PDH Source, LLC · Topics • Maintenance Statistics • Recommended Best Practices for Maintenance...

Facilities Management

Bobby Rauf, ©

9/24/2010 Facilities Mgt. Seminar; © B. Rauf 1

Table of Contents

• Maintenance Engineering and Management

• Electrical and Controls

• Plant Project Engineering and Management

• Safety in Industrial Environment

• HVAC

• Energy Conservation and Management

9/24/2010 Facilities Mgt. Seminar; © B. Rauf 2

Maintenance Engineering and Management

Bobby Rauf ©

9/24/2010 Facilities Mgt. Seminar - Maint. Management; © B. Rauf 3

Topics

• Maintenance Statistics

• Recommended Best Practices for Maintenance Organizations

• Examples of Computer Based Work Order Systems

• Maintenance Personnel Leadership and Management Skills

• Maintenance’s Role In Plant Spare Parts Inventory.

• Preventive Maintenance

• Predictive Maintenance

• Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization

• Maintenance Training and Support

• Motor Repair vs. Replace Decisions

• Cost Reduction, Repair vs. Replace Decisions


Maintenance Statistics:

• Approximately, 30% of Manufacturing and Process Plants have Maintenance Planners and some sort of Work Order System.

• Less than 15% of the Maintenance Planners are utilized effectively and efficiently.

• A significant majority of Maintenance Organizations view their Work Order Systems as inadequate and inefficient.

• Most Maintenance Organizations lack specific Missions Statements, Goals, and Measurable Targets.

• Most Maintenance Organizations lack established Performance Monitoring, Performance Analysis and Feedback Systems that are geared toward enhancing their Effectiveness and Continuous Improvement.

• A vast number of Manufacturing Facilities and Process Plants don’t pursue Failure Analysis of Systems or Significant Components.

• A significant portion of Maintenance Organizations do not perform Predictive Maintenance and consider it a Luxury.


Recommended Best Practices for Maint. Organizations:

• Perform Maintenance Cost Analysis:– Rank Maintenance Categories by Cost

• List Top Five to Ten Areas of Cost• Does the 80 – 20 Rule Apply?

– For instance, is 80% of the Maintenance Cost associated with a few Maintenance Areas, while 20% of the cost might pertain to a multitude of small cost categories?

• Have maintenance craft and planners provide quotes on planned work and compare with outside sources. Cost or price competition yields higher labor efficiency and lower cost.

• Maintenance Efficiency is directly proportional to Maintenance Planning.– Minimize Unplanned Maintenance Work and Maximize Planned

Maintenance Work• All maintenance work must be covered by Maintenance Work Order System

– Minimize Break of Schedules or Scheduled Work Orders• In Successful and Effective Maintenance Organizations, most of the Work

Orders originate from Preventive Maintenance Inspections and Predictive Maintenance Programs.


Recommended Best Practices for Maintenance Organizations, Continued:

• Maximize Facilities or Manufacturing Equipment O.E., Operating Efficiency:– Operating Efficiency is defined in terms of the following formula:

• O.E. (%) = (Equipment Up Time / Total Expected Run Time of Equipment) x 100

• Maximize or Optimize Equipment Life through some of the following means, as applicable:– Correct application and optimized operation of equipment.

– Strict discipline in scheduling and implementing periodic preventive and predictive maintenance.


Examples of Computer Based Work Order Systems:

• Maximo, by MRO Software Co.– Work Order Entry

• Work Plan• Recommends Parts, Equipment and Craft

– Work Order Tracking• Work Order Originator and Other Pertinent History• Schedule• Maintenance Person Assigned to the Work Order• Cost

– Spare Parts Inventory– Illustrated Parts Catalog

• Equipment Diagrams/Drawings• Bill of Materials

– Preventive and Predictive Maintenance Schedules– Purchasing– Pertinent Safety Information and Regulations.– Key Performance Indicators.


Examples of Computer Based Work Order Systems, Contd:

• Express Maintenance offers many powerful features and data entry fields you simply will not find in other maintenance programs. Here are just a few examples:

• Save photos and images of equipment, parts and employees• Built-in Report Designer lets you design your own reports• Create unlimited sites / locations for equipment and parts• Create unlimited categories of equipment, parts and services• Create unlimited services, intervals, periods and estimates• Include general and safety notes with every service• Create and print barcodes with parts and equipment• Data entry fields for devices and valves including types, pressures, sizes, connectors, outlet

/ inlet size, volts, amps, etc.• Complete vehicle and equipment fields including serial numbers for engine, transmission,

chassis, and body• Complete warranty and lease data fields• Units screen includes fields for everything you need to track plus user definable fields and

selection lists• Units screen includes tab for tracking & graphing downtime.• Quickly review maintenance that is due and automatically generate work orders.• Track work orders performed by your staff as well as outside sources• Track part and equipment suppliers and costs• Issue purchase orders and track receiving of parts• User setup screen allows administrator to determine to which screens each user will have

access and what level of access


Examples of Computer Based Work Order Systems, Contd.:

• Express Maintenance will save your company plenty of money in the short and long run. Now, you will be able to accurately and effectively track scheduled and un-scheduled maintenance on all sorts of equipment and parts. Here are a few of the benefits you'll see from Express Maintenance immediately:

• Protect inventory and reduce shrinkage of parts• Maintain equipment more efficiently and effectively• Generate work orders and manage personnel time more effectively• Track actual and estimated expenses of various services• Track safety and other notes on any service• Track scheduled and non-scheduled services• Monitor supplier pricing and know who is the best source• Track equipment warranty information• Know what services have been performed on equipment with unlimited service

history• Save time by having services automatically scheduled for you and know when

they should be performed next• Save time with instant reports and information always at your fingertips


Examples of Computer Based Work Order Systems:General Features

• Better support for multiple database or locations setups.

• Get email support from within the application's main menu.

• Automatic Email of work orders to people responsible for their completion. (Learn More)

• User defined fields added to Equipment, Mechanics, Parts and Contacts modules.

• Attach external files and documents to Work Orders, Inventory Items and Equipment (3.2)**

• Barcode labeling added to Equipment and Parts and Inventory modules.

• New Database backup and repair utilities.

• New Budget support for Purchasing and Work Orders (3.2)

• Support for the new optional Work Orders Request module.

• Join tables to custom reports in the Reports and Graphics module. (3.2)

• New Predictive Maintenance Worksheet report in the Issues module. (3.2)


http://www.simsofttech.com/Auto_email.htm

Maintenance Personnel Leadership and Management Skills:

• Goals Setting Guidelines for Front Line Supervision and Management:– S.M.A.R.T Goals

• “ S” stands for SPECIFIC

• “M” stands for MEASURABLE. “You can’t control what you can’t measure.

• “A” stands for ATTAINABLE.

• “R” stands for REASONABLE.

• “T” stands for “Time” specific.

• Zero Tolerance of Workplace Harassment

• Interpersonal Skills and Understanding Human Behavior– Maslow’s Hierarchy (See Next Slide)


Maintenance Personnel Leadership and Management Skills:


Maslow's Hierarchy of Needs

Abraham Maslow is known for establishing the theory of a hierarchy of needs, writing that human beings are motivated by unsatisfied needs, and that certain lower needs need to be satisfied before higher needs can be satisfied. Maslow studied exemplary people such as Albert Einstein, Jane Adams, Eleanor Roosevelt, and Frederick Douglas rather than mentally ill or neurotic people.

http://www.ieee.org/

Maintenance’s Role In Plant Spare Parts Inventory:

• Maintenance Department must participate in and approve addition of spare parts to stores inventory. Some of the reasons for this approach are as follows:– Avoidance of spare part duplication when parts are common

between various types of plant equipment.

– Proper control of spare parts that repairable or serviceable

• Maintenance must play an active role in Periodic Inventory of Spare Parts


Preventive Maintenance:

• Reasons for Preventive Maintenance:– To prevent unanticipated equipment breakdowns.Sudden,

unanticipated equipment or structure failure can result in the following:

• Higher Repair Costs• Longer Down Times and Lost Production• Safety Hazards• Possible Cascaded Failures of Upstream and Downstream

Equipment in Multi-Component Systems– To maintain efficiency and productivity of equipment– To prorate and spread maintenance cost over time. This provides

maintenance organization greater control over the facility’s maintenance budget by preventing unexpected surges in negative variances against the budget.


Preventive Maintenance, Contd:

• Examples of Preventive Maintenance:1. Periodic Lubrication of Equipment:

– Replenish or change oil and grease – Test the replaced oil or grease, if recommended by equipment

manufacturer. Tests performed on lubricants removed from large gear boxes, transmissions, bearings, compressors, engines, cranes, robots and other industrial equipment can diagnose and predict eminent failures.

2. Infrared Thermography – Infrared scan of Electrical Switchgear, Substation and Motor

Control Centers. Look for “hot-spots” and loose connections.– Infrared scan of steam traps.– Infrared scan of overheating motors, bearings and other

mechanical equipment.– Infrared scan of roofs to detect roof leaks.



Infra Red Thermography

– Cold transformer fins indicative of LOW oil level



• Examples of Preventive Maintenance, Contd:3. Compressed Air Leak Detection Using Sound Detection Systems:

– Compressed air leaks drop the pressure in compressed air headers and can cascade into malfunction of pressure sensitive equipment such as raw material or batch transport systems, air actuators, valves etc.

– Compressed air leaks are expensive. A 1/8” diameter air leak, at 100 psi, can cost more than $2,000 per year.


Predictive Maintenance:

• Reasons for Predictive Maintenance:– To prevent equipment failures through early diagnosis, and

prediction of eminent problems. Such predictions can then be followed by planned shut down and repair.

– Lack of Predictive Maintenance Program can result in the following:

• Higher Repair Costs due to Sudden Catastrophic Failures. Some Catastrophic Failures Require Total Replacement of Equipment.

• Longer Down Times and Lost Production• Safety Hazards; e.g. fire and explosion hazard with undetected

loose electrical connections.• Possible Cascaded Failures of Upstream and Downstream

Equipment in Multi-Component Systems; e.g. catastrophic bushing meltdown due to loss of process cooling water.


Predictive Maintenance, Contd.:

• Examples of Predictive Maintenance:1. Mechanalysis: The concept of relating the level of vibration and

noise, emitted by a machine, to the machine’s condition or performance is called mechanalysis.

– Vibration and noise are measured, recorded, charted and analyzed on critical mechanical equipment, where circular or linear motion is involved.

– All machines vibrate to a certain extent and generate a certain amount of noise.

– The normal noise and vibration constitute a fingerprint of sorts for a particular machine, under normal load.

– The vibration and noise caused by many factors. Some of the factors are listed below: – Unbalance or Misalignment

– Worn Gears or Defective Bearings

– Looseness


Predictive Maintenance, Contd.:• Examples of Predictive Maintenance:

1. Mechanalysis, General Method or Procedure, Contd:

a) Measure vibration at recommended points. Such as, at or near bearing and at specific points along the drive train

b) Vibration is measured and recorded in the following terms: Displacement or amplitude, in mils Vibration frequency, in CPM Vibration velocity, at peaks, in inches or mm per second Phase difference, in degrees, with respect to a fixed point or

another vibrating part.

c) Record the measured vibration, periodically.

d) Compare the data with established standards to assign a level of severity, or identify the type of problem (i .e. Unbalance, Looseness, Bad Gear or Bad Bearing) by examining the frequency of vibration.


Predictive Maintenance, Contd.:• Examples of Predictive Maintenance:

1. Mechanalysis, General Method or Procedure, Contd:

e) The periodic measurements of vibration are plotted, graphically, as a function of time or dates.

f) The graph plotted under item “e” depicts the trend of the vibration data. The objective is to look for: Any instantaneous peaks Gradual or sustained increase in vibration amplitude Correlate significant changes in the vibration data to chronological

events through the time or date axis of the chart.

g) Measure, record/chart the noise level, in db’s, using a sound level meter, at recommended points around the equipment.The objective is to look for: Any instantaneous surge in the measured noise level Gradual or sustained increase in the noise level Correlate significant changes in the noise data to chronological events

through the time or date axis of the chart.


Predictive Maintenance, Contd.:

• Examples of Predictive Maintenance:

– Components of a Typical Mechanalysis System:– Vibration detecting wand

– Microphone

– Monitor & Recorder

– Amplitude meter displays overall vibration level of machine in mils, in/sec, g's and g's se.

– Hard copy printout of vibration spectrum includes correct engineering units, filter bandwidth setting, amplitude and frequency scale values.

– Accelerometer is a rugged, high performance transducer which measures vibration, velocity, acceleration and "spike energy.”


Predictive Maintenance, Mechanalysis, Contd:


Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization:

• Break the age old paradigms that Instrument and Control Technicians must be groomed from within the plant’s existing personnel pool:– New technicians, with recent technical training and accreditation, frequently

offer greater service value, at lower wage expense.– New technicians, with recent technical training, bring fresh perspectives and

stimulate reexamining of traditional logic. • Assign a Senior Technician, Maintenance Supervisor or Maintenance Engineer the

responsibility to keep Control and Monitoring Software/Firmware current:– Too often software or firmware upgrade of control PLC’s (Programmable Logic

Controllers) is ignored until the equipment malfunctions or is modified.– Practice strict discipline in securing latest versions of controls and monitoring

programs, at multiple locations.• Maintain a secure documentation and program library, with authorized access

only.• In order to ascertain acquisition of complete documentation, on new projects,

Maintenance must be on the Engineering Project Completion Approval List.


Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization:

• Install CMMS, Computerized Maintenance Management Systems to simplify scheduling of Preventive Maintenance.


Maintenance Training and Support:

• Skills and Performance of Maintenance Technicians and Engineers, to a great extent, depend on training. Successful training of key technicians and engineers depends on some of the following factors:– Adequate availability and allocation of funds– Quality and effectiveness of the Training Program and Trainers– Maintenance Management’s Commitment to training– Selection of qualified and motivated technicians and engineers for

training:• On complex, specialized and critical equipment select only those technicians

and maintenance engineers for training who are expected to stay in their current assignments on longer term basis.

– Three (3) veteran technicians were trained through week long courses in robotics, vision system and Wonderware at a North Carolina Manufacturing facility, for a total cost of, approximately, $40,000. Six months later these technicians were a different assignment leaving no skilled maintenance coverage for the robot based automation system. Maintenance of this complex robot based system was contracted out to an external source.


Maintenance Training and Support, Continued:

• Funds for Maintenance Training:– Allocate funds for training purposes in the annual maintenance budget.– Engineering Projects, pertaining to new technologies, systems or equipment,

must be required to include appropriate amount of funds for mechanical, controls and electrical training

• Engineer, responsible for the engineering and installation of the system, must be required to support the plant for a definite period of time after commissioning of the system

• Evaluate the economics of outsourcing the maintenance function under the following situations:– Facilities with a limited maintenance staff– Prototype or pilot high-tech projects. For instance, a pilot or prototype

systems based on industrial robots, sophisticated vision systems, complex computer based HMI, Human Machine Interface Systems, etc.

– When “loaded” labor rates for in-house maintenance craft exceed the contract rates, significantly.


Motor Repair vs. Replace Decisions:Ten Questions to Answer Before You Call the Motor Service

Center

1. What is the basic nameplate information? (Include manufacturer, horsepower, speed, voltage, phase, enclosure, catalog, part and/or model number, frame size, and serial number.)

2. What does the motor operate? (A fan, blower, conveyor belt, pump?)3. How does the motor drive the load? (Does it have a direct drive, or is it

belted?)4. Is there auxiliary equipment attached? (A clutch, gearbox, or brake?)5. Why do you think the motor needs repair? (Does it smoke, not run, or

need preventive maintenance?)6. What is the motor’s past repair history? (Is it a “problem motor”?)7. How is the motor started? (Across the line, soft start, adjustable speed

drive, part winding start, wye start, or delta run?)8. What is the operating environment? (Indoors, outdoors, subject to

hazardous fumes or dusts, or water spray?)9. When do you need the motor back? Will you authorize overtime work if

necessary?10. Is the motor still under manufacturer’s warranty?11. Is this an EPACT motor? EPACT stands for Energy Policy Act.


Flow Chart, Motor Repair vs. Replace Decisions :


www.easa.comwww.oit.doe.gov/bestpractices/motors

Cost Reduction, Repair vs. Replace Decisions:

Repair vs. Replace decisions involve comparison of the life cycle cost of equipment under two mutually exclusive scenarios:

a) Life Cycle Cost of the piece of equipment in question if it is repaired, vs.

b) Life Cycle Cost if the equipment is replaced.

Life Cycle Cost:Total cost of owning and operating a piece of equipment over its

expected life. This cost would consist of the following:– Initial cost or investment – Total preventive, predictive and other typical maintenance cost over

the life span of the equipment– Fuel, electricity or other energy cost over the life of the equipment.

This would take into account the efficiency of equipment.– Opportunity cost or lost production if the equipment malfunctions.


Cost Based Motor Repair vs. Replace Decisions:

Sample Problem,

A 100 HP, 480 VAC, 3-Phase blower motor has experienced a ground fault due to winding failure. This motor has been repaired/rewound twice before. The motor has lost 5% of its efficiency during each of the past two (2) rewinds,due to core losses. The maximum actual load on the motor is 90 HP.

- A typical rewind or repair service, for a 100 HP motor is $1,600. - A new premium efficiency motor cost, approximately, $3,400. - Electricity cost at this facility averages $0.05/KWH. - Assume initial efficiency of 96% and a power factor of 0.9.

a) What is the cost of owning, maintaining and operating this motor over a period of 10 years?

– Assume that the motor experiences a ground fault at the 5th year, 8th year and the 10th year.

– Assume 24-7 operation and an average efficiency of 95% over 10 years. Assume that the electricity cost stays constant over 10 Years.

– Assume Lost Production Cost and Maintenance Labor Cost of $ 3,000 per Failure.



Original Efficiency of the Motor is = 96%Motor Efficiency after 1st Rewind = 96% x (1 - .05) = 91.2%Motor Efficiency after 2nd Rewind = 91.2% x (1 - .05) = 86.64%Motor Efficiency after 3rd Rewind = 86.64 HP x (1 - .05) = 82.31%Energy Cost, 1st Five (5) Years

= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 5Y / 0.96 x $0.05/KWH = $ 170,181 Line Current = 104 AmpsAnnual Energy Cost = $ 34,036

Energy Cost, After 1st Rewind, for Three (3) Years= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 3Y / 0.912 x $0.05/KWH = $ 107,483 Line Current = 109 AmpsAnnual Energy Cost = $ 35,828

Energy Cost, After 2nd Rewind, for Two (2) Years= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 2Y / 0.8664 x $0.05/KWH = $ 75,427 Line Current = 115, An 11% Rise in Line CurrentAnnual Energy Cost = $ 37,713

NOTE: After the second rewind, the motor Line Current has risen by 11%.QUESTION: After two (2) Rewinds, is the operating level of Line Current

approaching the Design Limit of the Conductors and the Circuit Breakers?


Life Cycle Cost of Owning and Operating a 100 HP Motor

Life Cycle Cost Comparison Without Time Value of Money Consideration:

Scenario (1):Rewind Twice, then Replace at 3rd Failure:=( $170,181+$107,483+$75,427)

+($1,600+$1,600+$3,400)+(3)x($3,000) = $ 368,691

Scenario (2):Replace upon 1st Failure:=( $34,036 x 10) + ($3,400+$3,400) + (2)x(3000) = $ 353,163

Replacement Option Life Cycle Cost is Favorable By:$15,528


Electrical Power & Controls

Bobby Rauf ©

9/24/2010 Facilities Management Seminar; © B. Rauf 39

Topics

• Essential Fundamentals Of Electricity in Industrial and Commercial Environment

• Standards

• Power Distribution Systems

• Pilot Devices

• Variable Frequency Drives

• Smart Motor Controllers (SMCs)


Fundamentals Of Electricity in Industrial and Commercial Environment

• Voltage• Current• Resistance• Capacitive Reactance• Inductive Reactance• Impedance• Power & Power Factor• Motor Speed Calculation• Motor Line Current Calculation



Voltage :

• Def: Electromotive Force or Electrical Potential Difference Between two Points

• Symbols for Voltage: E, V, VP, VM, VDC, VEff, VRMS,VAC

• Unit for Voltage: Volts



Current :

• Def: Movement of Electrons due to Electromotive Force or Electrical Potential Difference Between two Points is called current.

• Symbols for Current: I, i, I (t), IP, IM, IDC, IEff, IRMS, IAC,

• Unit for Current: Amperes or Amps.– One Amp = One Coulomb / Second



Resistance :• Def: The property of a material (conductor) to

impede or resist flow of current is known as resistance.

• Symbol for Resistance: R – R = ρ . L/A; Where, ρ = Resistivity of the Conductor,

L=Length of the Conductor and A=Area of Cross-Section of the Conductor.

• Unit for Resistance: Ohms or Ωs.– One Ohm = One Volt / One Amp



Capacitive Reactance :

• Definition of Capacitance: Capacity of a Capacitor to Store Electrical Charge.

• Symbol for Capacitance: C

• Symbol for Capacitive Reactance: Xc

• Where, Xc= 1/2πfC

• Unit for Capacitive Reactance: Ohms or Ωs.



Inductive Reactance :

• Definition of Inductance: Capacity of an Inductor to Resist Change in Current Flow.

• Symbol for Inductance: L

• Symbol for Inductive Reactance: Xl

• Where, Xl= 2πfL

• Unit for Inductive Reactance: Ohms or Ωs.



Impedance :• Def: Impedance is the current resisting and

impeding characteristic of load or conductor in an AC Circuit.

• Symbol for Impedance: Z Z = R + jXl - jXc

• Unit for Impedance: Ohms or Ωs.



Power :

• Def: Power is defined as the capacity of a system to perform

work or Rate of work performed by a system.

• Symbols and Types of Power:Papparent = S = Apparent Power (kVA) or Total AC Power

Preal = P = Real Power Component of Apparent Power (kW)

Preactive = Q = Reactive Component Apparent Power (kVAR)

• Papparent = (Preal)2 + (Preactive)2 orS = (P)2 + (Q)2

• Magnitude of Total (3 ∅ ) Power = S= √3 x VL x IL



Power Factor : • Def: Power is defined as the Ratio of Real Power (kW)

to Apparent Power (kVA). It is also defined as the quantity cos(θ - φ).

• PF = P/S or• PF = cos(θ - φ), • where θ is the angle of voltage v = VRMS ∠ θ and • φ is the angle of current i = I RMS ∠ φ• In Inductive Circuits, add Capacitance, or Capacitive

Reactance, Xc, to offset the Inductive Reactance, Xl, and to Increase the PF.



Power Factor Improvement Example:

• Problem:An air compressor station is consuming 2,000 kW at a power factor of 0.8. The

utility company charges a $4.00/kVa per month as demand charge for poor power factor. What would the annual, pre-tax, savings be if capacitors could be installed and power factor improved to 0.9?

• Solution:Apparent Power or Billing kVa at existing Power Factor of 0.8 = 2,000 kW / 0.8 =

2,500 kVaApparent Power or Billing Kva at an improved Power Factor of 0.9 = 2,000 kW /

0.9 = 2,222 kVaDemand Charge Savings = (2500-2222) kVa x $4.00/kVa x 12 Months/Year =

$13,344



Motor Speed Calculation:

• Given:Number of Poles = P = 4

Frequency of AC Power Supply to the Motor, in Hertz = f = 60 Hz

Speed, in RPM = S = ?

– Formula: S x P = 120 x f

» S = (120 x f ) / P

» S = (120 x 60) / 4 = 1800 RPM



Motor Power – Line Current Calculation:

• Motor Nameplate Information:Power rating, in HP (Horse Power) = P = 10 HPVoltage Rating = 480 VACNo. of Phases = 3; also stated as 3 ∅Power Factor = PF = 0.8Efficiency = Eff. = 0.9Magnitude of Line Current = FLA, Full Load Current = I = I = ?Note: 1 HP = 746 Watts = 746 W = 0.746 kW

– Formula: I = Power in Watts / PF / Eff./ (√3 x VL)» I = 10HP x 746 W/HP/0.8/0.9/(√3 x480VAC)

» I = 12.46 Amps


Standards

• NEMA: National Electrical Manufacturers Association; www.nema.org– NEMA, created in the fall of 1926 by the merger of the Electric Power

Club and the Associated Manufacturers of Electrical Supplies, provides a forum for the standardization of electrical equipment, enabling consumers to select from a range of safe, effective, and compatible electrical products.

• ANSI: American National Standards Institute; www.ansi.org– The American National Standards Institute (ANSI) is a private, non-

profit organization that administers and coordinates the U.S. voluntary standardization and conformity assessment system

• IEC: International Electrotechnical Commission. – IEC is the authoritative worldwide body responsible for developing

consensus global standards in the electrotechnical field


http://www.nema.org/

http://www.ansi.org/

Standards

• IEEE: Institute of Electrical and Electronic Engineers; www.ieee.org– The IEEE is a non-profit, technical professional association

for Electrical and Electronics Engineers.


http://www.ieee.org/

Power Distribution Systems

Power Distribution Systems Consist of:• MCC or Motor Control Centers

• Loop Switches

• Transformers

• Voltage Regulators

• Capacitor Banks

• Circuit Breakers

– OCB’s, Oil Circuit Breakers

– Air Circuit Breakers

• Disconnect Switches

• Fuses

• Starters and Combination Starters

• Power Monitoring and Control Systems



Switch Gear

Power Distribution System Example: 13.2 kV from Utility

13.2 kV from Utility


Low Voltage Systems:

• Up to and including 600 VAC or DC

Medium Voltage Systems:

• From 600 V up to 1,000 V, 1 KV

High Voltage Systems:

• From 1,000 V up to 800 KV



MCC’s or Motor Control Centers• Allen-Bradley Slide Show• Other Sources:

– Square-D

– ABB

– Seimens


Sections• 20” (508mm) wide

standard

• 15” (381mm) or 20” (508mm) deep

• 90” (2286mm) high standard,

– 71” (1790mm) high available

• Front mounted or back-to-back


Front MountedBack-to-Back

Presenter

Presentation Notes

An Allen-Bradley CENTERLINE Motor Control Center is made up of one or more vertical sections. A standard section is 90” (2286mm) high, 20” (508mm) wide, and either 15” (381mm) or 20” (508mm) deep for front mounted configurations. Greater widths are sometimes supplied when larger equipment is required. A 71” (1790mm) high MCC is available when installation height might be restricted. Back-to-back configured MCCs are also available in 30” (762mm) and 40” (1016mm) designs.

NEMA Enclosure Types

• Type 1

• Type 1 with gaskets

• Type 12 (also instainless steel)

• Type 3R

• Type 4 stainless steel


NEMA Type 1

NEMA Type 4

Presenter

Presentation Notes

Rockwell Automation offers a variety of NEMA type enclosures to meet specific requirements. The standard enclosure is NEMA Type 1. This compares to the IEC enclosure IP40. NEMA Type 1 with gaskets, which is unique to MCCs, provides gasketing for unit doors. This compares to the IEC enclosure IP41. Bottom plates are available for NEMA 1 and 1 with gaskets enclosures. NEMA Type 12 provides gasketing for unit doors, bottom plates, and all cover plates. A stainless steel NEMA Type 12 is also available. This is comparable to the IEC enclosure IP54. For outdoor use, Rockwell Automation offers NEMA Type 3R enclosures. This enclosure is essentially a metal shell around a NEMA Type 1 inner enclosure. This is comparable to the IEC enclosure IP44. For indoor or outdoor use, Rockwell Automation is the only MCC manufacturer to offer a NEMA Type 4 enclosure. This enclosure is essentially a stainless steel shell around a NEMA Type 1 inner enclosure. This is comparable to the IEC enclosure IP65. All metallic parts (except stainless steel) are painted or plated before assembly, providing protection on all mating surfaces.

Bus Connections• At least two bolts

– Horizontal-to-vertical– Horizontal splices – Extra bolt ensures integrity

• Front accessible


Horizontal to Vertical Connection

Presenter

Presentation Notes

Power bus connections in the Allen-Bradley CENTERLINE MCC are made with at least two bolts. The vertical-to-horizontal bus connection is made with two bolts, as you can see in this picture. The horizontal bus splice connections are made with at least two bolts on each side of the splice (depending on bus size). The load could be carried using one less bolt at each connection, but the extra bolt is used as a back-up to ensure the integrity of the connection. The two-bolt connection requires less maintenance and the extra bolt guards against the occurrence of “hot spots” (a result of loose connections), and arcing faults (a result of an open connection). All bus connections are front accessible for easy installation and maintenance.

Horizontal Ground Bus• 1/4” x 1” (6.4mm x

25.4mm) or 1/4” x 2” (6.4mm x 50.8mm)

• Unplated or tin-plated copper

• Located in wireway– Top or bottom– Top and bottom


Presenter

Presentation Notes

A 1/4” x 1” (6.4mm x 25.4mm) horizontal ground bus, rated 500A, is supplied, as standard, with each vertical section. A 1/4” x 2” (6.4mm x 50.8mm) horizontal ground bus, rated 900A, is optional. The bus can be unplated or supplied with optional tin plating. The horizontal ground bus can be mounted in the top or bottom horizontal wireway, or top and bottom horizontal wireways of the MCC.

Vertical Ground Bus• Plug-in ground bus

– Steel (standard)– Copper (optional)

• Unit load ground bus optional– Copper– For easier

termination of ground wires


Unit Load Ground Bus

Plug-in Ground Bus

Presenter

Presentation Notes

Each standard vertical section is supplied with a steel vertical “plug-in ground bus” on the left side of the section. The vertical ground bus is bolted to the horizontal ground bus, providing positive grounding for all plug-in units. An optional copper version is available. The optional copper “unit load ground bus”, located on the right side of the section, reduces installation time when 4-conductor cables are used. The load ground wire can be brought directly to the unit, rather than the horizontal ground bus, eliminating the need to strip back the wire jacket to connect the ground wire. A unit load connector (termination point) is provided at each unit, when specified.

Incoming Lug Compartment

• Top or bottom

• Straight pull for cables


Presenter

Presentation Notes

Power must be brought into the MCC. Therefore, the MCC needs to have some type of incoming compartment. There are 3 ways to accommodate the incoming power: incoming lug compartment, main fusible disconnect, and main circuit breaker. Typically, an incoming lug compartment is used when the main disconnecting means for the MCC is located in switchgear near the MCC. Incoming lug compartments are available for top or bottom entry of the power cables. The incoming lug compartment is designed so the cables are brought straight into the compartment. There is no power bus in the way and therefore, no need for sharp cable bends. Available sizes range from 600A, requiring no plug-in space, because lugs are in the top horizontal wireway, to full section compartments up to 3000A.

Main Fusible Disconnect

• Top or bottom

• Frame mounted

• 600A-2000A utilize “Bolted Pressure Switch”

• Visible blade


BoltedPressure

Switch

Presenter

Presentation Notes

Another way to accommodate the incoming cables is with a main fusible disconnect switch. Main fusible disconnect switches are available for top or bottom entry of power cables. They are frame-mounted (non plug-in), and hard-wired to the horizontal bus. For 600A to 2000A applications, a “Bolted Pressure Switch” is used. The bolted pressure switch features a contact system that tightly holds the blades during closure to provide a reliable current path and high withstand. All main disconnect switches provide visible blade indication.

Main Circuit Breaker

• Top or bottom

• Frame mounted

• Ground fault protection available


Presenter

Presentation Notes

A main circuit breaker is the other way that the incoming power cables can be accommodated. Main circuit breakers are available for top or bottom entry of power cables and, again, are frame-mounted (non plug-in) and hard-wired to the horizontal bus. They are available in sizes up to 2000A. Ground fault protection is available for 600A to 2000A main circuit breakers.

Space Factors

• One space factor equals 13” (330mm)

• Six space factors per section


78” (1981mm)

13” (330mm)

Presenter

Presentation Notes

The plug-in space of an Allen-Bradley CENTERLINE MCC is divided into space factors. One space factor equals 13” (330mm). The available plug-in space for each standard section is 78” (1981mm). Therefore, there are six space factors of available plug-in space in each standard vertical section.

Full Voltage Non-Reversing Starter Units


1.5 Space Factor Dual Size 1

(8 starters/section)

1.0 Space Factor Size 1


0.5 Space Factor Size 1


Presenter

Presentation Notes

With space factors in mind, let’s examine how many starter units will fit in a standard section. Most commonly, a NEMA Size 1 Full Voltage Non-Reversing (FVNR) starter unit requires 1.0 space factor. Therefore, a vertical section can accommodate six 1.0 space factor Size 1 FVNR starter units. A dual (two starters mounted side-by-side) Size 1 FVNR starter unit requires 1.5 space factors for both starters. So now, the same section can accommodate eight Size 1 FVNR starters. And lastly, Rockwell Automation offers a Size 1 FVNR starter unit in a 6.5” (165mm), or 0.5 space factor, design. With this design, the section can accommodate twelve (12) Size 1 FVNR starter units. This illustrates the flexibility with the Allen-Bradley CENTERLINE MCC offering.

Stab Assembly• Housing

– Isolates incoming phases acting as a fault barrier

• Stabs– Tin-plated– Rated 240A– Directly crimped– Steel spring backed– Free-floating and

self-aligning


Stab Assembly

Presenter

Presentation Notes

The stab assembly housing isolates each phase at the rear of the unit. Since the power wires are isolated within the stab assembly, a fault barrier is effectively formed between the units and the vertical bus. The tin-plated stabs, rated 240 amperes, are directly crimped to the power wires, minimizing any chance for a loose connection. The steel spring that backs the stab ensures a reliable high-pressure four-point connection on the vertical bus. The stabs are also free-floating and self-aligning, meaning they will position themselves for easy unit insertion.

Unit Grounding Provisions

• Unit ground stab– Used with unit plug-in

ground bus– Copper alloy (standard)– Solid copper (optional)

• Unit load ground connector– Used with unit load

ground bus– Solid copper– For easier termination of load

ground wire


Optional Plug-in Ground Stab

Unit Load Ground

Connector

Standard Plug-in Ground Stab

Presenter

Presentation Notes

A unit ground stab is provided on the back of each plug-in unit. The ground stab engages the ground bus before the power stabs contact the vertical bus, and disengages after the power stabs are withdrawn from the vertical bus. The standard unit ground stab is made of a copper alloy. An unplated or tin-plated solid copper unit ground stab is also available. A unit load connector is available to simplify termination of the ground wire when 4-conductor load cables are used (see Unit Load Ground Bus, Slide 15, for further details). This connector must be used with the vertical unit load ground bus. The connector has a mechanical lug to terminate the ground wire. The unit load ground connector is available in unplated copper or tin-plated copper.

Unit Handle

• Remains in control of disconnecting means

• Positive status identification

• Interlocked with door

• Padlockable


Presenter

Presentation Notes

The unit handle is flange mounted, and therefore stays in control of the disconnecting means at all times – whether the door is opened or closed. The unit handle has positive status indication: Color-coded: red for ON, green for OFF. Labeled: ON and OFF (international symbols – I for ON and O for OFF). Graphical representation: the handle position is depicted in the ON and OFF positions (and TRIPPED position for circuit breakers). The unit door is interlocked to the unit handle. The door can not be opened when the handle is in the ON position unless the operator “defeats” the mechanism using a screwdriver. The unit handle can be locked in the OFF position with up to 3 padlocks for personnel safety, and in the ON position with 1 padlock for process integrity.

Unit Interlock

• Prevents inserting or withdrawing unit with handle in ON position

• Padlockable


Presenter

Presentation Notes

Plug-in units are supplied with a “unit interlock” that prevents the unit from being inserted into or withdrawn from the section while the handle is in the ON position. When the handle is turned ON, the interlock mechanism moves upward engaging the unit support pan above the unit. The unit interlock can also be used to secure the unit in a service position to guard against accidental unit insertion. This is shown in the photo on the left. Lastly, the interlock can be padlocked during servicing to prevent unit insertion, shown in the photo on the right, even with the handle OFF.

Bulletin 2100 Unit Components


Bulletin 500 NEMA Contactor

Fusible Disconnect or Circuit Breaker

Bulletin 1492 Pull-Apart Terminal Blocks

Bulletin 592 Melting

Alloy or Solid-State

Overload Protection

Presenter

Presentation Notes

The heart of a CENTERLINE starter unit is the Bulletin 500 line of NEMA contactors and starters. The Bulletin 500 is designed for 10 million operations, and the coil is guaranteed for the life of the contactor. Solid-state overload protection is now available - the SMP Smart Motor Protector line. The disconnecting means can either be a fusible disconnect or circuit breaker. The fusible disconnects can accept, depending on unit type, Class CC, J, R, H, HRCII-C or L fuses. The standard circuit breaker for starter units is the Cutler-Hammer/Westinghouse HMCP magnetic only circuit breaker. Thermal magnetic circuit breakers are also available. Pull-apart terminal blocks are used in plug-in units. These terminal blocks have a front half and a rear half that detach for easy unit removal. The back half of the terminal block is factory wired, and the front half is where the customer terminates field wires. Pull-apart terminal blocks eliminate the need to remove wires when withdrawing the unit. The control terminal blocks are 5-pole, and the power terminal blocks, used for NEMA Size 3 units and smaller are 3-pole. The power terminal blocks for Size 3 units are non-pull-apart. Control circuit transformers are available. All control circuit transformers are supplied with a secondary fuse. The primary protection is either primary fusing or internal primary protection. All fusing is easily accessed from the front.

Pilot Devices

• Generally housed in control station

• Bulletin 800T – up to 3

• Bulletin 800MR – up to 8


Bulletin 800T

Bulletin 800MR 0.5 Space Factor Unit with Pilot Devices

Presenter

Presentation Notes

When pilot devices such as push buttons, selector switches, or pilot lights are specified, Bulletin 800T or 800MR devices are supplied. The Bulletin 800T is a 30.5mm pilot device, while the 800MR is a 22.5mm pilot device. The pilot devices are generally housed in a control station mounted on the unit door. The control station recesses the pilot device contact blocks, minimizing the hazard of accidental contact with live parts when the door is open. The control station is removable so the unit can be unplugged without unwiring the pilot devices. Bulletin 800T pilot devices are used when up to 3 pilot devices are specified. Bulletin 800MR pilot devices are used because of their smaller size, when 4 to 8 pilot devices are specified. Half space factor units may have up to 3 Bulletin 800MR pilot devices. No control station is used. The pilot devices are mounted on the front flange of the unit.

Variety of Units

Plus: Full Voltage Contactors, Two-Speed Starters,Reduced Voltage Autotransformer Starters


Full Voltage Non-Reversing Starters

Full Voltage Reversing Starters

Feeders

Lighting Transformers

Presenter

Presentation Notes

Rockwell Automation offers the broadest variety of motor control center units. Naturally, Full Voltage Non-Reversing Starter units are available. Other units include: Full Voltage Reversing Starter units, Full Voltage Lighting Contactor units, Two-Speed Starter units, Reduced-Voltage Autotransformer Starter units, Lighting Transformer units, Lighting Panel units, and Feeder Disconnect and Circuit Breaker units. Rockwell Automation also offers the latest automation products in MCC units. Let’s take a look at some of those units.

Variable Frequency Drives - Up to 250HP


Bulletin 1305

Bulletin 1336 PLUS or Bulletin 1336 PLUS II

Presenter

Presentation Notes

Over 25% of Allen-Bradley CENTERLINE MCC line-ups contain variable frequency drives. In fact, the smaller Allen-Bradley variable frequency drives were specifically designed to fit into plug-in units. The Bulletin 1305 drive is available through 3HP at 240V and through 5HP at 480V. All units are plug-in design. The Bulletin 1336 PLUS and 1336 PLUS II drives are available as follows: 1/2 – 30HP at 480V, plug-in design 40 – 125HP at 480V, frame-mounted design 150 – 250HP at 480V, roll-out design

Smart Motor Controllers (SMCs) - Up to 500A

9/24/2010 Facilities Management Seminar; © B. Rauf 77SMC-2

SMC Dialog Plus

Presenter

Presentation Notes

Smart Motor Controllers are also offered in the Allen-Bradley CENTERLINE MCC. The family of smart motor controllers available is the SMC-2, SMC PLUS and SMC Dialog Plus. These units utilize solid state technology for controlled starting and stopping of motors up to 500A. The SMC-2 units are available in 5-16A ratings. The units are a plug-in design. The SMC PLUS and SMC Dialog Plus are available in 24-500A ratings. These are a plug-in design through 54A and are a full section frame-mounted design for 97-500A ratings.

PLC I/O Chassis


Bulletin 1771

SLC-500

Bulletin 1771 Full Section

Presenter

Presentation Notes

Rockwell Automation pioneered the use of PLC chassis in MCCs in the early 1980’s. Today, Rockwell Automation offers the Bulletin 1746 (SLC 500) and the Bulletin 1771 PLC chassis as standard. The SLC 500 plug-in units contain a 7-slot rack for the mounting of I/O modules, and is available with or without a disconnecting means. The Bulletin 1771 PLC plug-in units accommodate 4-slot or 8-slot chassis for the mounting of I/O modules. Full section 8-slot and 16-slot rack units are also available, as shown on the right. The units are available with or without a disconnecting means. The PLC units can be incorporated into a Class II interwired MCC, reducing start-up time and installed cost.

Metering Units


Analog Metering Unit Powermonitor II Metering Unit

Presenter

Presentation Notes

A wide range of metering units is available for monitoring the incoming power supply. Basic analog ammeter and voltmeter units, with switches, are available to measure and indicate current and voltage for all phases. Digital metering units display current, voltage, frequency, watts, VARS, watt hours, power factor, and demand watts. Protection is also provided against over or undervoltage, phase imbalance, phase loss, and phase reversal. The premier digital meter from Rockwell Automation, the Bulletin 1403 Powermonitor II can also log min/max values, snapshot values, events with date stamp, and harmonic waveforms. It also has communication capability via DeviceNet, A-B remote I/O, or RS-232/RS-485. CONCLUSION The CENTERLINE MCC offering expands beyond the bounds of a traditional MCC. AC drive units…, solid-state motor controllers…, smart overload relays…, power monitors..., PLC I/O chassis…– all standard offerings. The Allen-Bradley CENTERLINE motor control center truly is “The Center of Automation.” The next 3 slides are optional and only apply if you plan on discussing Bulletin 2400, application-rated units.

Bulletin 2400 Units

• Application-rated

• IEC components

• Reduced space

• IEC standards– Units – IEC 60947– Sections – IEC 60439-1– Witness tested by:

• KEMA• ASTA

– CE rating upon request


Presenter

Presentation Notes

Rockwell Automation offers an application-rated line of plug-in units, Bulletin 2400 units. These units are for customers who prefer IEC components and for customers who have space limitations. Bulletin 2400 units can reduce the cost of the MCC, because the units are smaller, and therefore, fewer sections are required. Of interest to customers outside North America, the 2400 units comply with IEC standards. The Bulletin 2400 unit components comply with IEC 60947, and the CENTERLINE section complies with IEC 60439-1. Allen-Bradley’s CENTERLINE Motor Control Center was successfully witness tested by KEMA (Kuering van Elektrotechnische Materialen) and ASTA (Association of Short Circuit Testing Authorities). The MCC can also be CE labeled (consult factory for options required to meet CE).

Bulletin 2400 Components


Bulletin 100 IEC Contactors

Bulletin 193 IEC Overload RelayFusible

Disconnect or Circuit Breaker

Bulletin 800E IEC Pilot Devices

Presenter

Presentation Notes

The same high quality built into Bulletin 2100 units is built into Bulletin 2400 units. Highlights of the unit shown include: Bulletin 100 IEC contactors. Bulletin 193 overload relay. This relay provides ambient compensated overload protection, convertible manual or automatic reset, and an isolated N.O. auxiliary alarm contact as standard. The SMP Smart Motor Protectors are also available. Bulletin 800E, 22.5mm, IEC pilot devices where possible. Up to 3 pilot devices can be supplied on 0.5 space factor units. A disconnect switch can accommodate Class CC or J fuses, and is provided for applications through 30A. Above 30A, the traditional visible blade disconnect is provided. Magnetic only and thermal magnetic circuit breakers are also available. Pull-apart terminal blocks. For 0.5 space factor units, the IEC style is used, and for larger units the Bulletin 1492 blocks are used.

FacilitiesProject Engineering

Bobby Rauf ©


Topics

• Project Flow Chart

• Project Gantt Chart

• Cost Reduction, Repair vs. Replace Decisions

• Life Cycle Cost, With Time Value of Money

• Cost Justification Case Study


Project Flow Chart


ENGINEERING PHASE

Develop Functional Specifications

Develop Project Schedule

Procurement Planning

Preliminary Engr.

CONSTRUCTION PHASE

MAINT. OPERA-TIONS

Perform Value / Cost Analysis

Detailed Design

Develop Bid Packages

Obtain Bids and Award Contracts

Constructibility Reviews

Mobilization Planning

Safety and Security Plan

Long Lead Procurement

Construction and Field Engineering

Site Safety and Security

Testing, Start-up & Commissioning

Maintenance Program Development

Training Program Development

Issue Fab. & Instl. Drawings

Construction SupportAs Built

Drawings

Material & Equipment Tracking, Expediting & Receiving

Maintenance and Operations Training

Proj. Phases

ENGINEERING

PURCHASING / PROCUREMENT

CONSTRUCT-ION

MANAGEMENT

OPERATIONS &MAINTENANCE

Tasks/Resp.

Req. Funds for Engr. & Long Lead

Develop and Maintain Project Schedule

Develop Preliminary Budgetary Estimates

Develop Detailed Estimates Manage Changes in Scope of the Project

PROJECTMANAGEMENT

Project Gantt Chart


Cost Reduction, Repair vs. Replace Decisions:Repair vs. Replace decisions involve comparison of the life cycle cost of

equipment under two mutually exclusive scenarios: a) Life Cycle Cost if the equipment is replaced.b) Life Cycle Cost of the piece of equipment in question if it is

repaired.

Life Cycle Cost:Total cost of owning and operating a piece of equipment over its

expected life. This cost would consist of the following:– Initial cost or investment – Total preventive, predictive and other typical maintenance cost

over the life span of the equipment– Fuel, electricity or other energy cost over the life of the

equipment. This would take into account the efficiency of equipment.

– Opportunity cost or lost production if the equipment malfunctions.

– Depreciation: D (S/L) = (Original Cost – Salvage Value) /Life in # of Years



Sample Problem,

A 100 HP, 480 VAC, 3-Phase blower motor has experienced a ground fault due to winding failure. This motor has been repaired/rewound twice before. The motor has lost 5% of its efficiency during each of the past two (2) rewinds,due to core losses. The maximum actual load on the motor is 90 HP.

- A typical rewind or repair service, for a 100 HP motor is $1,600. - A new premium efficiency motor cost, approximately, $3,400. - Electricity cost at this facility averages $0.05/KWH. - Assume initial efficiency of 96% and a power factor of 0.9.

a) What is the cost of owning, maintaining and operating this motor over a period of 10 years?

– Assume that the motor experiences a ground fault at the 5th year, 8th year and the 10th year.

– Assume 24-7 operation and an average efficiency of 95% over 10 years. Assume that the electricity cost stays constant over 10 Years.

– Assume Lost Production Cost and Maintenance Labor Cost of $ 3,000 per Failure.



Original Efficiency of the Motor is = 96%Motor Efficiency after 1st Rewind = 96% x (1 - .05) = 91.2%Motor Efficiency after 2nd Rewind = 91.2% x (1 - .05) = 86.64%Motor Efficiency after 3rd Rewind = 86.64 HP x (1 - .05) = 82.31%Energy Cost, 1st Five (5) Years

= 100 HP x 0.746 KW/HP x 24 x 365 x 5 / 0.96 x 0.05 = $ 170,181 Line Current = 104 AmpsAnnual Energy Cost = $ 34,036

Energy Cost, After 1st Rewind, for Three (3) Years= 100 HP x 0.746 KW/HP x 24 x 365 x 3 / 0.912 x 0.05 = $ 107,483 Line Current = 109 AmpsAnnual Energy Cost = $ 35,828

Energy Cost, After 2nd Rewind, for Two (2) Years= 100 HP x 0.746 KW/HP x 24 x 365 x 2 / 0.8664 x 0.05 = $ 75,427 Line Current = 115, An 11% Rise in Line CurrentAnnual Energy Cost = $ 37,713

NOTE: After the second rewind, the motor Line Current has risen by 11%.QUESTION: After two (2) Rewinds, is the operating level of Line Current

approaching the Design Limit of the Conductors and the Circuit Breakers?



Life Cycle Cost Comparison Without Time Value of Money Consideration:

Scenario (1):Rewind Twice, then Replace at 3rd Failure:=( $170,181+$107,483+$75,427)

+($1,600+$1,600+$3,400)+(3)x($3,000) = $ 368,691

Scenario (2):Replace upon 1st Failure:=( $34,036 x 10) + ($3,400+$3,400) + (2)x(3000) = $ 353,163

Replacement Option Life Cycle Cost is Favorable By:$15,528


Energy Cost

Rewind & Repl. Cost Lost Prod. Cost



Life Cycle Cost Comparison Based on Time Value of Money:

Discount Rate: 10%

Scenario (1): Rewind Twice, then Replace at 3rd Failure:Year #1 Year #2 Year #3 Year #4 Year #5 Year #6 Year #7 Year #8 Year #9 Year #10

Actual Energy Cost: -34036 -34036 -34036 -34036 -34036 -35828 -35828 -35828 -37713 -37713Purchase & Rewind Cost -3400 -1600 -1600Lost Prod & Maint. Cost: -3000 -3000 -3000

Cash Flows: -37436 -34036 -34036 -34036 -34036 -40428 -35828 -40428 -37713 -40713

Present Value of EC: ($223,871)

Scenario (2): Replace Upon 1st Failure:Year #1 Year #2 Year #3 Year #4 Year #5 Year #6 Year #7 Year #8 Year #9 Year #10

Actual Energy Cost: -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036Purchase & Rewind Cost -3400 -3400 0Lost Prod & Maint. Cost: -3000 0 -3000

Cash Flows: -37436 -34036 -34036 -34036 -34036 -40436 -34036 -34036 -34036 -37036

Present Value of EC: ($216,997)

Cost Diff. Sceraio (1) vs. Scenario (2): ($6,874)


Cost Justification Example:

NOTE: This is a simplified version of customary financial analysis conducted for development of Project Justification. - Assume that the Investment or Project is Commissioned into Service at the Beginning of Year 1

1. Annual Utilities Cost, @ Assumed Annual Discount $0.05/KWH; 24/7Operation (Interest) Rate: 10%on Equipment to be Replaced (32,675)$

Initial Cost of Project: Proj./Eq. Life Operating Years & Cash Flows200,000$ 10

Year 2nd 3rd 4th 5th 6th 7th 8th 9th 10thDescription: 1 2 3 4 5 6 7 8 9 10

COSTS:

Write-off of Existing Investme (50,000)$ @ Book Value

2. Depreciation Cost (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$

3. Taxes @: 0.65% (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$

SAVINGS:

1. Utilities / Energy: 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ Eff. Improvement. 15%

2. Productivity Improvement: 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 30%

3. Est. Annual Maint. Cost 1,000$ 1,000$ 1,000$ 1,000$ 1,000$ 500$ 500$ 500$ 500$ 500$ Reduction:

4. Reduced Safety Incident 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ Rate, Shoulder, Back or Arm Injuries *

Net Annual Cash Flows: 36,904$ 86,904$ 86,904$ 86,904$ 86,904$ 86,404$ 86,404$ 86,404$ 86,404$ 86,404$

FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEquipment Replacement Example


Cost Justification Example:



PV's, Present Values: $33,549 $71,821 $65,292 $59,356 $53,960 $48,773 $44,339 $40,308 $36,644 $33,312

NPV (1) $487,354 Sum of ALL Present Values from the ten Year Life of the Equipment or Project

NPV (2) $487,354 Excel Based Calculation

IRR 41% Average of ALL Cash Flows, or Net Savings Generated By the Project, During its Ten Year Life Expectancy Divided by the Total Investment

ROI: 43% Net Inc./Avg.Total Assets:

Payback Period, in YEARS: 2.31 Total Investment Divided By the Average of Cash Flows

* Note:Savings Based on Reduced Safety Incident Rate Include The Following Cost Assumptions:1) Approx. Cost for Back Surgery: 25,000$ 2) Approx. Cost for Carpel Tunnel Surgery: 15,000$ 3) Approx. Cost for Shoulder Surgery: 25,000$ 4) Approx. Cost Disability Settlements: 120,000$

Total 185,000$ However, for this calculation, the annual cost assumed for this category 92,500$

FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEquipment Replacement Example

Industrial Safety and Safety Systems

Bobby Rauf ©

9/24/2010 Facilities Mgt. Seminar - Ind. Safety & Safety Syst. © B. Rauf 93

Topics

• Safety Certifications in Industrial Environment

• Safety Products

• Safety Video


Safety Certifications in Industrial Environment:

• Look for the following safety related certifications, tests or labels on “off the shelf” equipment:– UL (United Laboratories) Listed– IEC, International Electrotechnical Commission– IEEE, Institute of Electronic and Electrical Engineers– NEC, National Electrical Code– IP Rating– CE Certification

• On custom engineered systems or equipment, look for Safety Compliance Statement from the manufacturer, engineering firm, general contractor or system integrator.


Safety Products


Safety Products


Safety Mat + Controller

Safety Light Curtain

Safety Relays

Key / Solenoid Interlock Switches

Cable PullSwitches

Safety Buttons

Trapped Key

Safety Contactors & Control Relays

Safety PLC

Safety Laser Scanners

Safety Limit Switches

Safety Guard Edges

Safety EOI

Network Communications

Presenter

Presentation Notes

If a person was to review how Rockwell Automation fulfills a customer’s safety product needs, it is apparent that Rockwell now has most of the components needed to protect an industrial application. In fact, the majority of components needed are available as Allen-Bradley Guardmaster products At this time, Rockwell offers a very expansive lineup of Safety products, and intend on being the strongest major Safety System Components vendor in the World.

Safety E-stop Devices

• E-Stops– Available in 30mm & 22mm sizes– Metal and plastic construction– Meet EN418 and IEC 60947-5-5

standards– Push-pull, push-pull/twist release, illuminated,

or key-operated devices• Self Monitoring Contact Blocks

– For use with 800T & 800E E-Stops– Patented technology improves reliability and safety– If contact block becomes separated from E-stop,

monitoring circuit automatically opens and shuts down the controlled process

– Essentially eliminates contact separation concernsfrom improper installation, damage or high-vibrationapplications


Series 800T/800E & Self Monitoring Contact Blocks

Presenter

Presentation Notes

We offer a full line of emergency cable pull switches. The Life line 3 and the Life line 4. The life line 2 is suitable for smaller machinery, that have a cable run no greater than 10M (32ft.). It incorporates a reset button on the front of the switch and is constructed in a die-cast alloy case. The Lifeline 4, our most popular switch we offer and the most popular in the world, is suitable for larger machines which have a cable of run up to 75M (246ft.) It incorporates a tensioning viewing window to ease in set-up of the cable tension. It also will trip on a pull or slack condition. It is unique in the fact, we have incorporated an e-stop on the device to allow easy operation of the switch. This was a customer driven requirement. Customers commented, that it was difficult to pull the cord close to the switch, so that is why we incorporated and e-stop. The other unique feature is we electrically and mechanically latch out the contacts simultaneously in accordance to EN 418. The reason is that if a person was to pull an ordinary cable pull switch as they were being dragged into a machine, the system would stop, but it would not prevent the system from being restarted at the other end by an operator, who did not see the switch being pulled. Thus the operator could start the machine again, dragging the other subject back into the machine. In order to reset the lifeline 4 switch, an operator has to physically go up to the switch and reset the device by moving the blue lever into the run position. This allows for inspection of the area, before the machine is restart. The switch is yellow in accordance to EN 60204-1 which states, all e-stops have a red button and yellow background. We also offer a full range of e-stops which can be found starting on page 219 of the specifiers guide.

Zero-ForceTM Touch Buttons

• 800Z GP (General Purpose) Line• 800Z HI (Heavy Industrial) Line


Global Mounting Offered Exclusive 22.5 mm line &

standard 30.5 mm line

Superior Rigid Guards Largest ergonomic interface NEMA and IP rating remain

when guard is used Optional Guard Colors -

Black, Red, Green and Yellow

BACK

Prosafe™ Trapped Key Interlocks


Solenoid Release

Access Locks

Key Exchange

Miniature ValvesPower IsolatorsBACK

Presenter

Presentation Notes

The Prosafe trapped interlock system is a unique system different from the interlocking switches we have discussed so far. With the other devices, they require wiring and power to operate effectively. The Prosafe system is a mechanical interlocking system to provide a means of sequencing a process without having wire into a control circuit. It uses mechanical coded keys to produce a predictable interlocking system. We can do this type of interlocking utilizing gate switches and also for the valving applications, in which a certain sequence of valves must be turned on/off to safely run the process and eliminate operator errors.

POC (Point of Operation Control)


Two box Design General Purpose Category 4 (control reliable) Safety

Light Curtain Can operate in Guard only mode (Transmitter/Receiver) Power supply and safety relays may be required

depending on the application 14mm resolution finger protection

Scanning range 6m (20ft) 30mm resolution hand protection

Scanning range 18m (60ft) Fast response time - 15ms Protective Heights from 300 mm (12”) to 1800mm (70”)

in 150mm increments Options with 440L-M8100 interface

Manual and automatic restart Fixed Blanking / Floating blanking Muting PSDI (Presence Sensing Device Initiation) User stored configurations Two sets of optic heads can be connected to one

controller IP 65 enclosure rating Mini quick disconnect

Safe Shield


New Generation Point of Operation Category Type 4 Safety Light Curtain(EN 61496)

Software Configured Features (RS 232 interface) EDM (External Device Monitoring) Internal or External integrated Restart

interlock Fixed Blanking/Floating Blanking

Maximum of Four Blanking fields at once

Reduced Resolution Cascadable

Up to 3 segments can be connected (Host/Guest/Guest)

Each segment is individually programmed

CE certified, cULus listed DeviceNet Light Curtain Interface Metal M23 style 12 pin connector IP 65 Beam Coding ( non-coded, 1 or 2 beam code

patterns)

SafeShield DeviceNet

• DNet module can be interfaced to any SafeShield product at any time

• Diagnostic information can be transferred via DeviceNet (Output status / EDM active / Restart required / Device faulted / Weak signal / Blanking selected)

• DNet Communication via DNet Module (Black)

• SCD Software for L.C. Configuration only, not for DNet


DCPowerSupply

PAC (Perimeter Access Control)


Enclosure rating IP 65 24Vdc Two box Design Complies with requirements for type 4 Meets CE requirements as pr EN 50 100 Ambient operating temperature 0 ... + 55

°C Response time - 20 ms Scanning range 0.5 – 70m Min. resolution 73 mm Number of beams 1-4 2 OSSD PNP Semiconductor outputs Mini Style connectors Integral Muting Module available Margin Indication

An output turns on when lens are dirty

AAC (Area Access Control)


Long Scan Range up to 70M (230Ft.)

Die Cast Aluminum Housing

Two Ranges available

- .5M to 18M (19.5” to 59”)

- 15M to 70M (4’ to 230’)

Easy Installation

Heated Front Screen, I.e. can be used in outdoor applications

Fast response time 22ms

24vd/115vac standard / 230vac (special order)

Built in monitored safety relays

- 2 NO/1NC / 2A Max switching Current

IP 65 enclosure rating

Operating temp. -25°C to 50°C

PG connector IP 67

BACK

Cable Pull Switches


Lifeline 4

Lifeline 3

LRTS

Lifeline 2

BACK

Presenter

Presentation Notes

We offer a full line of emergency cable pull switches. The Life line 2, 3 and the Life line 4. The life line 2 is suitable for smaller machinery, that have a cable run no greater than 10M (32ft.). It incorporates a reset button on the front of the switch and is constructed in a die-cast alloy case. The Lifeline 4, our most popular switch we offer and the most popular in the world, is suitable for larger machines which have a cable of run up to 75M (246ft.) It incorporates a tensioning viewing window to ease in set-up of the cable tension. It also will trip on a pull or slack condition. It is unique in the fact, we have incorporated an e-stop on the device to allow easy operation of the switch. This was a customer driven requirement. Customers commented, that it was difficult to pull the cord close to the switch, so that is why we incorporated and e-stop. The other unique feature is we electrically and mechanically latch out the contacts simultaneously in accordance to EN 418. The reason is that if a person was to pull an ordinary cable pull switch as they were being dragged into a machine, the system would stop, but it would not prevent the system from being restarted at the other end by an operator, who did not see the switch being pulled. Thus the operator could start the machine again, dragging the other subject back into the machine. In order to reset the lifeline 4 switch, an operator has to physically go up to the switch and reset the device by moving the blue lever into the run position. This allows for inspection of the area, before the machine is restart. The switch is yellow in accordance to EN 60204-1 which states, all e-stops have a red button and yellow background. We also offer a full range of e-stops which can be found starting on page 219 of the specifiers guide.

Safety Laser Scanner


Future Product Release forthcoming

BACK

Hinge & Tongue Interlock Switches

•Trojan QD


Elf

Trojan5

Cadet

Trojan5GD2

TrojanEX

ISOMAGRotocam

Sprite

Bolt Lock

MT-GD2

Presenter

Presentation Notes

This slide is good to review the entire product family of hinge and tongue operated interlock switches. Point out the different models of Trojans, (GD2, Quick Disconnect, Explosion Proof, etc.) Also point out the different keys that are available for each switch (Trojan= standard, semi-Flexible, fully-flexible) (elf/cadet=standard/semi-flexible, right angle). Discuss the options available for the switches. Conduit adapters to change metric into 1/2” threads. Light beacons to give visual indication of the switch status. GD2 stainless steel key actuator guide kit available for Elf/Cadet.

Noncontact Magnetic Switches


FerrogardSentinelFerrotek

Ferrocode

Sipha

Multiple Switch & Magnetic Actuators - Custom matched

Defeat-Resistant Non-Contact Switch

Wire to Safety Relay to check the switch’s operation

Air Gap Actuation Range ~0.375 -0.75 inch

High Tolerance to misalignment Electrical Configurations: NO. NC.

SPDT Advantage: Magnets can be epoxied

Presenter

Presentation Notes

This slide give an overview of our entire non-contact family. The ferrogard family, our most popular non-contact switches, offer a variety of housing. They can come pre-wires or quick disconnect. We offer brass, stainless steel and explosion proof housing. This is a stand alone system, not requiring an additional controller. The ferrocode and Sentinel, our most robust systems utilizing magnetic coding/electrical resonance technology, come in two packaged housings. The Ferrocode consists a of switch, actuator and controller. And the Sentinel which incorporates an actuator and a switch that has the control embedded. Finally the Sipha product family, which is our newest introduction to our coded magnetic family. We offer three body types shown above, with addition of our new stainless steel cylindrical body for use in food processing applications. The Sipha is unique, in the fact it was engineered as a result of a customer request. They wanted something small, reliable and low cost, and as a result the Sipha family was born. It is the first time a manufacturer was able to bring the cost of non-contact coded switches down to the same level as mechanical switches. A Trojan 5 cost $ 59 list, a Sipha head costs $59 list. It is required to use a controller with the Sipha heads. The Sipha 1 controller, mounted in a 22mm package, is supplies with 24vdc and has one safety and one auxiliary output. Sipha 2 controller has two safety outputs for redundancy and auxiliaries and is mounted in a 45mm package. You can use multiple Sipha heads off of one controller (up to 10) or a combination of switches to design a cost effective safety solution.

Key Interlock Solenoid Switches


Spartan

TLS GD2

Atlas 4

Atlas 5 w/Trap Key

Atlas 5 w/Key

CU1 (Time Delay)CU2 (Stop Motion)CU3 (Back EMF)

BACK

Presenter

Presentation Notes

The next family of switches are solenoid locking switches. They are used to prevent access to a hazardous area until the hazard motion has been contained. An example would be to have a gate locked until a set of cutting shears have come to rest, after which time a voltage is applied to the coil of the solenoid, releasing the key, allowing access to the area. We have three families of product. Spartan being the first. This is our low heavy duty application switch. It has a holding force of 270 lbs. Meaning it would require a force of 270lbs or more to defeat this switch. In some applications, this would not be the solution, due to the low holding force, so make the customer aware. This switch is offered in a power to unlock version only. It incorporates an LED on the cover of the switch to indicate when power is applied to the solenoid, releasing the key. The coil is available in 24v, 110v, or 230v. The switch also incorporates a catch kit to relieve stress on the locking solenoid and to protect the unit from actuator damage due to poor guard alignment. It also prevents the door from swinging open when power is applied to the solenoid releasing the key. It also incorporates three manual release points with security screws or special key to allow the locked Spartan to release the key in the event of total power failure on a machine. The TLS-GD2 is the most popular switch of the solenoid locking family. It has a holding force of 450 lbs and is available in power to lock or power to un-lock. It has a rotating actuator head which allows for flexibility in mounting. Offered as accessories is an solenoid led indicator and manual release point on the cover. The GD2 stainless steel actuator guide protects the unit from actuator damage due to poor guard alignment or guard wear. Finally, our heaviest duty offering the Atlas 4 and 5. The Atlas 4/5 has a holding force of 1236 lbs. This is used in rugged environments to meet the most demanding applications. It is offered in a power to un-lock version only. It is incorporates a rugged metal die-cast housing. The Atlas 5 incorporates the same features of the Atlas 4, with the addition of a trapped key mounted into the side of the switch. The purpose of the key is to give the operator the ability to lock out switch and remove the key when entering the hazardous area. This ensures that the operator cannot be trapped or locked in the area and prevents the machine from being started until the key is replaced and un-locks the switch. This switch is a very popular in the automotive, robotic cell and tooling industries. We offer 3 safety relays that can be used in conjunction with our solenoid locking switches. The CU1, which is a on-delay timer adjustable from 0.1 seconds to 40 minutes. This relay would be applied to applications which had a predictable run down time. If the run down time was constant, you could set the time delay in the unit. After the unit timed out, the relay would output 24v/110v/230v depending on the solenoid selected, energizing the solenoid, thus allowing release of the key. The CU2, stopped motion detection relay, utilizes proximity sensors to sense movement of the machine. If the run down time was not predictable, as in the case with most centrifuge machinery, you would utilize a CU2 system. Once the sensors have indicated no movement, the output relay would energize the coil in the solenoid locking switch. The CU3, back EMF relay, detects the presence of EMF being generated from a motor. If the stopping of the machine is inconsistent and the stopping time of the motor is directly related to the stopping of the machine, you can utilize a CU3 system. When the CU3 detects no electro magnetic field being generated by the motor, the output relay energizes the solenoid of the solenoid locking switch.

Safety Limit Switches


2-Circuit, Snap-Acting contact design 802T Plug-in Family of products

— Mounts and operates in accordance to NEMA style limit switches.

— Rugged metal body— Meets or exceeds durability requirements of

NEMA style Limit Switches– Longer Life and durability as compared

to IEC style Limit Switches Snap Acting contacts for fast change over and no

“contact tease” Normally Closed “safety contacts” are forced open

when switch is actuated Lower travel to operate Direct Opening Action

feature when compared to IEC style NEMA 6P enclosure rating Same Length Mounting Screws QD and pre-wired versions available cULus and CE certified and approved

BACK

GuardMat™ Safety Mats


Controllers

Mats

Edge Trim Uniting TrimBACK

Presenter

Presentation Notes

Guardmaster offers a full range of standard mats and controllers for all applications. The GuardMat system is a tripping device. When some one steps on the mat, their presence is detected and the safety output opens, shutting down the machine. The design of the mat includes two sheets of hardened rolled steel which are separated by small insulators. We run 24vd through both sheets of steel. When pressure is applied greater than 70lbs. the sheets make contact, creating a short circuit condition, changing the resistance, which is detected by the controller. We have 4 types of controllers. A metal housing with a manual reset button wire into the cover, a PVC version, a din rail mount version and our new controller (not pictured) allows for monitoring up to 8 individual mats. It was designed to indicated if a mat has failed. If there were 8 mats connected together, and there was a failure, with our standard controllers you would not be able to detect which one had failed without having to test each one. With our new controller we have that ability, which reduces maintenance down time. We offer a full range of trim and are able to unite multiple mats together via the use of uniting trim.. We can control up to 100M squared of mat, off of one controller. We also have the ability to do custom configurations in any shape and size. Consult your local sales office for further details. We manufacture our mats in Milwaukee and can turn around a custom order in 5 days, which is a big advantage over the competition.

GuardEdge™ Safety Edges


Component Parts

Profiles/Rails and Controllers

BACK

Presenter

Presentation Notes

The GuardEdge system, is a trip device which lends it self to several applications, which are portrayed on the next slide. The principle behind this system, is when a profile is depressed, the machine shuts down. We impregnate the rubber profile with a conductive carbon powder, which creates a conductive rubber. The system react in a change in resistance. When the profile is pressed the resistance changes, which is detected by the controller. There is a variety of profile to choose from, which are listed on page 95 of the specifiers guide. These profiles can be made up to 50 meter in length. The profiles can also be bent to a radius of 200mm to accommodate the most unusually applications. The can be run around corners, incorporating a active corner connection. There is also a large selection of “C” channel which the GuardEdge profile can slide into to offer a variety of mounting options. We offer two types of controllers, a PVC enclosure and a din rail mount version. The profiles can be wired in series or parallel, depending on system configurations. For additional information, please turn to pages 94-100.

MobileView Guard G750 Terminal

• Category 3 Safety • Maintain interface to control system with access to

safety system• 3-position enable switch

– Released, enabled, clenched– Sense both failure modes (dropped & panic)

• Optional Emergency Stop Switch• Ergonomic design

– Multiple hand positions– Light weight– Cable can exit housing on either side

• Thin Client Connection – Embedded 10 Base T Ethernet

• Rugged industrial connection cable– Single cable carries all signals

– Easy connect/disconnect

9/24/2010 Facilities Mgt. Seminar - Ind. Safety & Safety Syst. © B. Rauf 120 BACK

Presenter

Presentation Notes

The MobileView Guard Terminal is safety ready with the advanced 3-position enable switch and optional emergency stop switch. It’s ergonomic (round) design allows for easy handling by operators. MobileView Guard acts as a thin client to a server over Ethernet. It also has the power, memory options, and expandability to host local applications for custom and future software. It easily connects to the Ethernet network via a junction box.

Safety PLCs


GuardPLC 2000 and 1200 shipping since August– TÜV Certified (Entire System) - IEC 61508 SIL 3, DIN

VDE 19250 AK6, EN 954-1 Category 4, – UL Listed– Primary Target Market - Machinery Safety

GuardPLC 2000 - 6 I/O slot, modular design– 24 Input / 16 Output digital – 8 Channel Analog Input & Output (12 bit resolution)– 2 Channel HSC (100kHz, 24 bit)

Guard 1200 - packaged design– 20 Inputs / 8 Outputs + 2 HSC Inputs (100khz, 24 bit)

Communications – Proprietary GuardPLC Ethernet + ASCII– Peer to Peer Safety Communications

RSLogix Guard Software (2 versions)– Lite and Professional Versions– Windows NT/2000– RSLogix “Look & Feel”– IEC 1131 Function Block Programming – User Defined Function Block Capabilities (1755-PCS)

GuardPLC Communications

• GuardPLC Connectivity to RA PLC’s via RS-232 ASCII

• Peer to Peer via GuardPLC Ethernet - Series B Firmware (May 2002)– Enables Safe Communications Between GuardPLCs over the proprietary

GuardPLC Ethernet – Any combination of GuardPLC 2000s and 1200s

• Limited by maximum tag count of software• Maximum 650 tags with Professional Software package (1755-PCS)

– Enables Utilization of one or more controllers as ‘remote I/O’ units• Easy to Implement - No program needed in remote I/O units, just tag setup• GuardPLC 1200 - Full tag count for RIO just under 150 tags

– Tags for I/O points and full diagnostics available to Supervisory GuardPLC

– Less tags required if I/O or diagnostics are not fully utilized - Typically 75 to 100 Tags


BACK

http://209.3.205.179/

Network Communications


Standard Communications for Diagnostics Purposes Several Safety Products can be Connected to DeviceNet

– See you Local Representative for the current list of products GuardPLC’s Can Communicate to Standard PLCs

– ASCII to PLC Front Port Connectivity - SLC, PLC-5 and ControlLogix– Example Application Code is Available from RA

Safety Communications: Peer to Peer via GuardPLC Ethernet - Series B Firmware (May 2002)

– Safe Communications Between GuardPLCs via GuardPLC Ethernet – Enables Utilization of One or More GuardPLC’s as ‘Remote I/O’ Units

Requires only Tag Configuration - No Programming of Remote Units RA is Committed to Supporting Safety in the NetLinx Communications Architecture

– Target Availability for DeviceNet Safety is 2004

BACK

http://209.3.205.179/

Safety Relays

• Emergency Stop Relays– Monitors the E-stop Circuit– Monitors Safety Gate Limit

Switches– Monitors Light Curtains– Monitors Rope Pull Switches

• 2-Hand Control & Safety Gate Monitors

– 2-Hand Anti-tiedown & Anti-repeat relay

– Controls machine from safety gate limit switches

• Provides additional safety contacts


Two Hand Controllers

Single Channel

Dual Channel

BACK

Safety Contactors & Control Relays

• Safety Contactors: – Reversing & Non-reversing Assemblies– 9..85A (60HP)– AC & DC Coils

• Safety Control Relays:– 8 Pole Assemblies– AC & DC Coils

• Features:– Meets IEC 947-5-1 “mechanically

linked/positively guided contacts”– Meet GM NAO DHS-1 “MPS”

Requirements – SUVA Third Party Certified– Auxiliary Contact Blocks Permanently

Fixed


100S Safety Contactors

104-C ReversingSafety Contactor

700S-P700S-CF

BACK

HVAC in Industrial/Commercial Facilities

Bobby Rauf ©

9/24/2010 Facilities Mgt. Seminar - HVAC; © B. Rauf 126

Topics

• Definitions of common HVAC terms

• Maintenance and Performance Tips

• HVAC Systems; The Refrigeration Cycle

• Automated HVAC Systems


Definitions

• HVAC: Heating, Ventilation and Air Conditioning• Dry Bulb (DB): Temperature read or measured with a standard

thermometer.• Wet Bulb (WB): Wet bulb is the temperature measured or

indicated by a thermometer whose bulb is covered by a water saturated wick and exposed to a stream of air moving at, approximately, 100 ft./min.

• Relative Humidity (RH): Relative humidity is the ratio of the amount of vapor in the air, at a specific set of conditions, to the water vapor that could be held when saturated.

• Dew Point (DP): This is the temperature at which moisture will start to condense from the air

• Enthalpy (h): Enthalpy is the heat content of a system (air). It is measure of the amount of heat contained in a system.


Maintenance & Performance Tips

• Chillers: Periodic cleaning of Evaporator and Condenser Tubes– Install automatic tube cleaning systems in evaporator and condenser

tubes.

– Maintain insulation in a good state of repair.

• Air Washers:– Regular PM or cleaning of the Eliminators.

– Regular PM, repair or replacement of water spray nozzles.

• Cooling Towers: Periodic cleaning of Cooling Towers– Maintain water contact surfaces free of organic build up.


HVAC Systems; The Refrigeration Cycle:


Condenser

Compressor

Evaporator

Expansion Valve

High Pressure LiquidHigh Pressure Vapor

Low Pressure Liquid

To/From Cooling Load

Vapor

To/From Cooling Load

Automated HVAC Systems

• Many manufacturers:


Terminology

• At a conceptual level, a DDC, Direct Digital Control, system can be thought of as consisting of three groups of components: inputs, outputs, and intelligence (Fig. 1). The individual inputs and outputs are usually considered by the system to be "points"--a very useful, logical concept that we will come back to later.


Terminology

• Inputs. Input points can be divided into two broad categories--analog inputs (AI) and digital inputs (DI). – Analog input (AI): a point that is able to read a continuously

variable signal. Examples of analog input devices are temperature sensors, humidity sensors, pressure sensors, current and voltage sensing devices, and gas concentration sensors.

– Digital input (DI): a point that will accept only two states of information for the system, such as on-off or open-closed. Examples of digital input devices are dry contacts to sense relay status and fluid level sensors.

– Many manufacturers arrange the input circuitry in the intelligence so that the inputs are universal--i.e., they can be configured in software to recognize a digital or analog input device without having to change the panel hardware. This provides flexibility and

cost advantages.


Terminology

• Outputs. Output points, like inputs, can be divided into the same two categories of analog and digital, with the same defining characteristics of two states for digital devices and continuously variable for analog devices.– Analog outputs (AO) most commonly drive valve or damper

motors. 0-10Vdc and 4-20 mA are the most common signals

– Digital outputs (DO) almost always switch relays of some sort, whether starting motors, turning on lights, or moving two-position actuators.


Terminology

• Controlled devices. Controlled devices are the valves, dampers, and relays that the outputs act on to affect the mechanical systems we want to control. – Most analog-controlled devices are nonlinear in their action on

the fluids they control. An example is the commonly used butterfly valve. This used to be a huge issue for design and control of mechanical systems, but it doesn't really matter now that the conversions are in software.

– In fact, it has advantages in terms of not having to select devices for their linear characteristics. Nonlinear devices can provide operating cost benefits from lower average pressure drops, for example.

– However, it is left up to the controls engineer to have enough software and hardware expertise to compensate for sometimes questionable mechanical equipment selections.


Terminology

• Direct Digital Control. (DDC) The electronic measurement of an input (process) variable, comparison of the measured value to a setpoint to compute error and software logic to determine an output value that is transmitted to a control device (i.e.. Damper, valve etc.) to cause the desired action on the input.


Terminology

• Direct Digital Control: (DDC)


M

DDC Controllerw/Software

ElectronicSensor

M AB

AB4-20 mA I/P 3-15 Psi

Thermistor/RTD

4-20 mA

Current toPneumaticTransducer

Terminology

• Protocol: A defined set of instructions for programmer’s to allow computers to transfer information

• TCP/IP: Transport Control Protocol/Internet Protocol

• HTTP: Hypertext Transport Control Protocol

• HTML: Hypertext Markup Language


Terminology

• DDE: Dynamic Data Exchange. A Microsoft standard for communications between Windows programs

• OPC: OLE for Process Control. The current standard for control vendors to allow open communications from Windows based programs to their systems. Replaces DDE as a method of communicating with control systems using a Windows technology standard.



• Some common elements– PC based “front ends”– Local area networks– Global level controllers– Equipment level controllers – Terminal unit controllers – Operating software– Field devices (sensors, transducers etc.)

• Lets look at each one….



• Field devices– Temperature sensors

• Thermistor most prevalent

• RTD

• Solid state temp sensor (AD592)

• Thermocouple

• Some vendors require 4-20 ma transmitter for field device

• +/- .5 deg f accuracy/repeatability possible



• Field devices– Humidity sensors

• Resistive type (General Eastern)

• Capacitive type (Hy cal)

• Require 4-20 ma transmitter

• 3-5 % accuracy most common

• 2 % available ($$$)

• Require calibration (once a year)



• Field devices– Air Pressure sensors

• For VAV applications most vendors build into controller

• 4-20 ma most common

• Hard to calibrate in field



• Field devices– Water Flow meters

• Requires understanding of mechanical system for proper operation

• Most difficult sensor to apply

• 4-20 ma most common

• Get what you pay for $$$$$



• Field devices– Air Flow Meters

• Convert static/velocity pressure to electronic signal

• Most use and averaging principal

• Can be expensive $$$

• Industrial versions available with purge capability



• Field devices– E/P or I/P transducers

• Convert electronic signal to pneumatic (3-15 Psi)

• Some have feedback of branch pressure

• Some are zero use (no bleeding of air) when in steady state

• Usually panel mounted



• Field devices– Pneumatic actuators

• Convert pneumatic signal

to mechanical force to

open valve or damper.

• Most bang for $$$

• Common in retrofits

• Can have a fast response with positioner



• Field devices– Electric actuators

• Slow responding

• Expensive $$$

• Accurate (not much slop)

• Most prevalent in terminal unit control (VAV boxes, roof top units etc. )

• Take 4-20 ma or 0-10 VDC or PWM directly from controller



• Field devices– Lighting Control

• Intelligent Breakers

• No need for outboard relays

• Interface through RS232/RS485

• Lights can be Zoned/Grouped

• Phone Override capability



• Field devices– Indoor Air Quality

• Measurement range: Carbon Monoxide 200 PPM, Carbon Dioxide 2000 PPM

• Outputs are 4-20 mA or 0-10 VDC

• Wall and duct mount configurations

• Use to regulate outside air dampers for air quality



• PC based “Front End”– computer with Windows Software

• Graphic screens for operator interface

• Real time data presented

• Operator input for setpoint/schedules etc.

• Alarm management

• Trending/history functions

• Invaluable troubleshooting aid

• Modem communications from off-site

• Diagnose before dispatching service personnel !!



• Color Graphics– Allow accurate presentation of data from

Mechanical equipment and controlled area/process

– Real time data presented

– Operator input for setpoint/schedules etc.

– Alarm notification



Air Washer Control Screen - EMS


• Trending and Data Presentation– Allows collection of data to hard drive for

storage

– Provides for secure way of archiving data

– Allows for analysis of data while on-line and also offline in Excel, and other spreadsheet type programs



Air Washer Discharge Temperature Trend –EMS


Chiller Load EMS System Screen


• Alarm Management– Allows collection of alarm data to hard drive

for storage

– Should be used for “real” alarms. Alarm limits that are too tight become nuisances and get ignored.



Chilled Water Loop Screen – EMS System


Air Washer Safeties/Status /Limits


• EMS Control Routines– Scheduled start/stop

– Optimized start/stop

– DDC Temperature Control

– Enthalpy control

– Drybulb economizer control

– Temperature setback/setup

– Night time purge of facility

– Supply air setpoint reset



• EMS Control Routines– Boiler/Chiller optimization

– Custom strategies such as ice making systems

– Lighting control

– Demand Limiting

– Cogeneration Control

– Load Forecasting

– Utilities Submetering/Billing

– Metering and Verification



• EMS Control Routines– Scheduled Start/Stop - Starting and stopping

equipment based upon time of day, and the day of the week.

• Newer systems include tenant override and tracking

– Optimum Start/Stop - Adjust equipment operating schedule based upon space temperature, Outside temperature, humidity etc

• Newer systems constantly fine tune start/stop times



• EMS Control Routines– Enthalpy Control - Utilize outside air for cooling

whenever OA enthalpy is less than RA enthalpy• Can cause humidity problems in some systems

– Drybulb Economizer - Utilize outside air for cooling whenever OA temperature is less than the required mixed air setpoint



• EMS Control Routines– Temperature Setback/Setup - Lower the space

heating setpoint and raising the space cooling setpoint during unoccupied hours

• Usually combined with Optimum Start/Stop

– Night Time Purge - Purge the facility of stagnant humid air before startup to take advantage of cool morning temps.

• Can cause humidity problems in certain climates



• EMS Control Routines– Supply Air Setpoint Reset - Selects the

zone/area with the greatest heating/cooling requirement and establishes the minimum hot deck and cold deck temperature differential that will meet the requirement.

– Boiler/Chiller Optimization - A combination of Lead/Lag and chiller/boiler selection to run the most efficient combination of equipment to meet the building load.



• Primary/Secondary Chiller Plants– Useful in large distribution systems i.e..

Industrial, Campus, Airports etc.

– Reduces pumping Hp through use of VFD’s on secondary pumps

– Requires good understanding of mechanical design of HVAC units and chiller plants

– Is best controlled through DDC/BAS system

– Can be time consuming to get control sequence “right”



Automated HVAC System – EMS Screen

Energy Conservationin Industrial / Commercial

Facilities

Bobby Rauf ©

9/24/2010 Facilities Mgt. Seminar - Energy Conservation; © B. Rauf 177

Topics

• Definition

• Energy Unit Conversions

• Energy in its Common Forms

• Energy Audits

• Areas of Potential Savings

• Financial Justification for Energy Conservation Projects

• Metering, Monitoring and SCADA Systems

• Power Bill Calculation

• Automated Energy Management Systems


Definition:

• Energy: Capacity to perform work. Note: Energy is not the same as Power.– Formula for Energy: Energy = Force x Distance; or, E =

Work = F x S

– Units for Energy: • British or American: BTU’s; or British Thermal Units.

• Also, under the British System: foot-pounds or ft-lbf or horsepower-hours, or hp-hrs

• Metric: N-m; or Joules; 1.0 J = 1 N-m

• Also, under the Metric System: Kilowatt-hours, kWh

• Erg; from Greek word “ergon,” meaning: work; 1 erg 10-7Joules. One erg = Force of 1 Dyne applied through a Dist. of 1 cm.

• Other units for energy: Calories, kilocalories, therms, Evs and MEV


Energy Unit Conversions:

• BTU’s to kWh and KWh to BTU’s:– 1 BTU 1 BTU x (2.928 EE –4 kWh/BTU)

0.0002928 kWh

– 1 kWh 1 kWh x (3413 BTU/ kWh) 0.0002928 kWh

• MMBtu’s to Btu’s:– 1 MMBtu’s 1 MMBtu x (1000,000 Btu/MMBtu)

• MWh to kWh:– 1 MWh 1 MWh x (1000,000 kWh/MWh)


Energy Unit Conversions:

• BTU’s to tons and tons to BTU’s:

– 1 BTU 1 BTU x (8.333 EE-5 tons/BTU) 0.00008333 tons

– 1 ton 1 ton x (12,000 BTU/ ton) 12,000 BTU’s

• Deca Therms to BTU’s:

– 1 dT 1 dT x (1,000,000 BTU/dT) 1,000,000 BTU’s 1MMBTU’s


Energy in Its Common Forms:

Energy in various plants and facilities exists in the following most common forms:

1. Electrical Energy (kWh or MWh): The most direct uses of electrical energy are:

– Lighting.– Motor Loads: Fans, Blowers, Air Compressors, HVAC Equipment,

Conveyors, Pumps, Manufacturing Equipment Driven by Motors– Electrical Heating Elements in Resistive Heating Applications– IR, or Infra-red Heat– Electronic Equipment; through built-in power supplies– RF,or Radio Frequency Loads – Microwave Loads– Construction and Fabrication Equipment– Electromagnetic Control Devices


Energy in Its Common Forms, contd:

2. Gas and Petroleum (BTU’s or Decatherms):Natural Gas, Propane, Diesel, Gasoline, Kerosine and other types of fuels. The most direct uses of fuels are:

– Electrical Power Generation– Heating– Transportation and Hauling Equipment– Construction and Fabrication Equipment

3. Steam, an indirect form or energy4. Compressed Air, an indirect form or energy5. Stack Heat, a usable byproduct of heat energy

application in Ovens and Furnaces, etc.


Energy Audits:

• Energy audits identify major areas of energy usage in a facility and quantify energy productivity in those areas.

– Final end product of most audits include a list of energy conservation opportunities

– In certain cases audits are taken to the extent of developing proposals and economic justification of potential energy conservation projects

– Some Energy Consulting Firms provide comprehensive turnkey services by taking the results of an audit and proposing, guaranteed, turkey installation and commissioning of energy conservation measures


Energy Audits:

• In large facilities, with high diversity in type of equipment, for audits to be more focused and productive, they should be segmented as follows:

– Electrical Audit; to be conducted by a firm specializing in Electrical Engineering

– Compressed Air Audit; to be conducted by a firm specializing in Mechanical Engineering Discipline

– HVAC Audit; to be conducted by a firm specializing in HVAC or Mechanical Engineering


$$ Areas of Potential Savings $$:• Lighting: When possible, implement energy conservation

through the following measures:– Perform a lighting audit. Does your facility meet, fall short of or

exceed the lumen or foot-candle requirements for specific segments and applications within your facility?

– When possible, turn off lights that are not needed or when not needed. Apply IR occupancy sensor based automatic light switches. Apply timer type light turn off switches, where applicable.

– High Efficiency Lamps: Replace existing lamps higher efficiency type. One measure of light efficiency is lumens per watt. Typical payback on such projects ranges from 2 to 4 years, with some rebate incentive from the utility company• Replace Incandescent Lights with Fluorescent Type• Replace Fluorescent lighting with Metal Halide• When possible, replace incandescent, fluorescent, Metal

Halide and mercury lighting with Sodium Vapor lighting.


$$ Areas of Potential Savings $$:

• Lighting contd:- Opportunities in the Area of Light Fixtures: Could high

bay, transparent, light fixtures be applied with light colored ceiling paint?

– Group Re-lamping: Implement group re-lamping whenever possible. This is one way to maximize and maintain light efficiency/productivity.

– Demand Side Management: Check with the local utility company on availability of Demand Side Management Programs offering incentives for installation of energy efficient lighting systems.

– Lighting Audits: Take advantage of no cost or subsidized lighting audits offered by some utility companies.



• Motor Loads:- Optimize Fan, Blower and Pump Motor Speeds,

application of Fan Laws:- Apply VFD’s, Variable Frequency Drives

- Apply Pulleys

- Turn off motors that idle for significantly long periods of time

– Whenever possible, apply Premium Efficiency Motors



• Compressed Air:- Compressed Air Leak Management:

- Compressed Air Leak Detection Program, using Sound Detection Systems

- Compressed air leaks are expensive. A 1/8” diameter air leak, at 100 psi, can cost more than $2,000 per year.

- Minimize Air Pressure Requirements, whenever feasible. Higher header pressures result in greater air loss and drop in pressure. The 1/8” air leak stated above would cost only $1,300 per year at 50 psi.

- Evaluate the Types of Air Compressors Available. Cleanest or driest compressed air costs more.



• Temperature Optimization: Select a temperature set point such that human comfort and process requirements are met without causing high differential between indoor and outdoor temperatures.

• Air Flow Optimization: Minimize air flow whenever possible. This can be accomplished a follows:

1. Changing fan pulleys

2. Reducing the fan speed through the use of VFD’s, Variable Frequency Drives.

Basic Fan Laws:– Volume, or Air Flow Rate, is directly proportional to the speed of a fan:

• CFM2 = CFM1 (RPM2/RPM1)

– Pressure is directly proportional to the square of speed of a fan:• P2 = P1 (RPM2/RPM1)2

– Motor Horsepower is directly proportional to the cube of the speed of a fan:• HP2 = HP1 (RPM2/RPM1)3



• Operate on Outside Air: Switch the air handling system to outside air when outside temperature and dew point are in the range desired for indoor comfort and process requirements.

– When possible, install air or electric actuator operated dampers to control all air flow.

• Common Chilled Water Systems: – Take advantage of common chilled water headers. Schedule and optimize

operation of the chillers whenever possible. – Monitor chiller usage and loading. Look for the CW bypass valves that stay

open most of the time.

– Annual operating (energy) cost of 1000 ton chiller is in excess of $250,000 per year, or $270/ton/year.

• Application of VFD’s on the following equipment:– Supply and return pumps– Fans and blowers



• Boilers and Steam:- Are your boilers high efficiency?- Are the boiler burners high efficiency?- Is the insulation in a good state of repair?- Is the Steam temperature optimized?- Are the Steam Lines well insulated?- Use smaller, local, boilers to serve remote loads

instead of running a long header to a remote load. - Establish a steam trap maintenance and steam leak

detection program.- Cogeneration: Can lower pressure, return steam be

used for generating electric power?



• Stack Heat Recovery:- Is there a significant amount of heat

wasted/exhausted from your furnace and oven stacks?

- Investigate heat recovery potential at the stacks

- Studies can, sometimes, be funded through DSM programs.

- Possible applications for waste heat:- Hot Water

- Steam

- Space heat or HVAC

- Batch Preheat

- Combustion Air Preheat


Financial Justification for Energy Conservation Project


NOTE: This is a simplified version of customary financial analysis conducted for development of Project Justification. - Assume that the Investment or Project is Commissioned into Service at the Beginning of Year 1

1. Annual Utilities Cost, @ Assumed Annual Discount $0.05/KWH; 24/7Operation (Interest) Rate: 10%on Equipment to be Replaced (130,699)$

Initial Cost of Project: Proj./Eq. Life Operating Years & Cash Flows200,000$ 10


COSTS:

Write-off of Existing Investme (20,000)$ @ Book Value

2. Depreciation Cost (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$

3. Taxes @: 0.65% (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$

SAVINGS:

1. Utilities / Energy: 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ Eff. Improvement. 60%

2. Utility Company Rebate: 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 10%

3. Est. Annual Maint. Cost 4,000$ 4,000$ 4,000$ 4,000$ 4,000$ 3,000$ 3,000$ 3,000$ 3,000$ 3,000$ Reduction:

4. Reduced Safety Incident -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ Rate:


FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEnergy Conservation Project Example

Financial Justification for Energy Conservation Project




PV's, Present Values: $49,263 $61,314 $55,740 $50,672 $46,066 $41,314 $37,558 $34,143 $31,039 $28,218

NPV (1) $435,326 Sum of ALL Present Values from the ten Year Life of the Equipment or Project

NPV (2) $435,326 Excel Based Calculation

IRR 36% Average of ALL Cash Flows, or Net Savings Generated By the Project, During its Ten Year Life Expectancy Divided by the Total Investment

ROI: 37% Net Inc./Avg.Total Assets:

Payback Period, in YEARS: 2.72 Total Investment Divided By the Average of Cash Flows

FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEnergy Conservation Project Example

Metering Integration

• Products:–TRIDIUM–Orchestrator/Giallarhorn–Dialup Recorders/Stark RT–Veris/–PML–Square D–GE–Schlumberger–AEM/Engage


Services:Data AcquisitionDatabase/Historical DataPower Bill GenerationAd Hoc ReportingLoad ForecastingReal Time PricingWeather DataDemand ControlDepartmental Accounting

Metering from Utility down…


Cost Center Allocation



Load Forecast

Square D Power Logic


GE Power Leader


Substation Reporting


Web Based SCADA and Reporting

• Products:– TRIDIUM– Orchestrator/Giallarh

orn– JAVA Messaging

Software


Services:Data AcquisitionHistorical Data CollectionLoad VerificationCustom Reports Network DesignShared Savings Accounting

Web Based Architecture


LonMark Devices

JACE-NP

Router

BACnet Systems

Ethernet LAN

HubWorkstation

Pager or PDA

http://209.3.205.179/

Multi Site Web Based System


Pager or PDA

JACE-NP

Hub

Web Browser

Router

JACE-NP

HubRouter

Web Browser

Web Supervisor

JACE-NP

HubRouter

http://209.3.205.179/

Load Summaries


Performance Profiling


Power Bill Calculation


• Process HVAC Controls Including:– 2000 Point DDC System with 12+ Operator Stations

Operating on plant Ethernet Network– Historical Data on plant network. Info shipped with

product– Air Washer Control with Economizer Energy Control

and Dewpoint Process Control strategies– Chiller Control with Primary/Secondary Pumping

Systems– BACNet interface to TRANE Chillers– Overall Investment by PPG: $4-5 MM (includes

mechanical modifications)


Process HVAC Control Systems Example


EMS CW System Monitoring Screen


EMS Chiller Performance Monitoring Screen


Air Washer

• Customer Data Center & 990 Datacenters• Integration of Critical support Systems:

– Liebert A/C and UPS– Fike Fire Alarm– MGE/Square D Power Distribution Units– Russelectric Switchgear– Catepillar Generators– Water Detection Systems

• Alarming and Historical Data using Orchestrator and Giallarhorn system


Marlboro, Mass.

Staples Overview


Power Distribution Equipment


Power Usage Analysis



Generator Monitoring

Report Generation


Automated Energy Management Systems

• EMS Control Routines– Lighting Control - Schedule the lights in the

facility as required. Include tenant override from switches or phone.

• Intelligent Breaker Panels communicate w/EMS

– Demand Limiting - Temporarily shedding electrical load to prevent a demand peak being set for monthly electric utility billing.

• Need a thorough understanding of utility rate structure

• Real time pricing complicates issue



• EMS Control Routines– Duty Cycling - Shutting down equipment for

predetermined short periods to save KWh during operating hours.

• Not used much anymore due to equipment failures

– Load Forecasting - Utilizing the utility data, occupancy data (production data), and weather data to predict peak usage pattern. Allows forecast to be generated for several days at a time.

• Deregulated power buying



• The future– Web technology

• Starting to be integrated

• Graphics in controller or HVAC equipment

• Browser interface (Internet Explorer 5.0)

• Internet/intranet connectivity

• Connect to any PC with Internet Explorer with proper security access



• The future– Web technology integrated tightly

• Run your facility from anywhere in the world

– Control routines become smarter• Adaptive intelligence will be commonplace

– Costs remain constant or fall slightly• Capabilities will increase as computers become more

powerful and programmers create better tools.


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