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Why Can't I Get My

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Smart Environment
Controls / P.11
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The Reliability
Excellence Journey
PoweredByRx.com
SUSTAINABILITY
Performance Management
Audits & Assessments
Equipment History
Equipment & Process Design
Work Measurement
Management Reporting
PROCESSES
Work Management
Work Planning
Work Scheduling
Operator Care
Asset Care
Loss Elimination
Workforce Development OPTIMIZATION
Materials Management
Reliability Engineering
Management of Change
Information Management
Supervision
Organizational Behavior
Procurement
Facilities & Equipment
CULTURE
Governing Principles
Goals & Objectives
Organizational Structure
Budgeting & Cost Control
Occupational Health
& Safety
Employee Involvement PRINCIPLES
Management Commitment
Functional Partnership
The Reliability Excellence journey requires building the foundation of principles

and culture, establishing and optimizing the processes and procedures that
create reliability, and putting in place the management and reporting elements
that drive sustainability and continuous improvement.
Visit PoweredByRx.com to access more than 400 resources including
articles, videos, whitepapers, podcasts and classes and discover the power
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Save the Date February 23-24, 2017 for the new Reliability Excellence Conference!
800-556-9589 | PoweredByRx.com
TABLE OF CONTENTS
DECEMBER 2016 / VOL. 36, NO. 12
SPECIALISTS
07 / FROM THE EDITOR
Overall Leadership
Technology is just a tool to
achieve greater reliability
09 / HUMAN CAPITAL
Why Cant I Get My
Project Approved?
Learn why you may have to
challenge leadership if you
25.0
want to get things done
24.0
11 / TECHNOLOGY TOOLBOX
23.0
Smart Environment Controls
How the IoT can keep your
22.0 buildings more comfortable,
cost-efficent, and secure
21.0
13 / ASSET MANAGER
20.0 How to Manage Land
with Your CMMS
19.0
Keep track of whos doing
what where on the property
occupied by your plant
FEATURES DEPARTMENTS
20 / COVER STORY 28 / OPERATIONAL EXCELLENCE 16 / AUTOMATION ZONE

Light Touch The Future of Energy Management What to Watch For in 2017
Build the right combination of predictive The technology to better manage Interconnectivity, wireless, mobility,
tools and technologies to proactively production and energy systems is digital sensors, and smart MRO lead
monitor your electrical systems out there. Why is it taking so long the way
for industrial plants to adopt it?
25 / YEAR IN REVIEW 18 / TACTICS & PRACTICES
Best of Plant Services 2016 34 / BIG PICTURE INTERVIEW Condensate Management 101
Our annual review of the maintenance Bernard Norris, Director, GT Base Fleet Compressed air condensate is
issues and reliability trends that defined Product Line at GE Power & Water hazardous waste heres how
the past year Everything is going to be digitized. to manage it safely
30 / PRODUCT ROUNDUP
PLANT SERVICES (ISSN 0199-8013) is published monthly by Putman Media, Inc., 1501 E. Woodfield Road, Suite 400N, Schaumburg,
Asset Management Software
IL 60173. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals Postage Paid at Schaumburg, IL and additional mailing Offices. Leverage mobility and the IIoT
Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/
BWI,PO Box 1051, Fort Erie, Ontario, Canada, L2A 5N8. Printed in U.S.A. POSTMASTER: Send address changes to PLANT SERVICES, to maximize asset performance
Putman Media, Inc., PO Box 3435, Northbrook, IL 60065-3435. SUBSCRIPTIONS: Qualified reader subscriptions are accepted from
PLANT SERVICES managers, supervisors and engineers in manufacturing plants in the U.S. and Canada. To apply for qualified-reader and control costs
subscriptions, please go to www.plantservices.com. To non-qualified subscribers in the U.S., subscriptions are $96 per year. Single
copies are $15. Subscription to Canada and other international are accepted at $200 (Airmail only) 2016 by Putman Media, Inc.
All rights reserved. The contents of this publication may not be reproduced in whole or in part without consent of the copyright owner. 32 / CLASSIFIEDS / AD INDEX
In an effort to more closely align with our business partners in a manner that provides the most value to our readers, content published
in PLANT SERVICES magazine appears on the public domain of PLANT SERVICES Website, and December also appear on
Websites that apply to our growing marketplace. Putman Media, Inc. also publishes CHEMICAL PROCESSING, CONTROL,
CONTROL DESIGN, FOOD PROCESSING, THE JOURNAL, PHARMACEUTICAL MANUFACTURING and SMART INDUSTRY.
PLANT SERVICES assumes no responsibility for validity of claims in items published.
WWW.PLANTSERVICES.COM DECEMBER 2016 5

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IN MEMORY OF FROM THE EDITOR
JULIE CAPPELLETTI-LANGE, THOMAS WILK, EDITOR IN CHIEF
Vice President 1984-2012
PUTMAN MEDIA, INC.

1501 E. Woodfield Road, Suite
400N, Schaumburg, IL 60173
(630) 467-1300 Fax: (630) 467-1120
MIKE BRENNER
Group Publisher
OVERALL LEADERSHIP
mbrenner@putman.net
Technology is just a tool to achieve greater reliability
EDITORIAL STAFF
THOMAS WILK One of the more interesting stories makers whose job it is to set strategy
Editor in Chief to emerge from GEs 2016 Minds + Ma- and approve projects and initiatives that
twilk@putman.net
chines conference is a new type of indus- drive positive results for your business.
CHRISTINE LaFAVE GRACE try wearable. Just when you were kind of As Azima DLI CEO Burt Hurlock
Managing Editor
clafavegrace@putman.net
getting used to the idea of Google Glass wrote in the Q3 issue of sister publica-
and smartwatches, along comes some- tion Smart Industry: Like doctors to
ALEXIS GAJEWSKI thing completely different: medicine or construction workers to
Associate Editor, Digital Media
agajewski@putman.net Internet-connected overalls. building, industry needs leaders and
According to the story (http://plnt. managers and team builders to harness
STEPHEN C. HERNER
V.P., Creative & Production sv/1612-OV), a demo at the M+M event the new tools available to them. The
sherner@putman.net showcased how sensors sewn into technology will not deploy, implement,
overalls can interact with proximity
DEREK CHAMBERLAIN
Senior Art Director sensors can increase worker safety. In DID YOU SEE SMART OVER-
dchamberlain@putman.net the demo, a utility worker wearing the
overalls gets too close to an electrical ALLS COMING? DID ANYONE
DAVID BERGER, P.ENG.
Contributing Editor panel, triggering a cutoff to the flow of IN YOUR ORGANIZATION?
PETER GARFORTH
electricity to the panel.
Contributing Editor Stephanie Sireau of GE Digital is
quoted as saying that this new wearable or perform on its own, and putting it to
SHEILA KENNEDY, CMRP
Contributing Editor technology is part of an overall mission use correctly will demand specialized
to integrate the worker into a digital knowledge. (http://plnt.sv/1612-SI)
TOM MORIARTY, P.E., CMRP
Contributing Editor
industrial context, adding that the same If theres one recommendation I would
embedded sensors will also be able to make for 2017, its to embrace this chal-
PUBLICATION SERVICES deliver vital-signs data to help anticipate lenge of cultivating best-in-class leader-
CARMELA KAPPEL
workers health problems. ship. This kind of support is not always
Assistant to the Publisher Did you see smart overalls coming? common; for example, as our columnist
ckappel@putman.net Did anyone in your organization, includ- Tom Moriarty found in his 2015 leader-
JERRY CLARK ing the EH&S team and/or medical ship survey, supervisors in particular
V.P., Circulation health professionals? Do you know if IT often dont get quality leadership train-
jclark@putman.net
has a strategy in place on how to deploy ing before or after assuming leadership
JACK JONES wearables in the workplace? roles, yet they direct 80% to 90% of plant
Circulation Director The ongoing digital industrial trans- personnel, and have 70% influence over
jjones@putman.net
formation is challenging the regular way the attitudes and performance of their
RITA FITZGERALD of doing things, from operations and teams (http://plnt.sv/BEST16-12).
Production Manager
rfitzgerald@putman.net
maintenance to supply chain and safety. You can buy all the smart overalls you
As each new digital technology comes to want, but unless you have leaders who
RHONDA BROWN market, it can feel like a race to keep up help others understand why and how
Reprint Marketing Manager
Foster Reprints with the Joneses next door, who just in- new tools will help drive success, those
(866) 879-9144 ext.194 vested in the latest wireless-enabled test overalls are just another pair of pants.
rhondab@fosterprinting.com
tools or who might have just tied their
EXECUTIVE STAFF CMMS into their MES system.
The good news is that your facility
JOHN M. CAPPELLETTI
President/CEO
already has the strongest asset in place to
start (or continue) on your digital jour- Thomas Wilk, Editor in Chief
KEITH LARSON ney: your leadership team, the decision- twilk@putman.net, (630) 467-1300 x412
VP, Content and Group Publisher

Going home safely ELECTRICAL
at the end of the day INDUSTRIAL SAFETY FOR
FACILITIES
requires proper training.
Thats what weve been
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Explain the hazards of electricity and their effects
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Interpret applicable regulations

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Explain installation of temporary grounding for personal protection
Utilize safe work practices for work on or around substation equipment,
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Select appropriate PPE for a variety of applications
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Identify the functions of a substation grounding system

Identify the requirements for an electrical safety inspection of an industrial, utility
or utility-like installation following a comprehensive checklist
We can also bring the training to your facility, call 877-594-3156

for a quote or visit www.avotraining.com
HUMAN CAPITAL
TOM MORIARTY, P.E., CMRP
WHY CANT I GET MY PROJECT APPROVED?

Learn why you may have to challenge leadership if you want to get things done
You had consultants come into your plant to do an as- formance and capabilities beyond current performance
sessment. The consultants found a number of gaps between levels. These include renovations, implementation of new
current performance and best practices. They provided a processes that drive down costs or increase productivity,
detailed report with prioritized recommendations and a and/or expanded product or service offerings. From mis-
solid business case. sion goals, the organization can select the most worthwhile
You provided the report to the plant manager, scheduled initiatives that will meet those goals.
a meeting, and discussed the merits of going forward. Six So if your organization has strategic guidance with
months have passed, and no decision has been made to go performance and mission goals and your assessment report
forward. Meanwhile, several other projects were initiated.
Why did this project not get the green light? WITHOUT DEFINED STRATEGIC GUIDANCE,
In my 36 years of working in and around large, often YOU DEPEND ON A DECISION-MAKERS
bureaucratic organizations, there are some obvious answers
and some that take a bit more contemplation.
WIDE LATITUDE AND JUDGMENT. YOU ARE
Competing priorities require senior decision-makers FIGHTING THE WINDS AND TIDES.
to make choices based on their judgment. Their judgment
includes consideration of risk, which is based on the scale of
the initiative, the benefits of it if successful, and the prob- provides an implementation plan thats aligned with mission
ability of being successful. Small projects, small risk. Big goals, why has the project languished for six months?
projects, big risk. Relationships play a substantial role as Thats a different problem. Good strategic guidance is
well; having a history of success and being someone who is necessary, but its not sufficient. Guidance needs to be con-
easy to work with helps. sistently executed thats a leadership issue.
The answer that requires more thought is how much Culture happens by default and operates as a lagging indi-
latitude decision-makers have. How much autonomy the cator of leadership actions (or inactions). Leaders define the
decision-maker has should be defined by the organizations values and norms that they want projected throughout their
strategic guidance. If strategic guidance is weak, the deci- organization. When senior leaders dont challenge behaviors
sion-maker has more latitude. If strategic guidance is strong, that conflict with intended values, then those values and
the decision-maker will have less latitude. Strong strategic norms are viewed as optional.
guidance provides more clarity for goals to be achieved, con- Whether youre a shop supervisor who wants to start up a
straining the leaders latitude. vibration analysis program or a maintenance manager who
Defining and following strategic guidance for an or- wants to implement a best-practice maintenance manage-
ganization is analogous to defining and following a good ment process, the barriers are similar. Without defined
maintenance management process. Guidance creates the op- strategic guidance, you depend on a decision-makers wide
portunity for order control and stability. Defining strategic latitude and judgment. You are fighting the winds and tides.
guidance requires understanding the external market en- If youre a senior leader, decide what you want your cul-
vironment, forecasting the future desired state, and stating ture by default to look like.
the organizations mission, vision and values. From strategic If youre a maintenance manager or shop supervisor, see
guidance, an organization can specify goals. what strategic direction currently exists. Observe whether
There are two general categories of goals: organizational senior leaders walk the talk. If they dont, tactfully challenge
performance and organizational mission goals. Organiza- them by asking that they support the strategic guidance or
tional performance goals are your day-to-day performance change it to something they will support.
targets. These include achieving or maintaining productiv- Go forth and do great things.
ity, quality, unit costs, employee satisfaction, safety, and
regulatory compliance at defined levels. Organizational Tom Moriarty, P.E., CMRP, is president of Alidade MER.
mission goals are the initiatives that will advance per- Contact him at tjmpe@alidade-mer.com and (321) 773-3356.

Delivering the best technology for your needs.
Enable cost-effective upgrades to your

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TECHNOLOGY TOOLBOX
SHEILA KENNEDY, CMRP
SMART ENVIRONMENT CONTROLS

How the IoT can keep your buildings more comfortable, cost-efficent, and secure
Intelligent building systems and smart environment mation system product management at Johnson Controls.
controls are among the greatest representations of the internet Because its a distributed system, Metasys also supports a
of things (IoT). Integrating all of the automated technolo- variety of networking and wiring options ideal for industrial
gies used to manage temperature and humidity, light, water, spaces including serial-based wiring, IP/Ethernet-based wir-
energy, air quality, and motion in buildings allows owners ing, wireless, or a mixture of all three.
and operators to reduce their operating costs and improve SmartStruxure from Schneider Electric supports centralized,
performance while enhancing the comfort and security of all automated control of power, lighting, electrical distribution, fire
occupants and lowering buildings carbon footprint. Follow- safety, and HVAC systems to create healthier, more-productive
ing is a sampling of the enabling technologies and software.
NEW TECHNOLOGIES ALLOW OWNERS AND
INTEGRATION, AUTOMATION, AND CONTROL OPERATORS TO REDUCE THEIR OPERATING
Smart buildings allow for real-time monitoring of environ-
mental conditions. The integrated building management
COSTS AND IMPROVE PERFORMANCE WHILE
platform Desigo CC from Siemens improves control of heat- ENHANCING COMFORT.
ing, ventilation, air conditioning, lighting, and shading. All
disciplines can be accessed and managed remotely from any
device, at any time from the single platform. environments. SmartStruxures connected mobile technology,
The Metasys Building Automation System from Johnson says Robert Hemmerdinger, director of business development
Controls improves efficiency of industrial building energy for SmartStruxure at Schneider Electric, breaks down tradi-
management, including HVAC, lighting, security and tional information silos and delivers information and real-time
protection systems in industrial spaces. Metasys provides a data via web access, graphics, trend visualizations, rich reports,
completely mobile-optimized interface that can be accessed and mobile applications. This increases employee satisfaction,
from any phone, tablet or laptop. productivity, and real estate value, he says.
Metasys controls a variety of equipment types that serve Advantechs factory environmental monitoring solutions
very different spaces with very different comfort needs, address water, temperature, humidity and air quality, the
from small packaged units controlling the office spaces to latter of which includes dust, gas, and carbon dioxide. The
larger applied systems conditioning the manufacturing floor companys latest product technology supports more inter-
space, says Mark Ziolkowski, director of building auto- connected and intelligent environmental control systems.
Our WISE-4000 Ethernet-based wireless IoT devices are
integrated with IoT data acquisition, processing, and publish-
JOHNSON CONTROLS ing functions, and provide data pre-scaling, data logic, and data
logger functions in just one device, says Tom Wohlwender,
product engineer at Advantech. All of the data can be accessed
via mobile devices and published to the cloud with security
anytime, anywhere, in any type of environment.
CONDITION MONITORING SOFTWARE

Web-based energy and water monitoring software from
Noveda Technologies is compatible with building automa-
tion systems, energy management systems, and utility me-
ters. Noveda partners with a variety of platforms, including
Siemens and Honeywell, to simplify building systems inte-
gration, enabling real-time oversight of electric, gas, steam,
http://plnt.sv/1612TT-01
water, and oil sources as well as heating and cooling systems.

TECHNOLOGY TOOLBOX
SCHNEIDER ELECTRIC innovative approach to energy management. Some of its own

automated factories are capable of operating for extended
periods of time without lights, HVAC, or even personnel.
FANUCs factories in Japan are among the worlds most
highly automated lights-out manufacturing facilities, says
Claude Dinsmoor, general manager of material handling at
FANUC America. The automated lines utilize a large num-
ber of FANUC intelligent robots to robotize the operations
that were previously manual, he says.
Email Contributing Editor Sheila Kennedy, CMRP, managing

director of Additive Communications, at sheila@addcomm.com.
http://plnt.sv/1612TT-02
REFERENCE WEBSITES:
The proliferation of IoT-enabled devices amplifies the www.buildingtechnologies.siemens.com

need for interoperability of systems and access to integrated www.johnsoncontrols.com
intelligence, says Govi Rao, president and CEO of Noveda. www.schneider-electric.com
www.advantech.com
www.noveda.com
EXTREME ENERGY EFFICIENCY
www.fanucamerica.com
Robotic automation product manufacturer FANUC takes an
COMPRESSOR
SERVICE TIP #10
The Weather Outside
Is Frightful
Check your air compressors weather
stripping and replace areas that are
worn out. Also check the insulation to
make sure heat is staying inside. For
more helpful tips:
www.atlascopco.us 866-546-3588
ASSET MANAGER
DAVID BERGER, P.ENG.
HOW TO MANAGE LAND WITH YOUR CMMS

Keep track of whos doing what where on the property occupied by your plant
Land is a physical asset that must be managed like any not be registered as separate assets, depending on the level
other asset. So which technologies are your best options for of granularity required for tracking work history.
land management? You have a few options. Specialized soft- Another key feature of the land parcel asset registry is the
ware applications that support land acquisition and manage- ability to maintain active and inactive records. For example,
ment exist, but these applications are typically standalone. if a parcel of land is split or two parcels are combined, both
Alternatively, a geographical information system (GIS) the old and new reference information and history should
can be used to provide a geospatial representation of land be maintained with appropriate cross-referencing. This re-
parcels and the assets on them. However, a GIS is not hier- quirement is similar to that of all linear assets, such as water
archical and is not designed to manage transactions such
as projects, work orders, and so on. An enterprise resource YOUR CMMS WORK MANAGEMENT
planning (ERP) system is helpful in managing some trans- FUNCTIONALITY MOST LIKELY CAN PLAN
actions, such as lease payments, land-related document
control, and contacts made with landowners, but it may not
AND TRACK ALL PERMITTING AND
be fully integrated with other functions. MAINTENANCE WORK DONE ON THE LAND.
Given that land is essentially a linear asset, perhaps what
works best is a fully integrated land management solution
with a CMMS as the core application for managing land mains that are split, abandoned, replaced, or combined.
parcels, landowners, and other stakeholders, as well as work Thus, each land parcel should have a status and correspond-
order control, project management, contact management, ing from/to dates (also known as since/until dates) to
financial management, and integration with GIS. These keep more accurate records of land parcel history.
functions are discussed below. The capability and level of so-
phistication of your CMMS will dictate how much integra- STAKEHOLDER MANAGEMENT
tion is necessary with specialized land management, ERP, Every land parcel has one or more stakeholders the land-
and other systems. owner, property manager, tenants and/or contractors who
will be referenced As with the land parcel, each stakeholder
LAND PARCEL MANAGEMENT status should have a from and to reference date to keep
Central to a land management system (LMS) is a land asset track of active and inactive stakeholders.
registry to record key information about land parcels (iden- Stakeholder name and contact information will be
tification number, land type, location information, appraisal included, and its critical that the software accommodate
value, document reference numbers, etc.). Depending on multiple address, email, and phone number fields, as many
how sophisticated your CMMS is, this will be accommodat- stakeholders have multiple addresses or phone numbers.
ed through the CMMS asset register and/or integration with Each stakeholder must be cross-referenced to one or more
specialty LMS and GIS software. land parcels. Contracts and other documents as well as notes
The location information youll need to maintain will about preferred method of payment or correspondence may
depend on the local jurisdiction but may include lot and be included for a given stakeholder in the records, too.
plan numbers, a Crown description, a survey or map refer- Your CMMS may be able to record stakeholder informa-
ence, roadway intersections, GPS coordinates, and latitude tion through use of the supplier master or through integra-
and longitude coordinates. Depending on the land parcels tion with a specialty LMS and/or ERP package.
shape, multiple coordinates can reference the outer limits
or corners of the property, or one set of coordinates can WORK & PROJECT MANAGEMENT
represent the centroid. Your CMMS work management functionality most likely
There may be multiple assets on the land that require can plan and track all permitting and maintenance work
referencing, such as trees, bridges, signs, walkways, furni- done on the land parcel itself (e.g., grass-cutting) or work
ture, structures, and/or facilities. These assets may or may done on individual assets on the land (e.g., replacing a wind

ASSET MANAGER
turbine blade). The work tracked will cleaning up a pipeline oil leak reported CONTACT MANAGEMENT
depend heavily on your industry but by a landowner). For more-sophis- Keeping track of all contacts made with
can reflect a combination of condition- ticated work, such as a major dig or stakeholders and the general public
based maintenance, routine preventive construction project, some advanced likely is a top priority. Some CMMS
maintenance, and maintenance result- CMMS packages offer strong project packages have this functionality built in;
ing from asset failure (for example, management functionality. others offer it through integration with
their ERP or other specialty software.
Examples of these records include a
history of correspondence sent to land-
owners requesting land access or notes
VIBRATION entered regarding an encounter with

a tenant (or his or her dog) during an
inspection. Complaints received from a
AND BEARING stakeholder or the general public would

be recorded, too, regardless of whether
they lead to work-order initiation.
ANALYSIS IN HD FINANCIAL MANAGEMENT

Companies may have legal agreements
with stakeholders to pay on a regular
schedule, as with lease payments, or
on an as-needed basis, as with ac-
cess fees. Payment records should be
cross-referenced to an agreements
document ID number, land parcel,
landowner, and payee. Companies can
use the CMMS supplier management
functionality or an interface with their
ERP system to manage payments.
INTEGRATION WITH GIS

A key requirement of LMS functional-
Combining the two major condition monitoring technologies; ity is seamless integration with GIS.
Leonova Diamond and Emerald incorporate sophisticated vibra- The GIS interface provides a visual
tion analysis capabilities with HD ENV and Shock Pulse HD representation of land parcels, fi xed
technology to maximize your predictive maintenance programs
assets, points of interest, etc. The GIS
potential. Available options for 2 and 3 channel simultaneous
interface lets users fi lter and sort data
vibration measurements, orbit analysis, run up/coast down,
within the CMMS and display the
bump tests, dynamic balancing, laser alignment plus much more,
results on the map. Furthermore, users
in carbon fiber re-enforced rugged casing. Used with the user
friendly but powerful Condmaster software makes the Leonova
should be able to draw a polygon on
Diamond or Emerald the perfect fit for any industry. the map to generate a list of associ-
ated land parcels and stakeholders for
Intrinsically safe versions available. the purposes of, say, setting up a mail
merge for all landowners who need to
For a customized monitoring package to fit your specific needs,
be contacted within a given area.
contact SPM Instrument!
Email Contributing Editor David Berger,

P.Eng, executive partner and
president of StraNexus Inc., at
david.berger@stranexus.com.
Tel. 1-800-505-5636 leonovabyspm.com spminstrument.us

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AUTOMATION ZONE
WHAT TO WATCH FOR IN 2017

Interconnectivity, wireless, mobility, digital sensors, and smart MRO lead the way
For this year-end edition of Automation Zone, the maintenance or other workers of a quality or process prob-
Plant Services editors asked several industry professionals a lem.) These Andon solutions offer best practices for getting
simple question: What automation trend should MRO teams the right team to the right location quickly in order to solve
keep their eye on in 2017, and why? maintenance and reliability issues. With plug-and-play An-
don templates available, theres no reason not to implement
Jose M. Rivera, CEO, CSIA (Control these types of solutions in manufacturing.
System Integrators Association, (www.
controlsys.org) Bob Karschnia, VP and general manager of wireless, Emer-
son Process Management (www.emersonprocess.com)
Interconnectivity will continue to be the Wireless monitoring of plant equipment and instrumentation
main automation trend impacting MRO. will be a major trend in 2017. Wireless applications give the
Here is why: right information to the right person at the right time. For ex-
1. Interconnectivity is not only bridging diverse systems it ample, wireless monitoring of steam traps or pump health gives
is also forcing a closer collaboration between depart- a maintenance technician insight into the problem before going
ments. There is significant value in sharing predictive into the plant. He or she will know before they go.
maintenance requests with the production teams, as it Wireless monitoring is growing exponentially. Emerson has
empowers them to schedule a shutdown with the mini- installed more than 27,000 WirelessHART networks. Battery-
mum impact on productivity. powered wireless devices can be installed anywhere to monitor
2. Interconnectivity also means that information is inputted anythingespecially on equipment where the cost of installing
once and leveraged. This includes information captured in wired devices is cost-prohibitive. And, because WirelessHART
the field by service technicians. New systems are making provides access to all the diagnostic and status conditions avail-
the data acquisition and data download process very easy. able in HART instrumentation, plant engineers and techni-
This translates into higher utilization and better data to cians are now able to detect pending problems before they
drive decisions. become serious enough to shut down a process.
3. Interconnectivity will allow technology to bridge the
loss of expertise and experience from the retiring baby Michael Risse, vice president at Seeq (www.seeq.com)
boomer generation with the abilities of the digitally na- The locomotive pulling all other trends is commercial off
tive younger generations. the shelf technology, and the locomotives engine is Moores
Law; this is not just about doubling the density of transistors
Scott Kortier, InduSoft web studio senior technical engineer on a chip every 18 months. Instead, its the basis of a new
at Wonderware by Schneider Electric (www.indusoft.com) model for computing hardware, software, and networking.
Mobile access to machine interfaces will play a critical role In this context, Moores Law results in smaller comput-
for maintenance and reliability teams. Not only does a ing platforms and higher-capacity hard drives, faster chips
fully mobile remote HMI make it possible to troubleshoot, and cheaper components, and more pervasive connectivity.
diagnose, and service machines from anywhere in the What this means for 2017 is the tradition of expensive, pro-
plant, it also allows OEMs and value-added resellers to offer prietary, on-premise, and centralized systems in manufac-
more capabilities for maintenance as a service (MaaS) from turing facilities will continue to crumble.
remote locations. Better mobility allows maintenance opera- In its place will be less-expensive open systems, often
tors to run updates outside of business hours and allows cloud-based, giving new advantages to customers in terms of
operators to request remote assistance from maintenance cost, user mobility and interoperability. Certainly Exxon is
personnel at another plant. giving the open systems initiatives a push through its Lock-
We also expect to see Andon applications going into wider heed partnership, but its the engine in the locomotive doing
use in manufacturing beyond the automobile industry. the real work by driving down costs and setting expectations
(Andon is a visual system designed to notify management, of end users for a new type of plant computing ecosystem.
16 DECEMBER 2016 WWW.PLANTSERVICES.COM

Ryan Williams, product manager, Rockwell Automation
(www.rockwellautomation.com)
From an MRO perspective, asset intelligence from con-
verged information technology (IT) and operations technol-
ogy (OT) systems can help organizations streamline mainte-
nance and storeroom activities, reduce reliability risks, and
Reliability
create proactive maintenance strategies.
Implementing this smart MRO approach begins with a
comprehensive understanding of a companys installed asset
base. Although this can be done through a manual audit of
assets, a better alternative is a diagnostic reliability service
that automates the data-collection process. This involves Gerald Gerry Bauer
is everything
President, EccoFab - Rockford, IL
using a control-layer application that can scan and auto-
Sullair.com/GerrysStory
discover all active networked devices. The application col-
lects identity information for each asset, such as its location,
series, catalog number, and firmware. It also collects health
information, such as current, temperature, and voltage,
which is crucial to understanding asset integrity.
Once collected, the asset-intelligence data can be sent to
a database where it is stored, analyzed and modeled, and
then delivered to workers in the form of actionable infor-
mation through reports, dashboards, alerts and notifica-
tions. The data also is continuously scanned and updated
to support ongoing asset tracking and monitoring.
These automated, device-identification and health-
monitoring capabilities are at the heart of a smart MRO
approach, and in 2017 and beyond will provide the foun-
dation for creating data-driven maintenance and store-
room strategies.
Tracy Doane-Weideman, product manager for analytics, It doesnt quit.

Endress+Hauser (www.us.endress.com) It doesnt even think about quitting.
In 2017, digital sensors will reduce maintenance costs, im- In fact, it doesnt think of anything but the job at hand.
prove reliability and minimize process shutdowns for sensor
replacements. Analytical sensors, such as Sound familiar?
pH, conductivity, and dissolved oxygen Our compressors are a lot like the people who use them.
instruments, all have to be cleaned, cali-
Discover the complete line of Sullair stationary air compressors,
brated, and periodically replaced.
featuring the legendary Sullair air end.
Maintenance of sophisticated sensors
is proving to be a problem for some To learn more about our complete line, including air treatment
companies. Digital sensor technology products, contact your local distributor or visit our website.
solves the problem. Endress+Hauser in-
stalled pH sensors in the companys chlor-alkali process
with digital Memosens technology. Memosens probes
can be precalibrated in the laboratory.
The smart sensors also provide information on their state,
allowing technicians to replace the probes only when neces-
sary and to clean and calibrate them in the lab. And the
process only has to be shut down for the few minutes it takes
to replace a sensor. Sullair.com
2016 Sullair, LLC. All rights reserved.
TACTICS&PRACTICES
CONDENSATE MANAGEMENT 101

Compressed air condensate is hazardous waste heres how to manage it safely
by Mark Krisa, Ingersoll Rand
How a facility manages its compressed air condensate valve-type drains with a fixed or adjustable timer. Al-
influences operational reliability and, because of the hazard- though these drains are typically lower in cost, some are
ous waste that condensate contains, affects a plants impact reasonably robust and are less prone to failing. The draw-
on the environment. Its important that compressed air back is that these drains cycle only based on time, so they
systems have a condensate management network in place. either discharge too frequently, which wastes compressed
Knowing the environmental factors that produce more air, or they cycle infrequently, allowing condensate to col-
or less condensate, understanding the drain and piping lect and carry over into the system.
systems, and identifying what condensate is made of are Capacity-sensing drains are the most efficient and adaptive
integral to properly maintaining a compressed air system. type of drain, discharging only after a fixed volume of
liquid has collected in the drain. These drains can function
using some form of electronic sensing or can be completely
HAVING A GOOD GRASP ON YOUR mechanical using a float-type mechanism.
CONDENSATE PROPERTIES IS VALUABLE Some low-cost units can be sensitive to contamination
WHEN SELECTING COMPRESSED AIR and may fail easily due to obstruction. This needs to be con-
SYSTEM MATERIALS. sidered during the purchase process, with purchase direc-
tors weighing both application conditions and the degree
of maintenance required. One common issue to be aware
of is the use of strainers installed ahead of a drain valve. In
HOW CONDENSATE IS FORMED AND MANAGED theory, the strainer will collect larger particulate and protect
When atmospheric air is compressed, the amount of water that the drain from failing because of obstruction, but the strain-
can exist in a vapor state is reduced, causing the surplus water ers often are neglected and become clogged. Its important
to condense into a liquid. This water mixes with other airborne that if a strainer is installed, a manual valve and piping
constituents consumed from the environment along with arrangement also be installed ahead of the drain to facilitate
traces of lubricant/coolant from the compressor. The resulting easy isolation for servicing and testing.
emulsification is referred to as compressed air condensate.
The volume of condensate that is extracted from a PROPER PIPING TO MOVE CONDENSATE
compressor is based on the difference between how much Condensate piping must be configured to facilitate easy re-
water was present in the atmospheric air ingested into the moval of every drain for service or inspection. A bypass should
compressor and how much water can remain in a vapor state be installed on the discharge side of every drain to support test-
at the temperature and pressure of the compressed air. Thus, ing the drain operation. This should include a tethered hose for
a compressed air system will generate more condensate on a systems to periodically test the condensate discharge rate using
steamy summer day than on a cold, dry, winter day. a scaled collection device over a fixed period of time.
The quantity of condensate removed from the com-
PICKING THE RIGHT CONDENSATE DRAIN pressed air system will change based on the volume of
Choices abound when it comes to drain manufacturers, but compressed air consumed and the ambient conditions. On
there are only a few common types of drains for com- a hot summer day, a 100-horsepower compressor with a
pressed air systems. refrigerated air dryer can generate more than 45 gallons of
Drains can be categorized as manual drains, timer-based condensate in an eight-hour shift. The same system during
drains, or capacity-sensing drains. a subfreezing winter day would generate less than 1 gallon
Manual drains are a simple valve and are best suited for of condensate during a shift.
particulate filters in areas where condensate is low or Some maintenance programs may periodically measure
nonexistent. These drains require periodic draining by an the rate of condensate removal relative to operating condi-
operator, but quite often no liquid is found. tions to establish a performance baseline. This data could be
Timer-based drains are typically solenoid or actuated-ball used to identify a deviation from the desired performance

and facilitate a more prognostic ap- NON-CRITICAL-LOCATION SOLENOID DRAIN INSTALLATION
proach to maintaining compressed air
system performance.
Settings:
It is a good practice to periodically 1 second on
test condensate for concentration of 15 minute cycles
Check Valve
major constituents and pH level. This for Tie in to
From Strainer with
data can be helpful in troubleshooting Blowdown Valve
Other Valves
Single " Union
quality issues associated with contam- Drain
ination. It is not uncommon to assume Source Isolation Union Isolation
Valve Valve
that compressed air condensate is the Drain
source of contamination for a process- Inspection Valve
"
related issue only to find that the Bypass
"
actual source of the problem is a local
Bypass
airborne pollutant or lubricant. This Valve
Alternate Drain
is a common misdiagnosis in paint Inspection Valve
applications that can be very sensitive Location
to silicone or hydrocarbons.
KNOW YOUR CONDENSATE AND PRAC-

TICE SAFE DISPOSAL contaminants; therefore, its consid- age system, so the water from the oil/
Compressed air condensate can be ered a hazardous waste and must be water separator is discharged through
acidic or basic depending on the processed accordingly. Condensate an exterior wall and allowed to pool
environment. This can affect the rate cannot be discharged directly to a in the soil. Unfortunately, the water
of material degradation or corrosion. municipal sewage system and must be is not pure and will typically still
Having a good grasp on your conden- treated to reduce the concentration of have low concentrations of oil. Over
sate properties is valuable when select- contaminants to an acceptable level. time, the water will evaporate, leaving
ing compressed air system materials Some facilities have a central waste- behind the oil. Eventually, enough oil
such as piping, plastic tubing, valves, water treatment process that can treat will accumulate for the soil to be clas-
and fittings. the waste, but its important to con- sified as hazardous waste, requiring
Condensate should be tested during sider the cost associated with treating costly disposal.
both the summer and winter to ac- the condensate compared with use of Having a condensate management
count for changes in the concentration other methods. process, key data about a manu-
of water present in the atmosphere. One alternative option is to use facturing facility, and awareness of
When attempting to diagnose an a condensate separation product temperature conditions will give
issue associated with the presence of dedicated to the air compressors to maintenance staff the opportunity to
specific compounds in the condensate, reduce oil from condensate down to address a systems performance and
sampling frequency may also need to an environmentally acceptable level. It issues before big problems arise. Pro-
take into account wind and the inges- is important to investigate details re- actively correcting condensate issues
tion of airborne contaminants from garding the type of oil introduced into can help prevent excess condensate
processes outside of the compressors the condensate and the requirements from carrying over into the network,
intake. Depending on the chemical to separate it from the water. Some saturating the piping system and
compositions of neighboring exhaust, oils will separate based on dwell time, contaminating production equip-
temperature inversions may also be while others may require chemicals to ment. These factors will help facilities
influential, causing an increased den- separate the oil from the water. Some abide by hazardous-waste regulations
sity of contaminants during morning may choose a distillation-type product and optimize the reliability of their
hours when the ground is cold and air that uses an electric heater to boil compressed air systems.
temperatures start increasing. the water off as steam, leaving only
Compressed air condensate is an residual waste liquid to be processed Mark Krisa is global air system perfor-
emulsification of water, hydrocar- as hazardous waste. For some instal- mance leader for Ingersoll Rand Compres-
bons, and other potential airborne lations, there is no access to a drain- sion Technologies and Services.

PdM / ELECTRICAL SYSTEMS
by Sheila Kennedy, contributing editor
LIGHT TOUCH
25.0
24.0
23.0
22.0
21.0
Build the right combination of predictive tools and technologies 20.0
to proactively monitor your electrical systems 19.0
The potentially catastrophic consequences of electri- EFFECTIVE TOOLS AND TECHNOLOGIES

cal system failures and hazards must be avoided at all costs. Wide-ranging options exist for online/energized and offline
Regular predictive maintenance (PdM) on electrical systems testing of electrical systems. Tom Bishop, senior techni-
lets maintenance teams detect and correct problems before cal support specialist at the Electrical Apparatus Service
they can shut down equipment or production lines or cause Association (EASA) (www.easa.com), notes that theres a
a safety incident. wide scope of available inspection types with these common
Whether conducted in-house or outsourced to reliabil- motor tests:
ity specialists, PdM inspections followed up with timely, Offline tests for motors
precise repairs can help protect against electrical acci- Insulation resistance tests
dents and save companies millions of dollars by reducing Polarization index tests
unscheduled downtime, lowering equipment maintenance Motor electrical circuit parameters evaluation (resistance,
costs, and extending the useful life of machinery. inductance, and capacitance)
Is your electrical PdM program up to snuff ? Here, check Rotor influence tests to check for open rotor bars
out some of the newest electrical PdM tools and applications
as well as popular testing options and practical PdM recom- Online tests for motors
mendations from industry pros. Measuring line voltages and currents

Motor current signature analysis
Vibration analysis for electrically induced frequencies
Thermography
Ultrasonic inspection
Source: Schneider Electric

Technology has come a long way in the past 30 years,
remarks John Bernet, mechanical application and product
specialist at Fluke Industrial Group (www.fluke.com). There
are now easy-to-use tools available for operators to screen
components of electrical systems for potential problems, Ber-
net says. Technicians can then troubleshoot the problem to
find the specific fault and recommend a correction and then Monitoring the condition of electrical equipment will help plant
use the same screening tools to verify that the fault has been teams anticipate and plan maintenance activities.
corrected and quickly get the machine back into service.
The emergence of the internet of things (IoT) is extending
the value of PdM. By collecting data through connected development manager at FLIR Systems (www.fl ir.com).
maintenance technologies, personnel can better evaluate the With thermal imaging technology becoming more afford-
assets utilization, environment, lifecycle, and performance, able, facilities are able to have multiple cameras or eyes in
says Emanuel Kourounis, services business development the hands of their maintenance personnel, he says. If you
manager at Schneider Electric (www.schneider-electric.us). go back five years, users had to spend thousands of dollars
This data also enables a more condition-based maintenance on a thermal camera.
approach to help companies allocate limited resources in
managing their op-ex and cap-ex budgets along with maxi- Ultrasonic inspection
mizing their general maintenance activities. Ultrasonic inspection, another nondestructive test (NDT)
technique, detects and isolates high-frequency sounds that are
Thermal imaging otherwise inaudible to the human ear. It is used to differenti-
One of the most effective PdM technologies for operating ate electrical discharge noises from normal sound patterns.
electrical systems is infrared (IR) thermography, says R. Electrical inspection with ultrasound is being driven by
James Seff rin, director of the Infraspection Institute (www. three main factors: safety, electrical maintenance standards,
infraspection.com). A thermal imager converts the nor- and insurance company interest, says Adrian Messer, man-
mally invisible infrared radiation emitted by an object into ager of U.S. operations at UE Systems (www.uesystems.com).
a monochrome or multicolor image that is representative of Safety is improved because we are able to inspect the
the thermal patterns across the surface of the imaged ob- energized electrical equipment without having to open it up,
ject. Many thermal imagers also can provide temperatures Messer says. Electrical standards, such as NFPA 70B and
of imaged objects, he notes. CSA Z463, specifically mention the use of ultrasound to detect
Infrared inspections are conducted while the electrical corona, tracking, and arcing from energized electrical equip-
system is energized and under load. Typical defects that may be ment. He adds: And, insurance companies are writing into
found include loose/deteriorated connections, overloaded cir- procedures that before opening anything up to do visual and
cuits, unbalanced loads, and defective equipment, Seffrin says. infrared inspections, ultrasound should first be used to detect
Predictive IR technologies can be employed to mitigate any fault that may be producing high-frequency sound.
the potential for human error in monitoring and maintain- Its best practice to use both infrared and ultrasound tech-
ing assets, notes Schneider Electrics Kourounis. Asset-spe- nologies together, as they detect different failure modes and
cific algorithms, thresholds, and rules can be used to detect together provide significant safety benefits, suggests Doug
thermal abnormalities in the performance of the monitored Waetjen, vice president of global operations at UE Systems.
assets, which can then be further analyzed by industry Infrared detects resistance-based problems, like overheat-
experts to validate the findings and develop a list of recom- ing fuses and insulation breakdown, while ultrasound
mended next steps, he says. detects ionization-based problems like tracking on loose and
Infrared technology reduces troubleshooting time, saves faulty connections in switchgear, tracking on transformer
money, and can be safer especially when a user is put in windings as well as cracked insulators, and destructive
a potential arc-flash situation, adds Jim Huekels, business corona in substations, he notes.

Another effective combination is ultrasonic inspection and

vibration monitoring. EASAs Bishop said he has seen these
methods used together to detect failing bearings, a situation
that could have escalated into a rubbing fault between stator
and rotor that would have damaged the stator windings.
Finally, infrared and ultrasound windows from compa-
nies like Exiscan let inspectors look at and listen to ener-
Source: UE Systems
gized switchgear without being forced to open enclosed
cabinets, says UE Systems Waetjen. By listening to whats
going on internally and only opening the door when no evi-
dence of tracking or arcing sounds are present, the chances
of an arc flash incident are greatly reduced.
Motor current signature analysis

Motor current signature analysis records and analyzes
motor current readings to diagnose faults. This test is able Ultrasonic inspection of
to identify rotor cage failures that result in reduced output enclosed cabinets (above)
torque, increased stator current, and increased motor tem-
perature, says EASAs Bishop. Long-range ultrasonic
inspection (right)
Insulation resistance testing

Insulation degradation can be detected with insulation
resistance testing. This test is temperature-sensitive, and the equipment, and power transformers, says Schneider Elec-
readings must be corrected to a common base temperature. trics Kourounis. Continuous online monitoring is the ideal
Bishop has seen insulation resistance tests identify mo- methodology for capturing activity and facilitating trending
tors with ground insulation weakness caused by moisture based upon available data, he says.
contamination that could have resulted in winding failure to
ground if the motor had been started. Wireless temperature monitoring
Wireless temperature monitoring can be applied to every-
Partial discharge testing thing from dry-type transformers to cable connections.
Partial discharge (PD) monitoring looks for pockets of Thermal monitoring combined with load profiling has
electrical breakdown within the insulation of electrical proved to be a reliable means of monitoring equipment
equipment. In the past, PD monitoring was primarily used performance, says Kourounis.
on higher-voltage machines rated over five kilovolts, but
with the prevalence of low-voltage motors powered by vari- Oil analysis
able frequency drives (VFDs), the use of PD monitoring is Oil quality and gases-in-oil analyses are additional PdM
increasing, remarks Bishop. testing options. Transformer oil should be monitored for its
PD technology is applicable to voltages higher than 2400 physical characteristics compared to the ASTM standards,
volts AC and can be applied to a wide variety of assets which might include color, specific gravity, dielectric strength,
within an electrical distribution system, such as switchgear, moisture content, surface tension, contents of acids, carbon or
some cable types, some bus duct applications, large rotating furans, says Kourounis. Gases-in-oil analysis, as Kourounis
explains it, measures the existing percentages of specific com-
bustible gases, such as hydrogen, oxygen, methane, ethane,
ethylene, and acetylene, and indicates combinations and
ratios that indicate potential problems.
Source: Schneider Electric
Fresh approaches and new applications

A host of new tools and tactics are being used to inspect
electrical system components. For example, EASAs Bishop
has seen increasing use of semi-automated measuring equip-
ment along with software to analyze and trend data.
Continuous monitoring reveals abnormal temperature readings for
an aging transformer. FLIR is integrating thermal imaging into standard test
equipment, as with the companys new Infrared Guided

Measurement (IGM) line, consisting of digital multimeters
and clamp meters. IGM allows users to thermally scan
equipment and enclosures to see where the problems are
before they start hooking up test leads or start other trouble-
shooting measures, says Huekels.
The ubiquity of wireless connectivity, greater computing
power, and the lower cost of memory have made it possible
for test tools to automatically save data to a smartphone or
other connection point and then transmit it to the cloud for
storage and analysis, says Weishung Liu, product planner at
Fluke Industrial Group.
For example, Fluke test tools now have embedded Blue-
tooth radios, allowing the user to instantly save measure-
Source: UE Systems
ments to the software-as-a-service (SaaS) platform via a
smart device. Wireless sensors from Fluke allow techni-
cians and engineers to leave measurement tools in place
over a period of time to monitor, data-log, live-stream, and
analyze key data collected, says Frederic Baudart, Fluke
Connect product specialist. Ultrasonic inspection of electrical insulator
One of the newest thermal imaging applications involves
installed photovoltaic (PV) panels. Compared to properly
operating solar cells, defective solar cells operate at higher standpoint. Finding one electrical problem before it burns up
temperatures and are readily seen with a thermal imager. or blows up can save a significant amount of time and money,
Infrared imaging can also detect thermal anomalies caused says FLIRs Huekels. One save/find can pay for the all the
by faulty wiring, remarks Infraspection Institutes Sef- thermal cameras you deploy in your facility 100 times over.
frin. Imaging may be conducted on foot using a handheld Especially in a product line environment, a facility has to factor
thermal imager to inspect the top or underside of operating in its loss in production revenue for every hour that production
panels. Or, for large installations, it may be conducted using is offline. It can be hundreds of thousands of dollars.
purpose-built unmanned aerial vehicles (drones) or from a Schneider Electrics Kourounis describes a recent
helicopter using a high-resolution thermal imager. customer example in which abnormally elevated C-phase
temperature readings obtained through connected tem-
FINDS AND SAVES JUSTIFY THE INVESTMENT perature monitoring of a 30-year-old dry-type transformer
In addition to helping keep workers safe, electrical PdM can helped a facility director convince key decision-makers
offer a compelling return on investment from a production that the transformer was unreliable and could be at risk
Source: Fluke
Easy-to-use tools allow operators and technicians to inspect components of electrical systems for potential problems.

of failure. A similar experience at TOP TIPS FROM INDUSTRY PROS FLIRs Huekels recommends having
a sister substation four years prior What else can you do to optimize your maintenance personnel carry some
cost the company close to $1 million electrical PdM? Consider the following thermal imaging tools to use in regu-
in losses. Efforts are underway to recommendations from industry pros. lar checks throughout the workday
replace the aging transformer. Always look at all of the sections of and having IR windows installed in
For EASAs Bishop, detection of the plants electrical system from all electrical enclosures to minimize
unbalanced voltages and currents power coming into the plant to the exposure to arc flash dangers.
has led to corrective actions that drives and invertors, switchgear and Infraspection Institutes Seffrin cau-
reduced the power loss and heating motor controllers, and the motor tions that thermal imaging is not a
of electric motors and other three- that turns the pump or fan doing the point and shoot technology, despite
phase loads. Not only was electrical actual work, says Flukes Bernet. Any claims to the contrary. Proper ap-
energy use reduced, he says, but link in this chain is a potential failure plication of the technology requires
motor and other equipment reliabil- and can lead to machine downtime, a trained and experienced operator
ity was increased. Corrective actions lost production, and increased main- who is familiar with the equipment
as a result of these early findings re- tenance costs, he states. being inspected, he says. Thermog-
duced the direct cost of motor repair W hether youre doing inspections raphers should be certified and fol-
and the indirect cost of downtime internally or using an outside service low recognized infrared inspection
for the driven equipment. provider, insist on a multitechnol- standards, such as those published
When documenting the savings ogy approach, suggests UE Systems by Infraspection Institute.
from PdM, its important to include Waetjen. One technology cannot As experienced personnel are near-
downtime avoidance as well as any address all of the potential failure ing retirement, capturing critical
dollars saved from scrap or product modes, he says, so you will be put- data and accurately interpreting
imperfections related to production ting your people and your equipment the data in a digital world becomes
downtime, adds UE Systems Messer. at risk if you limit yourself to one. imperative, comments Schneider
Electrics Kourounis. At the same
time, leveraging the IoT will help
move a facility into next-generation
Its
Itslike
likean
anearly
earlywarning
warning asset performance management.
When replacing aging infrastruc-
system
systemfor foryour
yourmotors.
motors.
ture, consider switching to IoT-ready
equipment, he suggests.
EASAs Bishop suggests using
Reliably
Reliably
detect
detect
early-stage
early-stage digital equipment that can store and
compare the measured data at each
winding
windinginsulation
insulation interval during testing and ensuring
weaknesses
weaknesses with
with
Baker
BakerDXDX that equipment is calibrated so that
readings are accurate and repeatable.
TheTheSKFSKF
Static
Static
Motor
Motor
Analyzer
Analyzer
Baker
Baker
DX Surge
DX Surge
PD PD
identifies
identifies
earlyearly
problems
problemswithwith
coil coil
andand
winding
winding Bishop also cautions that sometimes
insulation
insulation
withwith
an innovative
an innovative resistive
resistive
measurement
measurement PdM activities are given low priority.
approach.
approach.
ThereThere
is noisquirky
no quirky
radio-frequency
radio-frequency Focus on maintaining the schedules
antenna
antenna
to adjust,
to adjust,
andand
it produces
it producesconsistently
consistently and make certain that PdM personnel
reliable
reliable
high-resolution
high-resolution PD waveforms
PD waveforms thatthat
identify
identify
are not reassigned to other functions,
insulation
insulation
defects
defects
andandweaknesses.
weaknesses.
he urges. Alternatively, consider out-
sourcing some or all of the activities if
www.skf.com/emcm,
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or email
or email
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salesEMCM@skf.com
for more
for more
information.
information. the schedules are at risk. Finally, when
issues are detected, corrective actions
THETHE
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ENGINEERING
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SKF Group.
| SKF
|
Group
SKF 2016
Group 2016
Sheila Kennedy, CMRP, is managing

director of Additive Communications.
Contact her at sheila@addcomm.com.

MAINTENANCE & RELIABILITY / YEAR IN REVIEW
OF PLA NT
BEST ICES 2O16
SERV What a ye ar. To
appear on the pa
clos e it out in grand
ges of Plant Serv
fashion, w
ices and at plan
e
ts
pr
er
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vice
ent
s.c
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om
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in 2016. Heres
me of th
to a sa
e
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m
pr
os
os
t m
pe
em
ro
or
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able and insigh
, and momentu
tful quotes to
m-filled 2017.
the Plant Se
rvices editors
www.plantservices.com
SMART SOLUT
IONS FOR MA
Mobility is essentially turning
INTENANCE &
RELIABILITY
(field services, operations,

While IIoT may be revolutionary and logistics) on its head.
in concept, it will be evolutionary The field is just a geographic
in adoption for most companies. Leap of location; mobility allows us
to give them access to all
In other words, the Industrial
Faith systems, people, and processes
Internet of Things is more IIoT adoption varies
leaders push to get
widely, but
out in front www.pl antserv
ices.com
that are in the enterprise.

of a journey than a thing. Break the reactive
maintenance cycle /
Right-size
SMAR
OLUT
T Syour
P.22
IONS
three-phase
induction motors / P.24
/ P.15
FOR M
AIN TEN ANCE
& REL
IAB ILITY
M&R wins
Four quick
Rohit Robinson, business line leader

on monito
IIC: Setting the
ring help
ConditiIIoT
via your HMI
standards / P.26
/ P.19
ty
your reliabili
Dene How
future / P.28 efficient is your
David White, senior analyst desiccant to dryer? / P.39

The IIoT comesair / P.32
compressed
at Honeywell
at ARC Advisory Group
Going Mobile, February
Leap of Faith, January
GOING E
MOBIL mobility is
ubiquitous
Now that e is it taking us
next?
inside
plants, wher your EAM/CM

MS / P.11
add-ons for
Plus: Mobile
People want to be portable, they want to be enabled, and the specific device doesnt matter. People are
expecting to do different things on the phone that, traditionally, industrial systems couldnt do.
Kyle Reissner, industrial mobility platform leader at Rockwell Automation Going Mobile, February
SMART SOLUTIONS F
OR MAINTENANCE &
RELIABILITY First and foremost, teach yourself Sometimes I get blank looks in the sense
to always think like an accountant that it sounds like Star Wars its off in
instead of a maintenance the future someplace. Yet at the same time,
professional. This is difficult for those same people are wearing Fitbits on
most of us, but how many of your their arms; theyre wearing Apple smart-
2O16 watches; theyre carrying smartphones
PdM FORECAST decisions actually generate
that give you access to vir-
NEW SURVEY:
Readers want more
RELIABILITY ROI:
Prove program a hard dollar payback?
from PdM / P.30 payback / P. 38
tually anything anywhere www.plantservices.com
Phil Beelendorf, maintenance technology in the world at any time. SMART SOLUT
IONS FOR MA
INTENANCE &
RELIABILITY
IIoT-Enabled Monitoring
senior manager at Roquette America Rick Veague,

Equipment / P.11
Industry Leaders Sound
Off
on PdM Survey / P.19
Energy Monitoring
2016 PdM Forecast:

Double Feature / P.32 & 34
Improve supervisor motivation
/ P.9
Tech that attracts young talent
/ P.11 CTO at IFS North America How (and Why) to
Calculate OEE / P.41
America's skilled trades dilemma

Reliability ROI, March
What context-aware
Quiz: Is your plant at risk of failure?

/ P.15
/ P.26 See the Future, April technology means

for your plant
Many people want to say they are using (PdM) technologies, so they acquire them. It looks
good on paper to say that they are using them, when in reality the knowledge, support, and
discipline needed to bring it to fruition does not exist.
Joe Anderson, CRL, CMRP, senior reliability manager at The Schwan Food Company Industry Responds to PdM Survey, April

MAINTENANCE & RELIABILITY / YEAR IN REVIEW
SMART SOLUT
IONS FOR MA
INTENANCE &
RELIABILITY
I think that this (technology) democratization thats happening

is changing the landscape of the tools that people have available
to them, especially young people, and giving them the freedom
Build compressed air
systems for
scalability, reliability,
to really go where their minds are taking them. while also meeting audit
and exibility
goals.
Should you stay or
should you go? / P.9
Picking up good
vibrations / P.19 & 22
Dorothy Jones-Davis, co-founder at NationofMakers.org Get your motor

running / P.38
Makers rising / P.50
Maker Faires: Building the Future, May
ices.com
www.pl antserv
SMART S
OLUTIO NS FOR
MAINTEN
ANCE &
RELIABIL
I TY
Weve got scary technology moving at a very fast pace in an industry that may
or may not be ready for it but that desperately needs it.
Kimberley Hagerty, lean transformation manager at Pratt & Whitney
You Are Going To Have To Move Fast, June
ds
g OSHA standar
What evolvin for
logies mean
and new techno
in your plant.
electrical safety
ce
Tools for Workfor
/ P.11
Development
y
Build Your Reliabilit
As we get older, we tend to be

Strategy / P.32
We are in the middle of the next

Together:
Get Your Stuff a Better
for
A Road Map
Storeroom /
P.38
Gets
Robotics Safety / P.42
an Upgrade
more reflective about our lives

industrial revolution. Known as Industry
and careers. It turns out that my
4.0 and synonymous with the industrial father, who was my hero, was pre-
internet of things (IIoT), this revolution will paring me to be a good reliability
require us to learn and apply knowledge and skills engineer long before I knew what I
faster than ever driving us to super-skill our abilities. wanted to do in life.
Tom Furnival, director of training services, Terry Hall, senior reliability subject
Marshall Institute Super-Skill Me blog matter expert at Life Cycle Engineering
The Thrivers Guide to the Next Industrial Revolution, June Six Reliability Life Lessons
from my Father, June
We want to cultivate that younger population. SMART SOLUTIONS F

OR MAINTENANCE &
Theres great value in aiming to

RELIABILITY
If Im going to expect them to stay doing an become multiskilled. The goal isnt
assembly job for 20 years or even five years, High tech gets
productive &
personal
perfection; the goal is to be above
(thats) probably not realistic. average and to adapt as necessary.
Colin Cosgrove, president at Laystrom Manufacturing Machine knowledge:
Share the wealth / P.11
Metrics that matter / P.22

Heinz P. Bloch, owner of
Pizza and Continuous Improvement, July
Interview: CMRP of the Year
Process Machinery Consulting

Nezar Alshammasi / P.26
Pizza and continuous

improvement / P.42
Real Talk About Finding,

Keeping a Job, September
Our surveys indicated that 28% of The next big leap in cost reduction
SMART SO
LUTION S FOR MAI
NTENANCE
& RELIABI
LITY
the respondents have experienced requires embracing a new paradigm:
(counterfeits) ... The known cost impact Industrial compressors are just
of CFSI per incident, according to electric heaters that happen to
the respondents, ranged from $100,000 make compressed air.
How is industry
tackling the problem
of counterfeit parts?
to $28 million.
Build your CMMS
Makarand Hastak, head of construction engineering Wayne Perry, senior technical
dream team / P.15
The secret to reliability
How (and why)

liftoff / P.23
to train operators
/ P.40
and management and professor at Purdue U. director at Kaeser Compressors
on maintenance
The key to IIoT:
Interoperability
/ P.43
This Is A Fake, August Industrial Compressor or

Electric Heater? September

LINKS TO ARTICLES
See the full list of the years best quotes
and articles at www.plantservices.com.
There was this thought that by buying this device, we now A Winning Compressed Air Strategy: Turn It Off!
http://plnt.sv/BEST16-01
have PdM, and life would be great. There wasnt really any
foresight into building a PdM program. Achieve PdM Success: Be Like Mike
Brendan Russ, reliability engineer at Southern Gardens Citrus Design for Reliability: Long May Your Assets Run
Shake Off the Rust: The Rocky Road http://plnt.sv/BEST16-06
to Reliability, September
SMART SOLUTIONS F
OR MAINTENANCE &
RELIABILITY Going Mobile: Jim Hilton interview
SMART SOLUTIONS F
Your 3-point strategy

for control system
maintenance / P.17
OR MAINTENANCE &
RELIABILITY
Manage the balance
Heinz Bloch: Keep between awareness
expanding your skills
and action / P.9
to survive / P.19
Attract more women to
Take stock of your industrial careers / P.32
spares program &
unlock prot / P.23
Doc Palmer: How

to make planning
Improve motor control
center safety / P.37
Be like Mike / P.46

Going mobile: Kyle Reissner interview
& scheduling work
for you / P.32
I recommend starting with
the one discipline that will How To Attract Women to Industrial Careers
SUSTAIN add the most value to your
PdM SUCCESS organization and making it How to Prevent Motor and Drive Faults
Recognize the seven critical
success factors that keep http://plnt.sv/BEST16-11
right before adding others.
new
Find the right leaders to breathe strong predictive maintenance
life into your PdM program programs on track
Also, all PdM programs How Motivated Is Your Team?

should be audited on an
The effort to start or restart annual basis to ensure Industrial Compressor or Electric Heater?
successful PdM programs they are operating as
begins with identifying effectively and efficiently Industry Responds to PdM Survey
leaders with the managerial as possible.
skills to build and institu- Involve the Reliability Engineer in Your CMMS
Paul Dufresne, CRL, CMRP, reliability Implementation
tionalize the program. http://plnt.sv/BEST16-15
improvement specialist
Burt Hurlock, CEO at Azima DLI Shake Off the Rust: Get Back on
Leap of Faith
Sustain PdM Success, October Track, September http://plnt.sv/BEST16-16
Make Energy Monitoring Mission-Critical

Maker Faires: Building the Future

Many plants have already tried to utilize PdM, and most have http://plnt.sv/BEST16-20
failed due to a lack of organizational ownership, lack of follow-
Pizza and Continuous Improvement
through, and lack of vision. Communicate your plan, docu- http://plnt.sv/BEST16-23
ment your wins, and stick with it.
Real Talk About Finding, Keeping a Job
Greg Padesky, SkillPoint account manager at Advanced Technology Services
Sustain PdM Success, October Reliability ROI: Show Em the Money
The new standard for gold stars is predicting failures and planning See the Future
the needed repairs around production needs. We now control when http://plnt.sv/BEST16-26
we fix things rather than when we have a breakdown. We own the Shake Off The Rust: The Rocky Road to Reliability
machines rather than the machines owning us. http://plnt.sv/BEST16-27
Michael Macsisak, predictive maintenance technician at Nestl Purina Shake Off The Rust: Getting Beck On Track
Achieve PdM Success: Be Like Mike, October
Six Reliability Life Lessons from my Father
Sustain PdM Success

You may not even know you are paying www.plantservices.com
SMART SOLUTIONS F
OR MAINTENANCE &
stupidity tax on your energy bill until you have

RELIABILITY
This Is A Fake
Embrace the "Grand
had a close look at your system during weekend
Energy Transition"
P.15
Simulation modeling and

advanced manufacturing
P.22
Monitor motor vibration or

optimize bearing lubrication?
Welcome to Super-Skill Me: The Thrivers Guide to

P.32
operation, and even then it may not be obvious. Take your pick of apps
and modules that
integrate with your core
The role of insurance in
reliability decisions
P.37
asset management system

to mitigate risk, extend
asset performance, and
manage the unexpected
the Next Industrial Revolution
Ron Marshall, Compressed Air Challenge, http://plnt.sv/BEST16-33
Compressed Air Efciency blog You Are Going To Have To Move Fast
A Winning Compressed Air Strategy: Turn It Off! November http://plnt.sv/BEST16-35

OP EX / ENERGY MANAGEMENT
Consumers, according to the Product Adoption Lifecycle, 5. Laggards Traditionalists, laggards are the very last
can be grouped into one of five categories: to adopt a new product. In my experience, this group largely
describes the entire energy establishment, which has built a
1. Innovators Interested in anything new, quick to huge bureaucracy that is the source of all of its income and is
adopt, and willing to pay a high price to be among the content to use 40-year-old methods in working with clients.
first to have a new product. Max Planck, the German theoretical physicist who origi-
Our early iDOS systems incorporated the Apple II nated quantum theory and won the Nobel Prize for physics
and Hayes modems shortly after they appeared on in 1918, put it directly: Any generation of established sci-
the market. We switched to the IBM PC when it was entists has too much vested interest in terms of reputation,
introduced. Starting with the Basic program language, pull, influence, money (grants), and huge amounts of ego
we moved to Microsoft Windows and Excel in 1985. involved to allow the so-called outlier theory to take all the
The technology to better manage production and energy systems is out there. I was at the Microsoft conference in New Orleans in limelight, glory, and spoils.
Why is it taking so long for industrial plants to adopt it? 1992 when Access was introduced. We immediately In other words, widespread adoption of our approach
adopted it for data storage. In 2008, we switched would mean that most in the energy efficiency profession
BY BILL HOLMES, HOLMES AUTOPILOT from a PC-based to a cloud-based system uti- would lose their sources of income.
lizing the MySQL database. Things are changing, though, as the first kids who grew
up with computers have risen to positions of authority in
In the early 1970s, I was part of the development team for In spite of the fact that this is ostensibly the 2. Early adopters Defined as young industry. Thats why cloud-based information systems are
the On-Condition Maintenance System for the F-15 fighter Information Age, not the Estimation Age, and restless, early adopters are opinion progressing so rapidly. Not only do younger leaders un-
jet. It was the first computer-based advanced instrumentation more cities and states are making old- leaders. They were our first clients. We derstand the value of information, but also they demand
system for a U.S. Air Force plane. It changed the whole con- fashioned energy audits mandatory. They always referred to them as our champions. information access.
cept of aircraft maintenance from one of scheduled mainte- seem to be following the advice of the late According to Planck, New scientific ideas never spring
nance to conditioned-based and predictive maintenance. management consultant Peter Drucker: 3. Early majority Value shoppers. from a communal body, however organized, but rather
In the early 1980s, when I was an assistant professor at When a subject becomes obsolete, we make Members of the early majority care- from the head of an individually inspired researcher who
Purdue University and consulting with building owners it a required course. fully observe the early adopters but wait struggles with his problems in lonely thought and unites
to help them reduce their energy costs, I used what I had to adopt innovative products until they all his thought on one single point which is his whole world
learned about monitoring airplane systems to design, build, BARRIERS TO PROGRESS are sure they will get value from them. They for the moment. He adds, Experiment is the only means
install, and operate a similar system for all types of facilities. Why dont industrial plants have the informa- became clients only after visiting sites where of knowledge at our disposal. Many in government, utility
Using real-time screens and historical reporting, the system tion they need to operate all of their production iDOS had been in operation, talking to the companies and other large organizations with deep pockets
showed when, where, and how efficiently every utility dollar and energy systems as efficiently as possible on owners, and viewing the results. are convinced they know all of the answers and have built
was spent within a facility. That first system evolved over an ongoing basis? The technology obvi- bureaucracies to support their theories. They dont under-
time into the AutoPilot Industrial Diagnostics & Optimiza- ously exists. Just look at airplanes, 4. Late majority As skeptics, stand that those of us who have spent our entire careers
tion System (iDOS) as it exists today. automobiles, medicine, smart- members of the late majority actually working with and trying to improve energy systems
The system was designed to monitor key parameters and phones, and nearly every wait until an innova- in the field are the ones with the real understanding.
continuously analyze the thermodynamic efficiency of not other sophisticated device or tion has been accepted
just production and energy systems but the facility as a system other than buildings. by a majority of con- THE FUTURE
whole as well. It also identified waste and diagnosed specific And yet those in the sumers before adopt- Technology has advanced to the point that it is now pos-
problems, allowing operations and maintenance to move energy profession still ing it themselves. sible to inexpensively monitor, analyze, and securely store a
from a reactive to a proactive approach. dont give clients the We had few of virtually unlimited amount of data on giant servers on the
I understood that what I learned in the Air Force about information they need. these. Most skep- cloud. Anyone in the world with access to the Web can view
planes also applied to buildings. To fly a plane, a pilot They still use temporary tics wanted us to that data with a variety of devices.
must have real-time data on all aircraft systems and have instrumentation, energy guarantee savings We have been proving in every project for nearly 40 years
it presented in a clear and easy-to-understand format via audits, and bench- ahead of time. that permanent instrumentation with sophisticated analyt-
cockpit gauges. To run a building efficiently, operators must marking to produce Many took the offer ics can optimize the operation of all production and energy
have the same information. mountains of reports of utility compa- systems as well as total facilities on a continuous basis.
Fast-forward to December 2016. Unfortunately, little real and justify capital nies who claimed Dont be a laggard. Jump into the future today: Add sen-
progress has been made in the past 35 years. Rather than projects. they could provide sors to monitor your critical equipment and systems. Send
energy professionals basing fees on creating, verifying, and One answer to why the same informa- production and energy data to a server on the cloud. Add
maintaining actual savings, a billion-dollar industry has this occurs can be tion and service for software and analytics to put the data in the most usable
emerged based only on preparing to save energy. Prac- found in the Product free. However, the form. Make the resulting information easily available to
titioners make their money from energy auditing, bench- Adoption Lifecycle (as utilities didnt have your employees, and train them to use it.
marking, training classes, certifications, energy modeling, can be found online at the same expertise or As the IIoT and other tools continue to be defined and
writing reports, filling out forms, and selling equipment. www.study.com). information. improved, you will already be decades ahead.
28 DECEMBER 2016 WWW.PLANTSERVICES.COM WWW.PLANTSERVICES.COM DECEMBER 2016 29

PRODUCT ROUNDUP
ASSET MANAGEMENT SOFTWARE

Leverage mobility and the IIoT to maximize asset performance and control costs
IFS IoT BUSINESS CONNECTOR EMERSON ASSET MANAGEMENT PLATFORM

IFS IoT Business Connector provides the ability to har- Emerson Process
ness data gathered from products, assets, and equipment to Management intro-
identify actionable observations that trigger user-defined duces the AMS ARES
workflows in IFS enterprise soft ware. The IoT Business asset management
Connector provides plug-and-play connectivity with the platform, which gath-
Microsoft Azure IoT Suite for device communications and ers data from mul-
data analytics alongside open APIs to connect other IoT tiple sensing tech-
platforms or specialized IoT discovery applications. nologies and provides
IFS a holistic view of the current health status of plant assets.
www.ifsworld.com/iot Persona-based access to information ensures that the right
personnel have access to clear health overviews of assets.
IBM MAXIMO ASSET HEALTH INSIGHTS Emerson
Maximo Asset Health Insights is used to join condition www.emerson.com
assessment readings from assets to historic information
from work and equipment records and other influencers, BIGFOOT CMMS MOBILE APP
such as weather incidents and maintenance history. These Smartware Group Inc. launched its first native mobile appli-
data sources are ana- cation for Bigfoot CMMS. Developed for iOS and Android
lyzed by the Watson IoT devices, users can quickly navigate parts, work orders, and
Platform, which feeds assets through the apps QR code or swipe-gesture function-
results back to Maximo ality. The app also provides offline editing access.
in the Asset Health Bigfoot
Insights work center. www.bigfootcmms.com
IBM
ibm.co/asset-mgt eMAINT CMMS INTERACTIVE PLANNING AND MAPPING
eMaint, a Fluke company, has added an interactive plans and
INFOR EAM 11.2 mapping feature to its CMMS software, allowing organiza-
Infor EAM v11.2 builds on the latest cloud-enabled offer- tions to visualize their maintenance management data on a
ing and enables faster, more-effective maintenance services, floor plan, schematic, site map,
providing capabilities to track and record incidents with or any other image. Users upload
workflow tasks and follow-up work orders. Core enhance- an image and place pins on it that
ments include case management, key management, asset point to their asset, work order,
reservations, and a contractor service portal module. work request, or inventory record.
Infor eMaint
www.infor.com www.emaint.com
ROCKWELL AUTOMATION FACTORYTALK ASSETCENTRE 7.0 MERIDIUM ASSET ANSWERS 2.1.1

FactoryTalk AssetCentre v7.0 soft ware from Rockwell Auto- Meridium Inc.s Asset Answers v2.1.1 cloud-based asset
mation automates discovery and tracks the status of devices, performance diagnostics solution provides comparative ana-
network switches, and soft ware on workstation comput- lytics and delivers visibility into asset data. Benefits include
ers across an entire facility or production operation and a weighting capability in the bad-actor function as well as
includes a mobile-friendly dashboard. the ability to benchmark asset performance anonymously
Rockwell Automation against global industry peers.
www.rockwellautomation.com Meridium Inc.
www.meridium.com

TOFINO ASSET UTILIZATION REPORT SUITE
Tofino Soft ware has released its latest suite of enhanced asset
utilization reports, which includes asset availability report-
ing in support of OEE, asset down-
time, production downtime, mean
downtime between
failures, and mean time
to repair.
Tofino
www.tofinosoftware.com
NATIONAL INSTRUMENTS InsightCM ENTERPRISE

National Instruments enhanced version of its InsightCM
Enterprise soft ware can help companies gain insight into the
health of capital equipment. Offering multiple measurement
tools in one, the soft ware features a workforce multiplier
and complete accessibility to data and third-party packages.
National Instruments
www.ni.com
MAINBOSS ADVANCED
MAINTENANCE MANAGEMENT
MainBoss advanced maintenance
management soft ware lets users
track problem reports, complete
work orders, schedule inspec-
tions and preventive maintenance Delivering leading-edge
work, and control inventory. content by showcasing
Role-based security is offered. smart technology,
Thinkage Ltd. reliable asset
www.mainboss.com
management and
promoting a culture
MAPCON CMMS MOBILE APP
of safe, sustainable
Mapcon Technologies mobile CMMS
plant operations.
includes image and document at-
tachment, instant notification of www.plantservices.com
dispatched work orders and pur- SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY
IIoT-Enabled Monitoring
chase order approvals, collection of

www.plantservices.com www.plantservices.com
Equipment / P.11
Industry Leaders Sound Off

on PdM Survey / P.19 www.plantservices.com
SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY
Energy Monitoring
Your 3-point strategy
Double Feature / P.32 & 34
www.plantservices.com www.plantservices.com
S M A R T S O L U T I O N S F O R M A I N T E N A N C E & R E L I A Bfor
I L control
ITY system SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY
meter/gauge readings, and vendor

maintenance / P.17
Heinz Bloch: Keep

How (and Why) to
SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY
expanding your skills
to survive / P.19
Calculate OEE / P.41 SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY
Take stock of your

spares program &
unlock profit / P.23
Doc Palmer: How

to make planning
& scheduling work
for you / P.32
What context-aware
technology means
information storage.
High tech gets
productive &
for your plant
personal
2O16
PdM FORECAST
NEW SURVEY: RELIABILITY ROI:
Readers want more Prove program
from PdM / P.30 payback / P. 38
What evolving OSHA standards
How is industry tackling the problem and new technologies mean for
of counterfeit parts? electrical safety in your plant.
Build compressed air systems for
scalability, reliability, and flexibility
Mapcon Technologies
while also meeting audit goals.
Should you stay or
should you go? / P.9
Machine knowledge:
Share the wealth / P.11 Improve supervisor motivation / P.9
Metrics that matter / P.22 Build your CMMS Picking up good Tech that attracts young talent / P.11
dream team / P.15 Tools for Workforce
Interview: CMRP of the Year
Nezar Alshammasi / P.26 vibrations / P.19 & 22 Development / P.11
America's skilled trades dilemma / P.15
Pizza and continuous The secret to reliability Build Your Reliability Quiz: Is your plant at risk of failure? / P.26
improvement / P.42 liftoff / P.23 Strategy / P.32
Get your motor
How (and why) to train operators running / P.38 Get Your Stuff Together:
on maintenance / P.40 A Road Map for a Better
Storeroom / P.38
The key to IIoT: Makers rising / P.50 Robotics Safety Gets
Interoperability / P.43 an Upgrade / P.42
www.mapcon.com
Find the right leaders to breathe new
life into your PdM program
METEGRITY VISIONS ENTERPRISE

As a complete asset integrity management solution, Visions
Enterprise manages fixed and rotating equipment from a
single platform, delivering extended asset life, seamless regu-
latory compliance, reduced shutdowns, and maximized ROI.
Metegrity Inc.
www.metegrity.com w w w. Pl a n t S e r v i c e s .c o m
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BIG PICTURE INTERVIEW
EVERYTHING IS GOING TO BE DIGITIZED

Maintenance expertise is moving outside plant walls, GE steam turbine pro says
Bernard Norris is the steam turbine services product line leader for GEs legacy fleet. Based
in Atlanta, where GE houses its remote Monitoring & Diagnostics (M&D) Center, he is part
of the team involved in the companys first-ever ESP installations for GE D11 steam tur-
bines at combined-cycle power plants in Johnson, RI, and Elk Hills, CA. He spoke with Plant
Services about the value of remote monitoring as a cost-savings tool and an aid in mak-
ing repair-or-replace decisions, as well as what the future of monitoring looks like.
PS What value do GE customers get from having someone in is for two years with payback. But it also will show the cost
Atlanta keeping an eye on their equipment? to replace the entire rotor. And when you replace the entire
rotor, you also get the additional 1.5% of output, as well as
BN Our team is looking at performance, output, heat rate. you get up to a 1% increase on efficiency of the unit.
Theyre able to calculate or identify vibration issues or
different load swings or decrease in the output. The team is PS Can you go into a little more detail about that process?
proactively looking at the data and seeing if there are any
issues with any unit in particular. BN We have around 200 units in our D11 fleet. About 70%
With the project in California, we saw some potential of those are monitored through our facility here in Atlanta.
rotor-bow issues, and that rotor-bow issue could impact An engineer is pretty much on call 24/7. Theres always
operability or availability of the unit. We get involved and someone in the center looking at data. The teams look and
we say, This is how much your unit is vibrating or theres a see, OK, theres a particular unit thats having some issues.
rotor bow that could lead to vibration issues. And then we We then dispatch our regional application engineering team.
propose to do a repair. In some cases customers will take the In the case of Elk Hills, theres an engineer out in Utah
repair option. But in other cases, the customer will make whos talking to them quite a bit, visits them, etc.
a different decision and say, I dont want you to repair my The regional application engineer will take a look at the
rotor, I want you to replace it. The benefit of replacing it is data, based on the M&D, and assess the unit configuration
to reset the clock of the high-pressure and the intermediate- and unit history. Theyll then tie that back to our sales and
pressure section of the steam turbine, extending the life of commercial process. Theyll engage the sales manager and
the unit as well as mitigating future risk of forced outage. present a high-level summary of findings stating, Heres
We have the ability, the analytics, and the algorithms to what we believe the issue to be; heres the remedy. The sales
assess a unit to tell a customer, Your unit is experiencing manager looks at it and says, OK, I know what the value
rotor bow; heres a way that we can mitigate this risk. drivers are for my customer; in this case thats availability,
more around life extension.
PS Do the algorithms reliably indicate whether a repair or The salespersons have some discussions with the appli-
replacement is the best option? cation engineering team. And then they have a discovery
session with the customer. Its not, Hey, we want to sell you
BN The M&D algorithm will identify the severity of the rotor the latest whiz-bang technology, and you have to buy it. We
bow, whether (a bow is) 10 mils (0.01 inches) or 2 or 3 mils. want to put all the options on the table.
We have the ability to measure to that level of accuracy.
I wont say that the repair solution is a quick fix. It will ad- PS Is this the future of plant maintenance a collaborative,
dress the rotor, but the cycle is outside of the normal outage. remote-based team effort?
Essentially it straightens the rotor and removes the bow so
when the rotor is installed, it helps drives the right level of BN Thats exactly where the industry is headed. GE is really
eccentricities and clearances. committed to developing the plant of the future, the digital
We have a value economic model that well run where power plant. Everything is going to be digitized, with the
well say, Heres the option for repair; heres what the price ability to monitor, the ability to analyze.

COMPRESSORS
Not Getting Enough Supervision?
S
ure. We make a better compressor. More reliable. More Air for less energy.
Easier to maintain. And quieter. But when it comes to efficiency, system design is critical.
You can run several very efficient machines, but not run them efficiently. Thats why we are such
sticklers for system controls. Our Sigma Air Manager 4.0 makes compressors play well with others. Under
SAMs supervision, compressors
dont fight each other. And when they
arent playing, they are off. No wasting
energy idling or cycling.
Beyond saving energy, SAM 4.0
ensures reliable steady pressure
for production. It also minimizes run
time which extends service intervals.
Reduced cycling and idling means
less wear and tear on the motor,
starter, valves, etc. SAM 4.0 also
provides full time energy monitoring
and easy integration into plant
control/IIoT systems. Stop neglecting
your compressor and give it the
supervision it needs with SAM 4.0.
Kaesers Sigma Air Manager 4.0 (SAM) compressed air management system brings the IIoT to industrial
plants with its adaptive control, data storage, analysis, and predictive maintenance capabilities, and it does
it all while ensuring a reliable, consistent supply of compressed air. Learn more at us.kaeser.com/sam.
Kaeser Compressors, Inc. 866-516-6888 us.kaeser.com/PS

Built for a lifetime is a trademark of Kaeser Compressors, Inc. 2016 Kaeser Compressors, Inc. customer.us@kaeser.com

Light Touch: Smart Solutions For Maintenance & Reliability

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SMART SOLUTIONS FOR MAINTENANCE & RELIABILITY

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SCHNEIDER ELECTRIC innovative approach to energy management. Some of its own

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VIBRATION entered regarding an encounter with

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Tracy Doane-Weideman, product manager for analytics, It doesnt quit.

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