the toughest of applications
in the harshest of environments. Thats why our
customers know us as the air systems specialist.
Contact us today for a custom solution for your
compressed air needs.

customer.us@kaeser.com | 866-516-6888 | www.us.kaeser.com


input #40 at www.plantengineering.com/information

A DV E R T I S E M E N T

Lubriplates Complimentary ESP Extra Services Package


helps maximize your lubrication maintenance program

Complimentary Value Added Services


Offered Include...
A Toll Free Technical Support Hotline and E-mail

You can call Lubriplates technical service center toll free at 800-347-5343 for
quick answers to tough lubrication questions by phone, or you can e-mail
questions to LubeXpert@lubriplate.com seven days a week.

Complete Plant Surveys and Lubricant Inventory Consolidation

Complete plant surveys by Lubriplates professional staff of lubrication engineers


are also available to determine your exact lubricant requirements and identify
opportunities for lubricant inventory consolidation.

Color Coded, Lubricant Specification, Machinery Tags

Lubriplate offers customized, color coded machinery tags to help prevent lubricant
misapplication and ensure that the proper lubricant is used when servicing a
particular piece of equipment. Based on a complete plant survey, tags can be
provided for each piece of equipment in your plant.

Lubrication Maintenance Software

Lubriplate offers a PC based computer software program that puts your entire
lubrication and maintenance schedules at your fingertips. This service is based
on a complete survey of your entire plant. Contact Dan Moroses (Newark office)
for details at 973-589-9150.

No-Charge Follow-up Oil/Fluid and Grease Analysis

Lubriplates Oil|Fluid and Grease Analysis Program is offered at no-charge on all


Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment
and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO Cleanliness (optional). An interpretation of the results is included along with suggested
actions to take.

In Plant User Lubrication Training Programs

We offer training programs tailored to your needs. These educational training


sessions focus on all facets of machinery lubrication and are not a sales
presentation. Seminars are graphically presented with overheads and other support material. Available on-site at your facility or in a local conference room.
Contact us at 800-733-4755 for more information.

Lubriplate Lubricants Company


1-800-733-4755 | www.lubriplate.com | LubeXpert@lubriplate.com
input #41 at www.plantengineering.com/information

A DV E R T I S E M E N T

Field proven vibration monitoring solutions


ensure uptime, all the time
and costly delays. The quality and performance of our
sensors ensure accurate signals for faster detection,
enabling successful condition monitoring of critical
and balance-of-plant assets. Our extensive offering of
sensors includes general purpose, high/low frequency,
high temperature, underwater, dual-output, triaxial
and 4-20 mA.
Advanced sensors for specialized applications include
radiation rated, high-EMI resistant, and low power/
low voltage. Wilcoxon Research sensors offer
outstanding measurements under extreme conditions
to help solve faults before they become problems.

Innovative solutions for


industrial monitoring

Meggitt Sensing Systems manufactures reliable, field


proven Wilcoxon Research vibration monitoring
solutions for improved production efficiency and
equipment stability, enabling longer deployments
and reducing service intervals. Our reputation as an
industry leader of quality products is backed by more
than 60 years of experience providing innovative, costeffective sensors.

Portable verification:
field test the entire
measurement
chain

The ReferenceMate
portable vibration reference
source provides a constant 1 g
test level to easily verify sensor
performance and the integrity
connections between sensor and the data
acquisition system. Three frequency outputs
eliminate conversions between imperial, metric
or calibration sheet values. With a number of selfdiagnostic features to ensure data integrity, the REF2500
is a cost-effective and trustworthy solution. Instill
confidence in your entire measurement chain before
beginning expensive tests or taking critical data.

High performance sensors keep


equipment available

Early detection of changes in the vibration signature of


rotating machinery is critical in preventing damage

Solutions enclosed:
unbeatable accuracy, faster readings

The new generation of Vibralink enclosures has a


range of features offering unparalleled reliability,
flexibility and compatibility as well as reducing
data-collection time. The rugged enclosures are
backed by lifetime warranty, have 66% more interior
space for easy wiring and are compatibile with most
IEPE sensors including dual-output and triaxial models.
A collection point for up to 48 permanently-mounted
accelerometers monitoring vibration of rotating
machinery informs technicians if misalignment,
imbalance or bearing wear is occurring. Industry
exclusive data-ready LEDs (patent pending) illuminate
when BOV levels have stabilized and reliable data can
be collected. Save up to seven seconds waiting time
per channel and up to one hour per typical route.

Contact wilcoxon@meggitt.com
800 WILCOXON | www.wilcoxon.com

input #42 at www.plantengineering.com/information

A DV E R T I S E M E N T

MiVending Demos Inventory Savings Opportunities


Motion Industries is a leading industrial parts
distributor of bearings, mechanical power transmission,
electrical and industrial automation, hydraulic and
industrial hose, hydraulic and pneumatic components,
industrial and safety products, and material handling.
The utmost commitment to its valued supplier and
customer relationships solidifies Motions strong sense
of customer orientation and a culture of support.

where a large coil or carousel machine would be too


much. The unit can be stacked, and can be customized
to any combination of coils, carousels, and shelving.
Second is the Cab-Lock, a drawer unit which although
is already in place in some of Motions customer sites,
will be seen for the first time by some of the customers
who visit the new trucks.

Inventory Management

The companys industrial expertise seems to know no


limits, and one of its fast-growing areas is inventory
management. The MiVending program as particularly
taken off, with more and more customer facilities
realizing savings in costs, product usage, and
manpower hours with the program.
The easy, hassle-free vending solution that keeps
facilities valuable inventory under control and makes
it accessible only to authorized personnel. Product
usage has been proven to be reduced by up to 35%,
and the system also automatically reorders products,
reduces maintenance downtime, customizes usage
restrictions, and provides detailed reporting.

Above: the X3 combines smaller versions of the Coil and


Carousel solutions. To the right of it stands a Cab-Lock model, with
the photo below showing the cutaways in the top drawer.

MiVending on the Road

Two air-conditioned, 26-foot box trucks regularly visit


both Motion branch and customer sites, introducing
MiVending to interested visitors. Inside are five
working, inventory-filled demo models.
In addition to the traditional Coil and Carousel models,
the trucks house several new or upgraded solutions.
The first is a small hybrid machine called the X3, which
combines smaller versions of both the coil machine
and the carousel. The X3 provides the perfect best of
both worlds, with flexibility for smaller locations

Through effective customer solutions, innovative ideas,


systems and best-in-class business practices, Motion
Industries will continue to strengthen its assets
People, Products, and Processes.

input #43 at www.plantengineering.com/information

A DV E R T I S E M E N T

Paratherm Innovates Antioxidant Additive


for Heat Transfer Fluid Systems
Breakthrough Paratherm AP
rejuvenates oxidized hot oil

Usually, a new product from Paratherm is a heat


transfer fluid, or sometimes a liquid for cleaning out
deposits of sludge and carbon that form inside the
system when the fluid deteriorates.
But, a new product introduction for hot oil systems
doesnt fit in either of those categories. The
Paratherm AP (Antioxidant Protection) Additive is
designed to be added to operating hot-oil systems to
extend the oils useful life.
Acids are the cause of the most common hot-oil
system problem sludge says Jim Oetinger,
technical director for Paratherm. When expansion
tanks are installed and operated properly, the oil stays
cool and acid formation is very slow. However some
expansion tanks arent installed properly. Sometimes
the expansion line is insulated or is less than 4 long.
Warm-up valves are left open or sunlight hits a tank
that is painted a dark color. These can cause the tank
to run hot enough to form acids when the oil reacts
with oxygen. And once the Acid Number reaches
0.3-0.4, carbon starts to form.

A sample of used thermal oil was spiked with 10% Paratherm AP


and then subjected to accelerated oxidation testing. Test results show
the AP additive stopped sludge generation dead in its tracks.

Incorporating a sacrificial antioxidant, Paratherm AP


prevents the acids from converting to sludge. Its not
a permanent cure sacrificial additives become
depleted over time and eventually the protection
stops. Antioxidants dont eliminate the need for preventive maintenance, they just reduce or delay the need for oil
change-out. Periodic testing is the only truly accurate way to tell whether the additive is still present.
In 20+ years of analyzing samples and advising customers Ive seen more problems from
oxidation than from overheating or any other single issue, says Oetinger.
Before this product came on the market, the only alternative to an elevated acid number was
to change out the fluid, entirely or in part. But Paratherm recognizes that change-out isnt
always convenient, or even possible, in certain processing situations. In particular, seasonal
operations like asphalt production have no time for downtime when the paving push is on.
Paratherm AP Additive is available in 55-gallon drums. If theres a need, for smaller systems,
5-gallon pails may be introduced as well.
Jim Oetinger
Dir. of Technology

Toll Free: 888-373-1299 | www.paratherm.com/plant-engineering


input #44 at www.plantengineering.com/information

A DV E R T I S E M E N T

Send I/O signals a long distance


without pulling wires or trenching
The systems are conformal coated
and can be operated in temperatures
ranging from -40 C to 85 C. This
secure, point-to-point system allows
for down to 100 ms response time.
The system is scalable, letting you
add up to 16 pairs of modules. Single
power termination per station allows
you to cut down on wiring time.

ProSoft Technologys new Wireless I/O system requires no


software configuration and can be deployed in a few hours.

If you need to wire I/O from one point


to another, you can be looking at a long
process if you go with traditional hardwire
infrastructure between trenching, running
conduit, pulling wires and permits, youre
facing a process that will cost a lot of time
and money.
ProSoft Technology has a solution for you:
Our Wireless I/O system takes only a few
hours to deploy not months. Its setup
requires no software conguration, and
mounts onto a 35 mm DIN rail with no tools.

The system features 128-bit AES


encryption, ensuring that your
information is safe from outside
intrusion. The system identies and alerts
you to any RF and I/O failure. The FailSafe
feature allows the user to dene output state
in the event that I/O communication is
ever lost.
For more information on how ProSoft
Technologys Wireless I/O system can
help you in your application, visit
http://psft.com/A5C.

Radio, discrete and analog modules are


available. The radio modules have a range
of up to 4 miles (900 MHz) and 1 mile
(2.4 GHz), and various antenna and cable
combinations are available.

ProSoft Technology | www.prosoft-technology.com | 661-716-5100


input #45 at www.plantengineering.com/information

A DV E R T I S E M E N T

A trusted leader in the field of drive technology


Engineering excellence and customer responsiveness distinguish
SEW-EURODRIVE, a leading global manufacturer of integrated power
transmission and motion control systems.

MOVIDRIVE

Got lean staffing? Then, lean on SEW-EURODRIVE. Their MOVIDRIVE


inverter requires zero programming. So, you dont need an engineer
who speaks IEC 61131, C#, or C++. Simply enter your parameters into its
solution modules. Startup couldnt be easier or faster! MOVIDRIVE also
substantially reduces the load from your main PLC and dramatically
improves the PLCs performance. Plus, you can even use your existing
control system because MOVIDRIVE speaks your fieldbus language.

MOVIGEAR
The MOVIGEAR Mechatronic Drive System for horizontal material
handling from SEW-EURODRIVE sets new standards in efficiency and
functionality. MOVIGEAR combines the gear unit, motor and drive
electronics within one highly efficient and hygienically designed unit.
Independent research has proven that MOVIGEAR reduces total startup cost and annual operating costs in material handling by
20-30%. However, actual installations have shown even higher savings
to 50% or more! If thats not enough, MOVIGEAR even reduces your
inventory expense with its unique ability to cover a broad range of
gear ratios with a single unit. Less really is more

PT Pilot Drive Selection Tool


Compatible with smartphones and tablets!
TIME = MONEY. That is why SEW-EURODRIVE developed PT Pilot.
This online program quickly provides a complete quote with options,
parts lists, and 2D/3D CAD drawings for a gear unit or gearmotor.
The entire process is intuitive from start to finish and completely
paperless. It is accessible via a standard web browser no special
software or plug-ins. Plus, PT Pilot is compatible with smartphones
and tablets so it can be accessed anytime, anywhere!
PT Pilot contains a special section for design engineers. Its
engineering calculator automatically sizes a drive for conveyors, travel cars, and hoists
with or without an inverter. Just enter the design parameters and let PT Pilot do all the work.
SEW-EURODRIVE . . . Driving the World

U.S. Headquarters Lyman, SC | Telephone: 864-439-7537 | cslyman@seweurodrive.com


www.ptpilot.com | www.seweurodrive.com
input #46 at www.plantengineering.com/information

A DV E R T I S E M E N T

Yaskawa Industrial AC Drives


Yaskawa drives incorporate the latest technological advancements in variable speed AC motor control,
made possible by experience and dedication to quality. From simple to complex applications, Yaskawa has
a variety of drive products to fit your needs, providing low voltage solutions from fractional HP up to 2250 HP
and medium voltage solutions up to 5000 HP.

U1000 Industrial Matrix Drive - Yaskawas latest innovation, the U1000 Industrial Matrix Drive, is
the companys greenest drive ever, going beyond the performance of conventional drives. Enjoy extremely
low harmonic distortion and regeneration in a space-saving design, completely without the need for
additional components. Unlike conventional drives, Yaskawas Matrix technology employs a system of
9 bi-directional switches that are arranged in a matrix to convert a three-phase AC input voltage
directly into a three phase AC output voltage. This eliminates the need for a rectifying circuit
and DC smoothing circuit that are used in traditional AC drive inverters. The result is a
compact drive with full regenerative capability and reduced harmonic distortion.
Full Power Regeneration: Traditional drives utilize regenerative braking resistors to
dissipate energy as heat, reducing energy efficiency. The U1000 Industrial Matrix drive
allows you to return regenerative energy directly back to the power supply, increasing
energy efficiency and saving money.
Power Quality Improvement: When a conventional AC drive converts power, the input
current becomes distorted, resulting in reduced power quality. Matrix technology reduces
total harmonic distortion levels to 5%, without the need for reactors and filters. The result
is a smoother current waveform that reduces stress on the system power supply and
infrastructure. Additionally, reduced distortion improves power factor and thus, reduces
energy costs.

Primary Features

Fully Regenerative
Low Input Distortion Across a Wide Load
and Speed Range
IEEE-519 Compliant (<5% THD)
Eco-Mode to Achieve Near Across-the-Line THD
Near Unity Power Factor
Integrated Input Fusing Provides 100kA SCCR
Compact Design

Available in these
voltage and power ranges:
240V Class: 10 100 HP Normal Duty
(7.5 75HP Heavy Duty)
480V Class: 7.5 350 HP Normal Duty
(5 300HP Heavy Duty

1-800-YASKAWA (927-5292) or (847) 887-7318 | www.yaskawa.com | marcom@yaskawa.com


input #47 at www.plantengineering.com/information

ADVERTISEMENT

AVO Training offers


over 52 Electrical Safety &
Maintenance Courses
AVO Training offers the most prolific
Electrical Maintenance Safety Course
selections in the industry. Act before
quipment is destroyed, people injured
or worse.
Thats why we do what we do.

Electrical safety is essential

www.avotraining.com/courses/electrical-maintenance-training/

input #48 at www.plantengineering.com/information


pe201506_innovind_HalfAVO.indd 1

5/15/2015 12:09:56 PM

ADVERTISEMENT

World-Wide leaders to support all applications


SPM Instrument, established 1970 in Sweden, is today a leading provider of
products and services for the Vibration Analysis Industry. Sales and service
representatives in over 50 countries support the comprehensive and innovative
SPM product lines. SPMs goal of providing state-of-the-art equipment with the
longest possible fault pre-warning times, while presenting data in an easy-touse format has resulted in continuous development of new products and
technologies for the Vibration Industry.

Most advanced instruments on the market

Intrinsically Safe ATEX/IECEx certified for use in zones 0 to 2 complies with the
strictest IS standards. Options for 3-channel simultaneous vibration
measurements, up to 40 kHz, 25,600 line FFT, Single & Dual plane balancing,
Laser RPM sensor, IR Temperature, Stethoscope, Voice recording capability,
SPM HD, plus much more, make the Leonova Diamond/Emerald instruments the
most advanced currently available for the IS market.
The recently released SPM HD allows for accurate and repeatable rolling
element bearing damage detection and lubrication information even for
bearings running < 10 RPM. SPM Instrument is one of the few condition
monitoring companies to be recognized as an Approved Service Supplier
by DNV GL a world-leading classification society.
input #49 at www.plantengineering.com/information

Lightweight rugged 3-Channel


Vibration in Leonova Diamond

info@spminstrument.com
1-800-505-5636
www.spminstrument.com

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VAC-U-MAX Defining the Leading Edge of Technology


As a single source supplier, VAC-U-MAX has defined
the leading edge of technology for bulk materials
handling, designing, manufacturing, selling and
supporting VAC-U-MAX systems worldwide. Product
range includes loaders, receivers, bulk bag loading/
unloading systems, mechanical / flexible screw
conveying, bag dump stations, diverter valves, feed
bins and vacuum pump packages.
Additionally VAC-U-MAX manufactures a full range
of portable and central industrial vacuum cleaning
systems for plant-wide clean-up maintenance, including portable units, continuous-duty electric vacuum
cleaners, and complete central vacuum cleaning
systems for high volume recovery of dusts, powders,
granular materials, liquids, sludge, metals, and any
flammable liquid or combustible dust. VAC-U-MAX

experience in cleaning
combustible dusts dates
back over 60 years, and
today VAC-U-MAX is
considered a subject
expert in the safe
collection of combustible
powders and metals,
flammable liquids and
pyrophoric materials.

Onsite bulk materials testing


incorporates pneumatic and
mechanical conveying
components and complete
material transfer systems

VAC-U-MAX is a UL-listed
designer and manufacturer
of control panels, maximizing
the coordination and movement of powders
and bulk materials for batch and
continuous processing.

1 (800) VAC-U-MAX, 973-759-4600 | Fax: 973-759-6449


info@vac-u-max.com | www.vac-u-max.com
input #50 at www.plantengineering.com/information

pe201506_innovHlf_Vacumax.indd 1

5/14/2015 11:42:13 AM

Check out Plant Engineerings NEW industry-focused eNewsletters!


Industry News & Products: Packaging

This newsletter will cover the industry highlights, products, and


technological advancements in the packaging industry every month.

Industry News & Products: Chemical Manufacturing


Get updates on chemical and process manufacturing trends,
industry highlights, and more.

Oil & Gas Engineering Newsletter

Your source for articles covering business-critical functions and


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midstream Oil & Gas sectors.

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Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

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Input #100 at plantengineering.hotims.com

Input #101 at plantengineering.hotims.com

Input #102 at plantengineering.hotims.com

Compressed Air System Installation Guide

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Input #103 at plantengineering.hotims.com

86 June
Month2015
2014 PLANT
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Written by Kaesers team of engineers


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Now available for
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Input #104 at plantengineering.hotims.com

Input #105 at plantengineering.hotims.com

www.plantengineering.com

IN NOVATIONS

Send new product releases to: peproducts@cfemedia.com

Torque inserts
A dual-ended attachment design as an additional mounting-profile option has been
developed for newly patented TI-300 Series Torque Inserts. The dual-ended
attachment version allows use of a single torque insert in an application and
results in even load bearing and design stability. This latest innovation expands
the portfolio of TI-300 Series mounting profiles, which also include exposed
shaft end, knurled zinc adapter (for installation into plastics), and oneway bearing adapter.
Reell Precision Manufacturing Corp.
www.reell.com
Input #200 at www.plantengineering.com/information

Manhole light fixture


The MMLP-150LED-RT-12P temporary manhole mount LED
light fixture from Larson Electronics provides operators with a
powerful and highly convenient alternative to traditional string
or tank lights. LED technology, an innovative 21-in. man-way
support bracket and compact design makes this lamp an
excellent lighting solution for operators working within storage
tanks. This Class 1 and 2, Division 1 and 2 tank mount explosion-proof light fixture provides 13,000 lumens of high quality
light while drawing only 150 W of power. This explosion proof
LED light is attached to a 21-in. supporting plate which allows
the light fixture to hang down 12 in. inside the tank.
Larson Electronics
larsonelectronics.com
Input #201 at www.plantengineering.com/information

Cleaner/degreaser
Oil Eater Original is a water-based
cleaner-degreaser that quickly and
safely dissolves grease, oil and grime
from machinery, motors, concrete
floors, tools and other surfaces. The
unique formula is ultra-concentrated,
low-VOC, non-flammable, non-toxic,
non-corrosive, biodegradable and
contains no acid, abrasives or petroleum solvents. It also can be used in
parts washers and pressure washing
systems.
Oil Eater
www.oileater.com
Input #202 at www.plantengineering.com/information

www.plantengineering.com

PLANT ENGINEERING

June 2015 87

IN NOVATIONS
Compressed air filters
UD+ coalescing compressed air filters are available
with capacities of 19 to 16950 scfm, which combine
two filtration processes into one product while reducing
pressure drops by 40 percent. The two-in-one UD+ filter
utilizes wrapped filter technologyan innovative glass
fiber filter media package wrapped around the filter
core. Compared with traditional pleated filters, one UD+
filter is more efficient and reliable than two in-line filters
that were previously required to bring oil aerosol and
solid particles in the compressed air down to levels that
meet ISO 8573-1 Oil Class 1 and 2 and ISO 8573-1 Solid
Particle Class 1 standards.
Atlas Copco
www.atlascopco.com
Input #203 at www.plantengineering.com/information

Calibrator
The 525B Automated thermocouple calibrator fits
in the palm of your hand and weighs less than 1
lb. The rugged design still allows for easy use in
the field with a protective rubber boot, low profile
switches, easy access AA battery compartment
and a backlit display. The easy to use double
click menu system allows for quick setup, fast
switching between functions, pre-programming
of set points and of step/ramp times. Standard
functions include sourcing and reading of 14 T/C
types, 12 RTD curves, millivolts and ohms.
Practical Instrument Electronics
www.piecal.com
Input #204 at www.plantengineering.com/information

88 June 2015

PLANT ENGINEERING

www.plantengineering.com

Send new product releases to: peproducts@cfemedia.com

Circuit breaker switchgear


HVL/cb Metal-Enclosed Vacuum Circuit Breaker Switchgear
features the unique combination of the industrys smallest
footprint vacuum circuit breaker with an integrated load disconnect switch. The low-cost solution offers a space-efficient
alternative to traditional metal-clad switchgear, maximizing
desirable facility floor space, while reducing operational and
maintenance costs. The HVL/cb switchgear offers reliability
through the limited number of moving components that must
be maintained. The reduced amount of lubricants and materials that need to be maintained traditionally is not required with
HVL/cb, making the switchgear virtually maintenance free.
Schneider Electric
www.schneider-electric.com/us
Input #205 at www.plantengineering.com/information

Vertical machining centers


The FV Series vertical machining centers are built in
both single-spindle and twin-spindle head designs
for mass production lines of complicated workpieces
in automotive, appliance, electronics, and energy
industries. Machines in this series are also suitable
for automatic production with the integration of a
robot on either a floor-type motion axis rail system or
overhead gantry. The fixed twin-spindle type is able
to process two individual machining tasks simultaneously. With the addition of an A-axis trunnion table, the
FV series instantly becomes a horizontal machining
center, offering two machines in one, reducing floor
space and additional machinery costs.
Absolute Machine Tools Inc.
http://absolutemachine.com
Input #206 at www.plantengineering.com/information

www.plantengineering.com

PLANT ENGINEERING

June 2015 89

Global System Integrator Database Featured Integrator

Superior Controls, Inc.


Rick Pierro, President
135 Folly Mill Road
PO Box 457
Seabrook, NH 03874
Telephone: (603) 468-3000
Email: rpierro@superiorcontrols.com
Website: www.superiorcontrols.com
Founded: 1993
Annual Revenue: $1049 M

Primary Industries
Chemicals, Petrochemicals
Food, Beverage
Life sciences, Biotechnology

Affiliations
CSIA
CSIA Certified
ISPE
SI Hall of Fame
Superior Controls, Inc. is New Englands largest, independent,
full service systems integrator specializing in the design and
implementation of turnkey industrial automation and information
systems. Superior Controls is also New Englands longest serving
certified member of CSIA. Superior Controls has successfully
implemented control systems utilizing all major PLC and DCS
systems and has extensive experience in Biotechnology, Food and
Beverage, Energy, and Chemicals. Documented project management procedures include design checks, rigorous simulation, and
full GAMP compliant, validation documentation.

For more information on Superior Controls, Inc. and to view


their full profile in the Global System Integrator Database, visit

www.plantengineering.com/
global-si-database/superiorcontrolsinc

The Global System Integrator Database is


now available on your mobile device!
Find and connect with the most suitable
service provider for your unique application.
To start searching the Global System
Integrator Database, or to create your own
System Integrator Corporate Profile visit

www.plantengineering.com/
global-si-database

IN NOVATIONS

Send new product releases to: peproducts@cfemedia.com

Crimping tools
The PZ 10 HEX and PZ 10 SQR crimping tools
are suitable for wire-end ferrules, with or without
plastic collars so there is no need to swap tools
when crimping wires of various gauges. Hexagonal or square wire-end ferrules provide a more
secure connection than other crimping forms for
screw, spring or direct plug-in clamping systems.
The shape of square crimped wire-end ferrules
offer optimal protection against twisting at the
contact point. An automatic stop prevents the
tools from being opened unintentionally during
crimping to eliminate costly errors and ensure
consistent crimping quality.
Weidmuller
www.weidmuller.com
Input #207 at www.plantengineering.com/information

Cold- weather cable


The extremelife-60 platform cable is designed with a
specially engineered proprietary cable jacket material
that allows it to remain flexible enough to work down to
-40 C, and carry UL -60 C cold bend and UL/CSA -40 C
cold impact listings, as well as an FT4 flame rating. The
extremelife-60 cables are available in a wide variety of
AWG sizes, constructions, conductor counts and cable
jacket colors. In addition to its cold bend, cold impact
and flame ratings, the extremelife-60 cables also have
ITC and PLTC approval from UL, as well as CIC approval
from CSA, which makes these cables code compliant
for NEC and CEC Class 1 Division 2 hazardous location
applications.
TURCK
www.turck.us
Input #208 at www.plantengineering.com/information

www.plantengineering.com

PLANT ENGINEERING

June 2015 91

IN NOVATIONS

Send new product releases to: peproducts@cfemedia.com

PCBN inserts
The CBN600 universal PCBN insert grade brings cost-effective performance to high-volume rough-turning operations that involve gray cast iron,
high chrome iron and high manganese steel workpiece materials. This solid
insert combines 90 percent cBN content, a multi-modal grain size and an
Al ceramic binder to easily tackle abrasive workpiece materials, heavy cutting forces and high levels of thermal shock for varying depths of cut conditions. It encompasses nine standard products with double-sided inserts
available in round, rhombic and square styles.
Seco Tools
www.secotools.com/us
Input #209 at www.plantengineering.com/information

Vacuum conveyors
The aluminum 3/8 and 1/2 NPT Threaded Line Vac Air Operated
Conveyors convert ordinary pipe into a powerful conveying system
for parts, scrap, trim and other bulk materials. Threaded Line Vac
Conveyors eject a small amount of compressed air to produce a
vacuum on one end with high output flows on the other. Regulating the compressed air pressure provides infinite control of the
conveying rate. Applications include scrap trim removal, material
conveying, part transfer, fiber tensioning, filling operations and
sampling.
EXAIR Corp.
www.exair.com
Input #210 at www.plantengineering.com/information

Wall-mounted air conditioners


The NEMA Type 3R Air Conditioners are off-the-shelf solutions that
are UL listed and ready for UL508A applications in both indoor and
outdoor environments, or anywhere water ingress is a concern. Typical applications include oil and gas, mining, paper and pulp, water
and wastewater, food and beverage, and pharmaceutical installations. Many of the Type 3R Air Conditioners energy performance
advantages are tied to its unique nano-coated condenser, a 5 m
thick ceramic coating that provides no loss of cooling capacity and
requires no solvents to clean and allows for longer maintenance
intervals. In most applications, no filter is required.
Rittal
www.rittal.us
Input #211 at www.plantengineering.com/information

92 June 2015

PLANT ENGINEERING

www.plantengineering.com

PRODUCTMART
OIL MIST & SMOKE
IN YOUR SHOP?
www.mistcollectors.com

Why Should You


Filter Your Water?

Tel: 1-800-645-4174

Input #100 at plantengineering.hotims.com

STAY INFORMED
Stay current with technology and trends
in electrical, mechanical, maintenance
and automation.

Scale formation reduces the heat transfer rate and


increases the water pressure drop through the heat
exchanger and pipes. In fact, one study has shown
that .002" fouling will increase pumping needs by 20%.

The Best Engineered Water Filtering


Solution Always Costs Less

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2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A
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w w w. t e k l e e n . c o m
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Input #101 at plantengineering.hotims.com

Input #102 at plantengineering.hotims.com

3.5

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meltric.com
800.433.7642
Input #103 at plantengineering.hotims.com

www.plantengineering.com

Input #104 at plantengineering.hotims.com

PLANT ENGINEERING

June 2015 93

For more information on how to advertise in Plant EnginEErings


Internet Connection, call Jim Langhenry at 630-571-4070 x2203
alliedelec.com

Allied Electronics is a small order, high service level distributor of electronic components and electromechanical
products with over 50 sales offices across the United
States and Canada.
Allied Electronics

automationdirect.com
AutomationDirect offers 6,500+ industrial automation
products through their free catalog and online store,
including PLCs, operator interfaces, sensors, and more.
AutomationDirect

baldor.com
Baldor Electric designs, manufacturers, and markets a
broad line of industrial energy-efficient electric motors,
mechanical power transmission products, and more.
Baldor Electric Co.

bimba.com
Bimba Manufacturing provides pneumatic, hydraulic and
electric solutions, including a variety of stainless steel
body air cylinders that are easy-to-use and reliable.
Bimba Manufacturing Co.

camfilapc.com

flexicon.com

rittal-corp.com

Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide
systems.
Flexicon Corp.

Rittal manufactures the worlds leading industrial and IT


enclosures, racks and accessories, including high-efficiency, high-density climate control and power management
systems.
Rittal Corp.

fs-elliot.com
Manufacturer of oil-free centrifugal air and gas compressors with sales, service, and manufacturing locations
around the world.
FS-Elliot

gtispindle.com
GTI Spindle Technology provides the highest quality and
most extensive range of machine tool spindle repair services.
GTI Spindle Technology

us.kaeser.com
Manufacturer of air system products, including rotary
screw compressors, portable compressors, rotary lobe
blowers, vacuum packages, refrigerated and desiccant
dryers, filters, and condensate management systems.
Kaeser Compressors Inc.

seweurodrive.com
One of the largest global suppliers of drive technology,
SEW-EURODRIVE specializes in gear reducers, motors
and electronic motor controls.
SEW-EURODRIVE USA

automation.siemens.com
Siemens is a leader of automation technology products for
all industrial sectors. Learn more about our unique range
of products and systems.
Siemens Automation Group

siemens.com/large-drives-products
Everywhere where large drives are required in industry and infrastructure, Siemens business division Large
Drives offers the ideal solution.
Siemens Large Drives Products

Camfil Air Pollution Control (APC) is a leading global


manufacturer of industrial dust, fume and mist collection
equipment and is part of Camfil, the worlds largest air filtration company.
Camfil APC

keysight.com

spminstrument.com

Keysight Technologies is an electronic measurement company that offers wireless, modular, and software solutions.
Keysight Technologies Inc.

SPM offers a wide product range from high-tech portable


instruments to online systems and a comprehensive software.
SPM

distanceissafety.com

Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and
NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.

CBS ArcSafe remote racking systems increase safety.


Rack low- and medium-voltage draw-out circuit breakers while standing outside the arc-flash hazard protection
boundary.
CBS ArcSafe Inc.

clarcorindustrialair.com
CLARCOR Industrial Air helps customers achieve air quality and plant performance goals with products and solutions for gas turbine inlet filtration, industrial filtration, and
membrane technologies.
CLARCOR Industrial Air

electroind.com
Electro Industries specializes in power meters and smart
grid solutions that excel at revenue grade energy measurement, power quality and advanced telemetry.
Electro Industries/Guage Tech

est-static.com
EST specializes in mitigating static charges, induced voltages and random discharges on rotating shafts, moving
surfaces, and all types of manufacturing equipment.
Electro Static Technology

erectastep.com
Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal
steps bolts together with no fabrication required and are
easily repurposeable.
ErectaStep

94 June 2015

plant engineering

lubriplate.com

movincool.com
The MovinCool division of DENSO has been responsible
for pioneering the use of portable air conditioning solutions
for a wide variety of U.S. markets since 1982.
MovinCool

oeo.com
OEOs mission is to deliver cost effective energy solutions
to businesses and institutions.
OEO Energy Solutions

orival.com
Orival is a leading manufacturer of self-cleaning water
filters, automatic water filters and strainers, for use as
industrial water filters, irrigation filters, cooling tower filters, and more.
Orival Inc.

paratherm.com
Paratherm service specialists and engineers evaluate,
understand, and improve hot-oil systems, heat transfer
fluids, and processes.
Paratherm Corp.

phoenixcontact.com
Phoenix Contact is a worldwide leader in the manufacture
of industrial automation, interconnection, and interface
solutions.
Phoenix Contact

stanleyproto.com
Stanley Proto offers high-quality hand tools developed
according to strict ergonomic standards, with features
that lets users work faster and easier, including enhanced
shock absorption and reduced slip.
Stanley Proto

sullair.com
Sullair is a designer and manufacturer of stationary and
portable rotary screw air compressors, air treatment
equipment, and pneumatic tools.
Sullair Corp.

klsummit.com
Industry leader in synthetic lubricant technology with a line
of over 200 products that can service almost any industrial
application.
Summit Industrial Products

unitedrentals.com
United Rentals is the largest equipment rental company
in the world with locations in 49 states and 10 Canadian
provinces.
United Rentals Inc.

vac-u-max.com
VAC-U-MAX specializes in design and manufacture of
pneumatic systems and support equipment for conveying,
weighing and batching of dry materials.
VAC-U-MAX

yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation
systems.
Yaskawa America Inc.

www.plantengineering.com

Place next to your computer or go online to www.plantengineering.com for hot links to these companies.

Remove at
Line

2015
June

CONTACTS

Advertiser Contacts for plant engineers

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
Page
Number

Advertiser

RSC
Number

Allied Electronics
800-433-5700

13

AutomationDirect
800-633-0405

C-2

Baldor Electric Company


800-828-4920

C-4

52

10
www.alliedelec.com
www.automationdirect.com
www.baldor.com

Bimba Manufacturing Company


800-442-4622

39

24
www.bimba.com/smarter

CALLING ALL SYSTEM INTEGRATORS


630-571-4070

56
www.plantengineering.com/SIYApplication

Camfil APC
800-479-6801

CBSArcSafe
877-4-SAFETY

21

Advertiser

Page
Number

16
www.CBSArcSafe.com

Electro Industies/GaugeTech
877-EIMETER

10

Electro Static Technology, Inc


866-738-1857

31
C-1, 11

Flexicon Corp
888-353-9426

50

27

MOVINCOOL
800-264-9573

15

11

OEO Energy Solutions


800-553-2112

18

13

Orival, Inc
800-567-9767

20

Paratherm Corporation
888-373-1299

35
22
www.paratherm.com/plant-engineering

Phoenix Contact

23
17
www.phoenixcontact.com/quintiq_hazloc

Plant Engineering Electronic Newsletters


630-571-4070

85
www.plantengineering.com/newsletters

www.motionindustries.com
www.movincool.com
www.oeo.com
15
www.orival.com

Plant Engineering Energy Research


45
630-571-4070
www.plantengineering.com/2015EnergyManagement

PROTO INDUSTRIAL TOOLS


800-800-8665

19
14
www.PROTOINDUSTRIAL.COM/TETHERED

20
www.est-aegis.com/handbook

Rittal Corporation
800-477-4000

37

23

SEW-EURODRIVE, Inc.
864-439-7537

65

31

Siemens Industry Inc

29, 45

www.ErectAStep.com
6

www.RittalEnclosures.com
www.seweurodrive.com
19, 26

www.flexicon.com

FS-Elliott Co., LLC


724-387-3200

33

21
www.fs-elliott.com

Global System Integrator Database


Featured Integrators
630-571-4070
GTI Spindle Technology
603-669-5993

90
www.plantengineering.com/global-si-database
12

9
www.gtipredictive.com

Industrial Internet of Things (IIoT)


Webcast Series
630-571-4070

63
www.plantengineering.com/IIoTWebcastSeries

Kaeser Compressors, Inc


866-516-6888

Keysight Technologies, Inc


800-829-4444

2
www.kaeser.com/PE

24

Send
Info

3
www.CLARCORindustrialair.com
www.electroind.com

ErectAStep
888-878-1839

RSC
Number

Motion Industries, Inc


800-523-9328

www.camfilapc.com

CLARCOR Industrial Air


800-821-2222

Lubriplate Lubricants Co
800-733-4755

Send
Info

www.sea.siemens.com
SPM Instrument
800-505-5636

62

Sullair Industrial Products


219-879-5451

41

Summit Industrial Products


800-749-5823

54

United Rentals
800-UR-RENTS

17

12

Vac-U-Max
973-759-4600

55

29

C-3

51

Yaskawa America, Inc


800-927-5292

30
www.spminstrument.us
25
www.sullair.com
28
www.klsummit.com
www.UnitedRentals.com
www.vac-u-max.com
www.yaskawa.com

5
www.keysight.com/find/Pminsight
18
www.lubriplate.com

Need More Info? FAX this page to: 630-214-4504

or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523

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Title
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www.plantengineering.com

PLANT ENGINEERING

June 2015 95

INCONCLUSION
Champion the cause of success assurance

Bob Vavra
Content Manager

While some view

a glass as halfempty and


others have seen
it as half-full,
Ive always felt
that the view of
the glass depends
mostly on how
thirsty you are.

96 June 2015

e are by nature a pessimistic


lot. Im not sure why that is,
except perhaps that everything is finite. Even by that
standard, there are infinite
ways to deal with a finite world.
While some view a glass as half-empty
and others have seen it as half-full, Ive
always felt that the view of the glass
depends mostly on how thirsty you are.
There are other factors that determine
whether thats enough water for your needs,
or too much water at this time.
If all this sounds a little too philosophical
for a column essentially about maintenance,
thats because I recently had a moment of
philosophical clarity. I was at an industry
event, and the discussion migrated to the
topic of failure avoidance in manufacturing operations. It occurred to me at that
moment that we were focused on the wrong
topicthat we were looking at a half-empty
glass.
Why, I asked out loud, arent we talking about success assurance?
Weve made great progress in two important areas in manufacturingsafety and
productivity. We talk about maintaining a
safe plant, because safety is the baseline
for success. We discuss productivity as a
positive outcome of excellent workplace
practices.
We also know that too much of our day
is spent putting out fires. Some of those
are the result of poor planning. And others
are the result of poor execution. It doesnt
much matter what caused the fire; what
youve got to do first is extinguish it.
But what if there was a mindset that you
wouldnt have to spend resources putting
out the fire if you made sure from the start
that there was no chance the fire would
start? How does that thinking change the
way we view everything we do in manufacturing? What if we engineer not just to
get a line up and running, but also to ensure
that our people are trained, our systems are
optimized, and our organization is aligned
to deliver nothing but success? If we start
with that philosophy, how does that change
our operational goals?

PLANT ENGINEERING

Many facilities try to make their operations foolproofanother phrase that perpetuates the negatives about an operation.
Broken down to its component parts, to
make something foolproof is to engineer
it so that even a fool couldnt break it.
Why would we even want to employ such
people in our organization?
We need to begin with the idea that success is inevitable. Too often, we begin
with the opposite idea in mind. Training
eliminates the need to foolproof our plant.
System engineering begins with the end
goal in mind, so that every component part
is aligned with that end goal. The idea that
we will succeed when we do all of these
things well is liberating.
It also, incidentally, is profitable. Better engineering and training and maintenance all lead to lower overall costs.
More product is producednotice I didnt
suggest there is less waste. Workers are
safe, which should be a constant state. To
suggest they are safer implies there was
a time when they were less safe. Thats
not a message that has any value for an
organization thirsting to be successful.
Perhaps this all sounds like semantics,
but I think they are important distinctions.
The approach we take to many things we
do begins with the idea that we have to
avoid trouble or minimize risk.
If success is the model we build toward,
it is implicit that problems are avoided
and minimized. Success can be measured
in several ways, of course, but all of the
outcomes are predetermined. They keep
our eyes up and focused on moving forward. Were not looking back. Were not
naive, but were not afraidand were
better able to add new technology and
new solutions because they will continue
our success.
We are in a data-driven world today.
We can quantify what success looks like.
Unlike sports, where no matter how well
we might score, someone else can always
match it or surpass it, we can define
individual success for our manufacturing plants.
We can assure success. PE
www.plantengineering.com

ENTER THE MATRIX

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YA S K A W A A M E R I C A , I N C .
D R I V E S & M OT I O N D I V I S I O N
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
input #51 at www.plantengineering.com/information

20

askawa America Inc.

For more info:


http://Ez.com/yai768

Save Energy. Save Money.


Motor-driven equipment accounts for 63% of your
plants electricity consumption every minute of
every day. Your choices are to let your electricity
bills continue to grow or call in Baldors Installed
Base Evaluation Team to identify improvements
you can start making today.

targeting inefficient motors and mechanical drives


as well as identifying systems where adjustable
speed drives could be added to save even more
energy. This report will provide recommendations for
immediate action along with long term strategies
all positively affecting your bottom line.

The Baldor IBE Team uses advanced data


collection equipment and software to work with
your plant maintenance personnel to take an
accurate account of your motors, drives and
mechanical power transmission products, both in
operation and from spares inventory. The IBE Team
will produce a comprehensive report and plan,

If youre ready to do something about your growing


electricity consumption, email the Baldor IBE
specialists at IBETeam@Baldor.com or call
(864) 281-2100 to receive case studies with realworld savings. Its an easy call with a big payoff.
baldor.com

2012 Baldor Electric Company

input #52 at www.plantengineering.com/information

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