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Sustainability at Volkswagen / p.11

Take Your Lube Practices to a Higher Level / p.21

Does Your CMMS Suffer From TMI? / p.37

U.S. Army Battles Waste and Emissions / p.50

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WWW.PLANTSERVICES.COM MARCH 2012 5

22 / COVER STORY

Wrench Time by DesignPlant upgrades are

opportunities to bring

engineering and maintenance

departments together

30 / COMPRESSED AIR SYSTEMS

Central or Departmental Air System?Size and confi gure air piping

for the right fi t

37 / ASSET MANAGEMENTSOFTWARE

Too Much Information — Part IIWork breakdown structure in

CMMS can streamline project

cost tracking

41 / MOTORS AND DRIVES

More Torque, Less MoneyFewer components give worm-

gear reducers a single-stage

advantage

44 / PRODUCT ROUNDUP

Thermal TechnologiesResources support HVAC and

combustion processes

FEATURES

SPECIALISTS

COLUMNS AND DEPARTMENTS

9 / MR. SUSTAINABILITY

Stale Fixed CostsCan Spoil Profi tsHow long ago were energy

costs baked into your

overhead?

15 / HUMAN CAPITAL

Step Up to The PlateRethink reliability in terms

of your equipment’s on-base

percentage

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Confi guration Without CustomizationModify software with no

expense or risk

21 / TECHNOLOGY TOOLBOX

Well-Oiled Testingand TrainingFormulations are just part of

lubrication improvements

50 / ENERGY EXPERT

Wage War onEnergy ImpactThe U.S. Army recognizes the

value of net-zero waste, water,

and emissions

7 / FROM THE EDITOR

Call Me RockheadedShould I be worried that the

Cloud can read my mind?

11 / WHAT WORKS

2 cleaning system

reduces environmental

impact and reject rates

48 / CLASSIFIEDS / AD INDEX

TABLE OF CONTENTS

apply for qualifi ed-reader subscriptions, please go to www.plantservices.com. To non-qualifi ed subscribers in

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

responsibility for validity of claims in items published.

Economy in Confl ict: Sustainability Vs. Consumerism Is the economy suffering from the effects of a contradiction?

http://community.plantservices.com/content/economy-confl ict-

sustainability-vs-consumerism

Supplies at Work: Automating a Lead and Zinc Processing Plant and More

Honeywell to deliver control and safety system for Australia

http://community.plantservices.com/content/supplies-work-auto-

mating-lead-and-zinc-processing-plant-and-more

You Know Dust Collectors, but Do You Know TCO?These three steps will help you calculate total cost of ownership.

http://www.plantservices.com/wp_downloads/Camfi ll-Farr-dust-

collector-fi lter.html

Plant Maintenance and Reliability Strategies WebinarJoin Plant Services editors and industry experts as we engage

in lively discussions about hot topics challenging today’s

manufacturing plant.

http://webcast.streamlogics.com/audience/index.

asp?eventid=53496950

PS1203_XX_TOC.indd 5 2/29/12 11:19 AM

Put a lid on energy waste

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

Hi, I'm Bob, Senior Marketing Support Specialist at Atlas Copco Compressors. For the last 38 years,I've been part of the team taking care of our valued customers in the United States. Today, let me tellyou how Variable Speed Drive technology represents a great value proposition for your production.

All across the globe, customers are compressing air that just goes to waste. Energy can representover 80% of a compressor’s lifecycle cost and generating compressed air can account for more than40% of a plant’s total electricity bill. Most production environments have a fluctuating air demanddepending on the time of day, week or even month. So put a lid on those energy costs with AtlasCopco’s VSD technology that mirrors air usage, automatically adjusting the motor speed dependingon the demand, making major energy costs savings a reality while helping to protect the environmentfor future generations.

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

PS1203_FPA.indd 6 2/29/12 11:23 AM

FROM THE EDITORMIKE BACIDORE, EDITOR IN CHIEF


CALL ME ROCKHEADEDShould I be worried that the Cloud can read my mind?

As we leave February in the rearview mirror and speed headlong into March, let’s check the GPS, or, better yet, ask Siri where we’re headed. Siri is an application that works on Apple’s iOS. But it is so much more than just another app.

Siri is the automated intelligent per-sonal assistant whose help is there for the asking. It understands your natural speech and will even ask you for more information, if necessary. You’ve seen and heard the ads on TV — “From now on, I’ll call you Rock God, OK?”

When you receive information from Siri, you also share information with Siri, just like you would a real personal assis-tant. Siri knows all. And, because Siri ex-ists in the Cloud, it grows smarter by the second, pooling and analyzing data from all users and giving it an almost Borg-like collective intelligence. Resistance is futile. You will be assimilated.

Th e information superhighway is paved with technology and driven by data, but ideas on where we’re going are far from road-tested. My favorite place to kick the tires on informed specula-tion and bankable prediction is at the ARC World Industry Forum. Almost 700 individuals from 21 countries at-tended. Andy Chatha, president and CEO of ARC Advisory Group (www.arcweb.com), began the conference with his annual assessment of what’s impor-tant. Th is year, he identifi ed the top four transformational technologies — social media, analytics, the mobile Internet, and cloud architecture.

“Th ese are no longer consumer technologies,” he explained. “Th ey have matured to the point where you can use them across the enterprise.”

Social media means being always con-nected with faster response and immedi-ate access to experts. Analytics are now

much easier to use. Th ey can now run in seconds, instead of days. And the strug-gle or challenge with the mobile Internet is in managing all of the devices. “Th ere are now more mobile devices than there are people on this planet,” said Chatha.

His cloud architecture is a bit less ambitious than that of the Borg, but for good reason. Industrial manufacturers are interested in production effi cien-cies. Th e architecture would include, for

example, an E&D applications platform and an operations applications platform within an enterprise applications plat-form, explained Chatha.

John Berra, former chairman of Emerson Process Management (www.emersonprocess.com), shared a real-world application of the concept, when he explained how one company reduced its total maintenance costs by 30% from using the predictive intelligence it had collected from 27 plants in its own pri-vate cloud.

Road-tested? Yes. Driven by data? Ab-solutely. Transformational? You betcha.

Th e path to manufacturing profi tabil-ity is a winding road that is best seen and understood from the bird’s-eye view. Th e more information we’re able to analyze, the smarter our maintenance strategies become. Surrender your data.

Resistance is futile.

“THERE ARE NOW MORE

MOBILE DEVICES THAN

PEOPLE ON THIS PLANET.”

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 STAFF

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]

ANGELA LABATEAssociate Art [email protected]

DAVID BERGER, P.ENG. Contributing Editor

PETER GARFORTH Contributing Editor

SHEILA KENNEDY Contributing Editor

TOM MORIARTY, P.E., CMRP Contributing Editor

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 Chief

[email protected], (630) 467-1300 x444

PS1203_XX_EV.indd 7 2/29/12 11:25 AM

PS1203_FPA.indd 8 2/29/12 11:27 AM

STALE FIXED COSTS CAN SPOIL PROFITSHow long ago were energy costs baked into your overhead?

I had lunch again the other day with a childhood friend, a tool and diemaker who’s worked his way up and is now quoting jobs for his multinational metalworking company. He said the poor economy has driven smaller, specialized mom-and-pop shops out of business, and he’s bidding on quite a few exotic new jobs. He’s seeing more requests for quotes on familiar kinds of work as demand is picking up.

With plants here and in Mexico and China, he has options for how and where to plan the work. Along with stellar qual-ity and service, he expects to have the lowest cost, but he’s surprised by reality. “Some competitors are beating us on price,” he told me. “I don’t know how they can do it.”

We talked about how and why some companies might take a job at a loss. And we acknowledged that any company can have a costing structure that misleads them about the margin on a specific part, causing them to think they’re making money on it when they’re not. Then, I asked him how well his company is paying attention to overhead items such as insurance and energy. He knew they’d done some work on the air compressors, but overhead isn‘t really in his area of responsibility.

His facility might have a better handle on its fixed costs, but it’s still not uncommon for even successful — perhaps especially the most successful — facilities to be complacent about overhead. If those successful companies have been in business a long time, they’re likely to have energy costs baked into that overhead, where they’re easy to ignore.

Some plants ignore energy costs until it’s too late. As Bill Holmes, owner of Holmes Energy (www.holmesenergy.com) observed, it’s a bad idea to wait until your plant is on the chopping block before you go after energy opportunities.

For example, participating in demand response gives electric power users an opportunity to save cash with little or no investment. But only about 20% of the market for load shedding signed up.

Time-of-use rates are cited as an advantage of smart grid, so I asked Gregg Dixon, senior vice president, EnerNOC (www.enernoc.com), if broader acceptance of automated load shedding is waiting for a consensus on smart grid standards.

Not at all, Dixon told me. “Today, we can put in a site server — an industrial PC with UPS and a wireless broad-band modem — and connect it to the building management system or plant SCADA with a dry contact or Ethernet,” said Dixon. “The site server is connected to our energy network

operations center (EnerNOC), and the software automati-cally curtails the load, for example, by raising the HVAC set-point, turning off lights, or shutting off non-critical loads.”

The operations center monitors the curtailment to see that it performs according to the commitment and then bills the power company. “It’s not rocket science,” said Dixon.

That sounds OK for a college campus or a shopping mall, but what about industrial facilities, I asked, where the main loads are critical for production? EnerNOC has a number of clients, including a steel mill that can turn off arc furnaces. “If you schedule it properly, it’s just like scheduling produc-tion, with two-hour notification or whatever is needed to not compromise safety or productivity,” said Dixon.

EnerNOC employs process experts, including refinery and chemical engineers, wastewater, and refrigeration techni-cians. “We know their operational sensitivities,” said Dixon. “We know what to look for. We sit down with plant person-nel and talk about the options, and we almost always find loads that can be curtailed.”

Along the way, they often find energy efficiency and peak load trimming opportunities plants can exploit 24/7, not just during a demand response event. “We call demand response ‘the skeleton key to energy efficiency,’” said Dixon.

EnerNOC’s consulting and system installation are done at no charge to the industrial facility.

Dixon said that, so far, demand response penetration is only about 20% of the opportunity. “We estimate there’s about 80,000 MW available, and about 16,000 MW has been done,” he said.

Say 20% of companies are spending less for electricity. That means, all else being equal, one plant in five can quote a lower price and still get their margin on a new job.

Email Paul Studebaker, editor in chief of Sustainable Plant

(www.sustainable plant.com), at [email protected].


PAUL STUDEBAKER, CMRP

MR. SUSTAINABILITY

IT’S STILL NOT UNCOMMON FOR EVEN

SUCCESSFUL — PERHAPS ESPECIALLY

THE MOST SUCCESSFUL — FACILITIES

TO BE COMPLACENT ABOUT OVERHEAD.

PS1203_09_MRSUSTAIN.indd 9 2/29/12 11:32 AM

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Less is more. Volkswagen Plastics Technology in Braun-schweig, Germany, started using a single-layer painting system for an interior component. The process reduces the consumption of resources and emissions. However, the painting system demands an absolutely clean, residue-free surface. This has been achieved with a dry CO2 snow jet cleaning technique designed to be gentle on materials.

CLEANLINESS

Every day, Plastics Technology processes approximately 45 tons of material to manufacture injection-molded parts. About 450 interior components of different colors are produced and installed into various passenger vehicles around the world. Some of the injection-molded parts have a high-gloss finish and can be installed without needing to be coated. One of the latest vehicle models is fitted with a high-gloss panel made from acrylonitrile-butadiene-styrene, polycarbonate (ABS-PC) blend, which is subsequently paint-ed with a semi-transparent high-gloss metallic paint. “This paint is applied to the component as a single layer without an undercoat, so the surface has to be flawless,“ explains Uwe Strauss, painting systems/plastics technology planning at the Braunschweig plant. “The tiniest dust particle or water mark would cause rejects. Therefore, we needed a cleaning solution that is efficient, is gentle on materials, and guaran-tees consistent results.”

CO2

SNOW

The classic alternative — wet-chemical cleaning witha powerwash system —was rejected for reasons of cost-effectiveness and sustainability. Due to its high space requirements, it would have been impossible to install such a cleaning system upstream of the paint shop. In tests with conventional dry-ice cleaning systems, the coarse ice pellets damaged the sensitive surface of components. The CO2 snow jet process from Advanced Clean Production (ACP, www.acp-micron.com) gave Volkswagen an alternative. “We told one of the company’s employees about what we needed,“ recalls Strauss. “It wasn’t long before we were sent a pro-posal and tests confirmed that we could achieve optimum

cleaning results with the process.” With the CO2 snow jet technique, liquid carbon dioxide is used instead of dry-ice pellets. Carbon dioxide gas is a by-product from a variety of manufacturing processes in the chemical industry; it is environmentally neutral and gentle on resources.

RESIDUE-FREE

The modularly constructed CO2 snow jet system achieves its cleaning power via the supersonic two-component ring nozzle integrated into the compact cleaning head. Liquid carbon dioxide is guided through the nozzle and expands on exit to form a mixture of snow and gas. Oil-free com-pressed air accelerates the non-toxic, non-combustible CO2snow crystals to supersonic speed. When the jet impacts on a surface, the snow crystals liquefy and sublimate. The sublimation impulse causes any particulate contamination present to detach and be carried away. In the liquid phase, carbon dioxide acts as a solvent that removes organic con-tamination. At the same time, the low degree of hardness of the snow crystals ensures gentle and reproducible cleaning results on the high-gloss surface. “We carried out test series with other components made of different materials,“ reports


WHAT WORKS

CARRIED-AWAY CONTAMINATIONCO

2 cleaning system reduces environmental impact and reject rates

CARBON DIOXIDE IS A BY-PRODUCT

FROM A VARIETY OF MANUFACTURING

PROCESSES IN THE CHEMICAL

INDUSTRY; IT IS ENVIRONMENTALLY

NEUTRAL AND GENTLE ON RESOURCES.

The CO2 snow jet system has been integrated into a large paint

booth measuring 5.5 x 4 x 3 m together with a turning station.

(Source: Volkswagen Plastics Technology)

PS1203_11_12_WHATWORKS1.indd 11 2/29/12 11:55 AM

WHAT WORKS

Strauss. “This proved that the CO2 cleaning process can be implemented for our entire range of workpieces.”

PAINTING INTEGRATION

ACP designed a robotic cleaning system with a nozzle array containing seven cleaning heads. The component-specific programs filed in the robot’s controls ensure that each workpiece is cleaned fully and automatically, according to its geometry. Oil-free compressed air and liquid carbon dioxide stored in tanks are fed to the array via a hose system.

The robot is integrated into a booth measuring about 5.5 by 4 by 3 m. The cleaning cell located at the rear wall has a continuous extraction unit. This prevents cleaned parts from becoming recontaminated by dirt as it’s removed. A turning station, which can be switched on separately, is located in the booth downstream of the cleaning process, allowing suspension gear to be rotated by 180°. “ACP provided us with ideal support both during the test phase and after-ward, when we started implementing the cleaning system, enabling us to integrate it into the painting process within the space of just three months,” says Strauss.

SERIES OPERATION

The CO2 snow jet system has been running in three-shift series operation at the Volkswagen plant since August 2010. Several thousand plastic parts are cleaned every day.

“The workpieces are suspended on special painting racks at the injection-molding plant,“ explains Strauss. “If high-gloss parts are handled, workers wear gloves.” The racks are mounted on trolleys, transported to the painting line, and fed into the painting chain. The first station in the line is the cleaning unit. To prevent dust from sediment-ing on the workpieces after cleaning, they’re fed through two ionizing rods. After being transported along a short stretch designed as a cleanroom, paint is then applied to the components by two robots in the painting booth. On leaving the evaporation zone, the parts are then dried at around 80 °C.

“With the CO2 snow jet system, we’ve not only founda cost-effective and reliable cleaning solution, we’ve suc-ceeded in reducing the workload on our staff, decreasing environmental pollution, and also lowering our reject rate by another 3%,” summarizes Strauss.

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PS1203_FPA.indd 13 2/29/12 11:34 AM

PS1203_FPA.indd 14 2/29/12 11:35 AM

STEP UP TO THE PLATERethink reliability in terms of your equipment’s on-base percentage

As I removed my laptop to get some work done on a three-and-a-half-hour flight home the other night, the flight attendant announced what the in-flight movie was going to be. I’m probably among the last people to have seen the movie, “Moneyball.” It might be that I’m too cheap to buy an $8.50 movie ticket, $5 bag of popcorn, and $4 Coke (Diet Coke, no less). I wanted to see the movie because it involved baseball and a view of things from a different perspective.

So, while the laptop remained on the tray table, it was benched for the flight.

The story was about Major League Baseball’s Oakland Ath-letics, a small-market team that couldn’t compete economi-cally with larger-market teams. The A’s had good coaches and developed some great players. However, they didn’t have the money to induce top talent to stay or to come over to the team. This meant that they would forever be handicapped in their quest of a World Series title. This isn’t unlike many industrial plants — it’s hard to find good talent to replace the aging workforce, and it’s even tougher to keep them as com-petitors offer a little more.

There were a number of interesting lessons from the story of Billy Beane, the general manager, and his unassuming sidekick — a young, Yale-trained, economics major named Peter Brand, who had no baseball experience, but could boil baseball success down to one thing — getting on base repeat-edly. Veteran scouts looked for attributes they believed would do two things — draw in fans and give the team a reasonable chance to win. They used an old formula that everyone else used, but one with which the A’s couldn’t compete.

The two main characters, Beane and Brand, developed a strategy that involved finding players with high on-base percentages who weren’t high-salary guys; it didn’t matter whether they were hits or walks. The old guard — Manager Art Howe, the veteran players, and the scouts — didn’t like the new strategy because it took them out of their comfort zone. The old guard knew better than some college kid, or so they thought. The strategy floundered as the manager circumvented the plan, a key player had to learn a new posi-tion, and an aging veteran player wasn’t brought in to relieve another player.

The manager resisted the plan as Beane tried to reason with him. Eventually, Beane took decisive and controversial action — trading two of the team’s best players. This kept Howe from reverting to the old management style. Beane

also showed confidence in the player who had to learn a new position and stuck with him. The aging veteran, David Justice, had a key role to play, and Beane appealed to him to be the veteran leader.

Beane faced decisions at a couple of key moments in the movie, each of which had serious consequences for his ca-reer. Because his vision and strategy were so unorthodox,he most certainly would have been on the unemployment line if it didn’t work.

Manager Howe needed much more than an explanation of Beane’s vision and strategy. Pivotal actions taken clearly could have led to Howe’s walking off the job.

It was a risk Beane took because the manager had to get in line or be gone. Combined with trading two young, star prospects in the middle of the season, Beane’s actions were akin to the old adage of “landing the troops and burning the boats” — there was no turning back. It was bold and made people aware of his deep commitment to the strategy. Beane also showed commitment by sticking with the player who had to learn the new position — acknowledging shortcom-ings, but staying the course as the player learned new skills to fit into the overall plan. In dealing with David Justice, Beane showed respect for the experienced player but asked him to step up and be a leader among his peers.

As with plant reliability, the practice of quickly fixing equipment and rewarding that practice is an out-of-date strategy. Getting on base, or avoiding outs in the first place, is like having reliable equipment. The strategy in how to get to the vision of high on-base percentages or high equipment reliability needs to be enacted by people, through focused and consistent leadership.

Beane was open to new thinking. But he also was ultimately accountable for the results. It’s why he made the big bucks.

Tom Moriarty, P.E., CMRP, is president of Alidade MER. Contact

him at [email protected] and (321) 773-3356.


HUMAN CAPITALTOM MORIARTY, P.E., CMRP

AS WITH PLANT RELIABILITY,

THE PRACTICE OF QUICKLY FIXING

EQUIPMENT AND REWARDING THAT

PRACTICE IS AN OUT-OF-DATE STRATEGY.

PS1203_15_HUMANCAPITAL.indd 15 2/29/12 12:00 PM

EASE YOUR PAIN.

IS YOUR ERP A PAIN IN THE ASSET?

Most ERP software does a poor job at enterprise asset management (EAM) tasks like mainte-nance and asset lifecycle management. Only IFS Applications offers class-leading EAM as part of an agile, fully integrated enterprise resources planning (ERP) suite. So you can implement EAM with components of ERP, an entire ERP package or even integrate EAM seamlessly with your legacy ERP system. So your business can be as agile as your thinking.

www.youragileassets.comIFS—FOR AGILE BUSINESS

PS1203_FPA.indd 16 2/29/12 11:38 AM

CONFIGURATION WITHOUT CUSTOMIZATIONModify software with no expense or risk

There are many factors to consider when selecting a CMMS, including an ability to meet your technical specifica-tions, vendor track record, and pricing. In this dynamic world, plants need software that can mold to the constant changes customers, employees, management, and regulatory bodies precipitate. CMMS vendors and their solutions must be flex-ible, agile, and configurable to meet the changing demands.

In earlier years, software packages were customized to close the gap between user requirements and the application’s capability. Typical areas of customization were industry- or company-specific anomalies, interfaces to other applications, and more complex requirements for data entry, reporting, and business logic (error-checking algorithms and workflow). Custom changes required considerable time and money to implement, and there was no guarantee that future releases of the base package would be compatible with the customized source code. Moreover, as business grows and needs evolve, the custom code no longer fits with current business realities.

Modern CMMS software can be configured to meet the needs of today and tomorrow without the expense and risk associated with customization. Configuration doesn’t require changes to the source code. Usually, all that’s required to con-figure the software is a one-time setup, for example, ticking a box on a master file, selecting a menu option, or dragging and dropping an object on a particular screen. This typically can be done by a system administrator or super-user, as opposed to the vendor. Let’s highlight some advanced features and func-tions that help you stay relevant as your business needs change.

USER CONFIGURABILITY

One of the most visible differences between modern CMMS packages and older, less flexible applications is the ability to tailor the software to a given user or user group, such as plan-ners. Examples of screen configuration options are:

-tions, and data fields are visible to the user

Sophisticated CMMS packages also will allow the addition of user-definable fields on a given menu, tab, or screen. In some cases, this includes whatever algorithm or Boolean logic that might be necessary to generate a value, such as generating a default value.

NAVIGATION AIDS

Another popular feature that ensures greater agility is the ability for users to navigate throughout the system to get at information quickly and easily. For example, the better CMMS packages not only have drill-down capability to reveal greater and greater levels of detail, but they allow users to drill around to find related information. For example, when viewing a pur-chase order line item on screen, a user might wish to jump to the relevant item’s master information, then do a “where used” query, and then drill into one of the assets that use the item.

A powerful navigation aid is the MS Explorer-style lookup capability for equipment, parts, projects, and many other data hierarchies. The more sophisticated CMMS packages allow users to drag and drop elements of the hierarchy, for example, moving a serialized component from one asset to another, including carrying its full history. Other high-end features are:

links to screens within the CMMS

a user-defined period of time

WORKFLOW ENGINE

A workflow engine is the backbone on which a CMMS is built, carrying the business rules and sequencing of virtually every process the software governs. For example, companies need to be able to adjust approval limits and signatories, as well as conditions (budget remaining) or contingencies (approver on vacation). The workflow engine can launch notifications or alarms when certain conditions are met, such as when a criti-cal PM is significantly past due or when a budget is exceeded.

Some CMMS vendors have a graphical workflow engine, where activities, arrows, and decision boxes within the flow can be dragged and dropped to allow users to build or adjust the workflow logic easily. For some packages, the procedural help (how to initiate a work order) can be linked to the graphi-cal workflow. Users can toggle back and forth between the


YOU NEED THE FLEXIBILITY TO ADD

FIELDS THAT ARE RELEVANT TO A

GIVEN ASSET CLASS OR TYPE.

ASSET MANAGERDAVID BERGER, P.ENG.

PS1203_17_ASSET.indd 17 2/29/12 12:07 PM

ASSET MANAGER

process flow and the appropriate help screens.

USER-DEFINABLE SPECIFICATION TEMPLATE

Different businesses describe their assets differently. Computer screens are sized in inches by referring to the diagonal distance across the screen. A motor has horsepower, voltage, speed, and torque. You need the flexibility to add fields that are relevant to an asset class or type such as computer monitors, motors, doors, and sewers. This is accomplished with user-definable templates for entering and reporting on tombstone data.

FORMS AND REPORT GENERATORS

There are three major activities for which your CMMS provides tremendous support — data entry, data analysis, and reporting. The forms generator gives users the ability to configure data input forms (work request, purchase request, timesheet) to maximize efficiency and reduce the chance of error. Modern features include:

given data entry field for the purpose of error checking

(most frequent, last used, fixed value, formula based).Data reporting must be easily modified, including:

-vanced math to any field or grouping of data

thereof, including a user-definable dashboard.

DOCUMENT MANAGEMENT

Another feature that brings tremendous flexibility is sophis-ticated document management capability. Relevant external documents such as equipment manuals, drawings, safety sheets, and contracts abound. Documents arrive in multiple formats, from handwritten notes scribbled on a scrap of paper to 3-D CAD drawings or training videos. It should be easy to attach these documents to the CMMS master file (drawings on the asset registry) or to objects such as work orders or purchase orders. More sophisticated features to look for are version control (management of change), application launch option, and the ability to edit, index, and redline.

Email Contributing Editor David Berger, P.Eng., partner, Western

Management Consultants, at [email protected].

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TECHNOLOGY TOOLBOXSHEILA KENNEDY

WELL-OILED TESTING AND TRAININGFormulations are just part of lubrication improvements

Choosing the right blend of lubrication training, testing, business processes, and formulations can help keep your machines and components healthy and running smoothly.

“The training and development of lubrication skills is the hottest thing out there right now, and I believe it will be with us for a long time in the future,” says Bill Lyons, mainte-nance optimization manager at Holcim U.S., a cement and component manufacturer in Waltham, Massachusetts.

During the past few years, many lubrication improvement projects were launched in most of Holcim’s 12 manufactur-ing plants, from storage and handling to regreasing bearings using ultrasonic measuring tools, explains Lyons. “I see our plants moving further with in-house oil analysis, helping to move us to a more proactive approach to better understand-ing the lubrication condition,” he says.

Lyons believes that increasing skill levels and using new technology has a great effect on costs. “I looked at our bear-ing spend five years ago, and the amount seemed very high to me,” he says. “Recently, I ran the same report, and I now see our bearing spend has dropped more than 50% since the previous report.”

Organizations such as the International Council for Ma-chinery Lubrication offer certification programs for lubrica-tion technicians and oil analysts.

Lab testing approaches: Independent oil analysis labs must adapt to evolving customer requirements and technology continually. Insight Services keeps its technicians abreast of changing base stocks and additive packages, and it’s improv-ing its testing and reporting capabilities.

“We’re currently working on two changes to oil analysis testing in our laboratory — varnish analysis and filter debris analysis,” says David Kirkwood, business development man-ager for Insight Services. “Varnish analysis improvements include changes that will allow us to categorize the type of varnish, the make-up of the soft contaminant, and ultimate-ly pinpoint the origin of the problem. Also, Insight will be able to use filter debris analysis to capture the organics that make up the varnish for closer examination.”

Reliability-focused practices: Lubrication process im-provement providers use existing products to get better results. “Manufacturers are becoming wise to the value that machine lube processes can deliver,” says Mike Johnson, principal consultant for Advanced Machine Reliability Re-sources. Johnson developed an analysis tool called

LubeCoach, a grease interval and volume calculator. It aids in selecting or correcting lube types, application volume, and frequency, and in solving process problems such as overfeed and underfeed. LubeCoach, available in multiple bearing application formats, is presently spreadsheet-based but will soon be offered in a Web-based format.

Advanced ester chemistry: Polyol ester (POE) fluid de-velopments resulted in new industrial lubricant products. “POEs are fantastic long-range solutions for air compressor lubrication. With fluid analysis, a customer can realize more than 8,000 hours of fluid life with POEs in air compressors,” says Jim Girard, vice president and chief marketing officer at Lubriplate Lubricants. Because fluid life is extended, less used oil requires disposal. POE-based fluids also minimize harmful air compressor deposits.

Targeted applications: Lubricant formulations often are designed to meet specific industrial conditions. Summit’s SumTech FGCO calcium oleate grease was designed specifi-cally for the food service, beverage, and food processing in-dustries. Among its properties are excellent water washout, higher weld load, and lower wear scar.

The Hydroguard hybrid breather from Des-Case increases lubricant reliability in low-flow applications by preventing contamination. Suitable for multiple industries, the product uses check valves and an expansion chamber to prevent moisture ingress. It breathes when pressured, and the air is cleaned and dried before it enters the system.

Email Contributing Editor Sheila Kennedy, managing director

of Additive Communications, at [email protected].


www.holcim.uswww.lubecouncil.orgwww.testoil.comwww.precisionlubrication.com

www.lubriplate.comwww.klsummit.comwww.descase.com

REFERENCE WEB SITES:

INDEPENDENT OIL ANALYSIS LABS MUST

ADAPT TO EVOLVING CUSTOMER

REQUIREMENTS AND TECHNOLOGY

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PS1203_XX_TECHTOOL.indd 21 2/29/12 4:19 PM

Plant upgrades and overhauls mean involving the engineering department and having the foresight to not only change what is lacking, but plan for future needs, as well. Th ree plants took advantage of facility modifi cations and parlayed them into better maintenance and reliability.

In the fi rst example, the addition of secondary wastewater treatment necessitated an upgrade in emergency standby power, which meant installing a new system that matched the existing one. Th e improvement allowed the treatment plant to meet EPA standards and gave it the backup power it required in the event of an outage.

Equipment stress protection made a diff erence in the second example, in which a fi rearm manufacturer increased reliability and productivity by implementing functional interface stress hardening. Engineering, operations, and maintenance personnel’s ability to work and plan together allowed the facility to mitigate equipment downtime.

Finally, when a food production plant had expanded to the point where it was unequipped to handle the breadth and volume of its products, a complete facility overhaul al-lowed for more effi cient operations and the plant moved to a predictive maintenance strategy.

STAND BY YOUR POWER

Built in the late 1990s, the South Bay International Waste-water Treatment plant is a joint eff ort between Mexico and the United States to treat sewage from Tijuana, Mexico, and

eliminate environmental concerns in the Tijuana River Val-ley just south of San Diego. Th e plant is located on a 75-acre site in the United States. Th e International Border and Water Commission (IBWC, www.ibwc.gov), the plant’s operator, needed to add secondary treatment to improve the quality of the discharge water because it was found not to meet current environmental standards set by the EPA.

Th e South Bay wastewater treatment plant has a capac-ity of 25 million gal/day. Its original design consisted of advanced primary treatment, which involved the addition of chemicals to the infl uent to promote removal of solids and dissolved organic compounds through settling. Th e treated water was then discharged via a 4.5-mile pipe extended out into the Pacifi c Ocean near the Mexico-California border.

Secondary treatment involves bacteria-activated sludge combined with aeration and additional settling. Encouraged by the large supply of oxygen bubbled through the sewage, aerobic bacteria consume the remaining organic compounds in the effl uent. Th e sludge is then removed by additional settling and then recycled to reuse the bacteria. Aft er secondary treatment, the water quality is much improved and meets EPA standards. Adding secondary treatment has greatly increased the plant’s electrical load. Th e large aeration pumps and activated sludge system necessitated the addition of another 2,000 kW of emergency standby power, so the plant turned to MTU Onsite Energy (www.mtuonsi-teenergy.com).

22 MARCH 2012 WWW.PLANTSERVICES.COM

ENGINEERING / PLANT MAINTENANCE

By Mike Bacidore, Editor in Chief

WrenchTimeby Design

Plant upgrades are opportunities to bring engineering and maintenance departments together

PS1203_XX_XX_COVERSTORY.indd 22 2/29/12 5:05 PM


“Th e plant hasn’t been expanded in terms of overall ca-pacity,” says Steve Smullen, area operations manager, IBWC. “It was originally designed for both advanced primary treat-ment and secondary treatment, but the secondary facilities were not immediately funded. Recently, we got the funding, and now we’ve added a biological system, aeration and set-tling facilities to meet our EPA permit requirements. As a consequence of completing the secondary treatment, we also added quite a bit of additional electrical load to the plant to operate three 700 hp aeration blowers and related equip-ment. In case of a utility outage, we needed the additional standby generation to handle those larger loads.”

Th e plant wanted the new power system installation to physically match that of an existing 2,000 kW generator that was installed during the original construction in the late ’90s, says Tim Oergel of W.W. Williams, the local distributor for MTU Onsite Energy. “Getting the two generators to fi t into identical packages was a challenge,” he says.

One design issue was that the MTU Onsite Energy unit was 16 years newer than its companion, which was from a diff erent manufacturer. Th e new unit operates at 12.47 kV housed in a specially designed ISO container. Th is newer generator set is EPA-certifi ed to meet Tier 2 emissions regu-lations, whereas the existing generator set was manufactured at the beginning of Tier requirements and was compliant with, but not EPA certifi ed to, Tier 1 standards.

In addition to not having modern emissions control hardware, the existing generator drive engine set did not have an electronic governor or other electronic controls to help it synchronize with the new generator drive engine. To get the two generators to communicate with each other, the existing generator’s governor was replaced, along with many other controls. Th e overhaul also included new paralleling switchgear, automatic transfer switches, and various com-munications interfaces.

“While the MTU Onsite Energy EPA-certifi ed Tier 2 generator set is more fuel ef-fi cient and has signifi cantly cleaner exhaust, it also has higher heat rejection that requires a specialized radiator,” says Oergel. “Because we had to match the size of the original 40-ft ISO container, we had to be creative in designing a radiator with higher heat rejection to fi t in the same-sized package as the original generator set. Th e solution was a specially designed radiator from R.F. Partridge & IEA Radiator that was direct-driven through a planetary gear off the engine’s crank shaft . With a larger surface area and greater airfl ow, the special radia-tor was able to fi t inside the container and still provide the necessary cooling.”

Th e physical installation of the containers is unique, as well. Each containerized generator set is mounted on a con-

crete pad outside of the plant’s main building. Because the plant is located in earthquake country, both generator-set containers are supported by a seismically reinforced mezza-nine structure consisting of I-beams connected in crisscross patterns (Figure 1). Th ese structures support the weight of the containers and are bolted to the concrete pad to prevent damage to the generators in the event of an earthquake.

Installation, fi nal commissioning, and load-bank testing were completed in the summer of 2010 to make sure that both units could carry the full plant’s load while operating in parallel. “Getting the diff erent units to operate together was a challenge,” says Oergel. “Th ere were many sequence-of-operation changes that were needed to make sure both units functioned properly and could carry the load.”

TEACH A MAINTENANCE ENGINEER TO FISH

Sturm Ruger (www.ruger.com) manufactures American-made fi rearms for the commercial sporting market, off ering more than 400 variations on more than 70 products across 25 product lines. Its main rifl e and pistol components manufacturing plant in Newport, New Hampshire, is more effi cient and profi table today than it was in 2007 because of a proactive maintenance department and a vice president of operations who understands the value and the necessity of reliable equipment.

In 2007, with unscheduled downtime on the automa-tion and manufacturing controls and CNC machine tools, David Ford, the hydraulic maintenance specialist, requested a portable oil fi ltration system to cut down on hydraulic oil contamination, save some money on oil costs, and, hope-fully, boost machine uptime.

Tom Sullivan, vice president of operations at the Newport plant, thought it was a good idea, but not all oil fi lter systems are equal. He asked Howard Cooper at Amemco (www.amemco.net) to prepare a plant-wide equipment survey and

conduct an orientation semi-nar on functional interface stress hardening (FISHing). Th ese meetings brought the maintenance and manu-facturing engineers, plant

management, and maintenance specialists together to hear Cooper explain how to replace preventive maintenance with condition-based maintenance (CBM) and how to maximize uptime and equipment reliability by going FISHing.

Cooper’s facility and equipment survey revealed one root-cause stress to be frequent power surges and voltage transients that were aff ecting CNCs, PLCs, computer and electronic controls, and drive systems. Th e survey identifi ed and prioritized other root-cause stresses and resulted in a machine-by-machine stress protection solutions report. Th is document served as a stress-hardening protection recom-mendation and installation guide.

“AT LEAST ONCE OR TWICE A WEEK, YOU’D

HEAR FROM A CNC OPERATOR THAT THE

MACHINE HAD JUST STOPPED.”

PS1203_XX_XX_COVERSTORY.indd 23 2/29/12 5:04 PM


Kim White, Sturm’s maintenance manager, authorized Bill Ross, Sturm’s maintenance electrician, to test the pro-posed solutions in the report. Th e initial testing involved installing high-speed clamping/fi ltering transient voltage surge suppression (TVSS) units from Total Protection Solu-tions (www.tpssurge.com) and air-to-air heat exchangers on two Portland reamers in the gun forge molding department.

Historically, Sturm Ruger was replacing at least one of these motion axis drives every other month and experienc-ing the loss of production. Since the replacement, there have been no costly axis drive replacements needed and no scrap being generated from marginal and failing axis drives.

Summer heat also was aff ecting the company’s Tech-nidrills and Extrom Carlson CNCs in the woodworking department. Frequently the cabinet doors were left open to keep the controls from malfunctioning or failing. Th e report included the size and type of control coolers to use, the proper connection points, and mounting details for the TVSS devices. Th e woodshop hasn’t experienced downtime or quirky malfunction problems since making the changes.

Based on these pilot-test results, Sturm Ruger began implementing the FISH report suggestions across the manu-facturing facility. “From the time I started with Sturm Ruger back in 2003,” says Ross, “at least once or twice a week,

you’d hear from a CNC operator that the machine had just stopped or wouldn’t start up correctly. We’d have to shut off the main power switch feeding the machine tool and turn it back on again to reset or reboot it. Th at seemed to fi x the problem until the next occurrence. Since completing this equipment stress protection project, I’ve not heard of that happening again.”

Th e overall eff ect was like installing a large UPS on every machine tool, but the real savings came from increased reli-ability, productivity, and uninterrupted profi ts.

Shortly aft er restructuring maintenance, the concepts and methods of the original project were expanded to include additional machining and process control areas, as well as TPS suppressors to protect Sturm’s low-voltage lighting.

FOOD PRODUCTION OVERHAUL

Minnesota-based Faribault Foods (www.faribaultfoods.com) is no stranger to the importance of sustainability in food production. As a producer of many foods including a wide variety of beans, chili, organic soup, juices, and canned pasta, Faribault Foods is a member of the Sustainability Initiative Team (SIT), a part of the Foundation for Strategic Sourcing. Th e group is comprised of executives from major consumer packaged goods, contract manufacturing, and

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packaging supplier companies that work together to develop industry standards to promote sustainability.

While business drivers might have progressed in recent years, the bean production process hasn’t changed much in the company’s 115-year history. Beans come to the primary production facility from all over the Midwest. Th ey’re placed

into a soaking and rehydration system, and then blanched and transferred to a canning line, where broth, sauce, or brine is added for fl avor. Th e cans are sealed and sent to the cooking system, where they’re held at a particular tempera-ture to make them a commercially sterile product. Finally, the cans are cooled, packed on pallets, and shipped to thou-sands of retail locations across the country.

“Th e Faribault bean plant was designed as a seasonal vegetable canning facility,” explains Phil Hines, director of engineering, Faribault Foods. “When I joined the company in 2005, it was being operated year-round as a rehydrated bean canning facility. We needed to modernize our produc-tion infrastructure to meet long-term business goals and deliver the high-quality, sustainable products our customers have come to expect.”

With several hundred varieties of product going through the facility each year, it simply wasn’t designed to keep pace with the company’s growing business. In addition to pro-ducing several of its own brands, the company also produces private-label brands for many large grocery retailers and provides copacking, or contract manufacturing services as well. “We needed to demonstrate and document reliable, repeatable production practices to our customers — particu-larly to those working with us on copack products,” explains

SEISMIC REINFORCEMENT

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and steam (WAGES) resource consumption (Figure 2).”Once the company decided to invest in a complete facility

overhaul, Hines and his team designed a comprehensive plan to identify opportunities for improvement, documenta-tion requirements, and an ongoing timeline for implementa-tion. “We knew this wasn’t going to be a one-time eff ort,” explains Hines, who, along with his team, selected a process solution based on the Rockwell Automation Integrated Architecture system, featuring eight Allen-Bradley Control-Logix programmable automation controllers (PACs). Each PAC communicates via a ControlNet network to intelligent fi eld devices and 12 human-machine interface (HMI) sta-tions comprised of Allen-Bradley PanelView Plus termi-nals and industrial computers running FactoryTalk View SE soft ware. Th e control system monitors the production infrastructure in real-time, including WAGES consumption information. Faribault Foods implemented instrumenta-tion from Endress+Hauser for seamless integration. “When we started this project, we were in the beginning stages of automating of our production system,” explains Hines. “As a result, this project represented a substantial technol-ogy change for the maintenance department. Th e biggest challenge was training. Every maintenance person needs to understand the functionality of the new sensing and controls devices in order to troubleshoot the operation and

TIGHT CONTROL

Figure 2. The control system monitors the entire production

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to be able to differentiate between control system issues and mechanical issues. We implemented a training program for all maintenance staff and specialty training for a selected group who would focus on maintaining and updating the new control systems.”

As part of the project, Faribault standardized many of the devices, says

Hines. “For example, we use the same VFD model throughout the facility,” he explains. “We also included elec-tronic documentation of the location, description, and function of each device and the ability to allow outside vendors to access our system through a VPN connection for data collection and troubleshooting.”

To ensure a smooth transition, Hines wanted to train his staff on the new technology as soon as the system was online. “Previously, one or two staff members possessed 90% of the control system knowledge,” he says. “With the new system, we wanted to make sure everyone understood how it worked.”

The company’s heat-and-energy-re-covery system reuses 100% of the heat from the can cooling process to warm city water for the soaking, blanching, and cooking operations. The result is a 38.2% decrease in natural gas usage, which won the company Xcel Energy’s 2009 award for the largest natural gas reduction among industrial customers in the state of Minnesota. In addi-tion, the system reuses cooled water to reduce the temperature of the cans in the cooking process, which cuts down on the company’s overall water usage by more than 100 million gal/year.

Tighter control of the process also allows for reduced waste in the manu-facturing process. To accommodate the cooking process, the company leaves “head space” in each can — es-sentially an air pocket between the can lid and the beans. Previously, at the end of the manufacturing line, the head space would be pushed out along with a few ounces of canning fluid, which would be flushed down the drain. Now, thanks to the increased process accuracy and reliability, the plant-floor team can fill to exact levels, ensuring that no fluid is wasted when the head space is forced out of the can.

As Faribault Foods moves to a predictive maintenance strategy, the asset management and training sup-port also are proving useful. Faribault Foods is now producing the same amount of product in five days that previously required seven.

When Hines first started the upgrade process, the plant typically was running at 75% of its maximum throughput. Now, the facility runs at 90%, and it has better product quality, as well.

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Which is better — a classical centralized air system or a departmental compressed air system? Reports suggest that neither system is better. Quite oft en, the right choice is a combination or variation of both. Here’s why.

A central air system satisfi es total plant air demand. Air from one or more compressors is distributed from a central point to areas requiring service. Th ese compressors are in-stalled in a powerhouse with other utilities. In a departmen-tal air system, several compressors are located at principal points of use throughout the plant. Th is approach can be used instead of, or in combination with, the central type.

VARIATION CAN PAY

Each has its advantages and disadvantages. In deciding which is best, weigh the benefi ts gained against the draw-backs for the choice. Th e case for one system over the other isn’t always clear cut. Th e judicious plant engineer, aft er weighing the facts and fi gures, might arrive at a combination, or even a variation. Here’s a hypothetical example.

A 50,000-cfm centralized air system has several compres-sors. However, the units have a 100-psig maximum discharge pressure. Th e plant requires 2,100 cfm at 150 psig in one department, 24 hours a day. Two options are available.

psig in the department. A complete system such as this will use about 500 hp and cost approximately $150,000 to $175,000, uninstalled.

2,100 cfm by kicking the 100-psig system pressure to the required 150 psig. A correctly applied, double-acting, single-stage reciprocating booster, requiring only 125 hp, will do the job for about $40,000 to $50,000, uninstalled.

Th is small booster represents savings. At a utility cost of $0.04/kWh, saving 375 hp can amount to more than $100,000 per year in power savings alone, not including the cost of the 100-psig inlet air. If all or part of the 2,100 cfm of 100-psig air is available from blow off , this might gener-ate more savings. Th ere are many situations off ering the plant engineer a chance to save on air system installation and operating costs. It takes planning and correctly applied knowledge of compressed air, compressed air systems, and compressed air equipment.

It’s important to understand the classical approaches to air systems and compressor selection. You also should be aware of what modern materials, air compressor designs, and com-pressed air requirements have done to increase the opportu-nities for both initial and continuing cost saving.

To get more work and effi ciency out of compressors, many manufacturers of production machinery and tools now require higher pressure and air that’s dryer and cleaner than the standard aft ercooler untreated air. Compressor manufac-turers responded with a variety of designs.

High-performance, oil-cooled rotary compressors, both vane and screw types available as fully packaged air systems,


RELIABILITY / COMPRESSED AIR

CENTRAL OR

DEPARTMENTAL

AIR SYSTEM?Size and confi gure air

piping for the right fi t

By Hank van Ormer, Air Power USA

PS1203_30_36_FEATURE1.indd 30 3/1/12 9:37 AM


offer nearly complete installation flexibility. These continu-ous duty units with oil coolers are relatively small and quiet. They can be used for departmental air and compromise nothing in durability. Single-stage, oil-cooled rotaries offer pressures to 175 psig, and two-stage units can go even higher.

Rotary units, lobe or screw type, non-lube, air- or water-cooled, two-stage compressors provide good efficiency and continuous duty from 50 hp to 600 hp. They’re usually higher in initial cost and somewhat less efficient than the air-cooled two-stage lubricant-cooled rotaries. Single and two-stage double-acting reciprocating, water-cooled units are the most expensive to buy, but they incur the lowest power cost com-pared with other types of similar sizes.

Modern compressor design produced heavy-duty, short-stroke, higher-rpm, smooth-running, lightweight, single-act-ing reciprocating, air- and water-cooled units that require no special foundation. They’re suitable for providing high pres-sure air for localized or departmental applications. Heavy-duty units generally are available from 5 hp to 75 hp, 20 cfm to 170 cfm, and 150 psig to 5,000 psig. They often serve as a departmental air to supply a special process requirement.

The need for filters that deliver instrument-quality, oil-free air continues to increase. Filter technology has come so far in recent years that virtually any degree of cleanliness can be reached economically with reasonable or no pressure drop.

After you determine what kind of system best suits your plant, you must address other considerations.

-

CENTRALIZED SYSTEM: ADVANTAGES AND DISADVANTAGES

Centralized systems have several advantages.

-port equipment and tools usually are available nearby.

-cated in the same area.

air compared with dispersing those functions.-

ized system. These offer longer maintenance intervals than smaller air-cooled units.

screw compressors can help reduce plant heating costs. This form of energy conservation is achieved more ef-fectively from a central system.

There are disadvantages to a central system, too.

air pipes to avoid energy-draining pressure losses associ-

ated with carrying greater air volumes longer distances.-

ent, particularly higher, air pressures.

might require non-lubricated air or very dry air, while

to at least a +40 °F pressure dewpoint.

DEPARTMENTAL SYSTEM: ADVANTAGES AND DISADVANTAGES

A departmentalized system offers certain advantages.

amounts of air shorter distances. Air systems can be in-stalled at lower cost and with minimum pressure losses. Smaller compressors might have lower power ratings.

each department’s requirements.

without over-cleaning or over-drying the total system.-

partmental air systems together, enabling each depart-ment’s air system to back up the other.

The disadvantages of a departmental system are numer-ous, as well.

service tend to be more of a problem. Sometimes there’s uncertainty about who is responsible and less diligence about getting the job done. Service might need to be

CONDENSATION ACCELERATES

COATING BREAKDOWN, WHICH DEPENDS

ON WHERE THE COATING IS THINNEST.

Table 1. Typical pressure limits for thermoplastic pipe and fittings

are a function of temperature and line size. (N/R = not recom-

mended)

Temperature (F)

Max pressure rating (psi)

1/2 to 2 in. 3 to 4 in.

100 185 185

105 185 172

110 185 160

115 171 147

120 157 135

125 143 N/R

130 128 N/R

135 114 N/R

140 100 N/R


32 MARCH 2012 WWW.PLANTSERVICES.COM32 MARCH 2012 WWW.PLANTSERVICES.COM


relegated to the using department, rather than to plant maintenance.

equipment for major overhauls.

might be hard to bring in for units

can be mitigated by using smaller air-cooled units if they’re adequate for departmental air needs.

central air management system.

PIPE FOR CENTRAL SYSTEMS

topic, even storage. Like many topics in practical compressed air technol-ogy, a significant portion is controver-

to replace the appropriate volumes of information or misinformation and

-tions regarding a specific installation.

they’re based on performance and measured critical field data molded

TYPES OF PIPING

Consult federal, state, and local codes before deciding on the type of piping.

-

types: metal and non-metal.Non-metal pipe, commonly called

“plastic” pipe, has been offered for many years as compressed air piping.

easier to handle.

gluing material is fast.

metals, and the system often can

-

-

-ucts use material that doesn’t shatter.

have significant limitations.

non-performing aftercooler can -

and many synthetics in particular.

melt the plastic pipe and migrate around the plant.

-pressed air line active could melt the pipe from the outside causing additional catastrophic problems.

used, the piping system becomes

-

or compression fitting connections.

A FIRE IN THE PLANT

WITH THE COMPRESSED

AIR LINE ACTIVE COULD

MELT THE PIPE FROM

THE OUTSIDE.

Table 2. Comparisons of standard 100-psig class compressed air systems.

Feature Stainless Black iron Copper Thermoplastic Aluminum

Weight Sch 10 lighter Sch 40 heavy Less weight Lightweight Lightweight

Corrosion resistant? Yes No Yes Yes No

Strength Good Good Good Low Good

Ease of installation Less hard Hard Less hard Easy Easy

Connection types WeldedFlange/threaded/

weldedFlanged/soldered Cold glue Sealed reusable

Pressure drop Low High Low Low Low

Fouls? No Yes No No No

Modify easily? Yes No No Yes Yes

Special tools? Yes Yes Some No No

Skilled labor? Yes Yes Yes No No


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As with other thermoplastic com-ponents, the maximum non-shock operating pressure is a function of temperature (Table 1). Remove the heat of compression so as not to exceed maximum temperature ratings.

The pressure ratings for typical thermoplastic piping and fittings are a nearly constant 185 psi for all line sizes at temperatures from -20 °F to 100 °F, and are gradually reduced above 100 °F. The compressed air industry hasn’t accepted any type of plastic pipe as appropriate and safe for discharge and downstream compressed air. I agree with this view, given what’s available in today’s material, data, and available alternatives. There are no apparent benefits to offset the risk.

METALLIC OPTIONS

Metal pipe can be black iron, stainless steel, copper,, or extruded aluminum alloy having appropriate thermal and pressure characteristics.

Black iron or steel pipe corrodes when exposed to condensate and thus becomes a source of system contami-nation. This pipe usually is threaded 3-in. or smaller and is welded or flanged to pipe of a larger diameter. Compared to copper and extruded alu-minum alloy, it’s heavier and harder to install, but less expensive. Internal cor-rosion is much more significant with oil-free air and associated aggressive high-acid condensate characteristic than with lubricated compressors.

Extruded aluminum-alloy and stainless-steel compressed piping have become popular. A smooth, low-friction inner surface eliminates self-contamination and offers enhanced flexibility to meet ever-changing air distribution needs. This is particularly desirable in such plants with evolving assembly and subassembly areas. Most extruded aluminum alloy pipe is rated at +4 °F to 140 °F or 176 °F. The piping material usually has a melting point greater than 1,100 °F. For maximum flexibility, these often are installed with reusable fittings.

Copper pipe is a common selection for sensitive air systems. It’s rugged when selected and connected correctly. Its working pressure is 250 psi for Type M hard, Type L hard, and Type K soft, and 400 psi for Type K hard. Because 50/50 solder melts at 421 °F, copper lines are more resistant to high temperature. If it does fail, it will do so predictably — the pipe ends separate. According to the Piping Handbook, 6th edition, the working temperature limit for copper piping is about 400 °F.

Extruded aluminum alloy pipe can be installed in most areas where copper can be used. Alloy offers some significant advantages:

-rosion, depending on conditions

no skilled labor or soldering

COATINGS FOR AIR PIPING

The question of using galvanized piping instead of Schedule 40 black iron pipe for the nominal 100-psig air systems comes up often. Galvaniz-ing often is the coating of choice with many design engineers.

Galvanized inlet piping resists cor-rosion better than standard iron pipe. However, when corrosion sets in, the zinc can peel off. The inlet pipe then produces potentially damaging solid contaminants between the filter and the compressor. This is dangerous to the integrity of any compressor.

Galvanized discharge and distribu-tion piping used for interconnecting and distribution piping exhibits the same problem once it begins to peel. In all probability, because of condensate’s aggressive acidic characteristics, the galvanizing life might be much shorter.

This discussion about material selection as a function of use has five facets — inlet piping, discharge pip-ing, interconnecting piping, main line distribution, and distribution from the header to the process.

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INLET PIPING

The inlet pipe brings air from the filter to the compressor with no pressure loss and shouldn’t exhibit any interior contamination. The ambient inlet air might well dictate the selection of one type of pipe over another.

During high humidity, it’s conceivable that condensation will form in the inlet pipe. The OEM installation manu-als usually recommend a drain valve be installed upstream of the compressor inlet. Condensation accelerates coating breakdown, which depends on where the coating is thinnest.

Stainless steel inlet piping is an excellent material for large diameter, and low-pressure inlet air, as long as it’s installed properly and the inside is cleaned properly. Also, there are many grades of thermoplastic material suitable for inlet air piping. I recommend either stainless steel or proper thermo-plastic type material for inlet piping in lieu of galvanized pip-ing. Extruded aluminum alloy will work well but, depending on circumstances, might not be the economical choice.

Extruded aluminum alloy tubing can be assembled easily with hand tools to bring a great deal of flexibility to an oper-ating air system or subsystem. This approach is particularly effective for areas that are rearranged on a routine basis.

DISCHARGE PIPING

This side of the compressor has more complex consider-ations. The discharge air can be at 250 °F to 350 °F (for centrifugal, oil-free rotary screw, and reciprocating units), or from 200 °F to 220 °F (for lubricant-cooled rotary screw compressors). The pipe must be able to withstand those temperatures and any oil or condensate that might be highly acidic. Even if there’s an aftercooler to drop the temperature to 100 °F or less, consider the consequences if the aftercooler were to fail.

Air condensate tends to be acidic. In oil-free compressors, such as centrifugals and oil-free rotary screw, it’s usually particularly aggressive without the oil to neutralize it.

INTERCONNECTING PIPING

Its purpose is to deliver compressed air to the filters and dryers and then to the production air system with little or no pressure drop, and certainly with little or no self-con-tamination.

Regardless of the thermoplastic pipe manufacturer’s claims, we never recommend any non-metallic material for interconnecting piping and rarely for distribution header piping. Most of these materials carry cautions about not being exposed to temperatures greater than 200 °F and avoiding any type of oil or lubricant. We never recommend any type of above-ground nonmetallic or PVC piping for air or gas at any pressure.

Here again, stainless steel or appropriate extruded alumi-num alloy is the top recommendation for interconnecting piping between the compressor and the filter and dryers,

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if the compressed air is oil-free. Th is material of construction resists corro-sion much better than standard Sched-ule 40 black iron pipe and copper. Here are some other considerations.

10 stainless steel in lieu of Sched-ule 40 black iron.

installation labor cost.

Th is also reduces labor costs.

DISTRIBUTION PIPING

mum or no pressure drop. Th e line

motors need a minimum inlet pres-

Hank van Ormer owns Air Power USA

(www.airpowerusainc.com) and is an

Advanced Level Compressed Air Challenge

(www.compressedairchallenge.org) instruc-

tor. Contact him at hank@airpowerusainc.

com and (740) 862-4112.

The SewerGard™210S-Sprayable polymer

lining delivers lower permeability than

aggregate-filled systems and a high degree

of flexural strength. Its spray application

minimizes installation downtime,

as well. This protective lining

with fiber reinforcement

enables longevity for

municipal infrastructure

subject to corrosion and abrasion.

emai l : quest [email protected] tsburgh, PA 15238 U.S.Awww.sauereisen.com

Call Sauereisen for low permeability,

greater flexural strength and longer life.



OPTIMIZATION / ASSET MANAGEMENT SOFTWARE

Th is is the second of a two-part series on work breakdown structure. Th e fi rst part appeared in the January 2012 issue of Plant Services.

With the work breakdown structure (WBS) stored inside the CMMS soft ware, work orders can be tied to WBS cost accounts, purchase orders, receiving, and invoices. Th e result of this is one system, one report, and immediate cost analysis.

Quite oft en CMMS users will decide to use multiple soft ware tools for managing outages, also called shut-downs, and turnarounds. Asset-intensive industries oft en categorize work orders as to the system condition required for performing work. If this work is marked as outage, planners can quickly pull together a scope based on prior-ity and cost.

Th e goal of any outage manager, once given a budget,

is to create scope, get it approved, line up materials and resources, and establish a critical path using a scheduling tool. And once the outage is started, he wants to manage this scope, monitor schedule status, and track cost.

KEY DEFINITIONS

cost management within the CMMS and links work orders to cost accounts, and cost accounts to activities.

contain the budget, actual costs, and estimate-to-com-plete (ETC) values.

BENEFITS OF WBS-STYLE PROJECT COST TRACKING

cost perspective but does not want a detailed schedule or list

TOO MUCHINFORMATION— PART IIWork breakdown structure in CMMS

can streamline project cost tracking

By John Reeve, Cohesive Information Solutions

PS1203_37_40_FEATUREWBS.indd 37 3/1/12 9:51 AM

of work orders. By tracking costs with a cost report from within the CMMS, you can see a summary and indented view of the project, providing an over-view of problem areas. This strategy allows for standard comparison of effort across the fleet, where similar projects are being implemented.

OUTAGE TIMELINE

Outage preparation is important. If this process is to function, potential outage work must be properly catego-rized and planned within the CMMS (Figure 1). Important milestones in an outage timeline are:

-sion statement

Once the CFO provides the outge budget, the project coordinator sweeps up the work coded for the shutdown,

total cost. If it exceeds the budget, work must be cut to favor high-priority work.

TRACKING SYSTEM CHANGES

Manage scope and cost by using a single point of entry and project cost tracking reports. CMMS system re-quirements for outage work categoriza-tion and cost tracking are:

planned shutdown event

on-line maintenance work and shutdown work

separate application

cost account number to the work order main screen

-ated with individual work orders, such as regulatory dates

before outage starts”

of-importance for shutdown work — must, need, want

duration value that can be used for scheduling purposes

such as welding, painting, HVAC, which helps the contracts manager when building/releasing contracts

owner, such as contractor work, internal staff, or a mixture

plant system and subsystem

and task owner, which is useful for grouping like work and assigning ownership

require design changes.

SETTING UP THE WBS

terms of mutually exclusive cost ele-ments using a tiered level breakdown

tracking for the shutdown should:

orders

to schedule

accounts

tracking report

work order number (from labor, materials and invoices)

-tion tracking automatically.

OUTAGE SCOPE/COST REFINEMENT

specifying the scope. Some of the scope


UPPER MANAGEMENT

TYPICALLY WANTS TO BE

INFORMED OF PROJECT

STATUS FROM THE COST

PERSPECTIVE.

IN RACING,

A BROKEN $20 PART

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THE SAME IS TRUE

IN YOUR PLANT.

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PS1203_FPA.indd 39 3/1/12 9:09 AM


is must-do, but other parts are optional. This approach allows for dynamic scope selection and immediate visibility of the calculated dollar total, which is then compared to the budget cap. Minimize any deviation by changing the selection crite-ria or changing individual work order priorities. The screen design shown in Figure 2 shows the what-if design capability that allows for dynamic cost balancing. There’s also an auto-matic capture of scope changes.

PROJECT COST TRACKING REPORT

One of the many purposes of project cost reporting is to know whether the project is on schedule and on budget before project completion. This report can be used by any in-dustry performing project management. Transactional cap-

ture tells when, what, and why the scope was altered and who approved it. The change order column shows dollar changes. The report gets its data directly from the CMMS software. And it allows for a written explanation if the cost account manager determines the forecast will exceed the budget.

Project management is a critical process in many indus-tries. Improvements in this area affect costs and productiv-ity. Outage improvements can have a dramatic effect on the corporate bottom line. WBS-style project cost tracking embeds the WBS inside the CMMS product.

John Reeve is manager/practice leader maintenance & reliability so-

lutions at Cohesive Information Solutions. Contact him at jreeve@

cohesivesolutions.com or (423) 314-1312.

Outage-1

After completing previous outage, complete dept/team critiques

Issue final outage report

CFO provides rough budget

Query CMMS for outage work

Select potential work coded in CMMS for this outage

Work package preparation90% done

Perform what-ifscopeanalysisbased on budget

Downloadwork orders

Start schedulebuild

Verify all materialson-site

Stage material and tools

Perform pre-outagework

Verify tagoutsready

Scheduletasks

EstablishCPM

Resourcelevel

Verify completion

date

Freeze outage work scope in CMMS

Issuepreliminary schedule

Assign work to crews and contractors

Finalizecontingencyand risk planning

Finalizeschedule

Begin daily outagemeetings

Outage-2

Collect daily progress and actual hours

Monitor critical path and manage scope change requests

Produce final cost report for CFO

Outagecomplete

Dailyupdate

Plan for next outage

CATEGORIZE AND PLAN

Figure 1. The freeze date should be recorded in the CMMS such that any scope additions can easily be tracked.

CMMS/EAM system – Work order screen Project Cost

Transactional

Work order number

Asset Calculate priority

Description StatusProject ID

Project description

Target start Duration

Actual startApproved budget $13 million

Dynamic calculation $14 million

Revised budget

Status

Must Need Want

Type S/D

Target finish

Actual finishFreeze date

Outage manager

Worktype

GlaccountLocation

Project ID

Pre-shutdown Y/NLong-lead material Y/N

Outage type

Outage priorityContractor work Y/N

Contract type

Parent work orderPlannedOvernightWeekendAnnualOn-lineMust

WantNeed

CivilCarpenterElectricalNDTWeldersDiversScaffoldCranesWater treatmentCleaningHVACGas/steam turbine

Once the Project Freeze Date is passed, if any new work is linked up to this Project ID (e.g., outage code), thenan INSERT statement is made to a Transactional Table denoting, "ADD."If scope was removed then an INSERT statement is still made, but as "DELETE."

PlannedForced

WO # Project ID Freeze Action Sysdate Who ReasonWO # Project ID Freeze Action Sysdate Who ReasonWO # Project ID Freeze Action Sysdate Who ReasonWO # Project ID Freeze Action Sysdate Who Reason

New App

AddDelete

These toggles dynamically show total CMMS BASELINE cost - based on MUST, NEED, WANT

TRACK, UPDATE, MANAGE

Figure 2. Manage scope and cost through work-order tracking.




CATEGORY / TOPIC

When a piece of equipment needs slow input speed and high torque, it’s common to use an electric motor coupled to an industrial gear reducer to achieve the desired speed and torque. Th e gear reducer multiplies the output torque from the motor and reduces the motor output speed by the same ratio. Th ere are many kinds of industrial gear reducers from which to choose. Internally, those gear reducers might use worm gears, helical gears, or bevel gears to increase torque and reduce speed. One of the most popular types of gear reducers is based upon worm gears.

TORQUE VERSUS PURCHASE PRICE

When one selects a gear reducer, one of the most important decision criteria is the relationship between the reducer cost and the amount of torque generated from its output shaft . Worm reducers are the leaders when it comes to the cost-versus-torque comparison. A principal factor driving cost competitiveness of worm reducers relates to the overall gear reducer ratio. Th e overall gear reducer ratio is the number

of rotations of the input shaft that results in one rotation of the output shaft . Most worm gear reducers off er ratios of as much as 60:1 in a single stage of gearing, and a few off er even higher ratios. With only one stage of gearing, the related multiple shaft s, bearings, spacers, and other hard-ware that would be required in a multistage reducer aren’t required. It’s typical for a 60:1 helical or helical-bevel re-ducer to have three stages of gearing compared to one stage of gearing in a worm reducer. Th e gears, bearings, and shaft s are the most expensive gear reducer components. With fewer of these, worm reducers cost less than other types of gear reducers (Figure 1).

AVAILABILITY AND COMMONALITY

Most domestic manufacturers stock a substantial number of reducers in their warehouses. Th ose can be shipped on the same day the order is placed. In addition to readily available inventory, there’s also dimensional commonality on critical mounting dimensions among the major domestic worm

Fewer components give worm-gear

reducers a single-stage advantage

By Chuck Russell, Baldor

MORE TORQUE,

OPERATIONS / MOTORS & DRIVES

LESS MONEY

PS1203_XX_XX_FEATURE2.indd 41 3/1/12 9:59 AM


OPERATIONS / MOTORS & DRIVES

reducer manufacturers. Those critical dimensions include the output shaft diameter and length; mounting hole size and location in the housing; output shaft height; and overall reducer housing height. The gear ratios offered also have been standardized. Some have increased the output and in-put torque ratings of their products through improved gear designs along with the use of high-performance materials and synthetic lubricants. Those increases in input and out-put torque make it possible to replace an older reducer with a new reducer from a different manufacturer. The increased ratings provide a larger service factor and longer life than the original reducer.

MOUNTING OPTIONS AND FEATURES

The worm gear in a worm reducer runs at a right angle to the input worm shaft. Because the worm gear is mounted on the output shaft, both ends are available for use. Avail-able common output shaft configurations include single and double extended solid shafts along with hollow output shafts. The use of hollow output shafts is becoming more common in the United States, as it offers several advantages over a solid output shaft (Figure 2).

An equipment OEM can extend its drive shaft a relatively short distance and mount a hollow bore worm reducer on the extended shaft. That mounting eliminates the need for chains, belts, or other equipment to transmit torque from a solid-shaft reducer to the application. Guarding is simpli-fied, and the maintenance normally required for chains and

belts is eliminated. Several manufacturers offer a sealed-for-life reducer that doesn’t require a vent plug or oil level changes for different mounting positions. Those features allow mounting in multiple positions without the need to relocate the breather or add lubricating oil. Because of the popularity of worm reducers and the multitude of appli-cations, they’re available in standard and food industry washdown-duty packages, offer C-face inputs for standard NEMA motors, and have multiple options, such as mount-ing flanges and bases (Figure 3).

One aspect of worm gearing to avoid is the self-locking feature that some gear ratios might theoretically offer. Be-cause of the many variables that affect the reducer’s ability to self-lock, most manufacturers recommend a brake motor or other means to keep the reducer from being back-driven.

LONG LIFE

Industrial worm gear reducers have a hardened worm run-ning with a worm gear of a softer material — a bronze alloy selected with wear in mind. Unlike hardened helical or bevel gear sets, a worm gear set is designed to “wear in” over time. Some people think the wearing of the worm gear results in a shorter life than other gearing types. However, the wearing of the bronze drops off substantially after the wear-in finish-es. When worm gear manufacturers select a bronze material, they balance the resistance of the bronze to wear over time versus the ability to wear-in. During wear-in, the worm gear

UNLIKE HARDENED HELICAL OR BEVEL

GEAR SETS, A WORM GEAR SET IS

DESIGNED TO “WEAR IN” OVER TIME.

HOLLOW BORE

Figure 2. The right-angle configuration and the hollow shaft give

the worm gear reducer more flexibility in application.

Incr

easi

ng c

ost

Output torque

Helical-bevelreducer

Worm reducer

COST-TORQUE RATIO

Figure 1. It’s typical for a 60:1 helical or helical-bevel reducer to

have three stages of gearing compared to one stage of gearing in a

worm reducer.


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temperature temporarily increases. A softer bronze wears in more quickly with lower break-in temperatures, but it won’t last as long. A harder bronze lasts longer but generates higher break-in temperatures. A harder bronze is the best compromise between wear-in and wear-out. When properly sized to the application, worm gear reducers last at least as long as other gearing types.

NOISE

All gear reducers generate noise depending on the type of gearing used, the gearing accuracy, the quality of the manufacturing processes, and product design. Worm gear reducers have multiple advantages with respect to noise. Their teeth slide into contact with each other. That sliding action avoids the abrupt tooth-to-tooth contact that occurs with helical and bevel gearing. In addition to sliding into engagement, well-designed worm reducers have more teeth in contact in the gear mesh compared to a helical or bevel reducer, which results in lower noise levels. Also, worm re-ducers typically have only one set of gears that produce less noise than the multiple sets in helical and bevel reducers. The fewer number of bearings also helps to keep the worm reducer noise level lower.

Overall, gear reducers with worm gears offer advantages over helical and bevel gearing. Worm gear reducers have a low cost-versus-torque ratio, and domestic models are readily available and interchangeable. The right-angle mounting of a worm gear reducer, along with the hollow output shaft and sealed-for-life options make worm-gear reducers suitable for a host of applications. Also, the long life and reduced noise from worm gearing have contributed to their popularity.

Chuck Russell is senior principal engineer at Baldor (www.baldor.

com). Contact him at (864) 281-2438 or [email protected].

SOUP LINE

Figure 3. A sealed-for-life reducer doesn’t require a vent plug or oil

level changes for different mounting positions. A soup-producing

plant can use this same hollow-bore unit in multiple mounting

positions without the need to relocate the breather or add oil.



CONDENSING BOILERS

This line of condensing boilers range from 300,000 to 850,000 Btu/hr. The Caliber boiler is a condens-ing hydronic boiler with low emis-sions of CO and NOx. The product line features a full stainless heat exchanger suitable for hydronic heating. The boiler is equipped withHoneywell SOLA control and a variable-speed premixcombustion system capable of a 5:1 turndown.Fulton

(315) 298-5121 / www.fulton.com

AIR CONDITIONER

The CMW30 water-cooled, ceiling-mount air conditioner features a cooling capacity of 29,400 Btu/hr total and 22,000 Btu/hr sensible for computer rooms. The CMW30 is 20 in. high, enabling it to fit above a drop ceil-ing. No external condensing unit, refrigerant connection, or charging is necessary. The integrated-energy-efficiency ratio (IEER) of 17.0 is made possible by a variable-speed inverter compressor and inverter fan motors. Additional features include R-410A refrigerant and RoHS compliance.MovinCool

(800) 264-9573 / www.movincool.com

AC/REFRIGERATION MANIFOLD

The 557 Digital AC/Refrigeration System Manifold features four valves and a built-in vacuum gauge to analyze and maintain A/C, heat pump, and refrigeration systems. The 557 has two temperature inputs and can measure and display superheat and subcooling simulta-neously. It displays high/low side pressure, displays line temperature, and calculates saturation temperatures. It comes with two clamp probes, integrated hanger-hook, built-in hose holders and a hard carrying case.Testo

(800) 227-0729 / www.testo.com

VARIABLE-SPEED DRIVE

The Z1000 variable-speed drive is designed for building-automation applications such as fans and cooling towers having capacities to 500 hp. Its features begin with an LCD operator with hands-off-auto functions. An internal real-time clock with time/date stamping and timer is designed to control speed variations without the need for external controls. A built-in 5% line impedance is designed to reduce input harmonic distor-tion, and it offers a 5 kHz carrier frequency with dynamic noise control. An on-board EMI/RFI filter minimizes the effects of interference from sur-rounding equipment.Yaskawa

(800) 927-5292 / www.yaskawa.com

INDUSTRIAL FAN

The Powerfoil X industrial fan has an airfoil and winglet combination and is available in 8- to 24-ft. diameters. The NitroSeal Drive, a custom-built gearbox, is filled with nitrogen and sealed. Precision gearing is engineered to provide low friction for reduced heat and nearly 50% less backlash. The pre-wired on-board fan controls reside in a weather-resistant enclosure. A wall-mounted keypad con-nects to a standard junction box to allow floor-level control of multiple fans. Smoke detection, lights, cameras, and mo-tion sensor systems can be integrated into the fan.Big Ass Fans

(877) 244-3267 / www.bigassfans.com

PRODUCT ROUNDUP

THERMAL TECHNOLOGIESResources support HVAC and combustion processes

PS1203_44_46_ROUNDUP.indd 44 3/1/12 10:04 AM

ELIMINATE STRATIFICATION

Engineered to move air throughout a building quietly, these fans are designed to bring warm air down in cold weather and, if air-condi-tioned, force cold air to floor level in the warm months. By eliminat-ing the temperature differential between floor and ceiling, you can reap the financial bonus of reduced energy costs while enhancing occupant comfort year-round.Zoo Fans

(859) 918-9982 / www.zoofans.com

DISCHARGE BLOWER HEATER

Line horizontal or vertical dis-charge blower heaters at 20 kW and 50 kW are now part of the Chromalox HVH comfort heating product line. The HVH is designed to offer versatile mounting configu-rations for wall or ceiling, and its compact size is designed to allow for placement in tight spaces. Addi-tionally, the HVH is designed to be attractive in appearance, to be easy to install, to require minimum maintenance, and to have a long life. Chromalox HVH heaters are CSA certified for use in the United States and Canada, as well as CE certified to meet European standards.Chromalox

(800) 443-2640 / www.chromalox.com

TEMPERATURE-MONITORING DEVICE

The Delta T Alert is a self-contained, temperature-monitoring device that attaches magnetically to electrical enclosure cov-ers, revealing differences between the temperature inside the electrical enclosure and the ambient temperature in the room containing the enclosure. The unit collects data and sends it wirelessly to a desktop or other computer, allowinga building manager or engineer to monitor numerous points of the electrical system from a single online location. Readouts and reports can be generated daily.Delta T Engineering

(877) 321-0576 /

www.deltatengineering.com

STEAM DESIGN SOFTWARE

Steam DesignPro software is designed to use a drag-and-drop method for designing and modelling HVAC steam systems. The Windows–based software is engineered to allow for modeling steam generation, steam distribution, steam utilization, and condensate-handling systems. The program automatically performs many of the engineering calculations and design tasks that are currently accom-plished manually, including head loss and static pressure calculations, pipe and duct sizing, data recalculation, component insertion, full psychrometic calculations, and equipment changes on the fly.Spirax Sarco

(800) 575-0394 / www.spiraxsarco.com/us

HIGH-TEMPERATURE HOSES

Flex-Lok high-temperature hoses are made from materials that are locked around a galvanized or stainless steel metal clip and me-chanically crimped in a continu-ous process. These clip hoses are rated for service from -65 °F to 1,050 °F and are available in sizes ranging from 3 in. to 18 in. The standard hoses are constructed

with a single-ply, aluminum-coated fiberglass fabric, double-ply, silicone-coated fiberglass, single-ply Kevlar, or single-ply, neoprene-coated polyester. Other materials also are available.Flexaust

(800) 343-0428 / www.flexaust.com

IMAGERS CAPTURE INFRARED AND VISIBLE LIGHT

The P3 Series of imagers measure temperature from -20 °C to 600 °C and feature either a temperature color alarm or dewpoint color alarm, and allow voice annotation. They capture infrared and visible light images and display them fused together. All models feature high-resolution displays with infrared detector resolutions up to 320 x 240 pixels. They come with a 2 GB memory card, two rechargeable batteries that provide four hours of operating time each, AC charger/power supply, adjustable hand strap, and hard and soft transport cases.Fluke

(800) 760-4523 / www.fluke.com



PORTABLE CHILLER

The Iceman portable chillers deliver low-temperature process fluids as cold as -10 °F on mod-els to 10 tons with both air- and water-cooled condensing. The chiller’s main feature is its semi-hermetic discus compressor arrangement. Capacity control is achieved with a cylinder unloading/hot gas bypass feature and a microprocessor-based controller specifically pro-grammed for chillers. The chillers use R-507 refrigerant.Mokon

(716) 876-9951 / www.mokon.com

ELECTRIC IMMERSION HEATERS

The SmartOne line of positive tem-perature coefficient electric immersion heaters is cULus listed. The solid-state ceramic heating elements are designed not to burn out when operated in water or air or surrounded by buildup. If the temperature goes down, so does the

resistance, thereby increasing power output. If the heat transfer is restricted, the temperature increases, as will the resistance, resulting in reduced power output.Process Technology

(800) 621-1998 / www.process-technology.com

WIRELESS HUMIDITY METER/THERMOMETER

The Radio-Signal Remote Humidity Meter/Thermometer is designed to receive a radio signal from the remote wireless sensors that send signals to the main digital display every 30 sec. The unit transmits at 433 MHz with a range to 100 ft, depending on the location. Relative humidity range is 25% to 90% and the thermome-ter range is –4 °F to 140 °F. The main unit can display data from three remote sensors. A humidity and temperature alarm can sound when conditions exceed the setpoints.Control

(281) 482-1714 / www.control3.com

PRODUCT ROUNDUP



MRO MARKETPLACE

MIX THE AIRFederated Co-op Ltd. installed

five PowerfoilX fans for winter

indoor air destratification and

heating cost reduction. Trevor

Carlson, Environmental/Techni-

cal Services Manager says, “The fans immediately started bringing

the heat down, keeping workers comfortable. We saw a 10% reduc-

tion in natural gas usage when we saw a 20% increase in rates.

We saved $19,800 in the first year in natural gas consumption as

a result of the fans.” Visit www.BigAssFans.com, call (877) BIG

FANS, or e-mail us at [email protected].

Big Ass Fans

CLEAN YOUR COMPRESSOR

WHILE IT’S RUNNING

Petroleum lubricants in rotary screw and ro-

tary vane compressors result in varnish and

carbon deposits. These deposits cause a

number of serious operational problems, re-

sulting in high maintenance costs. Summit

Varnasolv is a lubricant additive that removes

and suspends varnish while the compressor is in operation. Use

Varnasolv to clean heat exchangers and high temperature chains.

(800) 749-5823 www.klsummit.com/varnasolv.pdf

Summit Industrial Products

MAXIMIZE EFFICIENCIES AND MINIMIZE COSTS

That’s just part of

the plan for any

well-run facility.

We’re here to help

with a wide variety

of energy efficiency and rebate programs. From customized solutions

to equipment efficiency, you can choose from a variety of options.

Visit ResponsibleByNature.com/Business to learn more.

(800) 481-4700

Xcel

ROTATING UNION CATALOG

Deublin has a new, updated 56-page catalog

that includes complete information for

selecting unions for a variety of applications,

from water and steam, to air and hydraulic,

oil and coolant. Both operating data and di-

mensional specifications are provided in one

comprehensive catalog, along with

installation and service information. The

catalog is available free via reader response.

Call (847) 689-8600 or e-mail [email protected].

Deublin Co.

OVERHEATING CONTROL PANELS?

Solve thermal problems before they start

or retrofit existing NEMA enclosures with

a Noren Products Heat Exchanger. Use the

power of heat pipe technology and reduce

your energy consumption by as much as

90% over other solutions. Noren Products

– Thermal Solutions for a high-tech world.

(650) 322-9500

www.norenproducts.com/ps

Noren Products

EXPANDED OIL SKIMMING

APPLICATIONS SOURCEBOOK

Abanaki’s 47-page handbook offers application

notes on 40 real-world implementations of oil skim-

ming, the lowest-cost way to remove oil from water.

Expanded second edition is indexed by industry and

application. Includes food processing, machining, manufacturing,

grease/water separation, groundwater remediation, and wastewater.

1-800-358-SKIM (7546) www.abanaki.com/216

Abanaki Corporation

PUMPS FOR INDUSTRIAL APPLICATIONS As the world’s leading manufacturer of pumps and

pumping systems, Gorman-Rupp offers you access

to one of the largest and highest quality lines of

industrial pumps available in the marketplace today.

Our products include self–priming centrifugal,

standard centrifugal, submersible, priming-assisted,

rotary gear, diaphragm and ReliaSource Industrial

Pump Packages. 419-755-1011 www.GRpumps.com

The Gorman-Rupp Company

AERO-MOTIVE COMPACT AB BALANCERS

Designed to allow workers to move suspended tools

or objects with minimal effort, the Aero-Motive

compact AB Balancers retain the same superior

spring performance for optimal tool balance, while

accommodating tighter work spaces and reducing

work area clutter and risk of accidental tool droppage

or start-up during handling. Suitable for a range of

manufacturing industries and assembly applications.

(800) 225-7724 www.molex.com

Molex

PS1203_47_AdLits.indd 47 3/1/12 11:56 AM


CLASSIFIEDSPRODUCTS AND SERVICES

ADVERTISER INDEX

Adalet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Agilent Technologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Allied Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Atlas Copco Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

AutomationDirect.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Baldor Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Big Ass Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Denso Sales California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Diamond Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Eventful Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Flir Commercial Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Fluke Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gardner Denver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

IFS North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Kaeser Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Kluber Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

La-Man Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Master Bond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Molex/Woodhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Nilfi sk-Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Noria Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,39

Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

PCB Piezotronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Robinson Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Sauereisen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

SPX Flow Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Summit Industrial Products . . . . . . . . . . . . . . . . . . . . . . . . .28

Thomas & Betts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Xcel Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

MIKE BRENNER,

GROUP PUBLISHER

AR, AZ, Northern CA, CO, ID, IL, MN, MT, NE,

NV, NM, ND, OK, OR, SD, UT, WA, WI, WY

Phone: (630) 467-1300, ext. 487

Fax: (630) 467-1120

e-mail: [email protected]

JERRY BURNS,

DISTRICT MANAGER

AL, Southern CA, CT, DE, FL, GA, LA, ME,

MD, MA, MS, NH, NJ, NY, NC, PA, RI, SC, TX,

VT, VA, DC, WV

Phone: (630) 467-1300, ext.427

Fax: (630) 467-1120


MICHAEL CONNAUGHTON,

ACCOUNT EXECUTIVE

IA, IN, KS, KY, MI, MO, OH, TN, Canada,

Literature Reviews, Inside Print and Digital SalesPhone: (513) 543-6432

Fax: (630) 467-1120


SALES OFFICES

POLLY DICKSON,

INSIDE SALES MANAGER

Classifi eds

Phone: (630) 467-1300, ext.396

Fax: (630) 364-4175


NORM KLIEMAN,

INSIDE SALES MANAGER

Digital Sales

Phone: (630) 467-1300, ext.344

Fax: (630) 467-1120


SUBSCRIPTION INFORMATION

(888) 644-1803 or (847) 559-7360

REPRINTS

JILL KALETHA

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

PUTMAN MEDIA, INC.

555 W. Pierce Rd., Ste. 301,

Itasca, IL 60143

Phone: (630) 467-1300,

Fax: (630) 467-1120

CUSTOM REPRINTS

For additional information, please contact Foster Printing Service, the official reprint

provider for Plant Services.

Call 866.879.9144 or [email protected]

New Product Announcements

Sales Aid For Your Field Force

PR Materials & Media Kits

Direct Mail Enclosures

Customer & Prospect Communications/Presentations

Trade Shows/Promotional Events

Conferences & Speaking Engagements

Recruitment & Training Packages

PS1203_48_49_CLASS.indd 48 3/1/12 11:57 AM


HOT & DIRTYCONTROL

ENCLOSURES?

Filter/Ventilators forcefullyblow out hot air & cool withfinely filtered ambient air!Less $$ than AC or VortexTubes! Five models for anysize enclosure! Since 1980!

ElectraKool

OILY WATER?

Collect economically! Severaltypes with 1 qt - 100 gph rates!Reach from 5” to 100 ft. down!Also use with coolants & partswash fluids! Thousands in usesince 1990!

Mini & MAXI-SkimmersTM

View product info atwww.wayneproducts.com

call 800 255-5665 or email [email protected]

OIL MIST & SMOKEIN YOUR SHOP?

www.mistcollectors.com

Tel: 1-800-645-4174

Buildings available up to

300' wide.

Low in cost per square foot.

Natural daytime lighting.

Easy to relocate.

Expandable.

Sustainable Design-Build Solutions

fabric structures

Call one of our ClearSpan specialists at 1.866.643.1010 or visit us at www.ClearSpan.com/ADPS2.

TUBE TYPE OIL SKIMMERS

Contact Brian - [email protected] 330-774-5044 330-757-7606 Fax

Skim Oils, Fats, And Grease 24/7 TigerTube® Collector Tubing

Model 6V Skimmer TubesSave 30% On New Collector Tubes

www.skimtech.com

STAND OUTFROM THE

CROWD

PLANT SERVICES HAS THECAREER RESOURCES

NEEDED TO FINDTHE PERFECT JOB.

Job search today atJOBS.PLANTSERVICES.COM

Plant ConnectionTHE CAREER RESOURCE FOR PLANT ENGINEERING PROFESSIONALS

PS1203_48_49_CLASS.indd 49 3/1/12 11:48 AM


WAGE WAR ON ENERGY IMPACTThe U.S. Army recognizes the value of net-zero waste, water, and emissions

In January, I had the honor to speak at a meeting of an organization that’s spelling out its route to having “net zero” energy impact for its facilities here and around the globe. The organization developed a logo for the program that summarizes the pathway to zero waste, zero water, and zero GHG emissions: Reduction, Re-Purposing, Recycling and Composting, Energy Recovery and Disposal. With branding like that, it might come as a surprise that this organization is the U.S. Army and not a group of environmental optimists.

Armies from the days of Genghis Khan understood the value of conservation. The most key but vulnerable part of any military’s effectiveness is its supply line, whether this is diesel tankers under threat on the road to Afghanistan, the electricity grid supplying West Point, or the horse and cart bringing wood to warm Napoleon’s soldiers in a Russian winter. It’s the most expensive variable, with gasoline cost-ing many times the price you pay at the local gas station.

Recognizing the strategic advantages of achieving near 100% renewable energy supply, the U.S. Army committed to achieve net-zero emissions at five major facilities by 2020. This will be replicated across another 25 bases by 2025. This is being done as much to reduce costs as it is to reduce risks from non-conventional attacks and other supply failures.

The U.S. Army benchmarked its performance around the world before designing the program. It reviewed its facili-ties and discovered its Japanese and European facilities were among the most efficient. The Army talked with agencies of other countries through the International Energy Agency to develop ways to retrofit buildings and assets. In fact, the U.S. Army Corps of Engineers chairs the committee that produced one of most comprehensive tool kits for assessing and retrofitting government facilities.

Based on its benchmarking, the U.S. Army realized that, to achieve net zero, it could borrow from the municipal and neighborhood Integrated Energy Master Planning common in Europe’s towns and cities. Recognizing that true patrio-

tism must be as effective as possible, the U.S. Army put the not-invented-here argument aside and teamed with global experts to develop energy master plans.

The pilot sites for the program include West Point and Fort Detrick, major training and storage sites in California, along with the electronic intelligence site at Kwajalein Atoll in the Marshall Islands, where electricity is produced from diesel generators with the fuel shipped in by tanker. The value of energy conservation there is self-evident.

The Army follows the classic loading order. The highest priority is energy and fuel efficiency, supported by effec-tive metering and controls. This is followed by integration, including upgrading heating and cooling networks. Supply security and efficiency are enhanced by on-site cogeneration. Once these are implemented, the site can be considered net-zero-ready with the last gap to zero emissions closed with various renewable electricity, thermal, and fuel options.

The value of efficiency was highlighted in Iraq. Insulating tents vastly reduced the need for fuel to power air condition-ing. This reduced the number of tankers that had to navigate dangerous supply routes. Efficiency was measured not only in dollars, but, far more importantly, in lives not lost.

The conference speakers exhibited a passion that went be-yond serving their units’ mission through the rational use of valuable resources. I saw their pride in being pathfinders for the wider community. If a large base can go net zero, so can the nearby city. I also detected that many clearly understood the science and risks of climate change and that their efforts could be the basis for a truly global contribution. The U.S. Department of Defense considers climate change to be one of the greatest security threats to the United States.

There was also a clear understanding that becoming net zero would require effective long-term planning and a systematic process. This couldn’t be achieved without engag-ing the senior leadership and everyone else on the base, and plans were developed to ensure this, as well. It was fascinat-ing to see the clear understanding that doing the right thing for the planet and the country wasn’t an optional extra, but was core and center to the U.S. Army’s mission. There surely are lessons for us to take from this level of understanding and organizational commitment.

Peter Garforth is principal of Garforth International, Toledo, Ohio.

He can be reached at [email protected].

ENERGY EXPERTPETER GARFORTH

THE U.S. ARMY PUT THE NOT-INVENTED-

HERE ARGUMENT ASIDE AND TEAMED

WITH GLOBAL EXPERTS TO DEVELOP

ENERGY MASTER PLANS.

PS1203_XX_ENERGYEXPERT.indd 50 3/1/12 10:06 AM

PS1203_FPA.indd 51 3/1/12 9:10 AM

© 2012 Thomas & Betts Corporation. All rights reserved.

Cut downtime, lower installed costs

BlueKote®

Conduit BodiesTrap-Eze ™ Connector

MaxGard ® Interconnection System

E-Z-Ground ®

Grounding Connectors

High-Temperature Wire Joints

Extra High-Temp Cable Ties

BlueKote® internal surface coating reduces force required to pull wires

coating

the trapeze

reused upon

of a trapeze

with standard NeopreneO-ringed interior components for watertight seal

construction for electrical

®” lock

Quicker disconnect – no cutting through melted tape or tough insulation. No risk of injury to installer.

Greater reliability – high-conductivity tin-plated copper, compression-crimp disconnects from 600V to 5kV.

Faster assembly –just snap together. No nuts, bolts, washers or insulating tape.

Easier insulation –simply slide on reusable insulation boot.

Change out electric motors faster, safer with Color-Keyed ® Motor Lead Disconnects

welding; reduces risk of poor

conditions

®

representative or visit www.tnb.com

PS1203_FPA.indd 52 3/1/12 9:11 AM

PLS20120301

Documents

Transcript of PLS20120301