Plant Services June 2011

WWW.PLANTSERVICES.COM

Decisions Make the Data / p.23

9 Vibration Questions / p.41

New Motors & Drives / p.45

3 Future Energy Risks / p.50JUN

E 2

01

1

Mobile and tablet devices attract a new wave of maintenance

applications to the plant fl oor

Apps ofSteel

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EXAIR Cabinet Cooler® SystemsEXAIR has a complete line of Cabinet Cooler Systems to dependably cool and purge your electrical enclosures. They convert an ordinary supply of compressed air into clean, cold 20ºF air. They mount in minutes through an ordinary electrical knockout and have no moving parts to wear out. The compressed air filtration that is provided keeps water, oil and other contaminants out of the enclosure.• Thereisnoroomairfiltertoclog

• Anaccurateelectricalthermostatcontrolminimizescompressedairuse

•AllCabinetCoolersareULListedtoUSandCanadiansafetystandards

•TheyaretheonlycompressedairpoweredcoolersthatareCEcompliant

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The “plastic box cooler” from a competitor uses an inaccurate mechanical thermostat that’s designed for liquids. This thermostat has a poor ability to react quickly to changes in air temperature.Itcostsupto85%moretooperatethanEXAIR’sETCCabinetCooler®SystemwiththesameSCFMratingandBtu/hr.output.•Electronicscanoverheat beforeitturnson

•Itrunsfarlongerthan necessarybeforeshuttingoff

•Increasedcycletimewastes compressedair

These coolers are prone to failure in dirty, industrial environments when dust and dirt clogs the filter.•Ittakesalmostaday toinstall

•Vibrationfrommachinery causesrefrigerantleaks andcomponentfailures

•Compressorlifeexpectancy istypically2.5yearsof continuousoperation

•Itrequiresafloordrain forthecondensation

•Averagecosttoreplace abadcompressoris$750

Opening the panel door and aiming a fan at the circuit boards is a bad idea.•ItisanOSHAviolation thatpresentsashock hazardtopersonnel

•Thefanblowshot,humid, dirtyairattheelectronics

•Thecoolingeffectis minimal

•Itislikelytofailagain sincetheenvironment isstillhot

These have serious limitations. On hot summer days when the temperatures of the room and inside of the enclosure are about equal, there’s not enough difference for effective heat exchange. •Theyfailwhendustand dirtclogsthefilter

•Thecoolingcapacityis limitedduetoambient conditions

How To Keep Your Electronics CoolWhen hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. There are several cooling options out there and it’s important to know the facts.Line up of cooLers that are prone to bad behavior

If you would like to discuss an application, contact an Application Engineer at:

EXAIR Cabinet CoolerEXAIR has a complete line of Cabinet Cooler Systems todependably cool and purge your electrical enclosures. Theyconvert an ordinary supply of compressed air into clean, cold 20mount in minutes through an ordinary electrical knockout and have no movingparts to wear out. The compressed air filtration that is provided keeps water, oil and other contaminants out of the enclosure.• There

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www.PLANTSERVICES.Com JuNE 2011 5

28 / COVER STORY

Apps of SteelMobile and tablet devices attract a new wave of maintenance applications to the plant floor

36 / PumPS

Positive DisplacementFundamentals, design, and applications of PD pumps

41 / PREDiCTiVE TEChnOlOgiES

Come to Your SensorsFind the right vibration device like an arrow finds its bull’s-eye

45 / PRODuCT ROunDuP

Don’t let motor Failure Ruin Your DayUse PdM and condition-based monitoring to avoid downtime

features

specialists

columns and departments

9 / mR. SuSTAinAbiliTY

Fix or ReplaceRepairing, rebuilding or reconditioning isn’t always the most sustainable option

21 / humAn CAPiTAl

use and misuse of leadership Power7 sources and the potential consequences of its application

23 / ASSET mAnAgER

more Than a Data AggregatorCMMS includes decision-support functionality to make information useful

27 / TEChnOlOgY TOOlbOx

Portable but ConnectedPredictive maintenance technologies integrate the best of both worlds

50 / EnERgY ExPERT

3 Risks That Determine Energy CostsAre you looking through a crystal ball or a rearview mirror?

7 / FROm ThE EDiTOR

The Picture of SafetyInternational suppliers need a reason to comply

11 / YOuR SPACE

Organized to AutomateUpdated instrument database enables calibration and maintenance

13 / WhAT WORKS• Vibration monitoring helps to increase MTBF and lower pump maintenance costs• Electric utility discovers quick WirelessHART payback• Real-time data improves lift truck purchase planning and maintenance management

48 / ClASSiFiEDS / AD inDEx

table of contentsJunE 2011 / Vol. 32, no. 6

PlAnT SERVICES (ISSn 0199-8013) is published monthly by Putman Media, Inc., 555 West Pierce Road, Suite 301, Itasca, Il 60143. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals Postage paid at Itasca, Il and additional mailing offices. Canada Post International Publications Mail Product Sales Agreement no. 40028661. Canadian Mail Distributor Information: Frontier/BWI,Po Box 1051, Fort Erie, ontario, Canada, l2A 5n8. Printed in u.S.A. PoSTMASTER: Send address changes to PlAnT SERVICES, Putman Media, Inc., PoBox 3435, northbrook, Il 60065-3435. SuBSCRIPTIonS: Qualified reader subscriptions are accepted from PlAnT SERVICES managers, supervisors and engineers in manufacturing plants in the u.S. and Canada. To apply for qualified-reader subscriptions, please go to www.plantservices.com. To non-qualified subscribers in the u.S., subscriptions are $96 per year. Single copies are $15. Subscription to Canada and other international are accepted at $200 (Airmail only) © 2011 by Putman Media, Inc. All rights reserved. The contents of this publication may not be reproduced in whole or in part without consent of the copyright owner. In an effort to more closely align with our business partners in a manner that provides the most value to our readers, content published in PlAnT SERVICES magazine appears on the public domain of PlAnT SERVICES’ Website, and may also appear on Websites that apply to our growing marketplace. Putman Media, Inc. also publishes CHEMICAlPRoCESSInG, ConTRol, ConTRol DESIGn, FooD PRoCESSInG, InDuSTRIAl nETWoRKInG, THE JouRnAl, PHARMACEuTICAl MAnuFACTuRInG and WEllnESS FooDS. PlAnT SERVICES assumes no responsibility for validity of claims in items published.

Thought leaders: An interview With Rick baldridgeRick Baldridge, corporate reliability excellence process leader at Cargill and chair of SMRP is interviewed.www.plantservices.com/multimedia/2011/thoughtleaders.html

gender ambiguity and cultural norms clash in the industrial workplaceIn this edition of In the Trenches, Acme’s first transsexual truck driver gets fired for doing what comes naturally.www.plantservices.com/articles/2011/02inthetrenches.html

Plant Services Webinar - Compressed Air SystemsThis Plant Services webinar explains how companies have reduced energy consumption from compressed air leaks. Register now.http://webcast.streamlogics.com/audience/index.asp?eventid=40540712

iSA100 and wireless standards convergenceISA100 is one of three standards competing in industrial wireless sensing. What is distinctive about ISA100? What are the prospects for convergence of standards?www.plantservices.com/whitepapers/2011/isa100-wireless-standards-convergence.html

PS1106_05_TOC.indd 5 6/1/11 11:41 AM

Clear the way for quality air

© Copyright 2011 Atlas Copco Compressors LLC. All rights reserved.

Hi, I’m Michelle and I have been working with our customers across the United States for thelast 10 years. Products that optimize quality in your air supply are not just accessories weoffer; they are a way of life for us at Atlas Copco. That’s why we produce such a wide varietyof dryers, aftercoolers, filters and oil-mist eliminators just to name a few.

We all perform best when working within our optimum environment, right? And, manufacturingenvironments are no different. Moisture in your air supply is something that should be avoidedat all costs. Water is a by-product of compressing air. But there are ways to ensure thismoisture doesn’t get downstream and cause equipment malfunction. And more importantly,moisture can lead to contamination of your end products, leading to costly product failuresand potentially harming your hard-earned reputation.

Our mission is to continue to bring sustainable productivity through safer, cleaner, moreenergy-efficient, and cost-effective compressed air technology. Simply log ontowww.atlascopco.us/michelleusa or call 866-688-9611 to learn more about us, our products,and how we have earned and will continue to earn our reputation.

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FROM THE EDITORMIKE BACIDORE, EDITOR IN CHIEF

WWW.PLANTSERVICES.COM JUNE 2011 7

THE PICTURE OF SAFETYInternational suppliers need a reason to comply

In May, the Occupational Safety and Health Administration (OSHA, www.osha.gov) kicked o� its Picture It! Safe Workplaces for Everyone photography contest (www.plantservices.com/os-haphotos). Coincidentally, weeks later, three workers were killed and at least 15 were injured in a blast at the Foxconn plant in Chengdu, China.

Yes, OSHA is indeed part of the U.S. Department of Labor, so what does its photo contest have to do with industrial plant safety in China? Well, that depends on how seriously U.S. companies are about safety.

Foxconn is the trade name of Taiwan’s Hon Hai Precision Industries, which op-erates manufacturing plants in a variety of countries, including Poland, India, Mexico, Brazil, and China. Fourteen Chinese workers at Foxconn also com-mitted suicide last year, allegedly due to severe labor conditions, and Foxconn employees now must sign a promise not to commit suicide.

Two weeks before the explosion, Students and Scholars Against Corporate Misbehaviour (SACOM), a group from Hong Kong, criticized Foxconn’s ventila-tion and protective equipment at the Chengdu facility. � e blast at the plant was attributed to the ignition of highly combustible magnesium dust in a duct.

So, again, what does this have to do with OSHA and its picture competition?

Foxconn’s plants are suppliers to the U.S. technology industry. In fact, more than a million Foxconn workers manu-facture products for companies such as Apple, Hewlett-Packard, and Dell. And that gives those U.S. companies quite a big opportunity and considerable lever-age. If ever there was a chance to force change in labor practices and industrial safety standards, this is it.

Getting the picture yet?While OSHA is challenging ama-

teur and professional photographers to capture an image of workplace safety and health, the goal of the contest is to collaborate with the public and raise na-tional awareness about workplace safety and health.

U.S. companies have a history of requiring supplier compliance on issues ranging from sustainability to quality management. Workplace safety is an im-portant issue that manufacturers should do their best to drive all the way up the international supply chain.

And every picture tells a story. How about a new Apple iPad advertising cam-paign that includes photos of safe work environments of the plants that supply the tech manufacturer?

And don’t forget the OSHA photo contest at your own plant. It’s part of the organization’s 40th anniversary celebra-tion, and it’s open to anyone 18 years or older. � e competition deadline is Aug. 12, and workplace safety and health may be interpreted and demonstrated in any way the photographer chooses. � e photos, however, must be taken in the United States and its territories.

If you have photos from outside the United States, they’re not eligible for the OSHA contest, but we’ll be more than happy to accept them here.

U.S. COMPANIES HAVE AHISTORY OF REQUIRINGSUPPLIER COMPLIANCE.

PUTMAN MEDIA, INC.555 W. Pierce Rd., Suite 301,Itasca, IL 60143(630) 467-1300 Fax: (630) 467-1120

MIKE BRENNER Group [email protected]

EDITORIAL S TAFF

PAUL STUDEBAKER, CMRP Editorial [email protected]

MIKE BACIDOREEditor in [email protected]

RUSSELL L. KRATOWICZ, P.E. CMRPExecutive [email protected]

ALEXIS GAJEWSKIAssociate Editor, Digital [email protected]

STEPHEN C. HERNER V.P., Creative [email protected]

JENNIFER DAKAS Art [email protected]

DAVID BERGER, P.ENG. Contributing Editor

PETER GARFORTH Contributing Editor

SHEILA KENNEDY Contributing Editor

JOEL LEONARD Contributing Editor

BOB SPERBER Editor at Large

PUBLICATION SERVICES

CARMELA KAPPELAssistant to the [email protected]

JERRY CLARK V.P., [email protected]

JACK JONES Circulation [email protected]

RITA FITZGERALD Production Managerrfi [email protected]

JILL KALETHA Reprints Marketing ManagerFoster Reprints (866) 879-9144 ext.168 [email protected]

EXECUTIVE STAFF

JOHN M. CAPPELLETTI President/CEO

JULIE CAPPELLETTI-LANGE Vice President

KEITH LARSON V.P., Content

ROSE SOUTHARD V.P., Technology

Mike Bacidore, Editor in [email protected], (630) 467-1300 x444

PS1106_07_Editorial.indd 7 6/1/11 2:39 PM

.

©2011 Schneider Electric. All Rights Reserved. Schneider Electric, Masterpact, Square D, and the D-in-a-square logo are trademarks owned by Schneider Electric IndustriesSAS or its affi liated companies. 998-4084_US

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Fix or replacerepairing, rebuilding or reconditioning isn’t always the most sustainable option

Walking out of my house on Sunday morning, May 22, I couldn’t tell whether or not the rapture had occurred. My family and I, as well as many of my neighbors, were still evident, but that was no surprise. Monday morning’s traffic was a little lighter than usual, and my coworkers showed up, but again, that’s no proof that the truly righteous had, or had not, been taken. Absolutely none of the usual email had gone missing.

But when I went to start my lawnmower, I saw a sign that, indeed, the apocalypse had arrived. For the first time in 29 years, the old Honda HRA214 SX would not start, because it wouldn’t make a spark.

For all those years, so long as I put a little Stabil in the gas, that mower would start on the second pull the first time out in the spring and on the first pull for the rest of the season. But this year, the old beast has become, relatively speaking, a parts-eating machine: a new blade, a new foam sock for the air cleaner, even a new pair of front wheel bushings. At this rate, I might have to replace the original spark plug.

A replacement ignition coil costs $80, which is pretty pricey. It still makes economic sense to fix the mower rather than buy a new one, but is it the right thing to do from a sustainability point of view?

When I bought the mower in 1982, I used it a lot more often. Now, I just run it about 15 minutes a week to do edges and tight areas where my riding mower doesn’t fit. When it was new, its four-stroke, overhead-valve efficiency and emis-sions were state-of-the-art in a market full of two-strokes and flatheads. Now, I could probably do the job with an electric mower. Back then, I needed the self-propulsion. Now I could use the exercise of pushing.

Even if the alternative was simply replacing it with a new, gas-powered, self-propelled mower, fixing the old one might not be the most sustainable choice. A new mower would probably be lighter and more efficient. It might leak less oil and gasoline fumes and have cleaner exhaust. Besides, run-ning to the Honda dealer for parts burns a lot of gas.

A recent MIT study of remanufacturing versus replace-ment (www.plantservices/rebuildvsreplace) looked at 25 cases in eight categories, from motor rewinds to retreading tires and refilling ink cartridges. Reconditioning by itself almost always saved energy over a new component, but researchers found that, when lifecycle energy consumption was considered, more than half of the rebuilds either used

more energy or the energy balance was too close to call.If the remanufactured item is less energy-efficient than a

new product, the extra energy used over its lifetime gener-ally cancels out the savings from the manufacturing stage. This is a big deal in motor rewinds, as new motors tend to be several percent more efficient than the ones that are wearing

out. This has some folks wondering if an older motor can be rewound to be more efficient, and motor experts say it’s not likely (www.plantservices.com/rewindmotorefficiency). New motors have differences in design, materials, bearings, and precision that old motors just can’t match.

But if the component in question doesn’t consume energy, the MIT researchers say you can usually be confident that reconditioning is the more sustainable option.

That’s the case with most of the electrical components that are reconditioned by members of the Professional Electrical Apparatus Recyclers League (PEARL), who met May 15 to discuss, among other things, why LEED doesn’t recognize using remanufactured electrical equipment as a way to earn points for incorporating recycled materials in a new structure (www.plantservices.com/pearl). You can get credit for using staves of old-growth redwood from recycled water towers hauled in from California instead of steel siding, but not for freshly rebuilt, certified switchgear or circuit break-ers. Go figure.

As for my mower, for me, the fix-or-replace decision boils down, as it often does, to knowledge and infrastructure. I have the manual and a collection of accessories, and I understand how that old machine works — even better now that I had to find and test the coil. We’ve been through a lot of grass together, and that’s green enough for me.

contact editorial Director paul Studebaker, cMrp, at [email protected].


paul studebaker, cmrpMr. SuStainability

When liFecycle energy conSuMption WaS conSiDereD, More than halF oF the rebuilDS either uSeD More energy or the energy balance WaS too cloSe to call.

PS1106_09_MrS.indd 9 5/27/11 2:30 PM

©2010 Fluke Corporation. Specifi cations are subject to change without notice. Ad 3542778C

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Organized tO autOmateupdated instrument database enables calibration and maintenanceBy Kenneth marse, galata Chemicals

assigning maintenance responsibility to an outside contractor might make economic sense, but that group must have information about plant equipment and systems. When long-term employees are no longer around to tell why a pump sometimes cavitates or warn that a sensor line plugs frequently, the new technicians do a lot of wheel-spinning.

After the maintenance department at the Galata Chemi-cals plant in Taft, Louisiana, was downsized in 2007, most records pertaining to the process control system fell into disarray. While the contractor was qualified, it couldn’t find needed information. Technical documentation was almost nonexistent, control-loop piping and instrumentation diagrams (P&IDs) couldn’t be found, and there was no way to determine how many field devices were in use. In some cases, dual records existed, but they weren’t identical.

Another factor was the time spent reacting to emergen-cies. The new group was fighting fires to keep the plant run-ning and neglecting routine maintenance. The cost of the contract service turned was much higher than anticipated.

asset management revitalizedTwo actions were taken almost simultaneously. I was hired in June 2008 as a control systems specialist with authority over instrument calibration and maintenance. The company also brought in a systems consultant from Emerson Process Management (www.emersonprocess.com), our control sys-tem supplier. His assignment was to help with instrumenta-tion questions, but he was soon asked to restore the asset management software.

Our first task was reconstructing the instrument data-base in the AMS Suite: Intelligent Device Manager asset management software, the system implemented in 1998 to maintain spec sheets, P&IDs, and calibration records. The instruments were entered into the database as conventional devices, meaning that information the plant’s HART-based smart devices generated wasn’t being used for maintenance. Later, the HART-enabled devices were turned on, making field-generated diagnostics available, but different device tags were assigned for this purpose. The numbers never were linked, causing confusion.

Using the general application launcher in the AMS Device Manager, we segregated the HART-enabled devices and linked the loop sheets, specifications, P&IDs, maintenance manuals, and calibration procedures. We eliminated dupli-

cations, and the instrumentation system had some structure.Now, all 1,650 instruments have unique tag numbers.

Anyone can find any information needed for troubleshoot-ing, determine the operating condition of any device and the associated process equipment, and can predict when an asset should be repaired or replaced. Using the principles of pre-dictive maintenance, the contractor now was able to provide the maintenance needed to prevent the unexpected fires.

alarm managementAMS Device Manager monitors the smart devices and raises alarms if any exceed preset operating limits. Alarms can indicate trouble brewing, and we monitor them daily. I can retrieve diagnostic information from any suspect device. An I&E technician can check the device and the equipment it monitors. Any of these steps can trigger predictive mainte-nance if conditions call for it. In quite a few cases, instru-ments or process equipment problems have been discovered before the control system operators knew they existed. Catching a potential problem before it occurs avoids a great deal of troubleshooting and eliminates downtime.

Calibrations are now completed on schedule following Emerson’s written procedures. When it’s time for a calibra-tion, specific variables are downloaded to the technician’s documenting calibrator. The results of each calibration are uploaded to the database, becoming part of the historical file. We now have accurate, up-to-date calibration records that satisfy corporate requirements and state regulatory agencies. We avoid potential environmental problems.

We’re now taking care of nearly 2,000 field devices with one instrument tech, an apprentice, and two electricians. Process control is more consistent, and equipment reliability better, product quality higher, and productivity greater.

Kenneth marse is control systems specialist at galata Chemicals (www.galatachemicals.com) in Hahnville, louisiana. Contact him at [email protected].


yOur spaCe

WHen it’s time fOr a CaliBratiOn, speCifiC variaBles are dOWnlOaded tO tHe teCHniCian’s dOCumenting CaliBratOr.

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what works

a refined taste in reliabilityVibration monitoring helps to increase Mtbf and lower pump maintenance costs

the ConocoPhillips ferndale Washington Refinery (www.conocophillips.com) is an integrated, single-train fuels refinery with a capacity of 110,000 barrels/day and it has about 1,000 pieces of equipment. The rotating equip-ment group has three reliability engineers, a part-time PdM technician, and a maintenance superintendent.

The plant had no vibration monitoring program and used a reactive maintenance approach. The team was so busy re-sponding to “hot” problems that there was no time to make long-term improvements. Operations had little confidence in its pumps and motors. It was a common expectation that even spared equipment had to be repaired and returned to service the same day. The result was a lot of overtime as the team routinely spent weekends overseeing machine repairs.

It became apparent that something had to change. The plant needed to get away from run-to-failure and move to a strategic, proactive approach to reliability and uptime.

The plant investigated oil analysis and thermography and concluded that, for the machinery and the types of failures seen, vibration monitoring offered the highest potential return. The team also recognized the necessity of regular, repetitive data collection to establish statistical baseline data from which deviations could be recognized.

“In my opinion, vibration monitoring is the cornerstone to identifying machinery problems,” says Ryan R. Barnes, maintenance superintendent of rotating equipment services at the refinery. “How else can you stand next to a running piece of equipment and determine, without shutting it down, that it suffers from impeller unbalance or misaligned shafts, or is at the early stages of bearing damage?”

The team searched for a vibration monitoring system that emphasized accurate and repeatable data collection and easy analysis. It considered several approaches to data collec-tion. One was to use Ferndale operators or machinists to collect the vibration data and have reliability engineers or contractors perform the analysis. The other was to outsource the condition monitoring program. The team decided to hire a committed, on-site data collector to be involved with everything from data collection to working with an outside vendor to handle primary analysis. This way the data collec-tor wouldn’t be pulled away for repairs or operator rounds. The plant has a small staff, so it was critical the vibration monitoring system be fast, accurate, and repeatable, and most importantly, diagnose potential problems easily.

After reviewing available monitoring offerings, Cono-coPhillips Ferndale selected the Azima DLI vibration data collector with ExpertAlert software. Triaxial data acquisi-tion can collect vibration data in three dimensions in less than 20 seconds per test location. This includes both low (0-10 orders) and high (0-100 orders) frequency ranges.

Technicians aim the bar code scanner at the label glued to the pump base or foundation and the data collector begins

recording immediately. The labels withstand years of harsh outdoor conditions. Test pads with a screw-mounted con-nection to the transducer ensure repeatable vibration data, especially in the higher frequencies. The bronze pads have an alignment notch to orient the transducer.

Vibration monitoring needs a data screening technique. Azima DLI uses an analysis program called ExpertAlert. It uses statistical analysis to compare the accumulated baseline spectral peaks against the test data using a complex set of rules. About 25% of the data collected generates a significant diagnostic report that requires follow-up manual analysis.

It was imperative to have one person, with interest, enthu-siasm, accountability, training, and certification, who owned and was responsible for the program. In addition to collect-ing and analyzing data, this person analyzes the machine problems that arise and track the metrics needed to refine the program and recommend plant improvements.

During the past 16 years, unplanned machine failures have diminished to near zero. The pump MTBF rate in-creased from 22 months to 52 months in a 10-year period after implementing the Azima DLI condition monitoring system. The annual maintenance costs for pump repairs dropped from $1,300,000/yr to $600,000/yr within 10 years. Nearly every maintenance job at the plant is planned. Equip-ment failures are few, and overtime has been eliminated.

The ConocoPhillips Ferndale plant has come a long way. What was once a run-to-failure plant now has a 91% on-stream availability with a staff of five machinists.

the Plant has a sMall staff, so it was CritiCal the Vibration Monitoring systeM be fast, aCCurate, and rePeatable.

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Progress Energy, an electric utility serving the south-east, has its SWAT team, the Performance Testing Group, to stamp out inefficiency. With four engineers and technicians led by Dick Fletcher, the team manager, it travels among 32 plants, testing, troubleshooting, and verifying equipment performance. Field testing requires portable data acquisition systems that collect data from many field devices. Typically, the test records time-stamped data through a gateway to a laptop-based spreadsheet-type application. Test equipment must be portable and flexible enough to operate with a con-stantly changing number of instruments and scan rates.

ThE ProblEm wiTh hard wirEsThe group maintained 240 transmitters, mainly for tem-perature and pressure, hardwired to HART multiplexers to accommodate cable runs to conduct tests. Testing entailed days for setup and another for teardown. Some multiplex-ers were failing because of wear and tear. The wiring risked damage as cables were used and reused connecting more than 100 instruments across the plant and roadways.

With the introduction of the WirelessHART protocol and network adapters, the group sought to replace its test equip-ment to go wireless. Fletcher explains that the engineers had a major investment in HART Smart Transmitters. “The logi-cal thing to do was get a common data acquisition system shared across the system,” he says.

He set short-term goals for a new system that could handle a variety of instruments, with special emphasis on high-accuracy pressure and temperature. The system also had to be easy to configure, because every plant had its own configuration. And the system would have to interface with standard commercial instruments using standard protocols.

Fletcher also set longer-term goals to achievie remote data flow over the corporate wide-area network (WAN) for remote testing. But first, they had to show proof of concept.

ProjEcT objEcTivEsTest setup was arduous before products had implemented the WirelessHART specification. One such adapter, the MACTek Bullet, allowed Fletcher’s group to connect eight HART-enabled devices in an all-digital multidrop network mode. Knowing this, the Performance Testing Group hoped to achieve several objectives: create a common data acquisi-tion system, share equipment, minimize hardware inven-

tory, collect multidrop mode data digitally, simplify equip-ment installation, and get an easily configurable system.

These objectives exceeded Fletcher’s initial expectations. The project focus in the early, research phase was mainly upon wired multiplexer-based systems, because “the wire-less equipment that we were initially aware of was expected to be out of our financial reach,” says Fletcher.

imPlEmEnTing wirElEssly“Like everyone else in these economically challenging times, we had to get the best bang for the buck,” says Fletcher, “and that meant that we had to maintain compatibility with our existing investment in HART-enabled transmitters. When we were planning our purchase, we learned that MACTek had working prototypes of the Bullet.”

The prototype, introduced in 2009, supports six HART transmitters in HART multidrop mode. It has since ex-panded to eight. For either iteration, this capability meant a wireless gateway could replace the failing multiplexers, and fewer cables would be needed for test installations. “The economics of a hybrid wireless-wired HART system became more feasible for us to consider,” says Fletcher.

The resulting system communicates HART data, includ-ing process variables, through the Emerson gateway, to a laptop PC, where data goes to an Excel spreadsheet using Matricon Analytics’ plug-in Excel Reporter, an OPC plug-in.

Fletcher has one caveat to using the wireless network adapt-ers. Because WirelessHART technology uses the same 2.4-GHz frequency band as Wi-Fi, users should be aware of the range limits and possibility of interference between objects and antennas. He also notes that a WirelessHART network can take 10 or 20 minutes to get fully established with all HART subde-vices reporting, and that Wi-Fi was designed for speed, while WirelessHART was designed for data reliability.

bEnEfiTsThe advantages of the system were apparent, from up-front cost to long-term data acquisition system reliability. Another


whaT works

on TargETElectric utility discovers quick wirelessharT payback

TEsT sETuP was arduous bEforE ProducTs had imPlEmEnTEd ThE wirElEssharT sPEcificaTion.

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wireless adapter provided the same kind of capability, but each handled only one transmitter. The cost of the hardware for the 240 transmitters the group main-

tains was roughly $180,000. Instead, the Bullets, which handle eight devices each, cost $158,000 less. The multidrop capability was key to project approval.

take the Bullet BusWhile HART is a hybrid analog/digital specification, wireless data transmis-sion is all-digital. This allows HART technology to enter the world of digital bus functionality. The wireless multi-drop mode doesn’t use the analog signal; instruments use the 4-20 mA signals for power, but process variables are transmitted digitally. So, the tech-nology might open the door for new applications previously thought to be the domain of digital fieldbus networks, such as condition monitoring and asset management. A MACTek Bullet trans-mitting data on eight multidropped in-struments once every 8 seconds makes real-time data acquisition a possibility. Fletcher notes the protocol is built for redundancy and reliability. For his test-ing purposes, he sets up the MACTek to poll Bullet transmitters every 16 seconds and for his gateways to poll at 20-second intervals.

Future potentialFletcher is considering expanding the scope of testing to other tests and diagnostic capabilities. With the proof of concept, Fletcher is in discussions to consider permanently installed Bullets in key locations. This can yield benefits at the plant level and beyond, if remote access is granted.

“The Web interface in the wireless gateways gives us good diagnostics and data on the Bullet radios and the HART devices,” says Fletcher. “Further gains stand to be realized if we can get the gateways linked to the corporate wide-area network.” The ba-sic principle is to connect the gateways to the corporate WAN instead of a laptop. Engineers could then evalu-ate data being collected at any plant without traveling to it. Alternately, the WAN approach also could allow the group or others in the company to make additional or more in-depth evaluation at any time.

what works

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what works

In a five-day, two-shift work week, a lift truck might be in operation for 80 hours. During a year, it will operate for more than 2,000 hours. Leveraging lift truck operating statistics properly can help managers run a more efficient operation and increase productivity.

Bunzl North America (www.bunzldistribution.com), with headquarters in St. Louis, supplies food packaging, dispos-able supplies, and cleaning and safety products to food processors, supermarkets, retailers, convenience stores, and others. Raymond’s iWarehouse fleet optimization system helps determine the true cost of lift truck ownership; assess when it’s appropriate to service or reassign equipment; and evaluate maintenance trends. At some locations, Bunzl re-duced its maintenance costs by more than 10%. “We wanted to get better control and understanding of our equipment,” says Rick Castetter, vice president of distribution and ware-housing for Bunzl North America. “If we can better plan for maintenance or even reduce and eliminate avoidable maintenance situations, then we’re more cost-efficient and productive.”

Data DelIveryBunzl’s operators use so many Raymond lift trucks, order-pickers, and electric pallet trucks that the company began using the iWarehouse system’s iTrack module, the data from which would help the company improve lift truck fleet management and its cost elements. “Managers at each distribution center, unless they had their own homegrown spreadsheets for tracking every month, wouldn’t really know how much a unit cost to operate,” says Jeff Earnhart, execu-tive vice president of operations for Bunzl North America. “They couldn’t answer certain questions. ‘How many hours am I using it? What’s my cost per hour? How many times has this been repaired? When was the last time this repair was done?’ It was a manual process.”

It’s helpful at the corporate and the individual distribu-tion center level to use the data to determine what is needed to budget for next year, in terms of capital expenditures, says Castetter. “Our distribution center managers will access the website and analyze the costs of individual units of equip-ment and the age of the equipment, to determine whether to keep the equipment for another year or if it’s starting to cost more than it should to keep it running,” he says.

Bunzl also uses the data to determine if a facility has the

right number and mix of trucks. The cost analysis helps to determine whether any facility has too many or too few trucks to meet throughput requirements.

Data proDuces cost savIngsEarnhart says iTrack provides multiple avenues of cost sav-ings, and nothing is considered too insignificant. The system also can help determine replacement component strategies. For example, data might indicate that a facility’s lift trucks require wheel and tire replacements more often than other facilities. “If it’s an older building, there could be cracks and uneven areas in the floors that damage tires and wheels,” says Earnhart. “The system allows us to determine the root cause of a problem.”

Bunzl relies on Raymond’s assistance for preventive maintenance and repairs, handled regionally by a network of Raymond service centers. Technicians there enter mainte-nance work order data into the iWarehouse system’s iTrack module to be reviewed and approved by the distribution center manager. Work orders are consolidated, and Bunzl receives a single invoice every other week, Raymond’s tech-nicians also help facilities incorporate new technologies.

Fleet, Don’t FaIl Me nowreal-time data improves lift truck purchase planning and maintenance management

An on-board module tracks lift truck data that determines the unit cost to operate.

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We can define leadership as influencing the activities of others toward accomplishing a goal. And we can define power as a leader’s potential to influence the activities of others toward accomplishing a goal. Without a source of power there can be no leadership.

We can define two different types of power bases: position and personal. Position power is the power that is given to leaders by their organizations. It is the power granted to leaders based on their job title.

Personal power is power given to the leader by other people. That includes subordinates, peers, and bosses of the leader and others. Personal power is an indication of the

level of commitment others have toward the leader. Personal power is linked to our personality, our competence, and our integrity. There are seven sources of power:

• coercive power (position) — the ability to impose sanc-tions or punishment to gain compliance

• reward power (position) — the ability to provide rewards or recognition to gain compliance

• legitimate power (position) — the right to influence the activities of others based on job title or position

• expert power (personal) — respect gained based on skills, expertise, or experience

• referent power (position and personal) — positive per-sonal traits or integrity

• information power (position and personal) — possession of or access to, valuable information

• connection power (position and personal) — access to others who can provide rewards or sanctions.

A leader should be able to incorporate these power sources appropriately. A leader should contemplate the best sources of power to be employed to achieve success and ef-fectiveness. So now you should be asking yourself, “Is there one best source of power?” The answer is yes, if you’re only concerned with immediate success — for instance, if a fire breaks out and you need to make sure a volatile process is safely shut down. In this case, position power is the best choice. In most other situations you need to move among the sources of power. Power can be quickly lost if the leader misuses power.

A leader must use power wisely and justly or it can become a liability rather than an asset. It only takes one incompetent act to result in an instantaneous loss of power. Good leaders work to build their sources of power, and they use their power to influence others wisely.

Tom Moriarty, P.E., CMRP, is president of Alidade MER. Contact him at [email protected] and (321) 773-3356.

UsE And MisUsE of LEAdERshiP PoWER7 sources and the potential consequences of its application


hUMAn CAPiTALTom moriarTy, P.E., CmrP

A LEAdER shoULd ConTEMPLATE ThE bEsT soURCEs of PoWER To bE EMPLoyEd To AChiEvE sUCCEss And EffECTivEnEss.

Leader action Typical effects Effect on power

Uses sanctions inappropriately,

misuses corrective feedback

Team loses respect for the leader

The boss notes the leader can’t handle sanction

authority

The leader loses respect from peers

reduces referent power with boss, team, and peers

might also erode coercive power

Threatens sanc-tions but never follows through

Team doesn’t per-ceive the leader

will use sanctions

reduces coercive power with the team

Gives rewards to everyone, regardless of performance

Team feels there is no need to work harder if

everyone gets the same reward

rewards be-come expected, as opposed to being perfor-mance-based

The boss notes the leader is abusing the

rewards system

reduces reward power with team

reduces referent power with boss, peers, and team

These are some examples of the negative fallout that can come from the abuse of power.

PS1106_21_HumanCap.indd 21 6/1/11 2:48 PM

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asset managerdavid berger, P.eng.

With complexity on the shop floor, in facilities, and in the field growing, there’s a need for better decision-support systems. Some CMMS vendors work hard to provide superb decision-support functionality. This includes condition monitoring features; workflow capability; analysis and reporting tools; mobile solutions; and the ability to easily integrate with other operational systems.

Condition monitoringIf the objective is optimization, a critical function is to monitor and control four aspects of operations — products, processes, environment, and assets. Low-level systems such as human-machine interfaces (HMIs), supervisory con-trol and data acquisition (SCADA), programmable logic controllers (PLCs), and proprietary data collection systems can track the four aspects. But operations seem to be more concerned with the first three than with the assets and rely heavily on maintenance to monitor or control key assets.

Competition, tension, and role ambiguity between opera-tions and maintenance is nothing new, and sophisticated monitoring and control systems make it hard to separate their duties. Behavior takes more time and effort to change than technology. For example, why so much union resis-tance to total productive maintenance (TPM), where opera-tors take on responsibility for minor maintenance tasks? The opposition stems from a power struggle at the management level and a fear that jobs will be lost or changed.

Optimization is the goal. Management must change the corporate culture to take advantage of the powerful systems at its disposal. Maintenance technicians no longer sit around reading the paper, waiting for a call from the field or shop floor to deal with a problem. Condition monitoring capa-bility allows operators, technicians, and engineers to react quickly to abnormal or suboptimal situations. We need better cooperation between operations, maintenance, and engineering at every level, and a new definition of roles and responsibilities that match the new reality.

WorkfloWA sophisticated workflow engine some CMMS vendors offer enhances the condition monitoring capability, in that data can be routed and actions taken in a predefined manner. For example, if a reading strays outside control limits, the CMMS can initiate a work order or send an email to the

maintenance supervisor. Workflows can be triggered by condition or trend in one or more variables. The vigilant CMMS optimizes operations through quick response.

Workflow isn’t only useful for monitoring shop-floor measures, but it also can be a useful management tool. For example, if PM compliance dips below, say, 90%, an email can be sent to the maintenance manager. If it drops below, say, 80%, an email can be sent to the plant manager. If PM

compliance goes below, say, 70%, an email can be sent to the COO, and so on. A workflow engine can perform any user-defined transfer of data and actions, based on any user-defined event, condition, measure, or combination thereof.

analysis and reportingCollecting information from thousands of field or shop-floor devices doesn’t optimize operations. Many companies suffer information overload when they implement advanced packages. It’s not clear what to do with the new data. CMMS vendors know this phenomenon. Some provide tools, tem-plates, samples, and predefined reports to assist in extract-ing knowledge. Others try a spin: “We don’t supply tools or templates, but our software is flexible enough to build any report, on demand,” as if the two are mutually exclusive.

The hottest software feature is the dashboard interface that allows users to configure the look and feel of a personal page on the CMMS, including table summary reports, KPIs, alarms and warnings, key messages, and links to relevant information. The user can configure display formats, such as a speedometer or stoplight graphic depicting variables. The range for each is user-definable. If the graphic shows a problem, the user can double-click on it to provide a de-tailed report and zoom in on the root cause with a series of double-clicks. If the dashboard is configured properly, users can identify problems, determine the root cause, and take appropriate action. Dashboards provide the visibility needed to optimize operations through better decision making.

management must Change the Corporate Culture to take advantage of the poWerful systems at its disposal.

more than a data aggregatorCmms includes decision-support functionality to make information useful

PS1106_23_24_AssetMgr.indd 23 6/1/11 11:42 AM

24 JUNE 2011 WWW.PLANTSERVICES.COM

ASSET MANAGER

MOBILE SOLUTIONSAnother useful tool for optimiz-ing operations is the mobile device. Some mistakenly think of a mobile

device as a small remote terminal with access to the CMMS. � is doesn’t do justice to the power of the mobile solution. Field or shop-� oor

workers are completely alienated by mobile solutions that require scroll-ing through reams of data on tiny screens. However, companies get sig-ni� cant productivity improvements if the so� ware renders properly on the device, provides the information required, and takes advantage of the powerful features, such as taking and attaching pictures, recording GPS coordinates, reading RFID, and read-ing bar codes.

INTEGRATIONAn important CMMS trend is bridging islands of automation in operations. � is includes � eld and shop-� oor data systems such as HMI, SCADA, and PLC systems, as well as systems such as time and attendance, asset tracking/locating, calibration, quality control, manufacturing execu-tion systems, building management systems, geographic information systems, and ERP systems. Integration means greater accuracy and timeli-ness of shared data because it’s entered only once at its source. Data storage and data entry costs are lower because there’s less duplication. Most impor-tantly, users have easier access to the data to make better decisions, regard-less of where it resides.

Some CMMS vendors integrate these applications into their products via so� ware. Others acquired or have been acquired by a company such as an ERP provider or plant automa-tion company that o� ers one or more of these applications. Others formed partnerships with companies that can build the appropriate interfaces to ensure seamless integration between partners. Finally, some CMMS vendors simply build the required interface as the need arises.

Email Contributing Editor David Berger, P.Eng., partner, Western Management Consultants, at [email protected].

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Technology ToolboxSheila Kennedy

PorTable buT connecTedPredictive maintenance technologies integrate the best of both worlds

assets can exhibit subtle changes before failure occurs. Detecting that and triggering corrections is increasingly sophisticated. Technology improvements are prominent in several recent product announcements.

Portability: Sometimes a two-channel portable vibration data collector is inadequate and a permanent monitoring system is impractical. Emerson offers the CSI 2600 Machin-ery Health Expert, a portable tool capable of unattended, continuous online monitoring and recording of 24 channels. “While traditional multi-channel devices focus on turbo-machinery, the CSI 2600 can detect rolling element and gearbox problems,” says Deane Horn, product manager for Emerson. “It identifies early indication of bearing wear and features transient analysis, fault frequency overlays, order tracking, and time synchronous averaging.”

Connectivity: Continuous monitoring and measuring can predict and circumvent degradation between PM cycles. Infor EAM offers out-of-the-box connections from devices that supply a PLC, building automation, and metering data to the Infor EAM software, where rule-based work orders for predictive maintenance can be generated automatically.

“We knew we had to provide not just software and ser-vices, but also hardware,” says Johnny Bofilios, Infor’s direc-tor of asset sustainability. “One of our hardware partners is Echelon, whose i.LON SmartServer is a standards-based energy manager. Energy spikes that i.LON reveals could be indicative of high motor temperature, phase imbalance, or other asset conditions that requires maintenance.”

Adding connectivity between devices also improves pro-ductivity. MeterLink from Extech Instruments automates sharing Extech electrical and environmental meter diag-nostics and Flir infrared camera diagnostics. “Previously, a camera would scan for a hot spot and a meter would collect electrical readings, and manual or audio note taking was required to integrate these readings for inspection reports. MeterLink records meter readings instantly and directly via Bluetooth into the infrared images,” says Andre Rebelo, global PR manager for Extech Instruments.

Affordability: Infrared thermometers provide a numeri-cal temperature readout of single spot, a time-consuming manual process that’s affordable compared to traditional infrared cameras. A low-priced imager has the potential to replace toolbox thermometers. The Flir i3 point-and-click thermal imager retails for $1,195. “Now, for about the same

price as a premium infrared unit, you can get a visual with thousands of pixels of data in a single image,” says Rebelo.

Usability: Performance and usability upgrades were made to Azima DLI’s Alert machinery condition assessment soft-ware, particularly in the area of data collection. A redesign of the DCX and DCA-60 data collection user interface improves functional and navigation efficiency and provides access to more information. It supports hands-free, voice-

controlled data collection with optional verbal feedback. The system accommodates complex notes and can record and play voice notes. Also, the automated diagnostic system technology has been improved, allowing expanded diagnos-tics and an unlimited number of machine test locations.

Ultrasonic units with touchscreen capabilities simplify inspections. The Ultraprobe 15,000 Touch from UE Systems is a handheld, full-featured inspection system that measures, analyzes, and collects data by touch. “The operating software enables inspectors to review important route information, such as baseline data, images of test points, and previously recorded baseline sounds, which can be viewed on the spec-tral analysis screen,” says Mark Goodman, vice president of engineering for UE Systems. “While the data can be down-loaded to a host computer, the on-board features provide for field analysis of fluid, electrical, and mechanical systems.”

Ultrasound image clarity is the target of University of California, Berkeley, scientists developing a metamate-rial that uses evanescent sound waves for super-resolution acoustic imaging. The metamaterial could potentially improve the images that are generated in non-destructive, ultrasonic testing.

email contributing editor Sheila Kennedy, managing director of additive communications, at [email protected].


ulTraSonic uniTS wiTh TouchScreen caPabiliTieS SimPlify inSPecTionS.

www.emersonprocess.comwww.infor.comwww.echelon.comwww.extech.com

www.flir.comwww.dliengineering.comwww.uesystems.comwww.berkeley.edu

reference web SiTeS:

PS1106_27_TechTool.indd 27 5/27/11 2:32 PM


Interest in industrial mobility can be credited to the con� uence of trendy devices, lower-cost connectivity, and tech-savvy “Millennials” — also known as Generation Y— now entering the workforce. Applications (apps) to foster operations and maintenance e� ciency abound for both rug-ged and consumer-grade wireless technologies, but getting the highest return on your mobility investment requires matching the strategy to your particular environment.

Rugged devices were the � rst to hit the plant � oor. So� dB, a manufacturer of acoustical equipment, chose DAP Technologies’ M8910 rugged tablet computer for acoustic and vibration measurement. “It allows us to be an innovator by integrating signal technology into a modern tablet PC,” says André L’Espérance, president of So� dB (www.so� db.com) in Quebec City, Quebec. “Once it’s fully deployed, we expect that hundreds of users will be using the device.”

Coatings and specialty products manufacturer PPG Industries uses Motorola’s MC9000 rugged handheld mobile computers for mobile human-machine interface (HMI) and asset management, and radios from Motorola to improve communications and security. “Although we’re just in the infancy of enabling the mobile operator and technician in our facility, the potential bene� ts in e� cien-cy, safety, and environment are huge,” says Rob Brooks, process control supervisor for PPG Industries (www.ppg.com) in Pittsburgh.

� e new wave in mobility is smart apps. One wholesale brewery is pilot testing Aurora Mobile Apps from Aurora Industrial Automation to access its Rockwell Automation

FactoryTalk visualization system from any location. With an Apple iPad or iPhone, users monitor and compare processes, such as the status of the mash � ltration system, in real time.

VENDOR OFFERINGS ARE MANY AND VARIED� e Flir Viewer App can send thermal images and data from a Flir E-Series or T-Series camera directly to an iPhone, iPad, or iPod touch without cables or swapping SD cards. “When you snap a picture of a problem with your Flir camera, you can call it up on your iPhone via Wi-Fi from the � oor and email it to any number of recipients,” says Ed Kochanek, director of sales, eastern region, for Flir Systems (www.� ir.com) “� e app is generating great excitement with our customers. With an iPhone or iPad, it’s easier to store, scroll through, analyze, and share pictures. It allows you to carry every picture ever taken anywhere you go.”

� e ProSo� i-View is a mobile app for Apple devices that enables remote process monitoring and control with real-time process data. “If you need to know immediately when there’s a fault in a line valve, or a motor seizes, or a drive stops working, the i-View can detect it,” says Chris Hines, training manager for ProSo� Technology (www.proso� -technology.com). “We recognized the inevitability of melding between consumer and industrial technologies via mobile apps, so we began investigating opportunities

Apps of Steel

Mobile and tablet devices attract a new wave of maintenance applications to the plant floor

By Sheila Kennedy, Contributing Editor

PS1106_28_35_CvrStry.indd 28 6/1/11 10:55 AM

CATEGORY / TOPIC


to leverage these tools to complement our solutions and our customers’ applications.”

� e SKF Microlog Inspector System simpli� es data col-lection and remote data transfer for condition monitoring, inspections, safety, and maintenance. It runs on Windows Mobile 6.1 devices and can connect automatically and wire-lessly to a central server using a LAN, Wi-Fi, or 3G/GPRS cellular data network.

Trial apps are good for gauging interest. “At last year’s Au-tomation Fair, we used iPads in the booth to display live data from three � ow instruments using an app developed speci� -cally for the show,” says Jeremy Farrow, marketing com-munications manager for Endress+Hauser (www.us.endress.com). “Customers thought it was great, and now we have to � gure out how we can turn it into something more.”

When vendor support is needed, mobility has its ad-vantages. Rockwell Automation customers can access the support center from a smartphone. “Previously, you needed an Internet connection and now all you need is a phone connection,” says Jon Furniss, product manager for remote support at Rockwell Automation (www.rockwellautomation.

com). � ere’s no application to download. � e system recog-nizes when the user is connecting with a smartphone, tablet, or other device and presents the small-screen user interface with the same capabilities as a traditional connection.

Mobile apps are bene� cial to maintenance contractors. Rockwell Automation’s installed base evaluation (IBE) service is faster because of its partnership with Meridium. “We collect information from the customer’s site, analyze it, and provide recommendations on how to optimize MRO in their facilities and manage obsolescence risk,” says Jes-sica Korpela, Rockwell Automation product manager for installed base evaluations. Meridium’s tablet application framework allows maintenance data to be synchronized in real time. “Using tablets for data collection allows IBEs to be done in half the time,” adds Korpela. � e program currently supports Dell-branded tablets.

NEW APPS ARE EMERGINGAt least three companies are testing Aurora Mobile Apps, the new iPad/iPhone app from Aurora Industrial Automa-tion. It gives real-time, read-only, remote access to plant-

Apps of Steel



Mobile ApplicAtions / Condition Monitoring

floor data through certain Rockwell Automation FactoryTalk visualization systems using an Internet browser. It reportedly won’t be made available on the iTunes library until the iPad and comparable device security features are improved, and they’re hardened for industrial use.

Further innovations are underway at Rockwell Automation’s support center. “We’re looking into having customers send SMS texts for technical support, and we’re investigating whether social media is a place for technical support,” says Furniss. “We’re currently testing the use of mobile video cameras so that when our engineers call with questions from the plant floor, we can see what they’re doing. And we’re investigating instant translations to convert online chat to the local language in real time automatically.”

MotivAtors for MobilityThe appeal of mobility is catching. ARC Advisory Group (www.arcweb.com) Research Director Ralph Rio found high interest in mobility in his March 2011 survey of industrial maintenance, IT, and executive professionals, “Survey Re-sults for EAM Systems: Current Practices and Future Plans.” Of the respondents, representing more than 5,000 plants globally, three-quarters have already implemented mobility software for EAM functions or plan to do so within one to three years (Figure 1).

Why so much interest? For one, because Millennials in the workforce grew up with computers and handheld devices, they expect them at work, explains June Ruby, manufacturing principal for the Motorola Solutions Industry Solutions Group (www.mo-torolasolutions.com). Additionally, the economy changed the manufacturing environment. “Demand and produc-tion is ramping up, but we’ve been left with a scaled-down workforce. We can’t afford to let people sit in a control room. The same person might need to perform safety rounds, quality inspections, and track processes,” explains Ruby.

prActicAl benefitsFirst and foremost, mobility can help to drive visibility. Mobility eliminates the paper trail, says Jerry Steenhoek, chief technologist/project manager for Inter-states (www.interstates.com). “Instead of turning in a sheet of paper at the end of the day, when information could be lost or misread, the data is entered once and is immediately accessible.”

The productivity potential is immense. “The impact of this newfound mobility on business processes will be signifi-cant, largely because a mobile workforce equals a more productive workforce,” says David Crump, marketing com-munications manager at Opto 22 (www.opto22.com).

“Mobile technology is doing what the laptop did for the office 20 years ago,” adds Scott Brady, senior manager of pub-lications, portables, and wireless at SKF Condition Monitoring Center (www.skf.com). “You’re not tied to one spot. If you’re out in the plant or even hundreds of miles away, you have all the data that’s available in the office at your fingertips.”

A big opportunity in mobility is add-ing discipline to standard processes, says Kevin Prouty, research director, for en-terprise applications at Aberdeen Group (www.aberdeen.com). “Before, you might have suspected not every item was being inspected. Now, when inspections are performed using a mobile device with a bar code scanner, you know when steps are skipped. It enforces discipline.”

A role for consuMer devicesEric Miller, vice president of sales for DAP Technologies (www.daptech.com), recognizes that consumer devices are gaining in prominence. “It’s a result of the proliferation of mobile devices, such as smartphones and iPads, in consumer markets and our everyday lives,” he says. “It’s natural that business users want to leverage the tools that allow the seamless exchange of data wirelessly and ease of communication in enterprise settings.”

Aberdeen’s Prouty agrees that com-panies are increasingly willing to try lower-cost, flexible consumer devices. A


PS1106_FPA.indd 31 6/1/11 12:09 PM


notable iPad advantage is that its battery charge lasts much longer than most lap-top batteries. Aurora observes that in an industrial setting, an iPad’s 10-hr charge could last a few days.

Why rugged still rulesThe main reasons that Soft dB decided to partner with DAP was the modular-ity and ruggedness of its computers. “It was one of the only tablet PCs that would allow for integration of our custom digi-tal signal processor board, and DAP’s computers are rugged enough to be used in the field in all kinds of weather and conditions,” says L’Espérance.

Companies that ban camera devices for proprietary or classified reasons ef-fectively eliminate most consumer-grade devices from consideration. Aurora would like to see additional security fea-tures in the consumer devices relative to

user access control, usage tracking, and feature lockdown.

Device price shouldn’t be a primary concern. “The perceived notion that a rug-ged tablet should cost the same as an iPad is a misconception,” says DAP’s Miller. “A consumer model might cost less up front, but it isn’t built for the challenges of field service or industrial use. The high failure rates for consumer models in these mar-kets produce a domino effect of downtime, lost productivity, and increased repair and replacement costs.”

While industrial PDAs are taking on some cell phone characteristics, there’s still room for improvement. Motorola is glad people are exploring new ways to use mobility, including with consumer de-vices, says Ruby. “Enterprise-grade device manufacturers benefit from those experi-ences because the customers validate the use case,” she explains. “Most customers

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Mobile ApplicAtions / CondiTion MoniToRinG


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Mobile ApplicAtions / Condition Monitoring

quickly realize that the reality of rolling out the mobile solution across an enterprise calls for an enterprise-grade device.”

choose the right deviceBefore selecting a device, Motorola Solutions suggests ex-ploring its use case. Will the device be assigned to some-one or part of a shared collection? Will the environment have carpet or concrete floors, and is it a Class I or Class II hazardous area? Will the device access intellectual property,

requiring data encryption and the ability to be wiped clean if it’s lost or stolen? Will IT have visibility to monitor and troubleshoot the device and access to push down security patches and upgrades? The total cost of ownership is another consideration. How long do you expect the devices to be in service before you do a refresh? If you’ve chosen cellular ser-vice, is one carrier enough or do you need multiple carriers for full, real-time coverage?

“For some users, the right device is a two-way radio providing voice communication,” explains Motorola’s Ruby. “Others might need a rugged mobile computer with a screen and keypad to access and update work orders and look up the equipment’s maintenance history.”

SKF found that customers want to use existing device in-vestments. DAP suggests using computers like theirs that of-fer ruggedness to increase uptime and decrease maintenance costs, flexibility to increase productivity and consolidate the

number of devices needed, and modularity so the computers work the way the business needs them to work.

Consumer-grade device competition is growing fast. “Apple devices have their limitations and might lose favor to suitable Androids as they emerge,” says ARC’s Rio. “For instance, many feel strongly about having a real keypad with tactile feedback, not a virtual one. Gloves and fat fingers are a particular hindrance for Apple devices.”

get the App rightRegardless of the device, the application’s user interface must fit the screen. Best-in-class companies are significantly more likely to customize and simplify the screens, according to the 2011 Aberdeen Group report, “Mobility in ERP 2011.” Shrinking a regular ERP screen to fit on a mobile device is one of the first reasons for users rejecting the system, says Aberdeen’s Prouty.

You don’t need an IT infrastructure if you have cell signals, says SKF’s Brady. “Cell phones are supporting faster and faster speeds, and now the data can be fed via GSM card, phone card, or Mi-Fi — a mini-router that acts like a mobile Wi-Fi hot spot for cell phones,” he says. “It takes the question of how to connect out of the equation.”

Advanced communications provide more benefits. “DAP is among the first to offer integrated ZigBee wireless tech-nology, a low-power sensor technology, and wireless USB, which allows for the connection of multiple peripherals and the wireless transmission of data at speeds similar to a wired connection,” says DAP’s Miller.

Coincidentally, there’s an app for planning and managing wireless networks. The ProSoft RadioLinx Calculator, which runs on Android devices, as well as the iPhone and iPad, takes the entered radio and hardware variables and calcu-lates the theoretical link signal strength between two sites so that adjustments to improve the link quality can be made.

If infrastructure isn’t your strong suit, SKF hosts software as a service (SaaS), helping customers upload and download data from remote locations because they don’t have to worry about internal firewall security. With SaaS, the vendor takes over the installation, backups, and the mobile connectivity.

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A big opportunity in Mobility is Adding discipline to stAndArd processes.



Security iS Job 1The question every company must ask is how to protect the mobile device and the data it accesses. A multi-pronged approach is desirable. ProSoft i-View makes cumulative use of security features such as passwords, encryption, and VPN tunneling to secure its process data.

Planning for security upfront is essential. “Mobile ac-cess applications are subject to security levels in the IT infrastructure,” says Ken Brunnbauer, Rockwell Auto-mation commercial programs manager for the services and support business. “Without the right planning, they might not work as designed because of established secu-rity configurations.” SKF recommends bringing the IT person into the sales discussion.

Looking forwardSoft dB intends to increase its investment in mobility. “We’ll be using more mobile devices because this replaces older, existing technology that was heavier and more cumbersome, had an inferior user interface, and relied on components that are no longer supported,” says L’Espérance.

Vendors such as Endress+Hauser and Interstates are weighing the benefits of wireless apps. “Our next task is

to figure out which apps we could provide that would be beneficial to an end user,” says Endress’ Farrow. “What is it they want or expect to be able to do with this sort of technology, and how does it fit into our business and what we offer?”

Others, like Rockwell Automation, are actively explor-ing new possibilities. One idea is to have customers install TiVo-like devices to capture and stream data, allowing them to review what happened within a period of time before and after a fault. Rockwell Automation could potentially log into its camera to help determine the cause.

Opto 22’s vision of mobility is expansive. “Moving forward, it won’t be limited simply to viewing data,” says Crump. “You can expect nearly all of the functionality auto-mation engineers currently have with a PC to be brought to a variety of different mobile platforms.”

As people continue to become more comfortable with the technology, acquire smarter devices, and build wireless in-frastructures into facilities, tablet and smartphone apps will become more commonplace, says Interstates’ Steenhoek.

email contributing editor Sheila kennedy, managing director of additive communications, at [email protected].



Positive displacement pumps are used in multiple industries. Users � nd them to be the solution to many pumping challenges. However, because of size, simplicity, and ruggedness, they o� en aren’t as well understood as other pump types. Technologies in the positive displacement (PD) family handle a broad range of horsepower, � uid, and pressure. � ese products merit consideration in your pump-selection process. To help you understand the de� nitions, applications, installation, operation, maintenance, and test-ing procedures, the Hydraulic Institute published 10 ANSI/HI Standards covering air-operated, controlled-volume-metering, reciprocating, and rotary PD pumps.

CENTRIFUGAL VERSUS PD PUMPSA centrifugal pump impeller moves liquid from the pump suction to a discharge, where gradually decreasing kinetic energy is converted to pressure energy. A PD pump doesn’t rely on a velocity change. Pressure rises as liquid is forced through the discharge into the system, thereby converting sha� work into pressure. An example is reciprocating mo-tion, in which a moving piston forces liquid out of a closed cylinder through inlet and outlet valves. Reciprocating pumps represent one form of PD technology. In portions of their operating range, these pumps are the single technology that can provide the pumping solution (Figure 1).

POSITIVE DISPLACEMENTFundamentals, design and applications of PD pumpsBy Hydraulic Institute PD Pump Members

ANSI/HI standards perform a vital function in pump-industry commerce and serve important roles in minimizing misun-derstandings in the marketplace. With the development of “Positive Displacement Pumps: Fundamentals, Design and Applications,” The Hydraulic Institute (HI) has extended its mission to include the development of a pump knowledge and educational portfolio in serving member companies and pump professionals. The Hydraulic Institute’s PD pump e-learning modules offer extensive materials that allow for expanded and detailed understanding of PD pump technol-ogy and applications. HI has also relaunched its centrifu-gal pump e-learning course. Material is highly visual and interactive and is designed to allow the student to take full advantage of the latest Web technology. Both fi ve-module courses are available at HI’s educational portal, www.

pumplearning.org. Each module, designed to stand alone or be combined with others, includes an examination and completion certifi cates suitable for submitting for profes-sional development hours or continuing education credit.

The website, www.pumplearning.org, is the knowledge center of the Hydraulic Institute, the largest association of pump producers in North America and the standard-setting resource for member companies and pump users world-wide. Pumplearning.org provides knowledge seekers with many resources and opportunities to gain the most current intelligence on pumps and pumping systems delivered in state-of-the-art, user-convenient, affordable formats. This user-focused website includes e-learning courses, webcasts, conferences and jointly sponsored programs with other organizations that feature recognized industry experts.

ABOUT THE HYDRAULIC INSTITUTE’S LEARNING MODULES

PS1106_36_40_pumps.indd 36 6/1/11 11:44 AM


Performance / PumPs

Rotary pumps constitute the second PD category. A rotating element inside a chamber drives the fluid. This family is distinguished by its lack of inlet and discharge valves. These are available in a number of pumping principles, each with its own features and benefits.

The third category is the controlled-volume metering pump (CVMP), often called a chemical-injection feed pump or dosing pump. These are reciprocat-ing PD pumps configured to dispense an accurate volume of liquid during a specified time period using any of several mechanisms. This pump type offers accurate, repeatable, adjustable flow rates.

PumPing solution ProductsPD pumps often are called “pump-ing solution products,” because they perform that function for applications across a range of process conditions. For example, rotary PD pumps handle viscous fluids (3 million SSU), whereas reciprocating pumps handle water-thin liquids. PD pumps handle flow rates from less than 1 gpm to 15,000 gpm and pressures from a few psi to more than 70,000 psi. It’s impor-tant to emphasize that PD pumps, at constant speed, are constant-flow de-vices, whereas centrifugal pumps are variable-flow devices. And PD system design requirements are very different from those for centrifugal pumps. For example, PD pumps require some type of pressure protection, and certain designs require pulsation control.

PD pumps can be used almost anywhere, but the generally accepted view is that more than nine out of 10 PD applications are in six industrial markets:

• oil and gas• water and wastewater treatment• chemical• food, beverage, pharmaceutical• power• marine/medical/OEM.Many of these industries are rep-

resentative of multiple markets. Oil and gas, as an example, has distinctly

extended family

figure 1. There are many types of positive displacement pumps that can find application in the plant.

’06-’07 ’07-’08Dec 14,270 14,270Jan 12,790 11,810Feb 18,970 14,050Mar 15,860 12,350Apr 14,190 10,540May 11,890 8,150 June 9,140 5,325July 9,660 5,325Aug 10,120 6,640Sept 11,346 7,100Oct 10,770 7,500Nov 13,780 10,900

5000

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Q(GPM)

Pres

sure

(PSI

)

Reciprocating

Centrifugal (Rotodynamic)

Rotary

What’s your regime?

figure 2. This chart shows the regions where the three pump technologies can function at their best.

Reciprocating pumps

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Double-acting

Double-acting

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PS1106_36_40_pumps.indd 37 6/1/11 11:47 AM


PERFORMANCE / PUMPS

di� erent applications for PD pumps across its segments: exploration, production, pipeline, processing and distribution marketing. � e food and beverage market is another market with multiple segments that include

beverage, bakery, confectionary, dairy and meat packaging.

BENEFITS OF PD PUMPSSome applications should use PD pumps and others should use

centrifugal pumps. It’s important to recognize the broad range of ap-plications in which both types could be used with selection based on the user’s desired results. Be aware of the reasons that positive-displacement pumps might be the best solution to a specific pumping problem. The reasons to select PD pumps, grouped by f luid characteristics, pressure conditions, environmental system requirements, and f low control are summarized below. Table 1 is a ma-trix of the 12 reasons compared to the primary markets of PD pumps. Some might surprise you.

High viscosity: Certain rotary technologies and air-operated piston pumps easily handle viscous f luids, whereas frictional losses degrade centrifugal pump f low rate and efficiency with f luids that have a viscosity above 500 SSU. Flow and efficiency in a rotary pump, however, typically increase with viscosity. PD pumps handle viscosities of several million SSU.

Low and variable viscosity: PD pumps, such as vane or air-operated double-diaphragm (AODD), o� en are used for thin � uids. Other liquids, such as oil, have viscosities that vary with temperature. With variable viscosity liquids, a moderately small change in viscosity can have a large ef-fect on centrifugal pump e� ciency but little e� ect on PD pump e� ciency.

Low-shear pumping: In many � uid applications, liquid shear isn’t a prob-lem; however, in some applications it is critical. PD pumps excel in the handling of shear-sensitive � uids.

Solids-handling capability: Pro-gressing-cavity pumps handling the high-solids-content sludge in a waste treatment plant and coal slurry pipelines use reciprocating pumps to handle � uids with a solids contents that can be as high as 40% by weight. You might � nd this to be a surprising PD pump characteristic, but widely varied applications serve as examples.

Multi-phase � ow: A centrifugal pump

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PS1106_36_40_pumps.indd 38 6/1/11 11:48 AM


MARKET APPLICATIONS VS. REQUIRED CHARACTERISTICS MATRIX

needs a constant source of liquid, but not all processes can provide it. With insu� cient liquid at the pump suction, a gas bubble forms, the pump loses its prime and the � uid stops.

Positive displacement pumps can handle a high percentage of air or gas entrainment.

High pressure: Beyond the range of centrifugal pumps

Reliability, durability and longevity are properties worth looking for in test equipment.Through the years Baker Instrument has been known for developing test instruments that hold up and saves money in the harshest envi-ronments. We pride ourselves in continually following that tradition and developing analyzers to provide maintenance professionals with the right tool to efficiently keep rotating electrical machinery operat-ing without downtime.As we transition to SKF durability, reliability and longevity will continue to be our focus. To obtain more informa-tion on these instruments contact us at 800/752-8272 or at our website at www.bakerinst.com.

Obtain results on efficiency estimation and torque analysis with the SKF Dynamic Motor Analyzer-EXP4000.

Verify the motor circuit and insulation with the Baker/SKF Static Motor Analyzer - AWA.

Monitor motors online from your office with the SKF Online Motor Analysis System - NetEP

Obtain results on efficiency

Slightly used workhorse

High viscosity

Low & variable viscositry

Sheer reduction

Solids handling

Multi-phase fl ow

High pressure Low fl ow Effi ciency

Sealless pumping

Self-priming

Constant fl ow

Accurate Repeatable

Oil &

Gas

Exploration • • •Production • • • • • • • •Pipleline • • • • • • • • •Processing • • • • • • •Marketing • • •Water & wastewater • • • • • • •Chemical • • • • • • • •Food & beverage • • • • • •

Powe

r

Thermo & hydro • • • • • •Diesel • • • • • •General Industrial • • • • • • • • • • • •

Table 1. These are the pump-application characteristics that prompt specifi c industries to select positive-displacement pumps.

PS1106_36_40_pumps.indd 39 6/1/11 11:48 AM


PERFORMANCE / PUMPS

are many chemical, sandblasting and high-pressure water-cutting applica-tions in which PD pump technology dominates. Figure 2 provides an over-view of the pressure and capabilities among pump technologies.

Low � ow: PD pump technology eas-ily handles � ows below 100 gpm and pressures greater than 200 psi.

E� ciency: For viscous � uids that PD and centrifugal pumps can handle, the positive-displacement option o� en can

be 10 points to 40 points more energy-e� cient than the centrifugal pump.

High pressure, low � ow, e� ciency demand: Any of the previous three individual characteristics are reason enough to use PD pumps. But, if the application features all three simul-taneously, the PD pump solution becomes the obvious choice.

Sealless pumping: Magnetic drives and canned motor pumps, which have no sha� seals, are available for PD pumps. Other designs that have no sha� penetration include peristaltic and diaphragm pumps.

Self-priming: � e PD pump’s abil-ity to self-prime is useful because it allows � exibility in system layout and eliminates the need for suction-prim-ing systems. PD pumps aren’t only self-priming, they also have excellent suction li� capabilities (raising liquids on the suction side) and are capable of drawing down to near vacuum.

Constant � ow/variable pressure: At a constant speed, PD pumps deliver nearly constant � ow, even if the system pressure varies, which is a desirable condition in certain systems.

Accurate, repeatable measurement:Because a PD pump is a constant-� ow device, designs that limit slip are use-ful for metering � uids into or out of systems. � is application, of course, requires accuracy and repeatability. It might also need � ow variation, which typically is obtained mechanically or electronically by speed variation.

� ere’s a universe of standard positive-displacement solutions in ad-dition to the baker’s dozen described in this article.

Because these pumps also must meet many other requirements, manufac-turers provide products with special options, such as jacketing, non-corrosive materials and built-in pressure relief valves, to name a few. Some PD units have duty-cycle limits that users should investigate. It’s important to note PD pumps are constant-torque devices. In variable-speed applications, VFDs must be rated with that understanding.

Time is money. And managing your own small parts inventory is costing you both. Most companies spend 50% of their time managing less than 10% of their spend. At Barnes Distribution, we’ll help you drive out cost and drive in productivity. As a leading full-service distributor of maintenance, repair and operating supplies, we’ll deliver a total solution that extends far beyond nuts and bolts.

By bringing you more than 1,000 sales and service employees, over 55,000 parts and supplies and a custom designed managed inventory services program, we’ll help your operation run fast, smooth and efficient.

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PS1106_36_40_pumps.indd 40 6/1/11 11:50 AM


Selecting the best accelerometer for a speci� c predictive maintenance application can be a daunting task, even for the most seasoned walk-around warrior. � e process typically can be � ltered down to a series of nine qualifying questions. By discovering the answers to the following nine questions, as it applies to your personal application, you’ll be able to � nd the best vibration monitoring solution.

QUESTION 1: WHAT DO YOU WANT TO MEASURE?� is might seem obvious at � rst, but stop for a second. What are you actually trying to measure? In other words, what are your goals? What are you expecting to get? What are you going to do with the data? Vibration can be monitored with accelerometers that provide raw vibration data or transmit-ters that provide the calculated overall root mean square (RMS) vibration. Analysts � nd raw vibration readings to be useful because it contains all the information in the vibra-tion signal, the true peak amplitudes and vibration frequen-cies. � e overall RMS or peak values are useful in control

systems such as PLC, DCS, SCADA, and PI because of their continuous 4-20 mA signal. Some applications use both. By determining which signal variety is required for your ap-plication, you can narrow your search signi� cantly. Also, are you measuring vibration in terms of acceleration, velocity, or displacement? Have you considered that some industrial sensors can output temperature along with vibration? Lastly, some applications, such as vertical pumps, ideally are moni-tored in more than one vibration axis. Does your application require uniaxial, biaxial, or triaxial measurement?

QUESTION 2: WHAT IS THE VIBRATION AMPLITUDE?� e maximum amplitude or range of the vibration be-ing measured determines the sensor range that can be used. Typical accelerometer sensitivities are 100 mV/g for a standard application (50 g range) and 500 mV/g for a low-frequency or low-amplitude application (10 g range). General industrial applications with 4-20 mA transmitters commonly use a range of 0-1 in./sec or 0-2 in./sec.

QUESTION 3: WHAT IS THE VIBRATION FREQUENCY?Physical structures and dynamic systems respond di� erently to varying excitation frequencies. A vibration sensor is no di� erent. Piezoelectric materials, by nature, act as high pass � lters, and, as a result, even the best piezoelectric sensor will

COME TO YOUR

SENSORSBy Frank Pereny, BSME, IMI Sensors

Find the right vibration device

like an arrow fi nds its bull’s-eye

PREDICTIVE TECHNOLOGIES / RELIABILITY

THE MAXIMUM AMPLITUDE OR RANGE OF THE VIBRATION BEING

MEASURED DETERMINES THE SENSOR RANGE THAT CAN BE USED.

PS1106_41_44_Vibration.indd 41 6/1/11 11:04 AM


Predictive technologies / Reliability

have a low-frequency limit near 0.2 Hz. A sensor that acts as a dynamic system with one degree of freedom exhibits natu-ral frequencies. The signal is greatly amplified at the natural frequency, leading to significant change in sensitivity and possible saturation. Most industrial accelerometers have single- or double-pole RC filters to combat saturation excita-tion at the resonant frequency. It’s critical to select a sensor with a usable frequency range that includes every frequency you’re interested in measuring.

Question 4: What is the environment temPerature?Applications with extremely high temperatures can pose a threat to the electronics built into accelerometers and 4-20 mA transmitters. Charge-mode accelerometers are available for use in very high temperature applications. These have no built-in electronics, but instead have remote charge ampli-fiers. Charge-mode accelerometers with integral hard-line cable are available for applications hotter than 500° F, such as gas turbine vibration monitoring.

Question 5: Will it be submersed in liQuid?Industrial accelerometers with integral polyurethane cable are completely submersible in liquid for permanent installa-tion. For high-pressure applications, it’s a good idea to test the sensors at pressure for one hour. Applications requiring complete submersion need integral cable. Integral cable is normally required as well if the application is sprayed rather than being completely submersed, such as cutting fluid on machine tools.

With Lutz throughthick and thinLutz B70V-Series progressive cavity pumps are available for high viscousproducts up to 60,000 cps, with capacities up to 30 gpm. EX models available.

Extensive 24 page catalognow available.

Please contact us for more information.

Lutz Pumps, Inc.1160 Beaver Ruin Road · Norcross, GA 30093-4898Phone: (770) 925-1222 · Tollfree: (800) 843-3901 · Fax: (770) 923-0334w w w . l u t z p u m p s . c o m · e - M a i l : i n f o @ l u t z p u m p s . c o m

14,000

12,000

10,000

8,000

6,000

4,000

2,000

0

Jan

Feb

Mar Apr

May Jun Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar Ap

r

May Jun Jul

Aug

Sep

Oct

Nov

Dec

Sensitivity Plot

Sensitivity Plot

Data Points

Data Points

Temperature: 66°F (19°C)

Temperature: 72°F (22°C)

Relative Humidity: 41%

Relative Humidity: 50%

202.8

150

100

50

06 10 100 1,000 12,000

mV/

gdB

CPM

CPM

’06-’07 ’07-’08Dec 14,270 14,270Jan 12,790 11,810Feb 18,970 14,050Mar 15,860 12,350Apr 14,190 10,540May 11,890 8,150 June 9,140 5,325July 9,660 5,325Aug 10,120 6,640Sept 11,346 7,100Oct 10,770 7,500Nov 13,780 10,900

5000

7500

10000

12500

15000

17500

20000

5000

7500

10000

12500

15000

17500

20000

x

x

obvious difference

figure 1. the upper plot corresponds to a low-cost accelerometer that was calibrated at one point, while the lower plot, with its continuous calibration line, corresponds to a higher-cost unit.

frequency (cPm) dev.(%)

frequency (cPm) dev.(%)

600 2.3

900 2.3

1800 1.4

3000 0.8

ReF. FReQ. 0.0

18000 -0.1

30000 -0.8

60000 -1.4

180000 -0.4

240000 0.9



Question 6: Will it see harmful chemicals or debris?Industrial accelerometers can be constructed with corro-sion- and chemical-resistant stainless steel bodies. Consider using PTFE cable with corrosion-resistant boot connectors if your application is in an environment with harmful chem-icals. It’s strongly recommended that you check a chemi-cal compatibility chart for any suspect chemicals. Integral armor-jacketed cables offer excellent protection for cables that might come into contact with debris such as cutting chips or workers’ tools.

Question 7: a precision or loW-cost sensor?There are two main differences between low-cost and preci-sion accelerometers. First, precision units typically receive a full calibration, that is, the sensitivity response is plotted with respect to the usable frequency range. Low-cost accel-erometers receive a single-point calibration and the sensitiv-ity is shown only at a single frequency. Second, precision accelerometers have tighter tolerances on some specifica-tions such as sensitivity and frequency range.

For example, a precision accelerometer (Figure 1) might have a nominal sensitivity of 100 mV/g ± 5% (95 mV/g to 105

mV/g), while a low-cost accelerometer might have a sensitivity of 100 mV/g ± 10% (90 mV/g to 110 mV/g). Customers with data acquisition systems often will normalize the inputs with respect to the calibrated sensitivity. This allows a group of low-cost sen-sors to provide accurate, repeatable data. Regarding frequency, a precision accelerometer typically has frequency ranges in

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multidirectional

figure 2. This is an example of a low-profile accelerometer with a side connection to jacketed cable.



which the maximum deviation is 5% while low-cost sensors might offer a 3 dB frequency band. Even so, a low-cost sensor might offer excellent frequency response.

Question 8: top or side exit, low-profile connection?Ultimately, the sensor will need to be installed on equipment in the space available. Sensor geometry has little effect on

its performance, but consider factors such as space available and where a maintenance engineer can operate safely. A low-profile accelerometer (Figure 2) with a locknut design allows them to be oriented in any direction, which can be helpful when working with integral cable.

Question 9: do you need special approvals?Accelerometers and 4-20 mA transmitters are both available

with CSA and ATEX approvals for use in hazardous areas. Compare the type of approval needed with the sensor’s pub-lished approvals to ensure it meets your needs.

The answers to these nine questions can greatly narrow your search to the best solution for the application.

Remember to keep in mind that some combination of answers might be mutually exclusive, that is, a solution for each

criteria doesn’t exist. For example, a particular model might not carry the proper ATEX certification for your hazardous area application. Additionally, specialized applications might have other considerations.

frank pereny, BsMe, is an application engineer for iMi sensors (www.imi-sensors.com). He can be reached at [email protected] and (800) 959-4464.

Receive Training Schedule UpdatesEmail: [email protected] call: 1-877-978-7246 and mention ‘Plant Services’

www.AmericanTrainco.com© 2011 American Trainco, Inc.

Training for Industrial, Facility and Building MaintenanceTraining for Industrial, Facility and Building Maintenance

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predictive tecHnologies / Reliability

sensor geoMetry Has little effect on its perforMance, But consider factors sucH as space availaBle and wHere a Maintenance engineer can operate safely.



product roundup

At your plant, as at others, electric motors and drives are probably the most widely used devices. Motor-driven equip-ment accounts for the majority of electricity consumed in U.S. manufacturing. They truly are our industrial workhors-es. And they are husky. Advanced Energy’s motor testing laboratory concluded that motors can ride through many momentary power interruptions without risking damage, thereby contradicting a commonly held belief.

Three-phase voltage imbalance at the service entrance is another story. Voltage imbalance degrades motor efficiency and is arguably the main cause of overheated windings and premature failure, and it’s likely that quite a few such con-nections are unbalanced. Although there’s not much you can do about conditions outside the battery limits, if the imbalance originates in-house, you can fix it.

Motor controls, on the other hand, can be more sensitive. It takes skilled people to troubleshoot and repair them. As we know, drive technology evolves, so training on that front is essential to keeping your technicians current. Relying only on the idea of on-the-job training might mean a techni-cian needs more than 10 years to gain full competency. In any case, build a good paper trail. It’s good documentation that will set you up for continuous improvement.

Don’t let failures determine what kind of day you’re go-ing to have. The only drive maintenance that makes sense is PdM or condition-based maintenance, both of which let you spot incipient failures early enough to have your plan in place. Consider up-front brainstorming to develop a list of ranked failure modes and an idea of how you’re going to know they’re on the horizon. Then, monitor, monitor, moni-tor, and follow through with effective communications.

Build momentum and document your successes at energy reduction initiatives using KPIs that have hard numbers and report them to management. They need to know. And it’s your motor-and-drive knowledge database that is going to be a key element in this effort. It brings meaning to the data and information needed for an effective program.

Once you select a compatible supply, drive, motor, and power conditioning hardware, enjoy the benefits by main-taining its efficiency and reliability. Remember, motor repair costs are nothing compared to downtime costs. Purchasing quality motors, drives, and repairs has a long-term payoff. Formulate a plan and commitment to replace inefficient mo-tors with better units that will save money.

Ac induction tEFc motorsQuantum LMV AC induction TEFC motors are designed for petrochemical, power, mining, and process industry pumps, blowers, compressors, and con-veyors. These motors meet NEMA, IEEE 841, IEC, CSA, API 547 and 541 4th ed., Div 1&2, ATEX and IEC Ex-n Zone 2 standards. The motors feature lower-than-IEEE-specified vibration levels, improved airflow, and low noise levels (< 88 dBA at 3,600 rpm standard, < 85 dBA low-noise option).GE(800) 541-7191 / www.gemotors.com

motors with shAFt GroundinGto prEvEnt bEArinG dAmAGEThe Super-E motors with AEGIS Shaft Grounding Rings are designed for end users looking for ways to prevent bear-ing damage caused by adjustable speed drive-induced currents. While most shaft ground applications use a shaft ground

on the outside of the motor, these have the grounding ring installed internally on the motor. This design is engineered to minimize exposure to the outside elements and keep the ground from being exposed to external forces that might damage the grounding ring. The line is stocked from 1-50 hp, 143T through 326T, in TEFC or ODP enclosures.baldor(479) 646-4711 / www.baldor.com

motors comply with EisA rEGulAtionsThis NEMA Premium line of motors is designed to help reduce energy consumption and comply with EISA regulations. This line features open drip-proof and totally enclosed motors that meet or exceed NEMA Premium requirements. They carry a nameplate includ-ing both 50 Hz and 60 Hz operating data, a NEMA Premium trademark, and European IE efficiency marks. A line of vertical motors will be available at premium efficiency levels. The NEMA Premium line also complies with pending Canadian and Mexican standards for use in North American facilities.nidec motor(888) 637-7333 / www.nidec-motor.com

don’t lEt motor FAilurE ruin your dAyuse predictive or condition-based monitoring to avoid downtime

PS1106_45_47_ProdRndUp.indd 45 5/27/11 2:32 PM

TENV aNd TEFC pErmaNENT-magNET moTorsIronHorse permanent-magnet DC 56C-frame motors feature TENV and TEFC models. They have rolled steel frames with cast aluminum end bells and are available from 0.33 hp to 2 hp. They’re designed for unfiltered SCR-type rectified AC. They can be used with PWM-type DC adjustable-speed drives. Features include linear characteristics, high starting torques, reversible rotation, and dynamic braking. Large brushes pro-vide for longer brush life. The motors are shipped with a set of brushes in the motor, with an extra set included in the box.automationdirect(800) 633-0405 / www.automationdirect.com

sErVomoTors dEliVEr grEaTEr TorquE dENsiTy

AKM 8 servo motors provide higher torque density using potted windings

and a one-piece housing that’s 30% shorter. Available in two flange/shaft combinations, the windings can oper-

ate at 230, 400, and 480 VAC. The motors have Class F insulation and provide stall torque from 75 Nm to 180 Nm, speeds to 2,500 rpm, and power to 19.8 KW, with bearing lifetime rated at 20,000 hr. The motors are RoHS and REACH-compliant and UL-listed, and carry the CE mark. High-resolution feedback options are available.Kollmorgen(540) 633-3545 / www.kollmorgen.com

ExplosioN-prooF moTorsThis line of XP100 motors are UL and CSA listed for gas and dust ignition-proof environments and are suitable for Division 1, Class I, Groups C & D, Class II, Groups F & G, hazardous area classifications. They’re also available for drill rig duty in Division 1, Class I, Group D hazardous loca-tions. Their designs are engineered to meet or exceed NEMA MG1 — Table 12-12 requirements. They have ratings from 1 hp through 300 hp and are modifiable. The design has cast-iron construction, epoxy enamel paint, polycarbonate cool-ing fan, non-hygroscopic insulation, and corrosion-resistant hardware. The motors are resistant to voltage spikes.siemenswww.usa.siemens.com/industry

modular moTor sysTEmThe DR motor modular system offers millions of drive combina-tions. Users specify the options needed. The coating and sealing options protect the motors in wet environments. The variety of sensor and feedback options for speed, position, and brake wear are suited for control systems. Modular brakes, encoders, and other options make retrofits and other field adjustments simple and fast. The DR motor comes in three efficiency levels. In addition, the motors also offer other customizable options, including brake size, cost-optimized encoders, and mounting type.sEW Eurodrive(864) 439-8792 / www.sewmotortruth.com

liNEar driVEs WiTh shaFT sCrapEr/grEasEFiTTiNg

The Uhing linear drives have shaft scrapers/grease fittings to remove grease, dust, and dirt from the shaft while the drive is running. The scrap-ers can be used alone, but the combination is recom-mended for fast, heavy-usage

applications. The scraper is a rubber O-ring in a Delrin fitting, one on each end bushing. When equipped with the grease fitting, a felt wiper ring wicks oil out of the grease and applies a thin oil film to the shaft as the drive runs.amacoil(800) 252-2645 / www.amacoil.com

aC VFd WiTh sENsorlEss VECTor CoNTrolThe L700 Series of VFDs uses a control algorithm that develops 150% torque at 0.5 Hz. A built-in programming func-tion provides the functionality of a PLC built into the inverter. The drive offers micro-surge voltage suppression, trip avoidance, configurable logic on digital inputs, built-in dynamic braking in models to 30 hp and built-in EMC filter in models to 200 hp. It features built-in communication options and can be con-figured via the front-mounted keypad.hitachiwww.hitachi-america.us / (800) 448-2244


produCT rouNdup



Shaft grounding bearing iSolatorThe SGi isolator is designed to protect bearings from electrical, lubricant loss, and contamina-tion damage. It diverts currents to ground, bypassing bearings and extending motor life. Circumfer-ential conductive microfibers are engineered for flexibility to prevent breakage. It provides an IP56 non-contact isolation seal designed to withstand dust and jetting liquids at temperatures from –22° F to 300° F. The unit is available for motor-shaft sizes ranging from 0.875 in. to 6 in. in flanged, flangeless, and custom configurations. garlock Sealing technologies(315) 597-3362 / www.garlock.com

Motor lead diSconnectSThe Color-Keyed Kube motor lead disconnects are snap-together connectors that are designed to eliminate the need to cut through insulating tape, as well as disas-sembling the typical connection from pad to pad. Simply crimp the disconnects onto the cables and plug them together. To disconnect

or de-energize, just cut the cable ties, slip off the boots, and unplug the disconnects. They’re color-coded to ensure se-lecting the correct crimping die and are available for 600-V applications and wire sizes from 16 AWG to 500 kcmil.thomas & betts(800) 816-7809 / www.tnb.com

two-Speed driveS offer high turndown, high torqueUse the Two-Speed Drive for applications to 30 hp that require secondary speeds as low as 60:1. High- and low-speed modes are selected by energizing the appropriate electrically con-trolled coils. Spring-set braking stops the drive. The design is engineered to provide internal surge suppression, stan-dard electrical connections and modular assembly designs. The drives are suitable for standard NEMA motor mounting and are available for a range of gear ratios. force control industries(513) 868-0900 / www.forcecontrol.com

StainleSS Steel MotorSThese motors are engineered for washdown applications. Construct-ed with 300-series stainless housing, end bells, output shaft, and conduit box, they’re UL/ULc certified and conform to 2007 EISA efficiency standards. All have Class F insulation, Class B rise @1.15 service factor, and encapsulated windings. Bearings are engineered to eliminate axial movement. Other features include shaft seals, O-rings between end bells and housing, and a smooth exterior with no mounting feet. The motors are totally enclosed and are available in sizes from 0.5 hp to 3 hp in fan-cooled and non-ventilated models.boston gear(888) 999-9860 / www.bostongear.com

driveS for variable torque applicationSThe VLT Automation VT Drives are engineered to save energy with fans, pumps, blowers, and compressors. They’re available for 240 and 480 VAC single- and three-phase, or 575 VAC and 690 VAC three-phase operation with 1/2 hp to 1,400 hp. They have an ambient tempera-ture rating of 50° C without derating. Integral main disconnects and fusing reduce panel space requirements. These drives provide autotuning of PI control-

lers, and password protection reduces the potential for unauthorized changes to the settings.danfoss drives(800) 432-6367 / www.danfossdrives.com

drive can be the heart of a control SySteMThe Altivar 32 variable-speed drive has a book-style design and ability to attach a self-protected disconnect in tight spaces. The drive can perform functions usually managed by a PLC and without encoder feedback with asynchronous or synchronous AC motors. A conformal coating protects circuit boards. It has embedded Bluetooth technology for monitoring, viewing, and performing diagnostics with the cabinet closed. It includes standard RJ45 connectors for Modbus and CANOpen networks, and on-board HMI and navigation wheel for adjustments.Schneider electric(847) 397-2600 / www.schneider-electric.us



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3 risks that determine energy costsare you looking through a crystal ball or a rearview mirror?

most organizations are still using a rearview mirror to manage energy risks, when increasingly they should be reaching for the crystal ball. The true cost of energy in a plant comes from three main areas of risk. The first and most obvious risk is the energy operating cost, itself a combination of energy unit price and efficiency. The second is the cost of production disturbances through energy sup-ply interruptions or poor supply quality. The third is the

impact on operating costs to comply with energy-related environmental legislation, or even the actual cost to manage environmental impacts.

On costs, the backward-looking version assumes mod-est, predictable price increases, where any volatility is short-lived. This is the backdrop against which efficiency investments are judged, resulting in the majority failing the attractiveness test. On supply quality, the past experience of reliable, predictable supply with minimal interruptions is so much part of the decision making, that the possibility that this might change is rarely even considered, along with the possible investments that could mitigate supply disturbance.

Clearly, on environmental legislation, the possible game changer is around climate change, and in North America the rearward view assessment is that this will be forever stalled in lawmaking debate. Mitigating the actual risks from climate change itself in the form of more frequent and severe weather events, with possible disturbances to suppliers, customers, and the site itself are rarely factored. Both these aspects of environmental risk are also highly colored by the views of decision makers around the validity of human-induced climate change.

The rearview mirror version results in energy manage-ment that incrementally, but modestly, improves efficiency, resists new technology that could create deep energy gains, and rarely has resilience to unexpected price, supply, or legislative shocks.

If we now reach for the crystal ball, the future energy

world now looks increasingly uncertain. The events of the past few months in North Africa, the Middle East, and Japan have further clouded the picture.

The events in Japan at the Fukushima Dai-Ichi reactor are an interesting crossover between energy growth, cost, and climate change. As much of the world saw a need for low-carbon energy at a time when China, India, Brazil, and others were growing fast, nuclear power was in resurgence as the only viable approach. This is now being reconsid-ered, delayed or halted with the long-term outcome highly uncertain. A rethinking of the nuclear area will inevitably position natural gas as the next lower-carbon fuel of choice on the strategic list. Can any of us predict the impact of a strategic rethink like this on price and availability of both electricity and natural gas?

The events in North Africa and the Middle East also are potential game changers, and, as is so often the case with energy, not unrelated. Much of the world’s proven reserves of natural gas are in these regions. If the world market shifts to natural gas as a fuel of choice for electricity, will these resources be available as a result of the social and political upheavals and even the physical damage to infrastructure.

The continuing concerns over climate change are some-what muted in the United States at present, but still very loud on a worldwide basis. The speed and scale of installa-tion of renewable sources is growing rapidly, driving down prices, increasing reliability, and accelerating the develop-ment of grid technology to manage these sources. As they become mainstream, what does this do for their potential inclusion in a plant’s operating considerations? It doesn’t take a wizard to see this is a part of the puzzle on rethinking the role of nuclear power, as well.

Some customers increasingly demand evidence of good sustainability practices from their suppliers, many of which relate directly to energy management, another factor un-known from the rearview mirror.

Have we collectively moved our energy investment habits to take into account not only the incremental benefits of good energy housekeeping, but also the multiple backup plans needed as the future uncertainty plays out? It’s still the minority who are using the crystal ball.

Peter garforth is principal of garforth international, toledo, ohio. he can be reached at [email protected].

energy exPertpeter garforth

the backward-looking version assumes modest, Predictable Price increases, where volatility is short-lived

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Plant Services June 2011

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