Plant Engineering April 2013

41 Selective coordination
47 Pipe joining systems
54 Fall arrest solutions
Brands You Count On,
3 573 Locations 3 14 Distribution Centers 3 50 Repair Facilities 3 Over 5.2 Million Quality Parts 3 Over 3,300 Sales Representatives 3 Extensive Training Programs 3 Over 200 Field Product Specialists in the following categories:
Bearings MeChaniCal Power TransMission eleCTriCal & indusTrial auToMaTion linear MoTion ProduCTs PneuMaTiCs hydrauliCs hydrauliC hose indusTrial hose MaTerial handling ProCess PuMPs & equiPMenT safeTy ProduCTs indusTrial ProduCTs seals & aCCessories
Motion Industries understands that machines least expect, leaving you with costly downtime Between extensive inventories and expertise get the right replacement parts to help reduce relationships with the suppliers you prefer, y you need them.
But our commitment doesnt stop there. Motion to support our customers with repairs and fabri specialized cost-savings programs and much m tapered roller bearing or a storeroom replenish
Motion Industries
C C V
People You Trust
and equipment usually break at times you if you dont get back up and running quickly. from over 500 branches, rest assured youll e costly downtime. And because we have you get the products you count onwhen
Representing North Americas Leading Brands In MRO Replacement Parts

Motion Industries partners with respected suppliers to provide quality, reliable brand namesresulting in solid, cost-effective product performance. Our partners include:
n Industries provides a wide range of services ication, inventory and storeroom management, more. So whether you need a hard-to-find hment system, count on the people you trust.
sMore Than Bearings
Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 550 Locations
Follow us on facebook.com/MotionInd
Best prices on pneumatics

Buy direct and save on high-quality components
All Stainless Steel Pneumatic Cylinders - F Series

The NITRA Pneumatics F-Series non-repairable round body stainless steel cylinders includes bore sizes from 3/4 to 2 and stroke lengths from 1/2 to 18 to meet a broad range of applications including washdown and corrosive environments. All Stainless Steel Pneumatic Cylinders - F Series - start at: $66.00 (F12005DN) Cylinder bore sizes from 3/4 to 2 Air Cylinder stroke lengths from 1/2 to 18 Double-acting cylinders Three pneumatic cylinder mounting congurations Also available is the A series non-repairable cylinders, with stainless bodies and aluminum end caps. In bore sizes from 7/16 to 2, the A series starts at just $10.50.
More cylinder series also interchangeable with popular brands

Dual Rod Guided Pneumatic Cylinders - "E" Series - start at: $94.00 (E12M010MD-M) 90 sizes available Eight bore sizes from 12mm to 63mm Cylinder stroke lengths from 10mm to 250mm Double-acting cylinders Compact Pneumatic Cylinders - "C" Series - start at: $34.50 (C090025D) Cylinder bore sizes from 9/16" to 3" Cylinder stroke lengths from 1/4" to 4" Double-acting mini air cylinders Interchangeable with other mini actuator, at cylinder or pancake cylinder brands
Tubing and Hose Fittings and Air Couplings Solenoid Valves and Manifolds
Heavy Duty NFPA Tie Rod Pneumatic Cylinders - "D" Series - start at: $96.00 (D24010DT-M) Cylinder bore sizes: 1-1/2", 2", 2-1/2", 3-1/4", 4" Cylinder stroke lengths from 1" to 24" Double-acting cylinders Flange, pivot and clevis cylinder mount options available
www.automationdirect.com/pneumatic-parts
www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order.
1-800-633-0405
Air Preparation Digital Pressure Switches/Transmitters Solenoid Valve Cables Pneumatic Air Blow Guns
Also Available
input #2 at www.plantengineering.com/information
Plant Maintenance and Operations
Miniature Infrared Temperature Sensor With Optional High-Ambient Sensing Head and Touch Screen Display "Ideal for Tight Spaces"
OS-MINI Series Starts at $ 302
Miniature Sensing Head and Configurable Electronics Module Screen Color Change Indicates Alarm Mode Optional Touch Screen for Temperature Indication and Configuration Optional High-Ambient Sensing Head Withstands Up to 180C (356F) Without Cooling Visit omega.com/os-mini
Humidity/Temperature Transmitter
HX400 Series Starts at $ 495
Compact Thermal Imager
Powered By
iBorescope for iPad/iPhone for WiFi-Enabled Real-Time Video Capture and Display on iPad/iPhone Platforms
*OSXL-I Series Starts at $ 1195
HHB-ISCOPE Starts at $ 299
Visit omega.com/hx400
Visit omega.com/osxl-i_series
Visit omega.com/hhb-iscope
omega.com
COPYRIGHT 2013 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

*Note: Not for Export - US & Canada only
[ MOTOR TRUTH #6 ]
Dont get torqued off. Get TorqLOC!

Cant remove your corroded gear unit from your machine shaft? Stop fretting about it. Get SEWs patented, stainless steel TorqLOC! With its keyless shaft and taper bushings, you can say goodbye to disassembly nightmares. Not only does TorqLOC eliminate your maintenance headaches, it also eliminates belts, chains, and sprockets to reduce your energy costs. Visit sewmotortruth.com/truth6 to learn all the ways to maximize your system efciency.
sewmotortruth.com/truth6 864-439-7537
Whats INside
6 Interactive 9 In Focus 56 Innovations 61 Product Mart 62 Internet Connection 63 Advertiser Contacts 64 In Conclusion 25 In Practice
March 2013
Volume 67, No. 2
17 Energy management
PLANT ENGINEERING (ISSN 0032-082X, Vol. 67, No. 2, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/ COO/Co-Founder. PLANT ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@ cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/ yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
Cover Story
30
Maintenance as a pro t center

The average impact of unplanned downtime in process industries is $20 billion, or almost 5% of production, according to a 2011 ARC Advisory Group report. With every 10 workers retiring, only five will take their place, which means fewer skilled people will be trying to support ever more advanced and technically interconnected plants. A strategic plan is in order, and it is in order right now if any facility is expecting to survive the continued national and international competitive pressures. 32 Selecting a maintenance vendor 35 Providing a saner approach to maintenance 36 Is your plant a profit center or a profit eater? 38 The evolution of work processes can deliver revolutionary results
www.plantengineering.com
PLANT ENGINEERING
March 2013 3
Courtesy: Rockwell Automation
Weld Smoke Collector
Paper Scrap Handling Systems
Abrasive Blast Dust Collectors
Laser Cutting Smoke
Looks Like a Safe Because Its

Bag-in Bag-out Filter Change
Large Agriculture Installations
TM
Food Processing Dust
Dust From Thermal Spraying
Dust From Chop Saw
Plasma Cutting Smoke Collector
is the most rugged, reliable, easy to maintain dust collector on the marketGUARANTEED!
Plant Engineers, the Camfil APC Farr Gold Series
The Farr Gold Series modular design allows for virtually unlimited customization and our exclusive stocking program assures that your Farr Gold Series is delivered when you need it.
Call us about NFPA and ATEX Explosive Dust compliance issues.
Toll Free:
International Calls:
866-354-8794
AIR POLLUTION CONTROL
1-870-933-8048
Follow. Connect. Watch. Learn.
www.camfilapc.com
Virtual ride and fly through a Farr Gold Series
9 In Focus
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph 630-571-4070, Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager 630-571-4070 x2212, BVavra@CFEMedia.com AMANDA MCLEMAN, Project Manager 630-571-4070 x2209, AMcLeman@CFEMedia.com BEN TAYLOR, Project Manager 630-571-4070 x2219, BTaylor@CFEMedia.com MARK HOSKE, Content Manager 630-571-4070 x2214, MHoske@CFEMedia.com AMARA ROZGUS, Content Manager 630-571-4070 x2211, ARozgus@CFEMedia.com PETER WELANDER, Content Manager 630-571-4070 x2213, PWelander@CFEMedia.com BRITTANY MERCHUT, Content Specialist 630-571-4070 x2220, BMerchut@CFEMedia.com CHRIS VAVRA, Content Specialist 630-571-4070 x2207, CVavra@CFEMedia.com
New wave of technology moves beyond theory Checklist for robotics survival Putin to open Hannover Messe 2013 on April 7 ARC president: Pick up the pace of technology adoption Training, mentoring needed to address skilled worker shortage Innovative energy management strategies help a Maine paper mill stay competitive Reduced corrective maintenance is found money Staying ahead of the curve
25 Benchmark your manufacturing
In Practice
performance to deliver results
Manufacturing leaders must establish production schedules, optimum workflows, effective maintenance procedures, and continuous improvement programs that will keep the organization moving forward.
PUBLICATION SERVICES
JIM LANGHENRY, LANGHENRY Co-Founder & Publisher 630-571-4070 x2203, JLanghenry@CFEMedia.com STEVE ROURKE, Co-Founder 630-571-4070 x2204, SRourke@CFEMedia.com TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com ELENA MOELLER-YOUNGER, Marketing Manager 630-571-4070 x2215, EMYounger@CFEMedia.com MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com PAUL BROUCH, Web Production Manager 630-571-4070 x2208, PBrouch@CFEMedia.com MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com MARIA BARTELL, Account Director, Director Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com RICK ELLIS, Audience Management nagement Director 303-246-1250, REllis@CFEMedia.com LETTERS TO THE EDITOR Please e-mail your opinions to BVavra@CFEMedia.com or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity. INFORMATION For a 2013 Media Kit or Editorial Calendar, e-mail Trudy Kelly at TKelly@CFEMedia.com. REPRINTS For custom reprints or electronic usage, contact: Wrights Media Nick Iademarco Phone: 877-652-5295 x102 Email: niademarco@wrightsmedia.com
Electrical Solutions
41 Achieving effective
selective coordination design
The concept of full selective coordination has changed the way engineers must think when designing electrical distribution systems.
Mechanical Solutions
47 Pipe joining systems
get in the groove
Of all the pipe joining methods available, maintenance on HVAC systems installed using grooved piping products is the fastest, most efficient, and simplest to perform.
Maintenance Solutions
PUBLICATION SALES
Tom Corcoran, West, TX, OK 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Karen Cira, Southeast 879 Autumn Rain Ln. Charlotte, NC 28209 Patrick Lynch, AL, FL 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Kerry Gottlieb, N. Central 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Richard A. Groth Jr., NJ/ E. PA 12 Pine St. Franklin, MA 02038 Stuart Smith, International SSM Global Media Ltd.
TCorcoran@CFEMedia.com Tel. 215-275-6420 Fax 484-631-0598 KCira@CFEMedia.com Tel. 704-523-5466 Fax 630-214-4504 PLynch@CFEMedia.com Tel. 630-571-4070 x2210 Fax 630-214-4504 KGottlieb@CFEMedia.com Tel. 312-965-8954 Fax 630-214-4504 RGroth@CFEMedia.com Tel. 774-277-7266 Fax 508-590-0432 stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588
51 Fall arrest solutions require
attention to detail, not scale
Big or small, implementing a fall protection system requires considering a number of factors. The project size is not one of those factors.
53 Making sense of process safety

A Process Safety Management (PSM) program and a more focused National Emphasis Program (NEP) are relatively new to U.S. manufacturing. While PSM-NEP makes sense, we must begin to make sense of it.
PLANT ENGINEERING
March 2013 5
MARCH
Is your plant a Top Plant?

2013 contest opens April 1 Deadline is Sept. 16, 2013.
www.plantengineering.com/top-plant
Connect with us!

www.facebook.com/PlantEng www.linkedin.com Group: Plant Engineering Professionals www.twitter.com/PlantEngMag
Media library
Exclusive blogs at www.plantengineering.com/blogs

CMMS horror stories: Five reasons a CMMS implementation can fail Machine Safety: Serious machine guarding issues Machine-tool industry limiting growth in the motion control market Government in the power business
Videos and Webcasts on demand Online training center Engineering education center Case studies130+ all in one place on dozens of topics Have you looked at an eGuide? Useful white papers on many topics
LinkedIn: Plant Engineering Professionals

Plant Engineerings LinkedIn audience has more than 2,200 manufacturing professionals from six continentsand were working on nding our rst manufacturing professional from Antarctica. Join the discussion in the Plant Engineering Professionals group at www.linkedin.com.
Services available
Site search engine: Search current and past articles at www.plantengineering.com by topic, keyword, author or company name to nd solutions to your plant issues. Channels, new products
Visit our specialized microsites providing feature news, products, applications, tutorials and research for engineering professionals.
Industry news
Here are the top stories for this month on www.plantengineering.com: PMI surges to highest point in almost two years Automation project road map: Advice for the journey ARC study: Additive manufacturing creates powerful incentive Hot technology jobs: arti cial intelligence, robotics ABB to fund 40 global research projects To keep up with important industry news, go to www.plantengineering.com/industry-news.
E-newsletters
Keep current with the latest information and news with our weekly Plant Mail and topicspeci c electronic newsletters.
Point, click, watch

SPECIAL REPORT: The electrical infrastructure business
Don Rickey, senior vice president for the U.S. Infrastructure Business at Schneider Electric discusses the medium-voltage electrical distribution business and a host of other items. Scan the QR code or visit www.plantengineering.com/videos.
System Integrator Guide
Consult our listing of more than 2,300 automation system integrators. You can nd a speci c company or run a seven-way multi-parameter search.
Digital edition
Plant Engineering is delivered every month in a digital format, with enhanced features to bring the print product alive on your screen.
6 March 2013
PLANT ENGINEERING
The Truth About Compressed Air!

If you think compressed air is too expensive and noisy - read this. The facts will surprise you!
Compare these Blowoffs

ere are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four dierent blowo methods: drilled pipe, at air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. e following comparison proves that the EXAIR Super Air Knife is the best choice for your blowo, cooling or drying application. e goal for each of the blowo choices was to use the least amount of air possible to get the job done (lowest energy and noise level). e compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water o. e blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. e table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd conguration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).
Facts about Blowers

Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of lters, belts and bearings. Here are some important facts: Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000. Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate eective airows. Poorly designed seals that allow dirt and moisture inltration and environments above 125F decrease the one year bearing life. Many bearings can not be replaced in the eld, resulting in downtime to send the assembly back to the manufacturer. Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often dicult to control since mechanical adjustments are required.
To discuss an application, contact:
Drilled Pipe
is common blowo is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. e initial cost of the drilled pipe is overshadowed by its high energy use. e holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.
Blower Air Knife

e blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and at air nozzle, but was comparable to EXAIRs Super Air Knife. e large blower with its two 3" (8cm) diameter hoses requires signicant mounting space compared to the others. Noise level was high at 90 dBA. ere was no option for cycling it on and o to conserve energy like the other blowos. Costly bearing and lter maintenance along with downtime were also negative factors.
Flat Air Nozzles

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. e at air nozzle provides some entrainment, but suers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers oer at air nozzles where the holes can be blocked an OSHA violation. Velocity was inconsistent with spikes of air.
EXAIR Super Air Knife

e Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airow. e sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and o is possible. Safe operation is not an issue since the Super Air Knife can not be deadended. Maintenance costs are low since there are no moving parts to wear out.
EXAIR Corporation 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 Fax: (513) 671-3363 email: techelp@exair.com www.exair.com/79/423.htm
The Super Air Knife is the low cost way to blowoff, dry, clean and cool.
See the Super Air Knife in action. www.exair.com/79/akvideo.htm
Blowo Comparison
Comp. Air Type of blowo Drilled Pipes Flat Air Nozzles Blower Air Knife Super Air Knife PSIG BAR 60 60 3 60 4.1 4.1 0.2 4.1 SCFM 174 257 N/A 55 SLPM 4,924 7,273 N/A 1,557 Horsepower Required 35 51 10 11 Sound Annual Approx. Annual Purchase Level Electrical Maintenance Price dBA Cost* Cost 91 102 90 69 $50 $208 $5,500 $534 $4,508 $6,569 $1,288 $1,417 $920 $1,450 $1,500 $300 First Year Cost $5,478 $8,227 $8,288 $2,251
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost re ects 40 hours per week, 52 weeks per year.
Now save time, money and space with BULK-OUT multi-function dischargers
Condition, de-lump, screen, feed, weigh batch, combine with liquids, and convey as you discharge, with a custom-integrated, performance-guaranteed discharger system from Flexicon
Dual Bulk Bag Weigh Batch Eductor conditions, discharges by weight, and blends into a liquid stream Bulk-Bag-To-Bin Weigh Batching System discharges, de-lumps and feeds material gravimetrically Continuous Loss-of-Weight Bulk Bag Unloader allows continuous gravimetric discharging Bulk Bag Unloader for Pneumatic Conveyors has surge hopper with rotary airlock feeder for metering Sanitary Bulk Bag Discharger with patented USDA-accepted flow control valve cleans rapidly
Bulk Bag Unloader for Pneumatic Conveyors has surge hopper with non-flowthrough pick-up adapter
Bulk Bag ConditionerUnloader loosens solidified material, then discharges, de-lumps and conveys
Half Frame Unloaders with Conveyor or Airlock require forklift, eliminating cost of upper frame
Combination Bulk Bag Discharger and Manual Dumping Station has multipurpose hopper interface
Split-Frame allows loading of bag frame or rigid bins onto subframe within 4 in. (100 mm) of ceiling
Unlimited configurations: All Flexicon dischargers are available as fully enclosed, dust-free systems with durable industrial finishes or in stainless steel finished to food, dairy, pharmaceutical or industrial standards, and as weigh batching systems complete with automated controls and pneumatic or mechanical conveying systems.
Flexicon innovations: SPOUT-LOCK clamp ring*: forms high-integrity seal between clean sides of bag and equipment TELE-TUBE telescoping tube: maintains constant downward tension on spout as bag empties/elongates, promoting complete discharge POWER-CINCHER flow control valve*: allows retying of partially empty bags dust-free by cinching spout concentrically.
See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems
USA sales@flexicon.com 1 888 FLEXICON
CHILE UK AUSTRALIA SOUTH AFRICA
+56 +44 +61 +27
2 2415 1286 (0)1227 374710 (0)7 3879 4180 (0)41 453 1871
BB-0470
2013 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world. *Patent(s) granted and/or pending.
IN FOCUS
Next wave of technology moves beyond theory
2013 Robotics Industry Forum speaker takes a long look into the future of everything.
By Mark T. Hoske, CFE Media
The fourth wave of innovative technology jobs will involve computers, telecommunications, biotechnology, artificial intelligence, and robotics, according to Dr. Michio Kaku, American theoretical physicist, best-selling author, TV host, and Feb. 21 keynote speaker at the 2013 Robotics Industry Forum, held in Orlando, Feb. 20-22. He also praised engineers in general and physicists in particular, credited for inventing the transistor, laser, computer, Internet, World Wide Web, TV, radio, x-rays, radar, the microwave, PET scans, the space program, and GPS satellite, among other innovations. Kaku, who is continuing work started by Einstein on a grand unified theory of the universe, has made the New York Times best seller list twice, with Physics of the Future, citing 300 top scientists, and Physics of the Impossible, a look at life and science 500 to 1,000 years in the future. Even so, in his keynote presentation, The Future of Technology, Kaku cited Yogi Berra, credited with explaining that prediction is very hard to do, especially if its about the future. Even so, hindsight is marvelous, showing that many economic downturns came after unsustainable economic speculation that followed waves of engineering innovation. Engineering innovation, he said, is the origin of all wealth. He called the first wave of economic innovation the rise of steam power in the 1800s, which was followed by the crash of 1850, resulting from more than 200 stocks on the London exchange related to steam poweran unsustainable number. The second wave resulted from innovations from electricity, magnetism, and the internal combustion engine, leading to speculation surrounding utilities and automotive stocks on the NYSE, a bubble that burst in 1929, Kaku said. The third wave came 80 years later, with high technologies, such as lasers,
computers, satellites, telecommunications, and the Internet, which led to the real estate bubble and what Kaku called the unsustainable Mediterranean lifestyle of Europe, leading to the 2008 recession, still felt in Europe today.
Robotics and other automation replace dull and dangerous jobs and we should celebrate that. Innovation is the source of jobs. Dont let bad press by 60 Minutes define you.
Dr. Michio Kaku
The fourth wave, Kaku said, will be telecommunications, computers, biotechnologies, artificial technologies, and nanotechnologies, driven and supported by motion control, machine vision, and robotics.
In each wave, there are those who resist, Kaku observed, and those who have resisted often faced bankruptcy and/ or unemployment. The automobile put many blacksmiths and stable hands out of work, but new jobs were created. Kaku challenged attendees, noting that recent negative coverage of robots is the latest in this nay-saying trend: Who will define your industry? Will you define yourself or will you allow your competitors to do so? Kaku said, Robotics and other automation replace dull and dangerous jobs, and we should celebrate that. Innovation is the source of jobs. Dont let bad press by 60 Minutes define you, he said, talking about the piece that suggested use of robots results in fewer jobs, when examples and research suggest otherwise. The progression of Moores Law is tied to the wealth and power of nations, Kaku said: Now, we have more computing power in our pocket cell phone than all of NASA did in 1969 to put men on E the moon. P
Checklist for robotics survival
obot designers who ignore one or more of three principles are doomed to fail, according to a roboticist with 22 patents who has worked for three robot companies and MIT Robotic Lab. Joseph L. Jones, co-founder and chief technology officer, Harvest Automation, told attendees at the Robotics Industries Forum about a checklist for robot survival. How are robots like sea turtles? For each 1,000 sea turtles hatched, only one lasts to adulthood. Its about the same statistic for robots. Robot
designers need to be really careful in choosing which robots to build, Jones said. He also worked at iRobot (which has sold 9 million Roomba robotic vacuums) and at Denning Mobile Robotics. In 30 years of watching the robotic industry, hes observed three key elements that need to be present with any robot project for success. 1. Do something that lots of people want done 2. Be built with existing technology, and
PLANT ENGINEERING
March 2013 9
IN FOCUS
3. Be cost-competitive with current solutions. pots are unloaded from wagons. After I observed that, While this seems perfectI thought, If we cannot ly logical, when in the thick build a cost-effective of things, roboticists usurobot to do this, were ally ignore one and often in the wrong business, all three, Jones said. In his Jones said. talk, Small Mobile Robots The first model, for Agriculture, Jones disHarvest Automacussed his current efforts at tion HV100, costs Harvest Automation, foundabout $30,000, with ed in 2007, return on investment now with 40 after 12-18 months employees. of use, Jones said. The Harvest Automation HV100 nursery Hes making Addressing labor scarand greenhouse robot is flexible and robots for city issues, Harvests scalable, fault tolerant, inherently safe agriculture. A robots are designed for operation near people, and easy and nursery and to work alongside intuitive to set up and operate. All greenhouse people, not replace photos courtesy of Harvest Automation. robot is the them, in a growers companys first product. operation, to create a Plants sold in garden stores often are grown in pots in sustainable workforce combining robots and people open fields that extend to the horizon. Armies of hardto increase efficiency, reliability, and plant quality, he to-find workers manually space pots in the field after the E noted. P
Only a Fluke ScopeMeter Oscilloscope is tough enough to take on the industrial world.
When its too dirty and dangerous for ordinary scopes, and a multimeter isnt quite enough, take a ScopeMeter Oscilloscope. Built to solve tough problems in harsh industrial environment, ScopeMeter even has a multimeter built-in, plus its: Rated CAT III 1000 V/ CAT IV 600 V The only completely sealed, drip proof, dust-proof, IP-51 rated scope Loaded with functions to make using an oscilloscope easy
uke.com/scopemeteristough
Watch how ScopeMeter was created:
IN fOCUS
ITS WHATS ON
THE INSIDE
No matter who made your dust collector, you can count on Donaldson Torit to have your next lter replacement. With more than 90,000 lters in stock, there is a Donaldson Torit lter to t most makes, models, sizes and styles of collectors. And, with our Ready2Ship program, your lters will be on their way within 24 hours. For the best lter selection and performance, Donaldson Torit has EXACTLY WHAT YOU NEED.
THAT COUNTS
Putin to open Hannover Messe 2013 on April 7
Learn more
DonaldsonTorit.com 800.365.1331
2012 Donaldson Company, Inc.
ussian president Vladimir Putin will help open Hannover Messe 2013 as part of Russias status as partner nation at this years event, April 8-12 in Hannover, Germany. The Russian head of state will be in the Hannover Congress Centrum for the opening ceremony on Sunday, April 7, and will also take part in the traditional opening tour of Hannover Messe on Monday, April 8. On both occasions, President Putin will be accompanied by German Chancellor Angela Merkel, who this year will again officially open the worlds most important technology event. We are delighted to have received confirmation of President Putins visit, said Dr. Jochen Kckler, member of the Board at Deutsche Messe AG. His presence offers convincing evidence of the international status enjoyed by Hannover Messe and at the same time underlines the importance of the Partner Country program. Every year a different country is invited to step into the spotlight and act as the Partner Country at Hannover Messe. This year, the Russian Federation will be the focus of attention, not only within the exhibition itself but also throughout the entire program of forums, conferences, and events that traditionally accompanies the worlds leading trade show. The lead theme of Integrated Industry signals Hannover Messes strong focus on the current trend toward integration across all areas of industry. Integrated Industry is about making industrial production smarter and more efficient. Its also about multidisciplinary cooperation between different industries and different enterprises, Dr. Kckler said. Hannover Messe 2013 will comprise 11 flagship fairs: Industrial Automation; Motion, Drive & Automation (MDA); Energy; Wind; MobiliTec; Digital Factory; ComVac; Industrial Supply; IndustrialGreenTec; Surface Technology; and E Research & Technology. P For more information, go to www.hannovermesse.de. Photo courtesy of Hannover Messe.
plant engineering
12 March 2013
Equipment de-energized during upgrade
Spending too much time and money on aging equipment?

Cost-effective electrical distribution upgrade solutions are available.
If your company is like most, it has reduced capital and operating budgets but still expects everything to run as it always has. Schneider Electric Services helps you renew equipment while staying within budget. Our nationwide team of quali ed technicians can upgrade existing switchgear no matter the make or model. By using proven technology like Masterpact replacement circuit breakers, we can revitalize aging equipment without the need for prolonged shutdowns saving you time and money. From equipment start-up to maintenance and testing services to custom equipment solutions, Schneider Electric Services is available 24/7, 365 days a year. Find out what we can do for you.
TM
Square D Services is now Schneider Electric Services!

Our proven electrical distribution services and solutions will continue to help customers: Increase electrical reliability Extend equipment life Enhance workplace safety Improve energy ef ciency Our global presence and breadth of solutions makes Schneider Electric your single-source provider.
Make the most of your energy

Ten Tips to Optimize Switchgear Life and Enhance Reliability
November 2010 / White Paper
SM
Visit our Resource Library for FREE white papers, including Ten Tips to Optimize Switchgear Life and Enhance Reliability, PLUS enter to WIN Bose Noise Cancelling headphones!
Learn how to optimize equipment performance.
Make the most of your energy
SM
Visit www.SEreply.com Key Code y362v
2013 Schneider Electric. All Rights Reserved. Schneider Electric, Masterpact, Square D, and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other trademarks are property of their respective owners. www.schneider-electric.com 998-1174108_US_Bose
IN fOCUS
ARC president: Pick up the pace of technology adoption
Rapid growth of devices, technology use requires faster implementation on plant floor.
By Bob Vavra, CFE Media
The speed of manufacturing information adoption is accelerating, and those who stay on the sidelines will find themselves falling farther and farther behind a fully optimized plant. That was the keynote message from ARC Advisory Group president Andy Chatha at the 2013 ARC Forum in Orlando Feb. 12. All of you have data, gathering information in real time. The challenge is that we havent had good tools to analyze that data, Chatha told more than 600 attendees at the ARC event. Now we do have powerful analytical tools. We think information-driven manufacturing is the way to leverage the information. You have to be able to make sense out of the information. Chatha noted that the accelerated use of smart devices, the pervasive influences of Wi-Fi and cloud computing, and the connective nature of devices all have created enormous opportunities to leverage the data now available on the plant floor. Its much easier now to get devices connected and add intelligence, Chatha said. In my view, one thing that is happening is that the cost of adding intelligence is coming way down. Com-
With powerful tools, you can look at all processes in the plant and information outside the plantin your supply chain, for example.
Andy Chatha, ARC Advisory Group
panies should be adding intelligence to all equipment. Data should be moving toward some sort of cloud. But the key for manufacturing to take advantage of this technology is speed,
and Chatha noted manufacturing is slow to embrace speed. Technology constantly is changing. Most manufacturing companies are very conservative. They only employ technology when it has been well-proven, he said. That strategy worked fine in the past. New technologies are more disruptive, and they are moving faster. Now you have to start testing technologies faster. If you are not testing technologies, it may take you too long to catch up. Youve got to start moving a little faster to develop new technologies. Chatha sees a continuing evolution of plant floor processes. With powerful tools, you can look at all processes in the plant and information outside the plant in your supply chain, for example, Chatha said. Look at how analyzing much larger amounts of information can optimize the performance of the plant. Developing such a plan will require new relationships from existing suppliers. The automation business already is moving toward being more of a service business, Chatha said. One model is looking at signing some sort of performance-based service agreement with suppliers, based on key metrics. Systems are becoming more complex, and it is more difficult for manufacturers to upgrade E them and manage them. P
Its not about the products on our shelves.
Its what we do with our products that makes the difference.
Training, mentoring needed to address skilled worker shortage

plants, said Brooke Robertson, project manager for Momentive Specialty Chemicals. At Momentive within 5 years just in engineering, 17% of our workforce will be eliespondents to Plant Engineerings 2012 Salary Survey again placed workforce development on top gible for retirement. How are we going to be able to retain of their list of plant floor issues. Attracting that next all of this information? generation of workers requires not just a need to attract Mike Resetarits of Fractional Research Inc., a company skills, but also to satisfy the changing nature of these that does distillation research for chemical and engineering workers. companies, cited estimates of 10,000 workers a day for the That was the conclusion of a panel of experts at the ARC next 20 years leaving the workforce. Advisory Group World Forum in Orlando Feb. 12. There That means were losing 400,000 years per day of is a skills gap, but also a generational gap in how workers experience, Resetarits said. The boomer generation puts operate and how they use technology. their job high on their list of priorities. Dick Hill of ARC Group, who moderatWere losing 400,000 years It allows them to achieve all the other ed the session, noted that workers on goals they have set for their lives. per day of experience. the cusp of retirement may walk away Confronting a transition in the with more than a pension or a 401K. workforce at Fractional Research Mike Resetarits, Fractional Research Inc. Experienced workers know how took some soul searchingand some the plant runs, and know when its not running well, but its tough choices. We had a problem. We were on the verge not written down, Hill said. of losing our best engineers and best technician operaCiting a Pew Research report that called the millennial tors, Resetarits said. There were several things we did to generation digital natives, Hill noted that the next genera- prepare. It took us about a year. tion expects modern technology and progressive corporate The company put its experienced engineers and techculture to greet them on their arrival in the workplace. nicians into a room and programmed all of the plants Have you built necessary training tools and training start-up and shutdown operations into the system. When environment? Hill said. Do you have a mentoring pronew operators came on, the procedures were already program? Is your plant equipment ready for them? Is your grammed, but Resetarits said it didnt change the operasoftware application smart, because knowledge of your tional knowledge in the department. current workers is going to go away? They embraced it, he said. They never stop thinking. That reality has forced companies such as Momentive They dont just push the button. They think about the proSpecialty Chemicals to change the way they train and cess, and the computer program corroborates what they deploy employees. New employees are learning the right were going to do anyway. way to operate the plant, and we want them to be able to Within that transition were some veteran workers who train cross-functionally. We can share resources between were unwilling to change. We had some people who
Get more from your MRO products provider.

Experience the independent difference with your local IDC Distributor at
www.IDC-USA.coop/difference
Does your CBM
analyst collect data
IN fOCUS
proved to me that they did not want to work with us. Theyre gone, he said. We released 11 people and none of those were easy, but now we have a group of engineers who are as good. Change is an every-minute experience in our control rooms, Resetarits said. We decided to hire happy people. There are people who wake up angry every day, and they infect the entire organization. When we interviewed, we looked for people who liked to smile. We looked for people who like people. The number one thing we looked for was attitude. One strategy was for Momentive to take a fresh look at its control system. Modernizing your control system will attract new workers but also will capture knowledge, Robertson said. Implement global DCS standards. It makes modernizations quick, and the benefit for the operators is they can now switch between units. Theyre not about learning the control systems. All they have to pick up is the process. She noted that many of the problems of data capture and system modernization are fixable through system alignment. When your engineering resources are low, your DCS vendor likely has a solution for you, Robertson said. You need to train operators on how to run operations, but a key is to run simulations. But you also need to keep simulators up to date. But all of the challenges we were faced with, there were solutions out there.
30,000
monthly?
Allied does.
Qualifications Standards Benchmarking
Allied Reliability employs over 200 associates nationally, combining more than 2,000 years of PdM experience. Allied Reliability has developed comprehensive data collection specifications and alarming criteria based on equipment types and their failure modes. With data from over 30,000 assets collected monthly, we have the statistical analysis to confidently advise our clients and partners on the widest array of assets in the industry.
from over
assets
In search of Gen X-ers

While the discussion in the workforce development issue revolves mostly around retiring baby boomers and up-and-coming millennials, a third group may actually hold the key to filling a widening Skills Gapif they can be found. The Generation X group, generally born between 1960 and 1980, normally would be the next in line to fill in the jobs currently occupied by baby boomers, but fewer of those people took manufacturing jobs in the period from 1985 through 2005, when they most likely would have been heading into the workforce. One thing that is not discussed is that if we look at workforce issues, as baby boomers retire, theres a big hole of Gen X-ers not there to fill in, said Peter Zornio of Emerson Process Management during the panel discussion. If you look at the timing, it was at a time when many of us werent hiring. In the modern market, where Facebook profiles for both employers and job seekers are now the norm, the challenge seems to be getting manufacturing careers a seat at the kitchen table when careers are discussed. How do we make what we do attractive to young people? asked Maurice Wilkins of Yokogawa. Do we need to bring apprenticeships back? We need to make E young people believe what we do isnt boring. P
Contact Us to Learn More About Allied Reliabilitys Condition Monitoring Program www.alliedreliability.com | 843.414.5760 | info@alliedreliability.com
16 March 2013
plant engineering
INDUSTRIALSOLUTIONS CATALOG
pg 2 pg 3 pg 4 pg 5
pg 6
pg 7
pg 14
pg 10-11
pg 8
pg 12
pg 13
pg 9
For more vendors, see our full line catalog.
Call. 855-302-5620 Click. www.miindustrialsupply.com Visit. Over 30 Locations
HAND PROTECTION
INDUSTRIAL SOLUTIONS CATALOG
Ultralight Cut-Resistant Glove

HyFlex 11-518
Medium Duty Cut-Resistant Glove

HyFlex 11-435
Barehand-like dexterity for high tactility First-to-market glove to provide ANSI Cut Level 2 in an 18 gauge style Dyneema Diamond Technology provides high cut-to-dexterity ratio for safety with comfort Soft, sheer fiber breathes to keep hands cool and dry Thin polyurethane coating enables high tactility High abrasion-resistance extends glove life Applications: Final assembly, handling and assembly of small or ultra-fine sharp parts, injection molding parts assembly, machining special metal blends, packaging areas with risk of cut, stamping-light and dry, wire assembly and fastening 12 pair per bag, 12 bags per case
Item # Mfr Part # Size
Eco-friendly, water-based polyurethane palm coating Enhanced dexterity and comfort due to no coating strike through Gray palm coat hides soil and provides long wear, reducing overall replacement costs Unique combination of Dyneema, Nylon, Lycra and glass fiber Ultra strong fibers provide extreme resistance to cuts and burrs Anti-static for improved safety in critical areas Silicone-free Applications: Cutting small dry or lightly oiled parts, handling glass or metal sheets, handling sharp-edged objects, maintenance, pre-assembling and stamping 12 pair per bag, 12 bags per case
05422706 05422707 05422708 05422709 05422710 05422711
11-518/6 11-518/7 11-518/8 11-518/9 11-518/10 11-518/11
6 7 8 9 10 11
05422712 05422713 05422714 05422715 05422716 05422717
11-435/6 11-435/7 11-435/8 11-435/9 11-435/10 11-435/11
6 7 8 9 10 11
Ultralight Multi-Purpose Glove

HyFlex 11-618
Lightest lined and coated HyFlex glove for outstanding comfort and sensitivity Enhanced flexibility, tactility and handling efficiency Ideal for workers who need a high level of touch and precision Thin polyurethane coating enables high tactility High abrasion-resistance extends glove life Dark liner and glove mask dirt and reduce glove waste 12 pair per bag, 12 bags per case Applications: Cosmetics/plastics (also packaging stage), final assembly, HVAC, electrical engines, wire harness assembly, adjustors work, finishing work, light assembly operations requiring a high degree of precision, picking and fitting small pieces (bearings, springs...), appliances and electrical goods
05422718 05422719 05422720 05422721 05422722 05422723
11-618/6 11-618/7 11-618/8 11-618/9 11-618/10 11-618/11
6 7 8 9 10 11
Some products may ship direct from the manufacturer 2 Call. 855-302-5620 Click. www.miindustrialsupply.com Visit. Over 30 Locations
LABELING / SECURITY / ABSORBENTS
Keyed Different Padlocks

1-1/2" Shackle
Sign & Labeling Machine

Single Color
Prints on 1/2" to 4" label widths; library of pre-made labels ready to pick and print; templates for quick creation of safety labels Preview labels before printing Smart chip supplies auto-communicate label set up and size to printer Large, high-resolution touch screen display Built-in design wizards for arc flash labels, Right-to-Know and WHIMIS chemical labels, and pipe markers Stand-alone or PC operation AC power supply
Item # Mfr Part # Color Capability Keyboard
Brady safety padlocks are the ultimate locks for all of your safety and security needs Unique cylinder is insulated to protect workers from shocks when key is inserted and is 6-pin precision-machined for more unique key cuts and better tamper-resistance Compact and lightweight Reserved, paracentric keyway provides optimal security and the special design prohibits the key from being released until the padlock shackle is closed Resists impact, temperature, chemicals and corrosion Non-conductive, non-sparking body features ribbed design for easier gripping and handling Lock body measures 1-3/4" H x 1-1/2" W x 4/5" D Locks come standard with English, French and Spanish language labels Custom keying and charting is available
Item # Mfr Part # Shackle Dia. Color Pkg Qty
05244420
BBP31
Single
Standard
03869539 03869957
99552 51339
1/4" 1/4"
Red Red
One Six
Labels
Indoor/Outdoor
Toughstripe
Oil Only Absorbents

ENVMAXX ENHANCED
Durable, low shrink vinyl with our most aggressive adhesive Conforms to irregular, curved, rough and highly textured surfaces (painted cinder blocks, uneven wood, textured plastics, paper-jacketed pipes, powder-coated surfaces) Adheres to difficult low-surface energy items (PVC piping, blow-molded equipment cases, ABS plastics, recycled plastics) 4" X 100 ft vinyl film labels are suitable both indoors and outdoors
Item # Mfr Part # Color
An oil-only sorbent that is equally as effective on land as on water One-ply, white, economy For use with oil and petroleum based fluids Greater performance without the extra weight Repels water and floats indefinitelyeven when saturated
Item # Mfr Part # Style Size Package
05244421 05226835 04724851 05226834 05226812
B30C-4000-595-WT B30C-4000-595-OR B30C-4000-595-YL B30C-4000-595-GN B30C-4000-595-BL
White Orange Yellow Green Blue
02567967 03091061 02728812 03091060 02728817
ENV200 Lt. Weight Pad ENV300 Med. Weight Pad ENV150 Med. Weight Roll ENV100 Heavy Weight Pad ENV50 Med. Weight Jumbo Pad
15" X 19" 15" X 19" 30" X 150 ft 15" X 19" 30" X 30"
200/bale 100/bale 1/bale 100/bale 50/bale
Universal Absorbents
Medium Absorbency
MRO Plus
Heavy-Duty Print Ribbon

Drop-and-Click print ribbons for quick and easy supply changes Ribbons are tough, smear-proof that produce long-lasting printed text Print can withstand years in industrial areas and outdoor conditions No calibrating, no threading, no waste, no hassles For use with BBP31 and BBP33 printers
Item # Mfr Part # Color
Absorbs all industrial liquids (water, petroleum and chemical-based fluids) Gray color masks drips and spills Heavy- and medium-weight alternatives For use with oil and water-based fluids Three-ply construction makes it stronger, more durable, reduces lint Dimpled and perforated, helps you use only what you need, reducing waste
Item # Mfr Part # Size Package
04684956
B30-R10000
Black
02728818 03882406 02567974
MRO300 MRO315P MRO350-DP
15" X 19" 15" X 150 ft 30" X 150 ft
100/case 1/case 1/case
Some products may ship direct from the manufacturer Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 500 Locations 3
BATTERIES
Watch Batteries Batteries

Procell
1.5 VoltSilver Oxide

High capacity, low self-discharge for longer service life Longer lasting to increase productivity Mercury-free
AlkalineProfessional
Dependable, long-lasting power with up to a seven-year freshness guarantee; date coded to guarantee freshness Operates reliably in temperature extremes of -20C to 54C Economical bulk packaging for professional applications Contains no added mercury Priced per each
Item # Mfr Part # Battery Size Pkg Count
Item #
Mfr Part #
Battery Size
Package
04784725 03139362
384/392 303/357
1.5V 384/5R41/K 1.5 Volt
Single Blister Pack
02537658 02537657 02538037 02452561 02537659
PC2400 PC1500 PC1400 PC1300 PC1604
AAA AA C D 9 Volt
24 24 12 12 12
Coin Cells

3 VoltLithium
For electronic devices including memory back-ups and testing meters High capacity, low self-discharge for longer service life Longer lasting to increase productivity Mercury-free
Lantern Battery
6 VoltAlkaline
CopperTop
Alkaline lantern batteries last up to twice as long as super heavy duty zinc carbon batteries and provide an extra measure of leakage resistance for critical applications Reliable performance at temperature extremes Date coding to ensure freshness and a long shelf life No added mercury
Item #
Mfr Part #
Battery Size
Package
04291799 03044852
DL2032 DL2450
3 Volt
Single Blister Pack
Lithium Photo Battery

3 Volt

1
ULTRA Photo
03113128
MN-908
6 Volt
Batteries
Alkaline
ULTRA Power
For applications with a high current pulse and continuous drain Reliability with more consistent performance Longer lasting to increase productivity Wide operating temperature extremes (-40F to 140F)
Seven-year guarantee in storage High battery output
Item #
Mfr Part #
Battery Size
Package
03279851
MX2500
AAAA
Double Blister Pack
Item #
Mfr Part #
Battery Size
Package
03844857 05396741
DL123 DLCR2
3 Volt
Single Blister Pack
BATTERIES / LIGHTING
Energizer Industrial Alkaline Batteries
Energizer Industrial 6 LED Headlight
Offers the longest lasting power source of all primary batteries over a range of sizes No mercury addedspecial disposal is not required Operates well in temperature extremes (-30C to 55C) Excellent shelf lifealkaline cells are ready for use even after 7 years of storage Priced per each
Four light modes: Area, spot, flood and red (for night vision) Light pivots up to 90 Easy On/Off push button switch Adjustable head strap with two built-in pencil holders Grips to safety helmets Packed with 3 AAA Energizer MAX batteries
Item # Mfr Part # Light Output Beam Distance
03462021
HDL33AINE
48 Lumens
33 Meters
02952094 02952092 02952096 02952097 02952090
EN92 EN91 EN93 EN95 EN22
AAA AA C D 9 Volt
24 24 12 12 12
Energizer Industrial 3 LED Headlight

Two light modes: White spot / red for night vision Light pivots up to 90 Shatter-proof lens On/Off switch Adjustable head strap Packed with 3 AAA Energizer MAX batteries Run time: 28 hours
Item # Mfr Part # Light Output Beam Distance
02952099
HD33A1EN
30 Lumens
23 Meters
POWER TOOLS / LIFTING PRODUCTS / PUMP
Air Angle Die Grinder

300 Series
1/2" 20V High-Torque Impact Wrench

Cordless
Impactool
780 ft-lbs of maximum reverse torque and 1100 ft-lb of nut-busting torquefrom cordless impact wrench that weighs only 6.8 lbs High-power rare earth magnet (neodymium) motoroffers a long life and high power Steel-lined aluminum hammer casedesigned to be strong and lightweight for maximum protection of the internal components All-metal drive train and hammer mechanismrobust, durable, and optimized for maximum power and efficiency 2,300 impacts per minute at 1,900 RPM Variable speed switch with electronic brakeprovides maximum control of the tool Patent-pending metal reinforced housingready to work even after repeated drops Patent-pending soft touch over-molded gripminimizes vibration, reduces fatigue, and enhances user comfort during extended use Best-in-class short length9.4" from tip to tail W7150-K2 Standard Anvil Two Battery Kit includes: One W7150 Impactool, one IQV20 Charger, two 20V Li-ion 3.0 Ah batteries and one blow-molded case
Item # Mfr Part # Volts
Features a composite grip for superior ergonomics and comfort, and can be used in various applications including porting, weld breaking, de-burring, polishing and grinding Durable ball-bearing construction improves balance, reduces vibration, and ensures a longer life Built-in lubricating wick increases angle gear life Lightweight, durable, ergonomic composite housing protects tool from cold air and offers greater operator comfort Integral safety-lock throttle lever prevents accidental start up Rear exhaust directs air away from the operator, piped-away exhaust kit optional Tool comes with 1/4" and 6 mm collets and two wrenches
Item # Mfr Part # HP Air Inlet Hose Size Max RPM
05212059
CLK Series
302B
0.33
1/4" NPT
3/8"
20,000
Air Chain Hoist

Meets ASME B30.16 specifications Rugged, lightweight and compact design Disc brake is non-asbestos and spring engaged with air release Quiet operation <75 dBA sound levels Upper and lower limit stops dangerous over-travel of the hook Full flow pendant for maximum control and enhanced load positioning 100% duty cycle multi-vane (6) air motor Hook or trolley mounted versions available Steel snap hooks with safety latches Standard lift is 10 feet; additional lifts are available Standard pendant length is 6 feet or 4 feet less than lift
Item # Mfr Part # Capacity Chain Falls
05416732
W7150-K2
20
05420543
CL250K-2C10-C6U
250 lb
Vibration Reduced Air Hammer

Long Barrel
Great for exhaust and front-end jobs, general bolt cutting, pin driving and body shearing work Anti-vibration feature reduces tool vibration by over 30% when compared to standard air hammers in its class, plus an ergonomic grip that provides comfort for extended use 15% increased in impact force over standard air hammers Quick-change retainer allows for faster chisel changeovers, so you can get the job done
Item # Mfr Part # Shank Opening Blows Per Minute Air Inlet (NPTF)
2" Classic Style Non-Metallic Pump
Air Operated Double Diaphragm

AROs patented unbalanced air valve ensures no-stall operation Bolted construction for leak-free fluid handling Ease of service through modular design Center, end, dual inlet/outlet, and swivel top manifold configurations to fit your specific application Manifold material: Polypropylene
Item # Mfr Part # Seat Material Ball Material Diaphragm Material
05162521
118MAX
.40"
2,500
1/4"
03743782 666053-0D2 Duck Bill Nitrile Nitrile 00466703 666053-388 Polypropylene Polyurethane Polyurethane
LUBRICANTS
Synthetic Air Compressor Fluids

SynXtreme AC Series
100% Polyol Ester (POE)-based, high performance fluids ECO-friendly; readily biodegradable (Pw1) Extended drain intervals up to +10,000 hours, monitored by Lubriplates complimentary fluid analysis program
Syn Lube Series
100% Synthetic, Polyalphaolefin (PAO)-based fluids Fully compatible OEM fluid replacement Extended drain intervals up to 8,000 hours, monitored by Lubriplates complimentary fluid analysis program
Synac Series
Syncool
100% synthetic, Polyglycolester-based fluid ECO-friendly; readily biodegradable (Pw1) Superior heat transfer properties
SFGO Ultra Series
100% Diester-based synthetic air compressor fluids High temperature fluids eliminate varnish buildup Extended drain intervals up to 8,000 hours, monitored by Lubriplates complimentary fluid analysis program
Viscosity Grade ISO 32 ISO 32 ISO 46 ISO 46 ISO 68 ISO 68 ISO 22 ISO 22 ISO 32 ISO 32 ISO 46 ISO 46 ISO 46 ISO 68 ISO 68 ISO 100 ISO 100 ISO 32 ISO 32 ISO 46 ISO 46 ISO 68 ISO 68 ISO 100 ISO 100 ISO 100 ISO 100 ISO 32/46 ISO 32/46
NSF H-1 registered food machinery grade For food processing and bottling operations 100% synthetic, (PAO) based compressor fluids
Item # 03450190 03450191 03450192 03450193 03450194 03450195
Mfr Part # L0939-060 L0939-062 L0940-060 L0940-062 L0941-060 L0941-062 L0968-062 L0970-060 L0970-062 L0971-057 L0968-060 L0971-060 L0971-062 L0972-060 L0972-062 L0973-060 L0973-062 L0932-060 L0932-062 L0933-060 L0933-062 L0934-060 L0934-062 L0935-054 L0935-057 L0935-060 L0935-062 L0964-060 L0964-062
Container 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 1 gallon Jug 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum 1 quart Bottle 1 gallon Jug 5 gallon Pail 55 gallon Drum 5 gallon Pail 55 gallon Drum
Item #
Mfr Part # L0912-057 L0912-060 L0912-061 L0912-062 L0930-057 L0930-060 L0930-061 L0930-062 L0931-057 L0931-060 L0931-061 L0931-062 L0915-057 L0915-060 L0915-061 L0915-062 L0916-057 L0916-060 L0916-061 L0916-062 L0917-057 L0917-060 L0917-061 L0917-062 L0983-057 L0983-060 L0983-061 L0983-062
Container 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum 1 gallon Jug 5 gallon Pail 16 gallon Drum 55 gallon Drum
Viscosity Grade ISO 7 ISO 7 ISO 7 ISO 7 ISO 15 ISO 15 ISO 15 ISO 15 ISO 22 ISO 22 ISO 22 ISO 22 ISO 32 ISO 32 ISO 32 ISO 32 ISO 46 ISO 46 ISO 46 ISO 46 ISO 68 ISO 68 ISO 68 ISO 68 ISO 100 ISO 100 ISO 100 ISO 100
SynXtreme AC Series
SFGO Ultra Series

03068409 02338483 05067605 02338484 04255094 02946753 05067607 04371475 05067608 04745440 05067609 05067610 03941473 01277054 02338485 01302652 05067606 01303055 02338486 01303065 02462236 01303472 02338487 01303480 02462231 02475058 02462238 02475059
Syn Lube Series

04398031 02338479 02318930 05067620 05067619 02309842 02338480 02338481 02338482 02248199 02248200
Synac Series
01467844 01467846 01467847 01467848 01467849 01467850 05067611 04229150 01467851 01467845
Syncool
03720571 03855067
LUBRICANTS
All Purpose Lubricant

The Protector LU 711
Moly Chain Lubricant

LU 202
A high-viscosity oil that clings to moving parts Foaming action penetrates close tolerances of chain drive bushings and pins to provide long-lasting lubrication Reduces friction wear on moving parts and in metal-to-metal applications The moly additive improves its capacity to handle greater pressure requirements of start up stress Spray Anyway Valve allows material to be applied to the surface when the can is being held in either upright or inverted position
Item # Mfr Part # Container Pkg Qty
An ultra-thin film, transparent blend of high quality petroleum distillates specifically formulated to ensure maximum moisture displacement Its film resists the collection of abrasive particles on delicate contacts and connectors Forms a continuous film that spreads evenly over metal surfaces, giving uniform protection against corrosion attack This spreadability also makes LU711 an excellent penetrant for freeing corroded parts and mechanisms and will not affect plastic, rubber, fabrics or painted surfaces
01487753
S00711
11 fl oz Aerosol
12/case
00866776
CD 757
S00202
11 fl oz Aerosol
12/case
Open Gear Wire & Rope Lubricant

Heavy Duty
LU 201
Heavy Duty Citrus Degreaser

Heavy-duty, multi-purpose degreaser, adhesive and graffiti remover Non-chlorinated formula has the cleaning power of solvents to remove grime, dirt, grease and oil An outstanding biodegradable cleaner for use in general maintenance, public buildings, transit systems, restrooms, locker rooms and schools Ideal as a cleaner prior to painting Leaves a refreshing, pleasant scent
High-performance lube that penetrates the pores of metal surfaces to reach the core of wire rope Provides a wide range of lubrication at high temperatures while adhering extremely well to surfaces Travels on metal surfaces to displace water, resulting in excellent rust protection Equipped with an extension tube for hard-to-reach areas or for use while equipment is in operation
00866569 12/case
SP 607
S00201
12 fl oz Aerosol
12/case
Belt Dressing
Has a proven record of effective performance, even when subjected to wet or outdoor conditions and will not glaze or collect dirt or dust This formulation conditions belts while increasing pulling power up to 50% Equipped with a Spray Anyway Valve which allows treatment to bottom surface of flat belts while the belt is running, or directly to sheaves of "V" belts Reduces squeaky noise, caused by old "V" belts
01375018
S00757
16 fl oz Aerosol
Heavy Duty Penetrant Oil

Rust Breaker LU 103
Fast-acting product that quickly loosens rust while penetrating grease and dirt A transparent, non-staining oil, its light film displaces moisture and acts as a corrosion preventative Jet stream sprays up to two feet for safe, accurate application A one-coat rust and corrosion preventive compound Pleasant vanilla scent
00866858
EL 2205
S00103
10 fl oz Aerosol
12/case
00872251
CD885
S00607
11 fl oz Aerosol
12/case
Electronic Degreaser Solvent

Penetrates instantly to remove dirt, oil, grease and wax Excellent cleaning properties on tools, electric motors, brakes, bearings and electrical equipment A fast evaporating formula equipped with extension tube for pinpoint application
Stainless Steel Cleaner

Cleans, polishes, brightens and protects stainless steel and other metal surfaces, such as chrome and aluminum; can also be used on porcelain, ceramic tile and laminated surfaces Water spots, spills, food soils and oil based stains are easily removed Invisible coating resists further soiling, fingerprints, watermarks and rusting and polishes to a non-greasy film
03595921
S02205
10 fl oz Aerosol
12/case
00877526
S00885
17 fl oz Aerosol
12/case
JANITORIAL SANITATION
Glass Cleaner
Ready-To-Use
Heavy-Duty Hand Cleaner Dispenser

Wall Mount
GreenLink
Heavy-duty hand care wall mount system For use with square gallons only
Save the time it takes to dilute concentrates with this easy, ready-to-use non-streaking glass cleaning option A non-aerosol spray that effectively cleans glass and any other surface not harmed by water Fortified with ammonia, this convenient spray quickly removes fingerprints, dirt and smudges
03972912 05246455 R09701 Gallon

Ready-To-Use
R04601
Quart Spray Bottle
12/case
General Purpose Cleaner

Formulated for use on all surfaces not harmed by water, this easy-to-use product has outstanding cleaning ability on a wide variety of soils such as wax build-up, black marks on floors, fingerprints and other types of soils encountered in daily cleaning
Soy Industrial Hand Cleaner

GreenLink
A green product that works Tough, yet gentle on hands No harsh petroleum solvents Walnut shell abrasive effectively loosens grime Will not clog drains
04339803
R17901
Quart Spray Bottle
12/case
Spray Disinfectant
4/case
05246454
R05325
Gallon Jug
Industrial Hand Cleaner w/ Abrasive

Industrial strength phosphate-free pumice hand cleaner with mild, low-odor solvents and a clean, fresh cherry fragrance Removes stubborn industrial soils, inks, resins, paint, general purpose adhesives, tar, carbon and asphalt easily Enriched with emollients but fortified with pumice, tackles stubborn industrial soils leaving the hands feeling great after repeated washings
Disinfects pre-cleaned surfaces or objects Kills TB, Salmonella, Paratyphoid B, Streptococcus pyogenes, canine-related and other viruses Kills athletes foot fungus, E-coli and Staphylococcus aureus as well as controlling mold and mildew Effective against HIV-1, Herpes and flu virus Dries instantly leaving no oily film Pleasant country garden fragrance attacks and destroys malodors at the source
05415377
Lemon Scented
R15601
20 fl oz Aerosol
12 cans/case
Disinfectant Deodorizing Cleaner

Concentrated Quat-based cleaner, disinfectant and deodorizer can be used at different dilutions for most any cleaning/disinfection task Effective against Staph, E-Coli, Salmonella and Canine Parvovirus Dilute, spray on, let stand and rinse Economicaldilutes up to 2 oz per gallon of water
05246453
R04825
Gallon Jug
4/case
Alcohol Hand Sanitizing Gel

This environmentally friendly, alcohol-based hand sanitizer effectively controls harmful micro-organisms and helps prevent the spread of germs For use in food plants, restaurants and food service areas Formulated for use without water or towels, no rinsing required May be used repeatedly throughout the day without irritation Use as a supplement to regular hand washing
03972868
GreenLink
R02201
Qt Bottle
12/case
Broad Spectrum Disinfectant Cleaner

A one-step disinfectant cleaner and deodorant, kills 99.9% of germs and bacteria Just spray on, let stand, wipe or rinse Quickly cuts grease and heavy soils Kills Canine Parvovirus and HIV 1
04245162
R10901
500 mL Dispenser
12/case
03972870
R02301
Quart Spray Bottle
12/case
ABSORBENTS
Oil-Only Pad Universal PadPrecut

MRO Universal Mat Pads
Heavy Weight, High Absorbency

MRO Oil-Only Mat Pads

Value-priced MRO Mat Pads grip the floor and absorb oils, coolants, solvents and water where you walk to keep floors dry and safe Size: 15" L x 19" W
Item # Mfr Part # Package
Value priced MRO Oil-Only mat pads repel water and quickly absorb oily spills or overspray Precut
02357345
MAT800
15" L x 19" W
100 pads / bale
Universal Mat
02422499
MAT700
100 pads / bale

Eight-layer, thermally bonded construction will not rip, tear or fray, even when saturated 100% polypropylene (now made with 50% recycled content) Exclusive dimple pattern speeds wicking of liquid throughout mat for faster, easier cleanup Absorbs and retains oils, coolants, solvents and water Perforated mat is easy to tear to size so you only use what you need Dispenser box makes mat easy to access, carry and store while protecting contents from dirt and moisture Flame-resistant material will not burn immediately like cellulose mats, melts when exposed to high heat while on the job Can be wrung out and incinerated after use to reduce waste or for fuels blending
Universal Mat
MRO Universal Mat Roll

Value-priced MRO Mat Rolls grip the floor and absorb oils, coolants, solvents and water where you walk to keep floors dry and safe Size: 150 ft L x 30" W
Item #
Mfr Part #
Package
02357339
MAT701
1 roll
Oil Only Mat
02394014 02851171
MAT240 MAT740
15" x 20" 15" x 19"
100 Pad Dispenser Box Bag
Heavy Weight, High Absorbency, Anti-Static

PIG STAT-MAT Absorbent
Universal Pad
Heavy Weight
Absorbs leaks, spills, drips and overspray of oils, coolants, solvents and water The primary use of the mat is to make and keep floors cleaner and safer, free of any water or oil-based fluids that may cause an accident The precut sheets are ready for immediate spill response Strong, durable PIG Mat lasts longer so you use less mat and spend less time replacing it
Package Item # Mfr Part # Size Package
Designed to float on water while absorbing only petroleum-derived fluids such as oil, gasoline, kerosene, diesel fuel, etc. Treated to dissipate static for added safety in flammable vapor environments Removes hydrocarbons from waterways such as ponds, lakes or lagoons Since they float, the absorbent stays in contact with the contaminant The fast wicking capability and large surface area ensure a quick cleanup Helps reduce the risk of electrostatic discharge Size: 150 ft L x 30" W
Item # Mfr Part #
02357343
MAT801
1 roll
02368033 01305083
MAT203 MAT230
20" L x 15" W 150' L x 30" W
100 pads / bag 1 roll / bag
ABSORBENTS
Universal Sock
PIG BLUE
Moderate Absorbency
Used primarily in everyday housekeeping around machines that leak, seep or spill coolants, cutting fluids and hydraulic oils Fits snugly against machine bases and wrap around corners, keeping the work area safe and dry Size: 3" dia. x 48" L
Absorbent Mat Pad

PIG BLUE
Highly Absorbent, Light Weight, Dispenser

New Pigs most absorbent matideal for everyday tasks and cleanups 75% pre-consumer recycled celluloseideal in situations where green products are desired or required Fire-retardant Dispenser box makes mat easy to access, carry and store while protecting contents from dirt and moisture Easy-tear perforations Fits snugly against machine bases and wraps around corners, keeping the work area safe and dry Size: 15" W x 19" L
02422154 02422157
2048 4048
20 socks/box 40 socks/box
04882490
BLU107
50 pads/box
Universal Sock
Low Absorbency
Cellulosic sorbent contained within a flexible polypropylene skin for the purpose of containing and absorbing hydraulic oils, coolants, solvents, water and other non-aggressive liquids that leak or drip from machinery or is otherwise spilled PIG ORIGINAL Absorbent Socks are used primarily in everyday housekeeping around machines that leak, seep or spill coolants and cutting hydraulic oils Size: 3" dia. x 42" L
Absorbent Mat
Medium Weight
Grippy
Spunbond top layer stands up to traffic while zig-zag stitching adds strength Eight layers of fine fiber polypropylene absorbs oils, coolants, solvents and water Poly backing keeps liquid from passing through to floors Adhesive back Size: 32" W x 100 ft L
02422153 02357349
204 404
20 socks / box 40 socks / box
04823012
MAT32100
1 Roll
Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 500 Locations Some products may ship direct from the manufacturer
11
LUBRICANTS
Penetrant Oil
Non-Aerosol
Trigger Pro
Penetrant Oil
Low surface tensionpenetrates, loosens and frees stuck, frozen or rusted parts Displaces moisturenon-conductive Excellent corrosion prohibitorprotects metal against moisture and corrosive elements Removes grease, grime, water deposits and much more Long-lasting multi-purpose lubricant for moving parts
Item # Mfr Part # Size Container
Spray trigger for more control, less mess and easy disposal Low surface tensionpenetrates, loosens and frees stuck, frozen or rusted parts Displaces moisturenonconductive Excellent corrosion prohibitorprotects metal against moisture and corrosive elements Removes grease, grime, water deposits, and much more
04177699
110184
20 fl oz
Trigger Can
03659567 01499905 01511735 00765821 00766242 00766370
110108 10100 10116 10110 10117 10118
3 fl oz 12 fl oz 16 fl oz 1 gal 5 gal 55 gal
Can Refillable Spray Bottle Aerosol Can Can Drum
Penetrant Spray
Rust Release
Blu Torch Technology
Penetrant Oil
Smart Straw
Now you can use WD-40 to protect, clean, and lubricate thousands upon thousands of itemswithout ever losing the straw again New Smart Straw features a permanently attached straw that sprays two ways Simply flip it up for a precision stream and down for a regular spray action
Extra-penetrating Blu Torch Technology Fast-acting Penetrates deep into crevices, threads and seams to break the bonds that hold stuck parts together Leaves behind a protective layer Helps prevent rust and corrosion from reforming Frees rusted parts 50% faster than the leading competitor Ideal for use on nuts, bolts, threads and locks 50-State VOC compliant
05351008
300004
11 fl oz
Aerosol
Corrosion Inhibitor
Long-Term
Specialist
00765785 01377529 05072626
110054 110078 10152
8 fl oz 11 fl oz 12 fl oz
Aerosol Aerosol Aerosol
Penetrant Oil
Big Blast
Blocks rust and corrosion Protects and lubricates metal Non-drying Protects metal up to two years indoors, one year outdoor 50-State VOC compliant
Cover everything faster Same legendary product inside, revolutionary delivery system outside Low surface tensionpenetrates, loosens and frees stuck, frozen or rusted parts Displaces moisturenon-conductive Excellent corrosion prohibitorprotects metal against moisture and corrosive elements Removes grease, grime, water deposits and much more Long-lasting multi-purpose lubricant for moving parts
05351012
300035
6.5 fl oz
Aerosol
Rust Remover
Soak

Aerosol
Specialist
Dissolves rust quickly Non-toxic and biodegradable Ideal for restoring rusted parts to bare metal 50-State VOC compliant
02712892
10124
18 fl oz
05351011
300042
1 gal
Jug
HAND PROTECTION
ANSI 2 Cut-Resistant Gloves

Touch Screen
Wired fingertips for use with touch screens Rugged HPPE fiber is 10 times stronger than steel and 40% stronger than blended fabrics Excellent cut protection in a comfortable glove Gray HPPE fiber shell with gray polyurethane coating Wired fingertips for use with touch screens Machine washable EN388 = 4342, ANSI 2 = 776gms Speckle gray shell with gray palm
ANSI 5 Kevlar Cut-Resistant Glove

Extended Cuff
ANSI 5, 3638 gms, EN388 = 3542 Antibacterial, DMF Free Microfoam nitrile palm coat Excellent abrasion resistance Olive-colored shell with black coated palm
05413091 05413092 05413093 05413094 05413095
710KSSN/S 710KSSN/M 710KSSN/L 710KSSN/XL 710KSSN/2XL
Small Medium Large X Large XX Large
05413116 05413117 05413118 05413119 05413120
713HUTS/S 713HUTS/M 713HUTS/L 713HUTS/XL 713HUTS/2XL

High Visibility
Rugged HPPE fiber is 10 times stronger than steel and 40% stronger than blended fabrics Excellent cut protection in a comfortable glove Hi-vis yellow HPPE shell with orange foam nitrile palm coating Seamless knit shell, silicone-free Machine washable EN388 = 4541, ANSI 4 = 1576 gms Yellow shell with orange coated palm
General Purpose Nitrile Gloves

Gray nylon shell with black palm coated foam nitrile with micro capillaries for flexibility, enhanced oil grip, breathability and comfort Foam nitrile coating with micro capillaries that channel oil from the surface of the glove Knit wrist, machine washable, antibacterial, silicone-free Excellent abrasion resistance EN388: 4141
05413101 05413102 05413103 05413104 05413105
HVY710HSNF/S HVY710HSNF/M HVY710HSNF/L HVY710HSNF/XL HVY710HSNF/2XL
05413106 05413107 05413108 05413109 05413110
715SNFTiP/S 715SNFTiP/M 715SNFTiP/L 715SNFTiP/XL 715SNFTiP/2XL

Knit Wrist
Rugged HPPE fiber is 10 times stronger than steel and 40% stronger than blended fabrics Excellent cut protection in a comfortable glove 18g HPPE fiber shell with gray polyurethane coating Seamless knit shell, silicone-free Machine washable EN388 = 3441, ANSI 3 = gms Blue shell with gray coated palm
General Purpose Polyurethane Gloves

High VisibilityTouch Screen Fingertips
Hi visibility yellow nylon shell with gray polyurethane palm coating for enhanced tactile sensitivity and high level of dexterity with touch screen fingertips EN388 = 4131 Polyurethane coating Knit wrist, machine washable Conductive threads in finger tips for use with touch screens Hi-visibility yellow polyurethane shell with gray palm
05413096 05413097 05413098 05413099 05413100
718HSPU/S 718HSPU/M 718HSPU/L 718HSPU/XL 718HSPU/XXL
05413111 05413112 05413113 05413114 05413115
HVY713SUTS/S HVY713SUTS/M HVY713SUTS/L HVY713SUTS/XL HVY713SUTS/2XL
MARKING PRODUCTS
All Purpose Paint Marker

Markal Valve Action
New xylene-free paint formula eliminates concern about California Proposition 65, EPA HAPS or SARA 313 materials Most colors contain low halogens and chlorides for use on stainless steel New faster-drying paint reduces smears and removed marks while allowing almost immediate handling of marked items New clip grip cap for convenient pocket storage and easier removal New Dura-Nib medium bullet tip allows writing on rougher surfaces than conventional nibs and holds up better in tough applications Temperature range: -50F to 150F (-46C to 66C) Made in the U.S.A.
Item #
Mfr Part #
Color
02463287 02366807 02521539 02521540 02521542 02521538 02521537 02521541 03238545 05048388 05048389 04881612 04765765
96820 96821 96822 96823 96824 96825 96826 96830 96835 97050 97051 97052 97053
White Yellow Red Black Orange Blue Green Pink Light Blue Fluorescent Yellow Fluorescent Green Fluorescent Orange Fluorescent Pink
Call. 855-302-5620 Click. www.miindustrialsupply.com Visit. Over 30 Locations

Lufkin 2109 West Frank Lufkin, TX 75904 936-639-1326 Port Arthur 740 Houston Avenue Port Arthur, TX 77640 409-983-4911 Spokane 9922 East Montgomery Ave. Unit 18 & 19 Spokane, WA 99207 509-995-1118 Tempe 2141 S. Industrial Park Ave., Suite 101 Tempe, AZ 85282 480-829-3835 Tucson 830 East 22nd Street Tucson, AZ 85713 520-624-6656
division
Cincinnati 7199 East Kemper Rd. Cincinnati, OH 45249 800-445-7534 513-489-3588 Dayton 507 East First St. Dayton, OH 45401 800-762-2336 937-461-4550 Mt. Vernon 1480 Industrial Park Dr. Mt. Vernon, OH 43050 800-662-2780 740-392-2100
division
Corinth 2754 South Harper Road Corinth, MS 38834 662-287-6107 Jackson 1665 North Parkway Jackson, TN 38301 731-424-5656 Memphis 3272 Democrat Road Memphis, TN 38118 901-525-6871
division
Boise 7451 Lemhi Street Boise, ID 83709 208-377-4334 Lewiston 116 Ninth Street Lewiston, ID 83501 208-798-3239 Morenci 4521 N US Highway 191 Morenci, AZ 85540 928-865-6294 Portland 2705 NW Nicolai Street Portland, OR 97210 503-226-3411 Seattle 355 Treck Drive Suite 110 Tukwila, WA 98188 206-762-1500
Hub Supply
division
Amarillo 401 Tiltrotor Drive Amarillo, TX 79111 806-231-1801
division
division
Geismar 35610 Highway 30 Geismar, LA 70734 225-673-6403 Houston 430 Miller Cut-Off Road LaPorte, TX 77571 281-471-7026 Lake Charles 1011 PPG Drive Westlake, LA 70669 337-882-0392
Chihuahua, MX Avenida Nicolas Gogol #11332-A Complejo Industrial Chihuahua CD. Chihuahua, CHIH, 31136 Mexico Ft. Worth 2517 Gravel Drive Ft. Worth, TX 76118 817-602-2084 Wichita 2546 South Leonine Wichita, KS 67217 316-265-9608
Abbeville 902 North John M. Hardy Drive Abbeville, LA 70510 337-898-0315 Amelia 2317 Hwy. 662 South Amelia, LA 70340 985-631-3609 Harvey 1020 MacArthur Avenue Harvey, LA 70058 504-818-0468 Houma 5837 Highway 311 Houma, LA 70360 985-868-4554 Houma/Enterprise 141-B Bayou Dularge Road Houma, LA 70363 985-873-9881 Lafayette 205 Monroe Street Lafayette, LA 70505 337-235-7545
division
division
Hub Supply
division
New Iberia 401 W. St. Peter Street New Iberia, LA 70560 337-364-2431
division
division
division
Equipment Services 410 W. St. Peter Street New Iberia, LA 70560 337-364-2431 Port of Iberia 4715 Curtis Lane New Iberia, LA 70560 337-365-7211
2013 Motion Industries, Inc.
Over 500 Locations

ALABAMA Birmingham, 205/251-3231 Brewton, 251/867-6363 Decatur, 256/355-0492 Demopolis, 205/287-0611 Dothan, 334/794-2747 Gadsden, 256/543-3441 Huntsville, 256/858-5020 Mobile, 251/661-7800 Monroeville, 251/743-4814 Montgomery, 334/262-5786 Muscle Shoals, 256/383-0862 Pennington, 205/654-2975 Tuscaloosa, 205/759-4261 ALASKA Anchorage, 907/563-5565 Fairbanks, 907/452-4488 ARIZONA Phoenix, 602/269-2331 Phoenix, 602/252-3700 Tucson, 520/882-6800 Yuma, 928/782-3919 ARKANSAS Blytheville, 870/763-6880 Crossett, 870/364-8120 Fort Smith, 479/646-6868 Jonesboro (JB), 870/974-7100 Little Rock, 501/568-3116 Pine Bluff, 870/534-1177 Russellville, 479/968-3422 Springdale, 479/756-6905 Stuttgart (JB), 870/672-4785 Texarkana, 870/774-2547 CALIFORNIA Anaheim, 714/780-1791 Bakerseld, 661/324-6741 Concord, 925/689-9880 Fontana, 909/357-9898 Fresno, 559/237-9131 Gardena, 310/327-5070 Gilroy, 408/848-3099 Hayward, 510/266-0200 Lancaster, 661/948-8436 Lodi, 209/334-2530 Los Angeles, 323/728-0281 Modesto, 209/529-0261 Modesto, 209/549-8155 Oxnard, 805/487-4877 Sacramento, 916/455-1990 Salinas, 831/758-3345 San Diego, 858/565-0092 San Fernando, 818/365-0300 Santa Clara, 408/727-6408 Santa Clara, 408/727-4979 Stockton, 209/943-2801 Ukiah, 707/462-9766 Visalia, 559/651-0111 Woodland, 530/662-9651 COLORADO Denver, 303/399-1500 Fort Morgan, 970/867-1045 Greeley, 970/336-6481 Pueblo, 719/546-0500 CONNECTICUT E. Windsor, 860/292-6091 FLORIDA Bartow, 863/533-0574 Clewiston, 863/983-5500 Fort Pierce, 772/464-5537 Jacksonville, 904/757-5080 Miami/Miramar, 954/704-8565 Orlando, 407/298-0380 Panama City, 850/769-2492 Pensacola, 850/433-0021 Tampa, 813/626-1191 GEORGIA Albany, 229/888-0910 Athens, 706/353-7780 Atlanta, 770/948-5300 Augusta, 706/724-7401 Brunswick, 912/265-0178 Cartersville, 770/387-0131 Columbus, 706/324-0313 Dalton, 706/272-3900 Gainesville, 770/532-4268 LaGrange, 706/883-7995 Macon, 478/784-0500 Norcross, 770/441-9909 Savannah, 912/236-1591 Valdosta, 229/244-4548 IDAHO Boise, 208/377-4334 Pocatello, 208/233-3894 ILLINOIS Addison, 630/627-4605 Bloomington, 309/827-0436 Bourbonnais, 815/939-4466 Champaign, 217/352-8550 Chicago S., 312/850-3700 Chicago Hhts., 708/754-6300 Countryside, 708/354-5900 Danville, 217/442-8800 Decatur, 217/877-3400 East Peoria, 309/694-6214 Elgin, 847/697-3100 Elk Grove Vill., 847/616-4001 Joliet, 815/725-6720 Machesney Pk, 815/654-1154 Mattoon, 217/235-7151 Melrose Park, 708/344-4433 Montgomery, 630/897-8652 Mt. Vernon, 618/241-9500 Oak Lawn, 708/422-2727 Peru, 815/223-7800 Quincy, 217/222-6168 Rockford, 815/874-9461 Springeld, 217/523-8337 Waukegan, 847/623-8770 W. Chicago, 630/231-4453 Wheeling, 847/459-7727 INDIANA Columbus, 812/379-2329 Crawfordsville, 765/362-7227 Elkhart, 574/293-4343 Evansville, 812/423-7701 Fort Wayne, 260/422-6451 Gary, 219/938-9200 Hammond N., 219/931-3010 Indianapolis, 317/248-2100 Kendallville, 260/347-4135 Kokomo, 765/453-2550 Lafayette, 765/448-6600 LaPorte, 219/362-8526 Madison, 812-273-1870 Muncie, 765/288-4474 Richmond, 765/966-3528 South Bend, 574/291-0770 Terre Haute, 812/232-8344 Warsaw, 574/268-0181 IOWA Ankeny, 515/965-1065 Cedar Rapids, 319/362-9940 Davenport, 563/391-8888 Dubuque, 563/556-3022 Fort Dodge, 515/573-5753 Fort Madison, 319/372-6611 Muscatine, 563/263-3452 Ottumwa, 641/682-5401 Sioux City, 712/258-0595 Waterloo, 319/235-7167 KANSAS Dodge City, 620/227-6080 Salina, 785/826-9970 Topeka, 785/233-6500 Wichita, 316/942-6700 KENTUCKY Bowling Green, 270/842-6195 Carrollton, 502/732-8114 London, 606/878-6312 Louisville, 502/964-4804 Owensboro, 270/926-0330 Paducah, 270/443-6291 Versailles, 859/873-7212 LOUISIANA Alexandria, 318/445-7446 Abita Springs, 985/871-8000 Broussard, 337/837-2230 Baton Rouge, 225/356-6131 Gonzales, 225/644-6568 Harvey, 504/340-2271 Morgan City, 985/384-9031 New Orleans, 504/733-5400 Ruston, 318/255-6721 Shreveport, 318/687-2110 Westlake, 337/882-6004 West Monroe, 318/387-6875 MAINE Bangor, 207/942-5571 Livermore Falls, 207/897-4877 Portland, 207/828-4727 Presque Isle, 207/764-7270 Rumford, 207/364-7933 Union, 207/785-4666 MARYLAND Baltimore, 410/687-2700 Salisbury, 410/749-2106 MASSACHUSETTS Marlborough, 508/229-2688 Woburn, 781/376-5850 MICHIGAN Benton Harbor, 269/926-7216 Escanaba, 906/786-8110 Grand Rapids, 616/791-9770 Jackson, 517/788-6700 Kalamazoo, 269/381-1540 Kingsford, 906/774-1100 Lansing, 517/322-0540 Livonia, 734/261-4920 Ludington, 231/845-6256 Madison Hhts, 248/583-8600 Saginaw, 989/771-2270 Taylor, 734/946-3788 Traverse City, 231/929-0074 MINNESOTA Duluth, 218/628-2825 Eden Prairie, 952/828-0800 Mankato, 507/345-7856 Marshall, 507/532-0198 Mountain Iron, 218/749-8663 St. Paul, 651/631-2430 Waite Park, 320/656-1111 MISSISSIPPI Columbus, 662/328-8041 Grenada, 662/226-6800 Jackson, 601/373-3383 Laurel, 601/649-1321 Meridian, 601/482-0433 McComb, 601/684-3666 Tupelo, 662/844-2119 MISSOURI Columbia, 573/814-0654 St. Louis, 314/770-2600 Joplin, 417/781-0010 Kansas City, 816/587-8844 Sedalia, 660/826-5661 Springeld, 417/862-5300 MONTANA Billings, 406/252-6641 Missoula, 406/542-6692 Helena, 406/449-6318 NEBRASKA Columbus, 402/562-7406 Grand Island, 308/381-2279 Lincoln, 402/467-1153 Omaha, 402/344-7323 NEVADA Las Vegas, 702/651-9490 Reno, 775/355-0555 NEW HAMPSHIRE Berlin, 603/752-3810 Manchester, 603/641-5649 NEW JERSEY Kenilworth, 908/241-1047 New Brunswick, 732/828-8711 Teterboro, 201/288-8111 Trenton, 609/588-0555 NEW MEXICO Albuquerque, 505/884-2606 Clovis, 505/762-4773 Farmington, 505/325-1809 NEW YORK Albany, 518/438-1771 Elmira, 607/734-2158 N. Tonawanda, 716/743-0691 New York City, 914/235-0029 Plattsburgh, 518/438-1771 Syracuse, 315/452-1775 NORTH CAROLINA Asheville, 828/684-3180 Charlotte, 704/588-4100 Greenville, 252/752-6400 Hickory, 828/324-5548 Kernersville, 336/993-2974 Lumberton, 910/738-4221 Raleigh, 919/779-7400 Rocky Mount, 252/972-3096 Wilmington, 910/343-1311 NORTH DAKOTA Bismarck, 701/223-5901 Dickinson, 701/225-9221 Fargo, 701/492-0444 Grand Forks, 701/772-7177 Ross, 701/755-3490 OHIO Chillicothe, 740/775-1226 Cincinnati, 513/533-4900 Cleveland, 216/398-2200 Columbus, 614/444-3030 Dayton, 937/236-7711 Deance, 419/784-4013 Findlay, 419/424-1003 Lancaster, 740/687-0405 Marion, 937/644-1613 Marysville, 937/644-1613 Middletown, 513/423-2833 North Canton, 330/305-1991 Piqua, 937/778-1905 Sandusky, 419/625-3432 Toledo, 419/726-7422 OKLAHOMA Broken Arrow, 918/459-6919 Lawton, 580/248-2211 Millerton, 580/746-2225 Muskogee, 918/682-3611 Oklahoma City, 405/943-3316 OREGON Albany (MS), 541/926-5831 Eugene (MS), 541/342-5946 Medford, 541/732-1552 Portland, 503/460-0403 Portland, 503/239-5021 Roseburg (MS), 541/784-9003 Salem (MS), 503/585-7411 PENNSYLVANIA Allentown, 610/366-9034 Altoona, 814/941-8330 Lancaster, 717/393-3901 Monroeville, 412/856-8034 New Castle, 724/654-6411 Pittsburgh, 412/787-1990 Reading, 610/376-7163 Sharon Hill, 610/616-8000 Williamsport, 570/322-2439 York, 717/848-1102 PUERTO RICO Toa Baja, 787/251-1550 RHODE ISLAND Warwick, 401/736-0515 SOUTH CAROLINA Columbia, 803/796-1071 Florence, 843/395-0095 Greenville, 864/288-7503 Hanahan, 843/554-9090 Spartanburg, 864/578-1470 SOUTH DAKOTA Rapid City, 605/399-9454 Sioux Falls, 605/334-5333 Watertown, 605/886-4114 TENNESSEE Chattanooga, 423/490-0852 Cookeville, 931/528-3797 Jackson, 731/423-4941 Kingsport, 423/349-5092 Knoxville, 865/546-1704 Memphis, 901/398-2000 Morristown, 423/587-6156 Murfreesboro, 615/895-0114 Nashville, 615/228-4020 Tullahoma, 931/454-0907 TEXAS Amarillo, 806/372-5300 Arlington, 817/277-5516 Austin, 512/989-5888 Brownsville, 956/546-5191 Brownwood, 325/643-9923 Conroe, 936/756-1522 Corpus Christi, 361/289-1773 Dallas, 214/351-2211 El Paso, 915/779-3335 Fort Worth, 817/838-7878 Friona, 806/250-5450 Garland, 972/278-0220 Groves, 409/962-7575 Houston, 713/688-9100 Houston Petroleum Bearing, 713/956-0150 Laredo, 956/718-2229 Longview, 903/757-2383 Lufkin, 936/634-4428 Odessa, 432/362-7315 Freeport, 979/233-6476 Pasadena, 281/542-1660 Plainview, 806/293-0100 San Antonio, 210/662-6772 Sherman, 903/892-4646 Temple, 254/773-4224 Tyler, 903/592-0873 Victoria, 361/576-0015 Waco, 254/772-1119 Wichita Falls, 940/766-3328 UTAH Logan, 435/753-7310 Ogden, 801/732-1881 Salt Lake City, 801/972-1036 VIRGINIA Chesapeake, 757/487-0311 Covington, 540/962-7161 Harrisonburg, 540/434-1919 Lynchburg, 434/239-7111 Manassas, 703/393-2314 Richmond, 804/743-8000 Roanoke, 540/362-7695 Winchester, 540/662-4800 WASHINGTON Bellingham, 360/752-3303 Longview, 360/425-4650 Moses Lake, 509/765-4367 Mukilteo, 425/315-8202 Pasco, 509/547-0721 Seattle, 206/762-3800 425/656-8307 Spokane, 509/924-4800 Tacoma (GB), 253/572-7070 Vancouver, 360/750-1464 WEST VIRGINIA Beckley, 304/254-0443 Charleston, 304/744-0201 Weirton, 304/527-0509 Huntington, 304/525-6706 WISCONSIN Appleton, 920/731-4121 DePere, 920/983-6604 Eau Claire, 715/833-2440 Fond Du Lac, 920/923-7500 Janesville, 608/754-4199 La Crosse, 608/785-1200 Madison, 608/221-3328 Marinette, 715/732-1714 Milwaukee S., 414/649-2400 Portage, 608/742-5129 Racine, 262/554-0110 Sheboygan, 920/208-5600 Waukesha, 262/896-3880 Wausau, 715/848-2994 WYOMING Cheyenne, 307/635-2056 Gillette, 307/682-8821 Mills, 307/266-2966 MOTION CANADA ALBERTA Calgary, 403/236-5581 Edmonton, 780/465-0821 Fort McMurray, 780/743-5504 Fort Saskatchewan, 780/992-6940 Grande Prairie, 780/539-5900 Hinton, 780/865-7976 Lethbridge, 403/327-1571 Peace River, 780/624-4777 Red Deer, 403/343-6733 BRITISH COLUMBIA Abbotsford, 604/556-0716 Burnaby, 604/433-6711 Cranbrook, 250/426-8060 Dawson Creek, 250/782-5824 Houston, 250/845-3308 Kamloops, 250/372-9518 Kitimat, 250/632-7107 Nanaimo, 250/753-6411 Prince George, 250/563-0452 Quesnel, 250/992-7935 MANITOBA Brandon, 204/725-1419 Winnipeg, 204/694-0050 NEW BRUNSWICK Hartland, 506/375-4441 Moncton, 506/859-4345 NEWFOUNDLAND Wabush, 709/282-5085 NOVA SCOTIA Dartmouth, 902/468-3231 New Glasgow, 902/755-3540 ONTARIO Belleville, 613/966-1923 Brockville, 613/342-8894 Dryden, 807/223-3928 Guelph, 519/763-0710 London, 519/681-5800 North Bay, 705/476-3119 Ottawa, 613/723-6200 Sarnia, 519/332-4500 Sudbury, 705/671-0000 Vaughan, 905/695-7878 Waterloo, 519/884-1220 QUBEC Joliette, 450/759-6343 Montreal, 514/459-3301 Pointe-Claire, 514/459-3316 Qubec City, 418/657-3000 Rimouski, 418/725-3750 Saguenay, 418/696-1221 Sept-Iles, 418/962-3232 Sherbrooke, 819/563-5732 Sorel Tracy, 450/742-3749 St-Hubert, 450/445-0633 St-Hyacinthe, 450/774-3050 Trois-Rivires, 819/374-2788 SASKATCHEWAN Regina, 306/721-7233 Saskatoon, 306/931-7771 MOTION MEXICO NUEVO LEON Monterrey, From Mexico, 011-52-818-231-5100 From U.S., 877/838-9161
55M0113 00003W12065
Innovative energy management strategies help a Maine paper mill stay competitive
By Hudson Gilmer, Genscape
Like much of the rest of Maine, the town of Rumford is well known for the beauty of its natural surroundings. But for more than a century Rumford in particular has also played host to one of the largest paper mills in the Northeast, churning out as much as 550,000 tons of paper and 125,000 tons of pulp annually. NewPage, which owns the Rumford facility and is among the leading domestic producers of printing paper and specialty paper, is working in a highly competitive and energy-intensive business. Through creative energy management strategies and the intelligent use of forecasting data, NewPage has transformed the Rumford mills energy costs from a burden to a source of competitive advantage.
The Rumford Paper Mill has seen its energy costs reduced thanks to aggressive energy management strategies. Photo courtesy of Genscape.
Breaking down the problem

Abradi started by created three broad buckets for energy management strategies: demand, procurement, and conversion. Demand would cover most of the approaches people usually identify with energy efficiency, the equivalent of adding insulation and replacing light bulbs in a house. On an industrial scale, it generally means finding ways to produce more pulp and paper with less steam and electricity. A bigger cost impact, though, came from procurementfinding a way to diversify, away from expensive coal to cheaper fuel sources. Despite being able to use some of its own waste products as fuel, the Rumford mills generator still relied on coal as the single largest fuel source for the boilers. With prices rising, diversification was the key to ensuring some measure of cost control. The mill operates two circulating fluidized bed that suspends fuel in jets of air. The Rumford mill is able to burn readily available biomass from wood chips and a fuel called TDFtire-derived fuel. Increasing the volume of these alternative fuel sources allowed Abradi to reduce coals share of total fuel consumption.
Need to improve
Producing paper and pulp is an energy-intensive operation, and the Rumford mill features three boilers and a generator to provide for the thermal and electrical needs of the mill. The generator can put out as much as 100mW, or roughly enough to power 100,000 homes. The Rumford mill was facing a crisis in the late 2000s, though, because the primary fuel for the generator was coal, and the price of coal was steadily rising. According to the U.S. Energy Information Administration, the market price of coal rose nearly 90% from 2000 to 2010, and transportation costs drove the price even higher in Maine. The problem is transportation to get coal from, say, West Virginia up here to western Maine relies on diesel, rail, ship or truck, or any other transportation mode, explains Rick Abradi, the head of energy management at the Rumford mill. Faced with rapidly increasing coal prices which jeopardized the Rumford mills competitiveness, NewPage assigned Rick Abradi the challenge of developing a strategy to bring overall energy costs under control.
In addition, NewPage gained greater operational flexibility to adjust fuel sources based on market prices and availability, reducing the dependence on any single supplier or fuel type.
Generators, forecasts and using them the right way

With the fuel sourcing problem solved, the next challenge was optimizing conversion. A big part of this is making a determination of when and at what level to run the generator. While the Rumford mills generator is more than capable of meeting its own needs, the plant sits within the region covered by electric utility Maine Central Power, and can just as easily draw power from the grid. When local power prices fall below what NewPage pays for generation costs, the plant can scale back its generator and instead draw from the grid. With so much excess generating capacity, the mill can also export power out onto the grid. When demand on the grid is high and prices rise far enough above the cost point, NewPage is able to take advantage of the cost differential. The biggest difficulty with trying to take advantage of the rise and fall of electricity prices is that it can be difficult to respond quickly to changes.
plant engineering
March 2013 17
IN fOCUS
Barring any breakdowns, operators have a good idea how much power the mill will need, but it still takes as much as 15 to 20 minutes to change output from the generator, so any mistakes or delay can mean a missed opportunity. This can be an even bigger problem for companies that only have the option of cutting back operations. dramatic impact on overall energy costs, namely, minimizing demand charges. Every utility imposes some sort of charge for using its grid, fees that cover everything from maintenance to expansions and upgrades. Generally, utilities charge a fixed amount, distributed among customers based on their proportion of but these transmission charges are really starting to escalate around the region. Easy as it might seem to avoid demand charges with an on-site generator, making guesses about when a new peak will occur comes along with very real costs.
Lessons for the rest of us

Most industrial plants dont have a 100 MW generator and the ability to sell surplus power to the grid, but that doesnt mean they cant benefit from the same energy management strategies employed by NewPage. Demand charges are an unfortunate fact of life for every industrial facility, and reducing load during forecasted peak demand periods can go a long way toward reducing overall energy costs. By using a forecasting service to accurately predict the days and hours of highest real-time prices, a participant can maximize the financial benefit from these programs and provide a benefit to the grid at the same time. NewPages Rumford mill stands as a testament to the significant savings that can be achieved through comprehensive energy management and accurate forecast data. In a highly competitive industry like paper, even modest reductions in energy costs can mean a major swing E in profitability. P Hudson Gilmer is vice president of commercial markets at Genscape.
The power of analytics.

Since the early 2000s, NewPage has turned to the energy information firm Genscape for daily forecasts of local power prices and regional power demand. Genscapes teams of analysts and meteorologists provide highly accurate forecasting reports using a combination of neural network models, proprietary monitor data, and fundamental models. When a morning forecast from Genscape calls for high real-time prices later in the day, the control room operators get the advanced notice to ramp up the generator and sell surplus power to the grid at a handsome profit. Sometimes when the price unexpectedly ramps up, we dont see it right away. And due to the nature of our equipment we cannot react instantly, said Abradi. So having a heads-up on that, the operators can anticipate that move.
Sometimes when the price unexpectedly ramps up, we dont see it right away. So having a heads-up on that, the operators can anticipate that move.
Rick Abradi, Rumford
Casting a small shadow

Theres another use of these types of power forecasts that can also have a
total usage when demand peaks during a given month. NewPage has largely managed to significantly reduce its demand charges by using monthly forecasts to determine which days are likely to result in a usage peak and running the generator to reduce or eliminate net usage from the grid during those periods. (Before these reports) it was me and my fancy Excel spreadsheet I built on the back of an envelope, looking at the National Weather Service weather forecast, remembers Abradi. Before that we didnt worry about it much because the cost penalty was relatively minor,
Thousands of enclosures Hundreds of sizes Next-day shipping

ENCLOSURES ENCLOSURES ENCLOSURES POWER POWER DISTRIBUTION POWER DISTRIBUTION DISTRIBUTION
CLIMATE CLIMATE CLIMATE CONTROL CONTROL CONTRO
Reduced corrective maintenance is found money

By Paul LaChance, Smartware Group
ou know that feeling you get when you find a $20 bill that you left in your jeans pocket after it went through the wash? Found money! That happened to me the other day and I thought to myself, where else can you find hidden money? In fact, there is a fair amount of money lurking in the corners of your maintenance department, but you have to know where to look. CMMS helps you cut needless expenses or improves asset capacity, which equals found money, with an added benefit: Management views you as a rock star.
improvement in uptime can give you greater capacity to produce goods. Found money! A dairy manufacturer reduced equipment downtime with its CMMS by scheduling simple tasks like replenishing the oil in a gear boxtasks that are often ignored until a machine breaks down. By creating PMslarge and small for more than 1,500 pieces of equipment, the maintenance department squeezed more than 30% out of the budget. The companys CMMS administrator trumpets his favorite slogan: Oil and grease is cheap, parts are not.
Asset preservation
Have you ever had equipment fail to the point where it needed to be replaced or overhauled, unexpectedly? A maintenance related issue had something to do with it, no doubt. Imagine catching those problems before they occur. CMMS shows impending problems, equipment likely to fail, problem trends, etc. Unattended, these problems can lead to catastrophic failure and a lot of disruption in your operations. Prevent these failures and you have found money! A small food processor in the Midwest improved machine uptime and food safety compliance while cutting maintenance costs by approximately $50,000 per year. While I probably should have checked my jeans pocket before I put it in the wash, CMMS users should look beyond the fundamental PM-work order capabilities and find money hidden in the benefits of proactive maintenance E management. P Paul LaChance is president and chief technology officer for Smartware Group, producer of Bigfoot CMMS for organizations worldwide. He can be contacted at paul.lachance@bigfootcmms.com. Check out his new blog at www.plantengineering.com/blogs.
Reduce overtime
CMMS can streamline your staff operations. Better management of corrective and preventive work orders means a more efficient maintenance team. In some cases your staff may want overtime, but management doesnt agree. Optimize the teams workload and schedule by analyzing work order data. These efficiencies will allow them to get more done during the day, giving them more capacity and reducing unnecessary overtime. Found money! A recycling companys East Coast plant claims CMMS gave it the ability to analyze staff performance through work order history and cut way back on overtime costs by hiring more qualified technicians. The CMMS also helped analyze replacement part usage. The result? Maintenance costs per ton dropped by nearly 40% annually.
Reduce downtime/improve uptime

One of the primary goals of CMMS is to give you an improved PM/corrective maintenance ratio. PMs are proven to reduce corrective maintenance, which leads to less downtime. Increase uptime, increase production, and improve service to clients. Do the math; even a small
OL
IT INFRASTRUCTURE IT INFRASTRUCTURE IT INFRASTRUCTURE
SOFTWARE SOFTWARE SOFTWARE & SERVICES & SERVICES & SERVICES

www.rittal.us www.rittal.us www.rittal.us
IN FOCUS
Staying ahead of the curve

Five trends in the evolution of mechatronics
By Chuck Edwards, Lenze Americas
Although not technically a standard, CoDeSys has emerged Pioneered in automotive among best practice tools for manufacturing plants, control programming controller appliin a series automation technologies have cations in compliance with intermade significant headway into national industrial standard IEC many other industries. Automated sys- 61131-3. Developed by German-based tems optimize space and productivity, 3S-Smart Software Solutions, CoDeSys performing tasks that otherwise require is a free licensed development software extensive manual labor, such as equip- tool that deals with PLC programming ment assembly, loading and unloading, language standards. picking and palletizing. These standards and tools have been Increased need for automation most instrumental in mitigating system in broader applications has spurred integration issues, including inconsistendemand for smarter, more efficient cies in mode control and error reactions, drives, controls, and software tools. The mechatronics approach results Successful execution requires in machines and systems that address that todays machines handle operational needs while being easier to integrate and maintain. Managing the more extensive machine process and recognizing mechatronic control tasks with greater trends are keys to staying ahead of the technology curve.
First
1: Evolving standards
Industry-wide automation system standards have vastly improved machine programming consistency. The most widely influential are the ISA standards, which strive to achieve total integration within the industry so users have better and more flexible equipment and software choices. ISA-88 defined terminology and models for batch control in the automation of machines and devices. The international standard for integrating enterprise and control systems, ISA-95, provided hierarchal and modular standards for the exchange of information between ERP and MES systems. Founded in 1994 to identify and define solutions to enable open architecture systems, OMAC (Organization for Machine Automation and Control) brings together manufacturers to share best practices and outline strategies for improving production operations. OMACs working groups for the packaging and machine tool industries have produced specific guidelines relevant to using automation for greater efficiency and productivity.
speed than in the past. The field is constantly evolving.
commonly associated with proprietary program development. By advancing open system architectures through industry standardization, machine builders can focus on their core technology.
2: Impact of modular code

Programming modular code presents unique design challenges. For every machine task, a distinct corresponding code does not exist. Programming code requires expertise in both motion control and the specific tasks needed to be accomplished. Modular programming has gained traction in automation control by providing software design modules that conceptually represent desired machine tasks. Application templates and readymade standard software modules support machine builders in efficiently creating modular control software. And, technologies exist that can quickly and reliably handle most of the engineering requirements for standardized machine modules.
Consider that about 80% or more of new machine tasks reflect some variation of past machine tasks. So, software for a new machine can be generated much more quickly using code developed for previous generations of machines in the form of these ready-made technology modules, which can be modified to meet any new requirements. Use of modular code programming relies on a control system and modular hardware, but the impact in terms of reducing machine design resources is phenomenal. This offers the machine designer greater freedom to devise and test special features of a machine to better meet end-user needs and provide purchasing incentives for prospective customers. An application template provides the necessary basic structures while allowing users to create their own machine modules. Software modules created using application templates can then be put together like bricks with minimal effort, creating complete systems that are customizable and reusable. Reused tested modules further reduce costs, allowing for new refinements and error reduction with each iteration. Standard machine software modules, for example, might include modules for feeding, unwinding, sealing, cross-sealing, and discharging.
3: Integrated hardware sets

Machine design by definition is customized to the requirements of a given task or set of tasks. Whether optimizing an existing machine, developing a new machine, or designing a complete end-toend automation system, successful execution requires that todays machines handle more extensive motion control tasks with greater speed than in the past. The field is constantly evolving, so it pays to leverage the best tools and technologies on the market. In drafting automation concepts, the approach should be to let the machine decide. Whether an automation system for central (controller-based) or
20 March 2013
PLANT ENGINEERING
The PIG Latching Drum Lid is the answer to easier drum access and regulation compliance. Features include an easy-open, one-hand latching handle, durable locking mechanism and nitrile gasket to help meet haz-waste regs like 40 CFR 264.34(c) and reduce vapor emissions. A New Pig exclusive! And, you can find the PIG Latching Drum Lid (DRM659) at your local Motion Industries location. Our local sales and service specialists are experts in application and technical Over 500 locations More than 4 million products support, providing the parts and Industrial maintenance training courses Call. Click. Visit. the know-how you need to stay up and running. The brands you count on from the people you trustthats New Pig and Motion Industries.
1-800-526-9328 for the location nearest you
2013 Motion Industries, Inc. input #15 at www.plantengineering.com/information
MotionIndustries.com
IN fOCUS
decentralized (drive-based) motion control from a single source, the individual system elements should be optimally matched to one another, while meeting the highest quality and efficiency standards. To optimize motion control efficiency and achieve scalability through precision performance matched components, its important to ensure the right gear box, pairing the right motor and drive. Equipped with options that may include L-force control and software, memory modules, online diagnostics, and integrated safety systems, scaled lines of frequency inverters enable the exact matching of speed and torque requirements. Whether its continuous positioning tasks, pick and place, storage and retrieval, rotary and lifting, or material handling and conveying systems, it is important to ensure optimal motor voltage and operational efficiency. Synchronization at the hardware level enables seamless integration of high dynamic drives. The latest inverter drives on the market offer improved functionality for motion control including automatic axis bus to enable easy construction of direct and cascade configurations. This optimizes the bus bandwidth through synchronization at the hardware level. The challenge remains to dovetail hardware sets that require parameterization at multiple levels, such as between a motor and drive, drive to controller, controller to HMI, etc. Modularization requires a modularized development environment. Drive solution design tools can simplify the process of drive dimensioning and energy optimization.
4: Industrial communications
The industry is trending toward high-speed field bus data rates up to a gigabyte. Modular industrial communications protocols are critical to incorporating machine components and ensuring an efficiently networked system. There are multiple open networks with proven performance and reliability in a broad range of industrial applications. Among those, the AS interface might be considered the easiest approach to industrial networking. InterBus can establish connections quickly in major installations. Widely used DeviceNet creates connections at the field level. ProfiBus is totally universal and suitable for any large machine application. CANOpen offers a fast, easy networking system for multiple components. EtherCAT and ProfiNet used in conjunction with EtherNet provide the most seamless exchange of information on all levels. The latest inverters on the market are equipped with an onboard field bus (CANOpen or EtherCAT) or may be expanded by adding pluggable communication modules. In that way the user can select and customize solutions using the field bus most suitable to a given application. It is worth noting that industrial network communications architecture and hardware platforms can and should be independent decisions based on the best available technologies. The more important decision is selection of a support team and supplier that can offer a powerful agile software structure to integrate existing and future system components efficiently and sustainably.
5: The people challenge

People are at the core of new innovations in machine building. Machine engineers face rapidly evolving and converging technologies, compounded by stiff competition driving faster times to market for increasingly complex machine designs. Many machine builders and supply partners are turning to mechatronics as a tool for abbreviating the design cycle, while ensuring the best possible machines. Mechatronics is the synergistic collaboration between mechanical engineering, electrical engineering, and information technology in the design and production of industrial products and processesor, more simply stated, the convergence of engineering disciplines. By streamlining the design process, mechatronics translates to better designs with lower total cost of ownership, from implementation to commissioning to maintenance. Mechatronics eliminates traditional engineering silos to reduce inefficiencies. With an ROI that applies to any industry, including packaging, consumer goods, airport baggage handling, automotive, and industrial, the mechatronic approach reduces numerous layers of design and decision-making, while improving machine E efficiency. P Chuck Edwards is president of Lenze Americas, a leading global manufacturer of electrical and mechanical drives, motion control, and automation technology.
22 March 2013
plant engineering
Guaranteed uptime
prOteCt aSSetS 24/7 WitH reLiaBLe COntinuOuS pOWer
Your Cat Dealers are ready for all your power generation demands . . . permanent or temporary, large or small, urban or rural, simple to complex. From diesel and gas generator sets to uninterruptible power supplies, automatic transfer switches and electrical switchgear, our experienced worldwide network can deliver the power systems and support you need. We like to think of it as guaranteed uptime. Any size or shape, in any regulatory environment. When you need power, Cat is equal to the challenge. Visit us online today at www.neCatdealers.com/power
SinCe 1927 Alban CAT

www.albancat.com Baltimore, MD 800-492-6994
SinCe 1948 Cleveland Brothers

www.clevelandbrothers.com Murrysville, PA 888-232-5948
SinCe 1923 H.O. Penn Machinery

www.hopenn.com Poughkeepsie, NY 845-437-4051
SinCe 1960 Milton CAT

www.miltoncat.com Milford, MA 866-385-8538
SinCe 1916 Giles & Ransome Inc.

www.ransome.com Bensalem, PA 877-RANSOME
2013 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com www.caterpillar.com
Clear the way for quality air
140 years of history, and the present is yours

Optimizing air supply quality is a way of life at Atlas Copco. Our dryers, aftercoolers, filters and oil-mist eliminators help ensure that your air is always clean, dry and ready for the summer heat. And it doesnt stop with quality air because the right air system components also save energy. Atlas Copco knows you have challenging targets to reduce energy costs. We know because we face those targets, too! With 14 production facilities in the United States and dozens more globally, we never stop looking for ways to help our manufacturing teams, and yours, save energy and increase productivity. In 2013 Atlas Copco celebrates our 140th birthday. To celebrate this key milestone we are offering a series of gifts: starting with simple air studies for free. Well log your plants actual air usage, show you ways to save money and compute the payback on any new investments. Sign up now and youll receive a limited edition anniversary baseball cap. Register at www.atlascopco.us/mboxusa or call 866-688-9611. We look forward to serving you far into the future.

Copyright 2013 Atlas Copco Compressors LLC. All rights reserved.
IN PRACTICE
Benchmark your manufacturing performance to deliver results
By Becky Partida, APQC
idespread outsourcing of production activities has put tremendous pressure on manufacturing managers to produce quality products that are delivered on time, at a competitive price, and with excellent customer service. To accomplish this, manufacturing leaders must establish production schedules, optimum workflows, effective maintenance procedures, and continuous improvement programs that will keep the organization moving forward. To determine which manufacturing areas need improvement, organizations can benchmark their performance against that of other organizations. APQC has used data from its Open Standards Benchmarking in Manufacturing to create APQCs Manufacturing Tune-Up Diagnostic, a collection of key performance indicators for manufacturing. Table 1 presents the indicators and how the participating organizations perform on these measures. In Table 1, top performer is the performance level below which 75% of responses fall, median is the value above and below which an equal number of responses fall, and bottom performer is the level below which 25% of responses fall. APQC also has identified practices that can improve manufacturing performance for each of the key measures.
helpful measure is the value of plant shipments per employee. Top performers ship more than $300,000 more product per employee than bottom performers do.
Unplanned machine downtime

The gap between top and bottom performers for unplanned downtime is 4% of scheduled run time. That unexpected downtime can wreak serious havoc on an organizations production schedule and, ultimately, its bottom line. If an organization determines the frequency of downtime, it can begin tracing and addressing the source of the interruptions. Preventative maintenance programs protect investments in equipment, thereby reducing the cost of delays resulting from unscheduled downtime.
Manufacturing cycle time

Manufacturing cycle times can vary dramatically. Among the participating organizations, bottom performers take 88 more hours to produce products than top performers takea difference of 11 working days. Long production lines and stacks of work-in-process inventory have been replaced by flexible work cells that pull materials from suppliers and customize products based on individual orders. Customizable processes can reduce customer order lead times and yield better returns on invested capital.
Total cost to manufacture

The amount spent by organizations to manufacture products varies widely. The $430 difference between top and bottom performers in manufacturing cost per $1,000 revenue represents a potential cost savings of $2.15 billion for an organization with $5 billion in annual revenue. A lower manufacturing cost is desirable for obvious reasons. However, using cost alone as the basis for decision-making can have unintended consequences on quality, cycle time, and other strategic concerns. When evaluating lower cost options including outsourcingconsider their effect on customer satisfaction and other key metrics.
Conclusion
Benchmarking is an important first step in evaluating your organizations manufacturing performance. By looking at how other organizations perform on key manufacturing measures, your organization can focus improvement efforts where they are needed most. APQC is an affiliate partner with AME, a Plant Engineering Content Partner. To learn more about APQCs Manufacturing Tune-Up Diagnostic and access an interactive version that quickly identifies areas for improvement, visit www.apqc.org/ E manufacturing-tune-up. P
Value of plant shipments

To understand the efficiency of manufacturing processes, a
Key performance indicator

Total cost to manufacture per $1,000 revenue Value of plant shipments per employee Unplanned machine downtime as a percentage of schedule run time Manufacturing cycle time in hours
Top performer
$222 $453,349 2% 8 hours
Median
$442 $283,000 4% 24 hours
Bottom performer
$652 $122,189 6% 96 hours
Table 1: Benchmarks with the key performance indicator, top performer, median, and bottom performer for manufacturing results.
PLANT ENGINEERING
March 2013 25
IN PrACTICE
Study finds optimism among mid-sized manufacturers
n its semi-annual Group Outlook Survey, manufacturing buying consortium Prime Advantage said its members are showing great optimism for growth in 2013 despite pressures over raw material and healthcare costs. Among the studys findings: n 68% of respondents expect revenues to increase n 87% of companies expect capital expenditures to grow or remain constant in 2013, with 39% planning to spend more than 2012 levels n 43% of companies plan to hire more employees in 2013 and 52% plan to maintain current employment levels. This is higher than the 39% that indicated they would be hiring in the second half of 2012 We are encouraged to see that our members expect to see growth in 2013, after a very strong 2012 for most, said Louise OSullivan, founder, president and CEO of Prime Advantage. As they focus on profitability and margins, we look forward to partnering with both Members and Endorsed Suppliers to fuel the bottom line, reflecting Total Cost of Ownership, along with the top line, greater sales and market share. Most small and midsized manufacturers expect to beat strong revenues of 2012, with 68% of respondents anticipating an increase in sales in 2013. New product launches
are the main reason for expected revenue increases, cited by 61%, followed by an expected increase in overall customer demand, cited by 57%. Manufacturers hiring plans remain in expansion mode, with 43% planning to hire more workers this year. Although this number is slightly down compared with 2012, when 56% of respondents planned hiring, it remains significantly above expectations in 2010, when only 24% of companies were hiring. The top concern of 2013, the cost of raw materials, is also a leading cost pressure concern. More than 90% of respondents included raw materials in their top three cost pressure concerns and 42% cited this concern first. Companies are seeking the benefits of near-shoring. In the past twelve months, more than one-in-five respondents have brought international sourcing closer to United States. These results are similar to the Grant Thornton Study on Nearshoring, where 25% of respondents indicated they brought sourcing closer to the U.S. More than 70% of respondents have increased material and service purchases from American suppliers and service providers. Mexico is the second choice for sourcing, with nearly 28% of respondents moving sourcing to that region. P E
Surface Finishing Shot Blasting
Consumables
Send us your challenge...Rosler can nd a better way.

It may be as simple as upgrading your mediaor maybe a different process would achieve the surface nish you need. From aerospace and automotive, to medical and general manufacturing, our state-ofthe-art test lab is here to solve your mass nishing and shot blasting challenges. Rosler specializes in providing complete, automated solutions and consistent, repeatable results for superior parts nishing.
Visit us at www.rosler.us or call us at 269-441-3000.

A new angle in conduit connections
Unique T&B blue interior coating with PTFE component reduces friction for easier wire pulling The LU replaces LL, LR, LB, and C conduit bodies
LU Universal Conduit Elbows: a 4-to-1 reduction over conventional conduit bodies

With a 4-to-1 SKU reduction, our T&B Fittings LU Universal Conduit Elbow simplies inventory management and on-site handling. And, with a radius that eliminates 90 angles and an interior coating that reduces friction, it also saves time and makes wire pulling easier. LU elbows also provide superior corrosion protection. For more information contact your T&B distributor or scan this QR code.
Increased wire capacity eliminates the need for system de-rating Four-layer coating for superior corrosion protection
Visit tnb.com for other products that help you make faster, easier installs, with fewer SKUs:
Faster, easier installs with 2" knockouts for pre-terminated AV cables. Plates for power, VDV.
Compression crimping avoids need for exothermic grounds in any weather
Construct metal framing supports in less time with minimum amount of pieces
Grounding Connectors
665-AV2 Floor Boxes
Modular Metal Framing
Wire & Cable Management Cable Protection Systems Power Connection & Control Safety Technology
2013 Thomas & Betts Corporation. All Rights Reserved.
Top 6 places to look for energy losses in commercial buildings.

A typical scan can show energy saving opportunities of up to 15%.
Small, consistent changes can make a big difference in the profitability of any facility. Find problems fast, fix them, and win by realizing the cost savings. Unlike regular digital cameras that capture images of the visible light reflected by objects, thermal imagers create pictures by detecting infrared energy or heat. The thermal imager then assigns colors based on the temperature differences it detects. With a small amount of training, most people can readily spot abnormal heat flow patterns and follow the heat trail to energy waste. The technique works best when used by people who already possess a good working knowledge of the structures and systems being scanned and can better interpret the temperature variances they see on camera. A typical scan can show energy saving opportunities of up to 15 percent, with varying degrees of repair investments. Thermal imagers have come down so far in price that most facilities can recoup the cost of purchase in terms of energy savings within six months. Plus, incorporating infrared inspection into regular maintenance provides significant efficiencies to a maintenance team as well as helping them identify and prevent expensive failures.
Download this asset at: http://support.fluke.com/ find-sales/Download/Asset/ 3511577_6251_ENG_A_W.PDF
Email: thermography@fluke.com www.fluke.com

Dew Point Sensing Technologies and their Performance Differences in Compressed Air Applications
Moisture is a constant issue in compressed air systems. When dew point sensors are working optimally, measures can be taken to avoid malfunctions, inefficient operations or poor quality end product. However, the measurement of dew point in compressed air systems can present many challenges that lead to erroneous readings, poor stability, and even sensor failures. The most common issues with dew point sensors in compressed air are usually centered on:
/ APPLICATION NOTE
Dew Point Sensing Technologies and their Performance Differences in Compressed Air Applications
sample passes over a metallic mirror surface which is chilled by a cooler. Light is then directed at the mirror allowing an optical sensor to measure the amount of reflected light. When the mirror is cooled to the point at which condensation begins to form on its surface (i.e. the dew point has been reached), the amount of light reflected by the mirror diminishes which is in turn detected by the optical sensor. The rate of cooling is then carefully regulated by a temperature sensor on the mirror. Once a state of equilibrium has been reached between the rate of evaporation and condensation, the mirror temperature is equal to the dew point. Due to the chilled mirrors optical measurement principle, the sensor is highly sensitive to the presence of dirt, oil, dust, and other contaminants on the mirror surface. Similarly, accurate chilled mirror devices tend to be expensive and are often employed when absolute accuracy is essential and frequent maintenance and cleaning can be performed.
Download the white paper at www.vaisala.com/ dewpointsensor
Moisture is a constant issue in compressed air systems. When dew point sensors are working optimally, measures can be taken to avoid malfunctions, inefficient operations or poor quality end product. However, the measurement of dew point in compressed air systems can present many challenges that lead to erroneous readings, poor stability, and even sensor failures. The most common issues with dew point sensors in compressed air are usually centered on the following: Response time Reliability of the reading Recovery from water spikes or condensation Exposure to compressor oil
Different Sensing Technologies

The three most common types of sensors for measuring dew point are chilled mirrors, metal oxide, and polymer sensors. Chilled mirror technology can offer the highest accuracy over a wide range of dew points. The operating principle is based on the fundamental definition of dew point cooling a volume of air until condensation forms. A gas
Sensor technology Wide High measureaccuracy ment range
Immune to dust and dirt
Immune to Longcondenterm sation stability
Reasonable price
Chilled Mirror Capacitive Metal oxide Capacitive Polymer
+++ ++ ++
+++ ++ ++ ++ +++ + +++ + +++ ++ ++
To better understand these challenges, it is worth first exploring the performance differences between the most common sensor technologies.
Response time Reliability of the reading Recovery from water spikes or condensation Exposure to compressor oil
This paper first explores the differences between the most common sensor technologies: chilled mirror, metal oxide, and polymer oxide. It then compares the performance of each sensor technology relative to the most common issues.
www.vaisala.com/dewpointsensor sales@vaisala.com input #22 at www.plantengineering.com/information

2/15/2013 1:52:20 PM
ple201303_whitePpr_vaisalaHLF.indd 1
Upload your Digital Ads to the CFE Ad Portal.

Its Easy and Secure!
Log on today at http://ads.cfemedia.com and start using this simple, fast and convenient service! Follow the easy step-by-step instructions to submit a new ad. Once uploaded, review your ad on screen for compliancy, then approve for submission. The portal also offers helpful tips for pdf creation, plus a useful archive and status report of all ads you have submitted.
day... o t p u Sign E! its FRE
Log on at:
http://ads.cfemedia.com
CoverStory
Maintenance as a profit center

If you increase uptime, you increase capacity. Thats only possible if you develop a strategic approach to maintenance.
By Rob Nugent Rockwell Automation
Creating a training assessment to analyze employees skills on maintenance critical tasks helps identify strengths and weaknesses in your maintenance process. All photos courtesy of Rockwell Automation.
T
plant engineering
he Oreo. On the surface it seems pretty black and white: two chocolate wafers separated by a cream filling. But in todays global marketplace fueled by increasingly diverse consumer preferences, its not quite so simple. The filling could be chocolate, vanilla, or mint flavored. Or maybe its dyed red and green for the holidays, or its double stuffed, or half the fat. The possibilities are seemingly endlessand that doesnt even consider the packaging options. While all these choices help generate consumer interest in hopes of growing profits, they also make productionand maintaining
the technology it requiresmuch more complex. Other challenges, such as regulatory requirements and workforce skills shortages, further complicate the landscape. Unfortunately, adding complexity in production processes doesnt mean more budget is available to maintain efficient operations. The opposite has happened in many organizations. Manufacturers are being pressured to reduce operational costs while increasing productivity. At the same time, resources for activities like maintenance that are traditionally viewed as an overhead cost and a liability have been cut to the quick in recent years. In many organizations these cuts are actually moving profitability in the wrong direction. With fewer resources, bare-bones maintenance staffs spend most of their time in firefighting mode reacting to unplanned maintenance crises. The average impact of unplanned downtime in process industries is $20 billion, or almost 5% of production, according to a 2011 ARC Advisory Group report. As productivity demands seem to get more intense each year,
30 March 2013
maintenance departments, like every other business function, cannot escape the demands to be more efficient while still curbing the rising costs of production downtime. With every 10 workers retiring, only five will take their place, which means fewer skilled people will be trying to support ever more advanced and technically interconnected plants. A strategic plan is in order, and it is in order right now if any facility is expecting to survive the continued national and international competitive pressures.
A strategic plan for maintenance

Establishing a holistic maintenance plan to survive this new reality is the best way to cope with increasing budget and skilled labor challenges while improving production KPIs. Just as any effective business plan would, a maintenance plan should include an assessment of the current situation, clearly defined objectives, and an outline of metrics that will gauge results. The maintenance plan must align with the overall facility business plan, as well as objectives such as accurate production forecasting. The maintenance plan should have two primary areas of focus: 1. Assets: The equipment running in your facility 2. People: The staff keeping the equipment running These two areas are interdependent and must be addressed holistically to effectively optimize costs through sustained adoption and facility improvement. Taking a disciplined approach gives flexibility based on the facilitys business plan, maintenance needs, and ability to invest. There are a number of steps needed to optimize your assets: 1. Implement a criticality-and risk-based approach Implementing an asset management program will improve equipment utilization and performance, reduce capital and asset-related operating costs, extend asset life, reduce spare parts inventory, and improve RONA, MTBF, and MTTR. With budget and people resources stretched to the max, prioritization is the key. In todays plants, at least 60% of preventive maintenance tasks are considered unnecessary. Defining equipment criticality and risk can help reverse this trend. A risk-based approach should also be taken to not only understand hierarchy, but also to determine risk of failure. Defining criticality is fundamentally a question of economics. To
determine which equipment is critical, consider the financial impact of downtime on production, such as costs associated with lost data, lost product, and loss of visualization. Also consider the impact of replacing or repairing equipment, and potential hazards associated with downtime. Addition of a risk-based approach also can help determine hierarchy of equipment and risk of failure. To get started, an experienced reliability engineer should perform a failure mode effects analysis (FMEA) to determine possible failure modes. For mission-critical equipment, this type of investment is necessary to put true reliability- Giving the power for maintenance decisions based maintenance processes to your staff empowers them to view the prointo place. Additional lower- cess as more than fixing broken parts, but cost risk mitigating activities keeping all parts functioning. should also be completed across the enterprise for less critical equipment that has the potential to wreak just as much havoc on productivity. 2. Assess the installed base Simply developing a complete understanding of the installed base of components can drive immediate risk reduction and financial gain. But many facilities still do not have a complete understanding of their installed A risk-based base. This is dangerous to both production approach should and finances. Understanding its installed base allows a also be taken to not staff to make prioritized decisions to mitigate or eliminate risk on obsolete equipment and only understand identify spare parts gaps. hierarchy, but Obsolescence risk can be mitigated through reserve repairs from an automation provider or also to determine eliminated by migrating the technology. Lack of risk of failure. spares can usually be cost-effectively overcome with vendor-managed inventory. As a financial Defining criticality benefit, understanding the installed base in a facility as well as in the storeroom presents is fundamentally an opportunity to remove excess and inactive a question of inventory from the books immediately. Defining equipment criticality and under- economics. standing the facilitys installed base, including obsolescence risk, is the best start toward taking control of a facilitys assets and command of equipment reliability. This leads to confident prioritization of investments, preventative maintenance, and other risk-mitigating activities that can drive adoption of sustainable
plant engineering
March 2013 31
CoverStory
A crucial part of developing an effective training program is prioritizing. Training dollars are often scarce, so its up to maintenance managers to be specific and deliberate about where to focus.
maintenance processes. At a minimum, select the most critical equipment to drive this endto-end approach, and collect the quick win and productivity gains before moving on to other areas. Or, for more comprehensive results, engage a workforce competency expert to assess, document, and align the facilitys skills need with its skills gaps. Following assessment, the next step for most facilities is to build a costoptimized training regimen. This may include several different delivery methodologies but ultimately delivers just enough training for each individual. 2. Build a community with the right expertise Prioritization and risk mitigation are key to effective asset management; however, not every downtime event can be predicted or prevented. Building a proactive plan streamlines unexpected circumstances by empowering existing staff to efficiently marshal the right resources whenever theyre needed. The status quo for many organizations is to call upon numerous resources when theres a problem with a system, while attempting to keep production flowing smoothly and efficiently. Complex, interconnected technologies make it harder to immediately diagnose and solve problems, and maintenance engineers often are left guessing about the correct cause of a failure. Self-diagnosis or the delegation of generalist staff members to specialist-level tasks can be unproductive, ineffective, and costly. Between swapping parts, deciphering true root
Give power to the people

To maximize the effectiveness of the people supporting the assets, its important to empower them with the right education and tools aligned to the facility needs. 1. Educate and train in-house resources As automation technology continues to evolve to meet productivity demands, so must training programs designed to teach employees how to operate innovative technology. Without highly trained, knowledgeable maintenance employees, manufacturers cant expect to truly optimize their production environment and maximize their profitability. A crucial part of developing an effective training program is prioritizing. Training dollars are often scarce, so its up to maintenance managers to be specific and deliberate about where to focus. Start with a training assessment to analyze employees skills on maintenance critical tasks. There are multiple ways to conduct skills gap assessments: Many times, an automation vendor can provide doit-yourself testing tools that are automatically included in standard support packages.
Selecting a maintenance vendor
ot all vendor support contracts are created equal. A few factors to consider when selecting a third-party maintenance provider include: n Guaranteed arrival of parts With this guarantee, the maintenance staff can rest assured that a machine wont sit idle due to an out-of-stock part. n Guaranteed arrival of service professional Once the failure point is detected and its determined that physical on-site support is needed, the provider should guarantee that the plants support workforce will be on the plant floor to provide immediate service. n Guaranteed remote support response The provider should be able to guarantee that the support team will be able to respond quickly to any machine failures. Failures can happen at any time, so 24/7 support is generally best. n Remote monitoring When a machine or line fails, every minute of downtime means lost profit. A provider that offers remote monitoring technology will be able to quickly and securely connect from any Internet connection to the plant and begin troubleshooting within minutes instead of hours or days. It also can gather real-time data and analytics in order to recognize quickly when a machine is not
plant engineering
working properly and efficiently repair the failure point. n Workforce enablement tools A third-party maintenance provider should always provide transparent integration to the facility staff and tools to facilitate better local execution, such as online resources, community sharing, chat, and self-assessment tools. n Periodic health checks When applied on a plantwide basis, periodic checks can help plants dramatically cut maintenance costs by providing greater insight into impending machine failures, reducing unplanned downtime and minimizing wear on critical equipment. This type of check can help ensure that basic maintenance activities are performed on a regular basiswhich can be reassuring when in-house staff is consumed with other critical tasks. n Fixed price billing In an atmosphere of relentless, quarter-by-quarter budget scrutiny, variances are unacceptable. Managers are left scrambling to prevent unexpected spikes or dips in maintenance spendfurther hampering their ability to meet productivity demands. Fixed-price billing by the provider, regardless of number of part ships and support engineer dispatches, eliminates these concerns and E helps flatten maintenance expenses. P
32 March 2013
Engineering is personal. So is the way you use information. CFE Media delivers a world of knowledge to you. Personally.
acquiring and applying design and build structures, machines, devices, systems, materials and processes that safely realize a solution to the needs of society. And, to do your job better each day, you need a trusted source of information: CFE Media Content For Engineers.
You take pride in your profession one of
Other opportunities to connect

While our print magazines remain the touchpoint for more than 200,000 qualied subscribers each month, we also recognize that there are so many other opportunities each day to reach busy end users. Thats why weve developed a wide range of ways to connect with our audience:
CFE Media strives to...

Inspire engineers to interact, respond to peers, and contribute to content that will assist other engineers with similar challenges. Develop an infrastructure that aligns, organizes and maps content to audiences specialized needs and business opportunities. Fully understand our audience and its changing needs for targeted information and delivery channels through the use of industry experts and leaders.
CFE Media is home to three of the most trusted names in the business:
Consulting-Specifying Engineer provides the latest knowledge on commercial and institutional facility construction and management. Visit www.csemag.com Control Engineering delivers a wide array of strategies and solutions to help control system designers create a more efcient process. Visit www.controleng.com Plant Engineering delivers plant-oor knowledge and expertise to help manufacturers operate smarter, safer and more efciently. Visit www.plantengineering.com
Webcasts Videos Newsletters Websites RSS feeds An expanding global video library iPhone and Droid apps Social networks
Our goal?
To give you the knowledge you need, when you need it, in the format you want it, delivered to the device youre using, with the ability to utilize that knowledge to do your job better.
CFE Media 1111 W. 22nd Street Oak Brook, IL 60523 630-571-4070
www.cfemedia.com
CoverStory
Your maintenance plan should have two primary areas of focus: The equipment running in your facility and the the staff keeping the equipment running.
When a team has direct, predictable access to the right qualified system engineers and parts, they are empowered to identify and resolve issues quickly, efficiently and without wasted time.
causes, finding and scheduling an expert to come on-site, and searching for necessary replacement parts, its easy to lose track of production goals. Industry-leading manufacturers are leaning on third-party vendors to provide support contracts and secure, costeffective remote monitoring that acts as an effective contingent workforce. When a team has direct, predictable access to the right qualified systems engineers and parts, they are empowered to identify and resolve issues quickly, efficiently, and without wasted time. An organizations maintenance leader can easily meet fluctuating demands for support without lengthy recruitment efforts, overtime costs, and expensive full-time salaries of harder-to-find talent, all the while protecting against retirements of skilled talent. Native intelligence is kept in-house, while staff builds upon their experience. With a larger pool of knowledge from which to draw, maintenance managers relieve the pressures of not having the right skill sets readily available, and further empower those they do have. Reactive, ad-hoc support provided by vendors is unpredictableits difficult to determine when a facility will be up and running
again after equipment fails, and it can wreak havoc on the maintenance budget. The production environment has evolved drastically, and a new approach may be in order. Having the right resources a phone call away makes it easy to troubleshoot downtime events quickly. Guaranteed response times for parts and labor reduces MTTR by streamlining the recovery process. Problems are fixed correctly and efficiently. Establishing a process that automatically executes means fewer people are needed to remedy problems and less time is spent justifying and approving expenditures. Ultimately teams are empowered to fix issues quickly, even those they are not experts on, and they can concentrate on preventative maintenance and improving production runs to fulfill current orders. Taking a holistic approach to maintenance that focuses on reliability of assets and empowerment of people will deliver measured results to the bottom line. Streamlining downtime support reduces MTTR, while building reliability-based maintenance processes on the most critical equipment helps improve MTBF. Ultimately, both drive higher OEE and RONA, which are common key performance indicators in most facilities. Get started todaymaintenance can drive up competiE tive advantage and profitability. P
34 March 2013
plant engineering
Providing a saner approach

to maintenance
Conflict with operations can be solved with better data, better communication
The keys are to create a cross-disciplined team that f production and maintenance are at loggerheads includes representatives from all departments affected by in your manufacturing plant, the way out of that jam the change. You have to demonstrate the importance of could be better communication tools. Some of those the change, communicate about the change frequently, tools are in the form of new technology that better and celebrate the change frequently. aligns the unique goals of each part of the process; Besides simplifying the companys need for rigorous others are human tools that require talking through the regulatory compliance, the move to the common platform issues involved. allowed for a single tagout procedure built into the softBoth were on display at the ARC Advisory Groups sesware. The tag-sharing program put in sion in Orlando named Synchronizing place saved staff time and focused Operations and Maintenance, which The keys are to create a effort without compromising personfeatured presentations from energy and transportation companies on how cross-disciplined team that nel safety or plant safety. Eric Winterberg with APM Termitheir operations evolved to overcome communication bottlenecks. includes representatives for all nals North America, a global port container operations company with Such issues are often a result of a departments affected by the terminals throughout the world, had lack of data sharing across platforms, said Ralph Rio of ARC Advisory change. You have to demon- a more fundamental problem. Were very operationally based so operaGroup, who moderated the session. strate the importance of the tions come first, maintenance secARCs Asset Lifecycle Management said Winterberg. There was a model puts a strong emphasis on change, communicate about ond, lack of consistency in data, but not improving assets during their lifecycle. one installation was the same. We We feel there is opportunity for the change frequently. had the challenge of standardizing further optimization if there is synRobert Scampton, Constellation Energy Nuclear Group that installation. Overall, the mainchronization across groups so when tenance process was disconnected maintenance schedules downtime, it from operations. We were trying to catch up the whole appears in the production schedule, Rio said. time to keep facilities operating. We live in a world thats very regimented, with lots Beginning three years ago with a CMMS system in of rules we have to follow, noted Robert Scampton of Constellation Energy Nuclear Group. His department was Belgium, APM Terminals will have rolled out its software to 95% of its worldwide terminals. Weve been able to responsible to bring five nuclear plants in three states standardize maintenance operations anywhere in the each with different maintenance systemsunder a comworld, Winterberg said. It allowed maintenance results mon maintenance and production platform. to be analyzed against operations data. We were able We had trouble getting everyone in line, Scampton to find a window of time for preventive maintenance. said. They didnt talk very well with each other. They Maintenance moved from reactive to preventive, and it needed to be aligned as a fleet. improved resource scheduling. The first part of that alignment was to determine what Winterberg said the biggest change is not in software each facility needed to haveissues such as alarm or in personnel; it is a confidence that both are producing events, tracking of equipment performance, when it better decisions. Its a mind-set change for an organizawas safe to perform maintenance work, and equipment licensing requirements. After settling on a single software tion, he said. It doesnt happen overnight. It took us a year and half just to design the solution. Our change in vendor, Constellation went about the process of pulling mind-set is evolving. But its a saner platform for us to together the team and the data under the new platform. move forward. P It was Change Management 101, Scampton said. E
plant engineering
March 2013 35
COVERSTORY
Is your maintenance strategy a profit center or a profit eater?

Set up a maintenance checklist to ensure your program is on the right track
By Dave Bertolini People and Processes
W
Complete
Y/N Y/N Y/N
hile Im not addressing the issue of plant maintenance from the profit center aspect, Im in actuality addressing this from a profit center aspect. Before you start thinking I may be better served by a career in politics
Issues identi ed
Check to be performed
1. Check for physical damage 2. Check fluid levels 3. Check operating controls
Above and below are example checklists.

Task description: Clean operator manifold Materials
Straight slot screwdriver Wire barrel brush Water pump sprayer Pry bar Allen wrench (3/8-in)
Personal protective equipment

Leather gloves Hearing protection Safety glasses (with side-shields) Hard hat
Required steps: 1. Remove operator side manifold a. Remove the 2 bolts from the manifold supporting the assembly b. Remove the 2 bolts from the manifold freeing the support brackets c. Rotate the manifold counterclockwise to expose the manifold bolts d. Remove the manifold bolts (2) Note: Removing the manifold sections may require a gentle tap 2. Locate operator side and drive side manifolds a. Look at the end of the manifold for distortion or discoloring 3. Remove operator side and drive side vacuum attachment a. On the operator side: Use a straight slot screwdriver to remove the hose clamp. b. Disconnect the vacuum tube c. Use an Allen wrench to remove the 4 bolts holding the vacuum port onto the manifold. d. Repeat for Drive Side e. Disconnect the flex tubing for cleaning
and not maintenance, let me explain my statement. If through existing maintenance practices you initiate catastrophic failure, wouldnt that impact company profitability? Wouldnt that be the ultimate profit eater of any company or organization? Every organization claims it has procedures or checklists to eliminate self-induced failures or missed steps, but are they followed? Are they accurate? Are they written to a sufficient level of detail? Have you ever reviewed them? As a maintenance craft, maintenance supervisor, or maintenance manager, perhaps you should since the profitability of your company may depend on them. In maintenance both checklists and procedures are utilized. There are appropriate places to use either, but lets start with a quick review of what each is by definition and example. A checklist is a type of informational job aid used to reduce failure by compensating for potential limits of human memory and attention. It helps to ensure consistency and completeness in carrying out a task. For example: Checklists are appropriate for vehicles, mobile equipment, equipment setups, equipment or line starts and stops, etc. A procedure specifies a method for performing a task (see example on left); it is written to a specification. A procedure is designed to describe who, what, where, when, and why by means of establishing accountability in support of the implementation of that specification. The how is further documented in the form of work instructions that aim to further support a procedure by providing a greater level of detail.
36 March 2013
PLANT ENGINEERING
Plant Engineerings NEW
electronic newsletters
deliver news and information on the latest trends in manufacturing in every corner of the plant oor. Plant engineers and managers refer to these sources of information for the up-to-the-minute news and trends that impact their business. View the new layouts for Plant Engineerings standard e-newsletters:
PlantMail HotWire Maintenance Connection Product Showcase Energy Management Safety & Security
Its time to get your plant ahead of the curve. Subscribe today.
www.plantengineering.com/newsletters
COVERSTORY
Can checklists and procedures help you establish your maintenance organization as a profit center? I dont think they alone can, but they can ensure your maintenance organization isnt a profit eater.
For example: Procedures are appropriate for preventive maintenance (PM), predictive maintenance (PdM), equipment rebuilds, refurbishments, overhauls, corrective maintenance activities, etc. Both checklists and procedures can only be utilized successfully if the individual(s) executing them have the fundamental skills (tools, safety, etc.) necessary to accomplish the activity and have been trained on the specifics of the equipment. The most important aspect to ensuring successful utilization of checklists and procedures is to ensure that they are in fact
The evolution of work processes can deliver revolutionary results
eliminate unnecessary steps in their overver the past two decades, manufacturing companies in a broad range of all process and to streamline performance. industries have come to understand More than 16 years after Hammer first that improving maintenance efficiency proposed that the process-centered revoand effectiveness is critical to minimizing lution was underway, many companies downtime and reaching higher levels of still have not determined how to make profitability. the full transition. Day & Zimmermann An estimated one-third of plant mainhas identified four steps companies must tenance costs are wasted because of take to achieve this transformation and unnecessary or improper practices, improve maintenance performance. according to a report from DuPont. The report states that the largest single con1. Map your maintenance processes trollable expenditure in a plant today is A company must first understand what By Ken Jobe, maintenance. This is a frightening fact for its maintenance processes are. It sounds Day & Zimmermann most companies when coupled with the simple enough, but many companies have fact that maintenance mistakes can result never broken down their maintenance in unplanned outages that decrease revprocesses to understand how goals are enue. Despite an understanding that effective mainteachieved. Even companies that believe they have a firm nance processes are critical, many companies struggle grasp on their maintenance processes can benefit from to implement them. revisiting them and mapping them out in specific detail. One way the manufacturing industry has attempted to Knowing the process in your head isnt good enough. meet this challenge is through the use of partnerships A visual representation of the process will make clear and alliances. To truly improve maintenance efficiency, where problems might exist. Whether its a communithere must be a deep level of integration between intercations bottleneck or a non-value-added activity, the nal engineering, operations, and maintenance functions, problem will show up more clearly once the process has as well as outside partners. Reaching this level of intebeen mapped out. Its easier to eliminate these issues gration requires companies to transform into processonce they are clearly identified. centered organizations. The concept of a process-centered organization was 2. Embrace changefrom the top first coined by MIT professor Michael Hammer in his For a work process transformation to be completed, 1996 book Beyond Reengineering. In short, Hammer every member of the organization must buy into change. suggested that for most of industrial history, compaThis includes leaders at the executive level all the way nies measured the performance and execution of tasks down to the front lines. This can be a challenge because rather than the performance and execution of their enda process-centered approach to maintenance chalto-end processes. lenges the role of management at every level. Existing By focusing on individual functions rather than bigparadigms intended to clearly define responsibilities give picture practices, companies missed opportunities to way to a structure that is more fluid.
PLANT ENGINEERING
38 March 2013
utilized. This requires supervisors and managers to routinely conduct audits so a culture of discipline becomes ingrained within the maintenance workforce to always utilize them. Additionally, the checklist and procedure content must routinely be audited to ensure they stay current with the equipment operating environment, configuration, and safety regulations. To summarize, can checklists and procedures help you establish your maintenance organization as a profit center? I
dont think they alone can, but they can ensure your maintenance organization isnt a profit eater. Or think of it this way: The next time you get on an airplane, is the pilot using a checklist or just winging it E from memory? P Dave Bertolini is a managing principal for People and Processes, Inc., a firm that specializes in changing cultures from reactive to proactive though the optimization of people and processes.
Managers can no longer focus on managing tasks; they must focus on evaluating the overall health of processes. This is often a drastic change for those who have become accustomed to doing things their way. If a company is serious about becoming a process-centered maintenance organization, the buy-in must come from the top first.
Once companies realize that the efficient management of maintenance processes is the ultimate goal, these excuses quickly fade away.
Conclusion
The transformation to a process-centered organization will not happen overnight. It takes time for a company to grow and evolve. Once achieved, the benefits are obvious. For companies striv3. Empower your people ing to improve, a process-centered Once buy-in has been secured by The transformation to a approach will ensure greater effithose at the top level, it is much easier ciency while decreasing the chances to empower those on the frontlines. process-centered orgaof an unexpected outage. When the More so than managers, those in the nization will not happen focus is put on the larger maintefield have spent most of their careers focusing on the task at hand. They finish overnight. It takes time for nance process, skilled workers have the latitude to make decisions that one job and then move to the next. In will ultimately benefit the overall a process-centered organization, these a company to grow and health of the organization. skilled workers come to understand that evolve. Once achieved, the In a tight economy, manufacturing they are part of something larger. plants can no longer afford to waste No longer identified merely by their benefits are obvious. one-third of maintenance costs. Its title, these workers are now identified by time to take the next step in the evolutheir ability to move the process forward. tionary process and become process-centered organizaWith elevated responsibility, workers are empowered to make independent decisions with the best interest of the tions. Only then can they realize revolutionary results. P E process in mind. Ken Jobe is vice president of process and industrial for Day & Zimmermann. 4. No excuses One of the biggest obstacles to completing the transition to a process-centered organization is company and Plant Engineering reader poll: employee perceptions about the value of existing roles and practices. These are artificial barriers. If the focus is Run to failure still the top option on the efficiency of the process, then companies should We asked Plant Engineering readers about maintenance find the best people to do the job and put them in posipractices at their facilities in an online poll this month. tion to do so. Traditional excuses are no longer acceptWhat is the prevailing maintenance strategy in able. your plant? A familiar refrain is, we dont trust our partner with this kind of information. If your partner is best suited 83% Run To Failure to do the job, have it sign a nondisclosure agreement. Similarly, a company might say, This job cant be done 7% Preventive by hourly workers; it can only be done by staff workers. 5% CMMS If the staff workers are adding an unnecessary step to the process, then the job should be transitioned to the 2% Predictive hourly workers.
plant engineering
March 2013 39
Supporting engineers In-Person and offering High-Value Content In-Print and Online
PLANT ENGINEERING has been helping plant engineers and managers understand how to make their operations run more efciently and effectively for more than 64 years.
Wherever, whenever accessibility to the news, data and information that connects engineers, suppliers and the world of knowledge for the manufacturing sector.
IANA Global Automation & Manufacturing Summit:
This event brings together some of the top industry experts to tackle key issues facing manufacturing in the U.S., and explores how manufacturers can take advantage of the rapidly-expanding global manufacturing market.
Salary Survey: The annual Salary Survey results are available in print, online, and in the January issue. The interactive survey will not only feature numbers and data, but also comment and insight. PlantEngineering.com: The engineers most popular
Website for up-to-the-minute information and onsite collection of knowledge offering important industry information in all multi-media formats the latest top stories, webcasts, podcasts, blogs, and videos.
Editorial Award Programs: We are pleased to honor engineers
and manufacturers with various editorial awards programs throughout the year. Leaders Under 40 recognizes young, up-andcoming engineers aged 40 and younger. Top Plant is a highly distinguished award that honors outstanding manufacturing facilities in the nation. Product of the Year grants awards to the years best new products decided upon by the Plant Engineering audience.
Webcasts: PLANT ENGINEERING brings the best and brightest
minds to your desktop for special interactive learning opportunities. Our successful series of Webcasts now offer the latest industry knowledge on hot topics for engineers, and provide not only a live opportunity to interact with our experts, but the ability to retrieve and review the knowledge from our Website archive.
Subscribe today at
www.PlantEngineering.com
ELECTRICALSOLUTIONS
Figure 1: Designing electrical systems requires knowledge of how overcurrent protective devices interact throughout the entire distribution systemfrom the available fault current supplied by the utility to the individual loads within the facility. All graphics courtesy of ASCO Power Technologies.
Achieving
By Dan Caron Bard, Rao + Athanas Consulting Engineers and Ron Schroeder ASCO Power Technologies
other aspects of power system design might be compromised (see Selective coordination issues on page 42). The concept of full selective coordination has changed the way engineers must think when designing electrical distribution systems (see Figure 1). For example, when selectively coordinating emergency and legally required standby power systems, overcurrent protective device specifications must accommodate a range of demands. All overcurrent protective devices must be fully selective with all upstream devices for all levels of overcurrent from all sources. Each overcurrent protective device must remain closed long enough for every device below it to clear for all levels of overcurrent, which include: Soft, low-current sources Stiff, high-current sources Low-impedance (bolted) faults High-impedance (arcing) faults Overloads
effective selective coordination design

The concept of full selective coordination has changed the way engineers must think when designing electrical distribution systems.
Defining selective coordination

The goal of selective coordination is to isolate a faulted circuit while maintaining power to the rest of the electrical distribution system. Although selective coordination will not prevent problems from occurring, it will help retain system reliability by decreasing the potential for a smaller scale problem to become a larger scale problem. Depending on the location, a fault could still cause a large-scale outage. According to NEC Article 100, selective coordination is the localization of an overcurrent condition to restrict outages to the affected circuit or equipment. It is accomplished by the choice of overcurrent protective devices and their ratings or settings. The overcurrent condition may be due to an overload, short circuit, or ground fault. In a selectively coordinated system, only the overcurrent protective device protecting that circuit in which a fault occurs opens. Upstream overcurrent protective devices will remain closed. In other words, they do not open, which averts cutting power to the complete panel.
PLANT ENGINEERING
elective coordination requires integrating different components, technologies, manufacturers, and standards. There is no standard, cookie-cutter approach that can be applied effectively across system designs. Although selective coordination is about to enter its third National Electrical Code (NEC) cycle as a mandated requirementnot left to engineering judgment since the 2005 cycleissues continue to circulate about the necessity of mandating it, what constitutes compliance, and how
March 2013 41
eLeCTRICALSOLUTIONS
Figure 2a: This schematic shows a conventional bus design based on loads, physical layout, reliability, cost, safety, owners standards, and code minimums. Design results are system layout, component sizes, and device selections.
Low-voltage circuit breakers: When selecting circuit breakers as overcurrent protective devices, tables can help determine proper upstream and downstream circuit breakers. Each manufacturer provides tables only for the overcurrent protective devices it produces. Tables and time-current curves should be used in tandem to meet selective-coordination requirements. Emergency, legally required, and critical operations power: Emergency, legally required, and critical operations power systems require selective coordination, except when selectively coordinating a system could create
Figure 2b: This time-current curve represents traditional device selections. Note that the time scale does not go to zero. The conventional design is considered to be selectively coordinated with the devices. The red dotted line indicates good coordination above 0.1 sec. The black circle indicates a lack of coordination for a bolted fault in certain locations. C and D are not required to coordinate if there are no loads in parallel with D.
Figure 2c: Greater control can be gained by using different trip units for A and B. Using larger frames for A and B produces greater withstand (higher instantaneous override) and also avoids an instantaneous trip. This design means more energy is released during a fault.
safety hazards such as disconnecting fire pumps. Selective coordination involves tradeoffs between personnel safety due to the threat of arc flash, and maintaining power to critical systems while preventing damage to electrical wiring and equipment. NEC requirements: Selective coordination is mandatory for emergency electrical systems for healthcare facilities, emergency systems, legally required standby systems and critical operations power systems. NEC requirements help
Selective coordination issues
roperly coordinating ac electrical power distribution systems with overcurrent protective devices can be complex and difficult. When selectively coordinating electrical systems, many issues confront engineers. These issues include: n Selective coordination may not be fully achievable for every system. n Selective coordination requires a high level of analysis and engineering judgment. n Typically, best-fit solutions are sought. n Cost plays a major role due to potentially increased design time, space requirements, and equipment. n Rote insistence on full selective coordination may impede the ability to deploy desirable alternate power protection. n Selective coordination is often impossible to achieve on conventional designs without major reconfiguration; it cannot succeed with device selections alone.
Source: Consulting-Specifying Engineer
ensure electrical circuit and system designs that provide reliable power for life safety and critical loads to help protect life, public safety, national security, and business continuity. Fault types: Types of faults include bolted, arcing, and ground. Bolted faults are rare. A bolted fault occurs when energized conductors are rigidly connected. The maximum available fault current flows until the overcurrent protective device clears the fault, which protects the circuit. Arcing faults occur when energized conductors come into proximity. While bolted faults and arcing faults are both short circuits, an arcing fault has significantly higher impedance than a bolted fault, resulting in lower current flow. Because the current flowing through an arcing fault is lower than current flowing through a bolted fault, the overcurrent protective device takes a longer amount of time to clear the fault condition. This is why arcing faults can present significant challenges to selective coordination. According to IEEE, the most common type of fault is a ground fault. A ground fault occurs when one or more electrical phase conductors come in contact with a grounded conductor, as opposed to a phase-to-phase fault. However, the same principles apply: the lower the impedance, the
42 March 2013
plant engineering
INTERACT
Protecting both personnel and equipment is vital. Every facility needs protection. Often, selective coordination is only one element in the overall protection scheme.
www.plantengineering.com/interact
Determining coordination
Effective selective coordination can be determined by two types of studies: a short-circuit current study and an overcurrent coordination study. A short-circuit current study identifies the maximum available short-circuit currents throughout the distribution system at the line-side terminals of each overcurrent protective device. This type of study is typically considered to be part of a facilitys required electrical documentation. An overcurrent coordination study compares the timing characteristics of various protective devices under consideration in relation to each other. These studies determine the degree of coordination, but only guarantee that selective coordination is achieved if all levels of
Q: Is selective coordination a prevailing strategy for your facility? What would you need to adopt it? overcurrent are consideredincluding bolted line-to-line faults. Mandated selective coordination demands selective coordination for the full range of overcurrents. It is the responsibility of the design engineer to provide substantiated documentation showing that the design achieves this goal. The two methods of achieving selective coordination among overcurrent protective devices are the graphical
Figure 2d: Increasing the distance between bus 1 and bus 2 reduces the available fault current at bus 2. Selective coordination is achieved if the available fault current at C is less than the instantaneous trip on B.
quicker the overcurrent protective device clears the fault. Bolted faults are comparatively simple to selectively coordinate; arcing faults, not so much.
Welcome to the Family

Like its big brothers before it, Ingersoll Rands newest rotary compressorthe R-Series 37-45 kWcombines the best time-proven designs with advanced components. Features such as Progressive Adaptive Control (PAC) that continuously monitors and adapts compressor performance, sequential coolers that improve servicability and web-enabled compressor controls continue the family tradition of delivering proven reliability, efficiency and maximum productivity.
R-Series 37-45 kW Rotary Compressor
www.ingersollrandproducts.com
eLeCTRICALSOLUTIONS
of the downstream circuit breaker if it begins to open faster than the upstream circuit breaker, as well as the resulting higher coordination levels. If curves overlap, the consulting engineer should reference the manufacturers circuit breaker tables to determine if selective coordination is achieved. The tables show results of tests of overcurrent protective devices connected together. Overlapping curves can indicate a potential lack of selectivity. Conversely, a lack of overlap indicates selectivity. However, time-current curve analysis alone ignores how current limitation affects the load-side overcurrent protective device. The load-side circuit breaker will react to the peak let-through current allowed to flow by the smalleror fasterovercurrent protective device for a given prospective fault current. The true time-current curve for overcurrent protective devices, such as circuit breakers and fuses, is really a band or region extending to either side of a single line. This variation from the ideal is due to the time difference between minimum response time and total clearing time as well as manufacturing and temperature variations. Consideration of all the timecurrent curve variations is required to eliminate possible errors when examining selective coordination. A table/chart-based method can also be used to determine coordination. It uses a matrix that shows response time in sec versus current in Amps. This method shows the level of short-circuit current to which the two breakers (upstream and downstream) coordinate. Both time-current curves and tables are necessary to achieve proper selective coordination. own studies with the selected breakers to ensure they still coordinate and that the correct breaker is provided. In many cases, achieving coordination with breakers requires specifying breakers with electronic trip, which are more expensive than standard molded case breakers (see Figure 3). Selective coordination can also be achieved with zone-selective-interlocking (ZSI) protection. This method allows two or more ground fault breakers to communicate over a network so a short circuit or fault clears by the breaker closest to the fault in the shortest time possible, regardless of the location of the fault. If there is a fault on the main bus, there will be more current coming in on the main and less current going out on the feeders. ZSI protection would open the main, which would protect against a bus fault in the substation.
Figure 3: Modern circuit breakers with electronic trip elements provide adjustability to selectively coordinate power systems.
and the table or chart methods. Timecurrent curves indicate the response of overcurrent protective devices to a range of fault current magnitudes. Typically, time-current curves can be divided into overload and instantaneous or shortcircuit regions (see Figures 2a-d). The graphical method examines curves for fuses and circuit breakers. The horizontal axis represents current, while the vertical axis shows the time it takes for the device to interrupt the circuit. Using the graph method, two circuit breakers crossing at any point in their respective instantaneous trip regions indicates that those two circuit breakers do not coordinate for fault currents above the crossover point. For current levels in the overload region, time-current curves for overcurrent protective devices can be overlaid for a visual indication of whether selective coordination is achievable. In the overload region, fault currents are relatively low, and device response time is usually not much faster than 1 sec. In this region, selective coordination can be relatively easy to accomplish and the time-current curve is typically an adequate tool for determining selective coordination between devices. The curve must include the level of available shortcircuit current. However, the fact of no overlap on the graph does not definitively prove selective coordination. At higher short-circuit current levels, the time-current curves alone do not show the total picture. The results do not include the effect of the added impedance
Design optimization
While the design engineer may select an overcurrent protective device that may seem well suited for satisfying the shortcircuit study requirements, it may not be the best choice for selective coordination. If the system has been expanded or upgraded over time, it may include both circuit breakers and fusespossibly from different manufacturers. In these cases, ensuring selective coordination becomes more problematic because a manufacturers tables provide data only for its products. Effective selective coordination during a systems lifecycle could require using the same type of overcurrent protective devices from the same manufacturer over time. Optimizing selective coordination is an iterative process. Depending on the systems complexity, the analysis may suggest that device selection indicates an imbalance or tilted trade-offs among selective coordination, equipment protection, and personnel safety (see Guide to selective coordination on page 45).
Imaginary systems, worst-case scenarios

The problem is that design engineers need to conduct a preliminary study based on an imaginary system including worstcase scenarios to ensure the design will be acceptablebefore manufacturers and their products are chosen. Engineers typically base the design on standard, generic equivalents. After the contractor chooses the material, the engineer requires manufacturers to conduct their
Selectively coordinating power transfer switches

Power transfer switches are essential in emergency, legally required standby and optional standby power systems. Consequently, they are essential to selective coordination systems as well. Optimized
44 March 2013
plant engineering
THE ULTIMATE POWER TRANSMISSION COMPONENT PACKAGE
Guide to selective coordination

lthough there is no effective cookie-cutter approach to engineering selectively coordinated systems, the following list provides general guidelines that can help ensure balance among potentially competing interests: n Obtain information from the utility (main facility power source) that identifies the maximum available fault current and transformer size. n Conduct overcurrent-coordination and short-circuit studies to lay the foundation for an effective designthis work should also include equipment full-load rating verification. n Reduce the number of levels of protective devices the fewer the levels, the easier the task of selectively coordinating overcurrent protective devices. n Reduce the available fault current by increasing system impedance or by using step-down or isolation transformers (see Figure 4). n Select long time settings to protect equipment from overload; select instantaneous timing and short time settings to selectively coordinate; or use tables for overload protection that coordinate up to the available fault-current level. n Select current-limiting type molded-case circuit breakers where possible for branch devices; they respond very quickly, significantly limiting let-through current so they coordinate better and even reduce the required upstream device trip-timer settings.
When its all about uptime its Tsubaki time.

Stop the clock on downtime. Start getting the productivity you deserve with the drive-system products you need. Let Tsubakis family of Chains, Sprockets, POWER-LOCK and Overload Protection products provide a single-source solution for your drive-system needs. Tsubaki components and customer support will keep you up and running with superior performance, design, build quality and compatibility. When time is money, its time you turned to Tsubaki. www.ustsubaki.com/pe
Figure 4: The value of short-circuit current at any point in a circuit is a function of the conductor sizes, the distance from the electrical source to the short circuit, and the current available from the source. When the service is a dedicated transformer, assuming an unlimited available kVA on the primary side of the transformer, a conservative estimate of fault current on the secondary side of the transformer can be determined.
2012 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.
plant engineering
March 2013 45
RIGHT CHAIN RIGHT SPROCKET RIGHT PROTECTION RIGHT CALL
eLeCTRICALSOLUTIONS
Typically, power transfer switches facilitate the selection of fuse-clearing times or breaker settings using increments between 0.5 to 30 cycles, with multiples of two or three cycles being popular. There are no ideal time-delay settings for selective coordination in design schemes. Also, UL doesnt require a specific time or specific number of cycles to qualify for short time ratings, although it does provide standard recommended values. The transfer switch location is significant in terms of effective selective coordination. Transfer switches located closer to their loads translate into: n Higher reliability n Smaller circuit breaker or fuse sizes for feeding the transfer switch n Fewer levels of distribution n Lower fault currents at the transfer switch terminals n Faster fault-clearing times n Improved load protection. Locating a switch closer to the source (as opposed to the load) can lower system or facility reliability, may cause downstream breakers to trip frequently, and may not isolateor startan alternate power source. Larger circuit breaker or fuse sizes may be needed. Higher fault currents may be experienced and short time protection may be required. Bottom line: locating a switch closer to the power source typically means relatively poor load protection. Every project should be considered to be custom. For example, even if two chain restaurants are built in two different locations using the same drawings, the coordination would be different. Effective coordination depends on the electrical utility and the available fault current. Inevitably, electrical characteristics and situations vary from place to place, building to building, design to design, and utility company to utility company. cycles. This can cause a significant increase in the cost of the feeder cabling. Of the engineers who participated in a survey following a webcast on selective coordination, 88% agreed selective coordination may not be optimal if 30-cycle transfer switches are used for an entire facility. Considering the custom nature of selective coordination, the better decision is specifying equipment, components, and overcurrent protective devices that precisely satisfy the requirements of that unique design. Achieving selective coordination can often be accomplished with transfer switches between 3 and 18 cycles. Matching time-based ratings to timing requirements of a given selective coordination design often better serves the design and the facility owner. If the design settings are at 3, 6, 9, 12, or 18 cycles, there is no reason to specify 30-cycle rated switches universally. Developing a transfer switch schedule that includes fault-current levels and time requirements helps optimize equipment performance and cost.
Engineers responsible for developing and vetting selective coordination systems that meet NEC requirement often face difficult challenges. Balancing the need for business continuity, equipment protection, personnel safety, and managing costs can be fraught withy pitfalls.
It might seem easy to specify 30-cycle transfer switches as a cookie-cutter approach for both the ceiling and floor of selective coordination timing. However, that decision introduces safety, cost, and reliability issues. In some installations, personnel safety and equipment integrity may be compromised by letting energy levels flow for 30 cycles within those electrical systems. Using short-time-rated trip units in low-voltage circuit breaker settings may allow fault currents to flow for 30 cycles, perhaps negating equipment protection and increasing arc-flash hazards. Specifying 30-cycle-rated transfer switches for every application can increase equipment and spare parts costssometimes as much as 15% to 30%. These switches may also require rear entry, a larger footprint, and more expensive maintenance. Specifying 30-cycle-rated transfer switches may also necessitate installing larger feeder cables than normally required in order to safely carry the available short-circuit current for 30
Summary
Mandated selective coordination has changed the way design engineers think about designing electrical distribution systems. Engineers responsible for developing and vetting selective coordination systems that meet NEC requirements often face difficult challenges. Balancing the need for business continuity, equipment protection, personnel safety, and managing costs can be fraught with pitfalls. Knowing NEC requirements, observing design optimization methods, coordinating transfer switch ratings with circuit breakers and fuses, and satisfying special application needs are essential for effective selective coorE dination. P Dan Caron is principal and the head of the electrical department at Bard, Rao + Athanas Consulting Engineers in Boston. He is also a principal member of NEC Code Making Panel 13. Ron Schroeder is director of applications engineering and product management for ASCO Power Technologies in Florham Park, N.J.
Specifying cycle times

Consulting engineers should recognize that specifying transfer-switch cycle times is necessarily project-specific. Most transfer switches specified by the co-authors company are 3-cycle switches. The firm has specified 30-cycle switches where at least one of the following conditions exists: n Larger projects with high emergencysystem fault current n Where the instantaneous trip setting is defeated to achieve selective coordination (note that this may change because of the acceptance of the latest NFPA 99) n Where transfer switches are served by ANSI switchgear, which also has 30-cycle withstand ratings.
46 March 2013
plant engineering
MECHANICALSOLUTIONS
Pipe joining systems get in the groove

Ease of maintenance cited as a major advantage
By Dave Hudson Victaulic
Consider the following when evaluating the best pipe joining method for your mechanical piping systems. 1. The design of grooved mechanical pipe joints makes them inherently easier to work with during maintenance activities. In fact, grooved couplings, grooved fittings, and grooved components offer many benefits to the owner over the life of the system. Grooved mechanical systems reduce the need for maintenance overall, but when system service, alterations, or expansions become necessary, they provide a union at every pipe joint for quick and easy system access, reducing maintenance time and hence system downtime. The ease of system access is created through the design of the grooved mechanical joint. The components of a grooved mechanical coupling include grooved-end pipe, coupling housing segments, an elastomer gasket, and bolts and nuts. The pipe is grooved by either a cold forming operation called roll grooving or machining a groove into the end
PLANT ENGINEERING
he importance of conducting regular maintenance in plant facilities is well documented, but when it comes to your mechanical system, why spend more time on maintenance than is necessary? For plant engineers, minimizing system shutdowns for maintenance is critical in order to maintain the plants bottom line. Of all the pipe joining methods available, maintenance on HVAC systems installed using grooved piping products is the fastest, most efficient, and simplest to perform. They allow plant engineers to complete maintenance such as strainer/suction diffuser servicing quickly, and move onto other crucial tasks, such as equipment repair.
March 2013 47
MECHANICALSOLUTIONS
Flexible couplings are used for pump and equipment connections not only because of their vibration attenuation characteristics, but also because of their ability to accommodate piping misalignments and reduce stresses at the pump or equipment connections.
of a pipe. The key sections of the coupling housings engage the groove. The gasket is resilient, C-shaped, and pressure-responsive. The bolts, which hold the housing segments together, are tightened with a socket or impact wrench. In the installed state, the coupling housing encases the gasket and engages the groove around the circumference of the pipe to create a unified joint that provides a leak-tight seal in a fully self-restrained pipe joint. A grooved mechanical joint is designed such that once installed and tested, it is maintenance free for the life of the system. The gaskets do not require periodic lubrication or replacement. The bolts and nuts will not loosen over time from being subjected to vibration from pumps or other equipment, or as a result of system thermal changes. 2. Grooved pipe joining systems attenuate vibration within the coupling, thereby eliminating the possibility of periodic product repair or replacement. Flexible grooved couplings provide allowances for controlled pipe movement, including expansion, contraction, and deflection. This allows the flexible couplings to accommodate piping thermal movement, settlement, and seismic activity, as well as dampen noise and vibration generated by system equipment. The design of flexible grooved couplingsin which the housing key section floats in the groove and the elastomer gasket is in full circumferential contact around both pipe ends and the housing interior diameterresults in a reduction of the noise and vibration being transmitted across the grooved joint, thereby localizing vibrations generated by equipment and reducing the amount of noise transmitted down the pipeline from pumps, chillers, and other components. Flexible couplings are used for pump and equipment connections not only because of their vibration attenuation characteristics, but also because of their ability to accommodate piping misalignments and reduce stresses at the pump or equipment connections. Additionally, the use of flexible grooved couplings around equipment connections will eliminate the need for elastomeric archtype connectors and braided flexible hoses, which can be long-term maintenance items for the facility owner. 3. A union at every joint allows for easy access to the system and flexibility for future system expansion. One of the most notable design features of grooved mechanical systems is that the grooved coupling creates a union at every joint, providing easy access to the system. To access the system through a grooved mechanical coupling, a worker simply loosens two bolts and removes the coupling housing segments and gasket. Removing two adjacent grooved couplings enables a section of pipe to be directly removed without the need for pushing or pulling adjacent piping or spreading the pipe ends at the joint. This makes required maintenance, such as cleaning strainers or suction diffusers, replacing corrupt pipe sections, removing equipment for repair, or slipping in a grooved tee to expand or join piping systems, much quicker and easier to accomplish. To complete the job, the gasket is reinstalled, the grooved coupling is placed back on the pipe or grooved fitting, and the two bolts are re-tightened. Since grooved mechanical pipe joining systems simplify assembly and disassembly, they also require less labor and increase the speed of installation during maintenance, retrofitting, and expansion projects. Serviceability in tight spaces is also easier and more time efficient with grooved systems because grooved couplings allow a full 360-degree rotation of the pipe and system components before tightening so that proper alignment can be achieved. In addition to routine maintenance, sometimes it is necessary to join two existing systems or reroute an existing system. With a union at every joint, a grooved system can be easily rerouted in retrofit projects. The grooved system does not require torches. As a result, there is no need to dry the piping around the joint. Grooved couplings can be installed on wet lines, making it easier for the facility to return to full operating capacity quickly, without disrupting plant personnel.
Properly installed, a grooved mechanical joint is maintenance free for the life of the system. All graphics courtesy of Victaulic.
48 March 2013
PLANT ENGINEERING
INTERACT
Why some industrial organizations find benchmarking difficult

By Matthew Littleeld, LNS Research
T
Q: How do you analyze, maintain and repair your piping system? What is the frequency of such a program? 4. Grooved piping increases safety during maintenance. No flame or cutting equipment is necessary and no fumes are created during the assembly and disassembly of grooved mechanical piping systems, eliminating fire hazards. This is particularly important in areas of the plant where volatile chemicals and combustible materials are present. By eliminating flame, sparks, and fumes, grooved piping reduces risk to property as well as maintenance personnel. In terms of speeding maintenance, the no-flame characteristic of grooved piping eliminates the need for a fire watch and jobsite preparation, such as ventilation, barriers, and signage. Mechanical piping systems and their components must be properly maintained to maximize operating efficiency and equipment lifetime, but there are actions plant engineers can take to reduce system servicing and refocus limited maintenance hours on process-critical tasks. The selection of a grooved pipe-joining system is one of those actions. Grooved piping offers the fastest, most efficient, and simplest access to piping systems among the number of pipe-joining methods available. The ease of installation, disassembly, and reinstallation makes grooved piping systems an efficient and effective way to reduce maintenance costs E for mechanical systems. P David L. Hudson is a senior engineer for Victaulic Company, Inc. He is a practicing mechanical engineer with 31 years of experience. He can be reached at dhudson@victaulic.com.
he concepts behind benchmarking research for industrial operations have been applied successfully by many leading organization in the world. However, many companies still struggle with the basics. Benchmarking, in the simplest terms, involves comparing performance to peers, understanding gaps in operations, and taking steps to close those gaps and improve performance. It is not as simple as it sounds. Below are the top three challenges Ive seen industrial organizations face while benchmarking operations.
Research is too general or too specific

For any benchmarking process to be successful, its critical to understand how the outcome of the process impacts the key goals of the division or plant or even the overall organization. This, in turn, means specific is good, but that can make the quest for data very challenging. A good example of this would be trying to benchmark the throughput and mean time to failure metrics for a very specialized piece of machinery in a specialized industry. All I can say is good luck getting a statistically relevant sample in such a case.
Is data relevant and available?

The second key challenge with benchmarking industrial operations is data. If all data had the following characteristics, benchmarking projects would almost always run smoothly: Easily available In one central location Using common definitions Having a statistically relevant sample size If youre planning to benchmark the quality processes of five plants in North America, and there is no consistency in the way data is collected across these plants or how metrics are defined, it will be an uphill battle.
Getting value from the results

The final challenge has two parts and focuses on the way the results of the benchmarking process are utilized. The first challenge is in understanding which actions need to be taken and also how to execute these actions. To accomplish this effectively there needs to be buy-in from all levels of the organization as well as the right culture in place to accept the change due to the new actions. The second part of this challenge lies in answering the question, What happens next? Organizations that think about the benchmarking process as a one-time exercise are likely to fail. The key to the success is in setting up a culture and process of continuous improvement. The real value of a benchmarking exercise is delivered when you learn from the results of the program, apply those recommendations, track the success of the actions, and continuously improve based on the results of E those actions. P Matthew Littlefield is principle for LNS Research, which will be holding the first meeting for the Global Quality Advisory Council in March.
PLANT ENGINEERING
March 2013 49
Lubriplate PGO & PGO-FGL Series

Polyalkylene Glycol (PAG)-Based, Synthetic Gear Oils.
The Next Generation Of Synthetic Gear Oils.

Lubriplate PGO and PGO-FGL Series Gear Oils are designed for gearboxes operating in the most demanding conditions. They provide outstanding thermal stability, excellent extreme pressure and anti-wear performance and protection against micropitting. They exceed 13 stages of the FZG test. They offer long service life and work well over extended fluid change intervals which conserves resources and helps ease waste oil disposal problems. They also effectively lubricate in areas of intense water contamination. Lubriplate PGO-FGL Series are NSF H-1 Registered Food Machinery Grade.
100% Synthetic Energy Saving 4x
Ultra High-Performance, Advanced Polyalkylene Glycol (PAG)-Based Oils.
Low Coefficient of Friction Reduces Energy Requirements (Up To 7% in Worm Gears).
Better Oxidation Resistance - Provides Long Service Life and Extended Drain Intervals which Conserves Resources.
Backed By:
Extra Services Package
ESP
Lubriplate
Plant Surveys Tech Support Lubrication Software Machinery Tags Training Follow-Up Oil Analysis
Lubriplate Lubricants
Newark, NJ 07105 / Toledo, OH 43605 1-800-733-4755 / E-Mail: LubeXpert@lubriplate.com To visit us on Facebook, Twitter or LinkedIn, go to www.lubriplate.com and click on the desired icon. input #25 at www.plantengineering.com/information
MAINTENANCESOLUTIONS
Fall arrest solutions require attention to detail, not scale

Five steps to help establish a safety program for your employees
By Kevin Duhamel Gorbel
Above: Fall arrest systems should be situated so that workers can safely access equipment, and also be repositioned for maximum production flexibility. All images courtesy of Gorbel.
ig or small, implementing a fall protection system requires considering a number of factors. To prove operation size has no bearing on the installation, lets take a look at a truly large-scale operation. A company building track trenching and surface mining machines was recently faced with the challenge of ensuring a safe work environment for those assembling the machines. Assembling one machine takes about eight weeks and requires moving very large, heavy components using 40-ton-capacity overhead bridge cranes. With each machine weighing nearly 200 tons, with a grinding surface almost 10 ft tall and treads as tall as a man, the machines presented a less-than-straight forward solution for safety.
It doesnt take long before the assembly process reaches a point where workers are working at heights that put them at risk for potential falls. Lucky for the assemblymen, the company building the machines had safety in mind. Because of the complicated assembly, any form of passive restraintsuch as handrails is impractical. While the company initially sought a permanent overhead fall arrest system, it quickly realized that most permanent solutions to protect the workers from falls would become obstacles for the cranes delivering components to those workers. The company in this example followed the same process for identifying the right fall protection that practically any company should. Lets examine the five key points:
PLANT ENGINEERING
March 2013 51
mAINTENANCESOLUTIONS
Proper fall arrest systems allow workers to move safely and unencumbered during the equipment construction.
1. The 4-foot rule, or do I need protection? The 4-foot rule refers to Section 29 of the Code of Federal Regulations (29 CFR). OSHA enforces safe and healthful working conditions for general industry, construction, and maritime trades. Employers have the duty of providing their workers with a place of employment free from recognized safety and health hazards. OSHA enforces regulation 1926, Subpart M for construction and regulation 1910, Subparts D and F for general industry, which require fall protection be provided at: 4 ft in general industry; 5 ft in shipyards; 6 ft in the construction industry; 8 ft in longshoring operations; and any height when working over dangerous equipment or machinery. If you have any of these conditions, then youre legally required to implement a suitable fall protection system. 2. Elimination or protection? Once a fall hazard has been identified, there are essentially two options: eliminate the hazard or protect against it. In some cases, it is possible to eliminate a fall hazard, typically known as engineering out the hazard, simply by changing the working environment, processes, and procedures. If this is not possible, fall prevention should be the next consideration.
Common fall prevention methods include installing guardrails, scaffolds, handrails, or barriers. When passive fall protection solutions such as elimination or prevention are not practical, personal fall protection equipment, such as harnesses, lanyards, and retractable lifelines, can be used. Personal fall protection may consist of a restraint system to keep the worker from reaching an area where a fall hazard exists, or a personal fall arrest system that enables a worker to perform his duties from the height required while tied off to the system. A restraint system prevents the worker from falling at all. It restrains the worker by fitting him in a harness with a tether attached. A fixed-length lanyard is then attached to the D-ring on the harness, and then to a code-compliant anchorage system. Restraint is typically the preferred fall protection system when the environment allows for it, because a fall is completely avoided. However, there are many environments where its not optimal. Restraint systems dont tend to be very flexible once theyre in place, they dont always handle multiple workers well, and the length of the system may be limited. Fall arrest systems allow the worker to fall, just not very far. The systems are typically professionally engineered, ideally custom designed for the specific work environment.
52 March 2013
plant engineering
INTERACT
3. The ABCs of a fall arrest system. There is an easy way to remember the components of a proper fall arrest systemthe ABCs of fall arrest: Anchorage Body support Connectors Anchorage is a secure point to attach a lifeline, lanyard, deceleration device, or any other fall arrest or rescue system. These include structural steel members, precast concrete beams, and wooden trusses. An anchorage connector (or an anchor) is a piece of equipment used as a safe means to attach the lanyard or lifeline to the anchorage, such as cable and synthetic slings, roof anchors, and beam clamps. Body support in a fall arrest system is a body harness. A body harness provides a connection point on the worker to distribute the forces evenly across the body in the event of a fall. A full body harness is a body support device that distributes fall arrest forces across the shoulders, thighs, and pelvis and has a center back fall arrest attachment for connection to the connecting device. Connectors include lanyards, snaphooks, carabineers, deceleration devices such as self-retracting lanyards (SRLs), vertical and horizontal lifelines, ladder climbing systems, and rope grabs. SRLs have developed into an excellent technology. An SRL is a deceleration device containing a drum-wound line that may be slowly extracted from or retracted onto the drum under slight tension during normal movement. After onset of a fall, it automatically locks the drum and arrests the fall within 3-1/2 ft (which meets both OSHA and ANSI standards). SRLs work much like a car seat belt. The devices are meant to be anchored directly above the worker and reduce the free fall of the worker as well as swing fallthe distance a worker swings from side to side as he or she falls. 4. Wire rope vs. rigid rail. In fall arrest there are two types of systems: those that use a wire rope to support a worker and those that use a rigid rail. Rigid rail systems, while slightly more
expensive in initial installation, are a superior choice for several reasons. Wire rope systems require additional fall clearance due to the initial sag of the wire. The dynamic sag, or the stretch of the rope during a fall, adds to this distance. Rigid rail fall arrest systems stop the fall sooner by eliminating any sag, stopping the fall in a much shorter distance than wire rope. Injuries occurring after the fall, such as swinging into obstacles, are minimized with a rigid rail fall arrest system, which stays firm and minimizes the total fall distance. When a worker falls on a wire rope system, the wires sag will make the trolley slide to the center of the nearest two supports, creating a risk for the worker to collide with nearby obstacles after a fall.
Q: How do you determine your plants fall protection needs? How is your policy communicated and enforced? A wire rope system must be replaced and recertified by a qualified engineer. 5. Rigid flexibility. While the name might imply otherwise, rigid rail systems are the most flexible forms of fall arrest. Ideal for environments where there is limited clearance between the working level and lower level or obstruction, these systems provide a shorter free-fall distance and a reduced risk of secondary injury due to impacts during the free fall or sudden deceleration. Rigid rail fall arrest systems are the perfect solution for permanent applications and can easily be customized to fit every situation. Fall arrest systems are now available in multiple configurations, including various track profiles and support center distances, and can be easily customized to fit every budget and application. If you have determined a fall protection need, add fall protection to the companys overall health and safety plan. A written site-specific program should be developed, including detailed work procedures to protect your employees. The fall protection portion of your plan should state what fall protection measures are to be used, how they are to be used, a rescue plan, as well as the individual responsible for overall supervision and training. Remember these five points and youre E on your way to a safer workplace. P Kevin Duhamel is a North American product manager with Gorbel Inc. Kevin has more than 15 years of safety industry experience and expertise and has specialized in fall protection since 2008.
PLANT ENGINEERING
If you have determined a fall protection need, add fall protection to the companys overall health and safety plan. A written site-specific program should be developed, including detailed work procedures to protect your employees.
A rigid rail fall arrest system allows for longer distances between supports, reducing both material and installation costs. When a worker falls on a wire rope system, any slack on the wire is eliminated. The result could be a sudden pull on the rope that could have a jarring effect on other workers on the same system. Rigid rail fall arrest systems provide uninterrupted protection for additional workers on the same system. In the event of one workers fall, the rigid rail system will not bend or deflect like a wire rope system, allowing additional workers to continue to move freely and safely. The worker can continue use of a rigid rail fall arrest system after a visual inspection.
March 2013 53
MAINTENANCESOLUTIONS
process safety
More than just a safety program, the National Emphasis Program focuses on change.
By John Ross Marshall Institute
Making sense of
First
of three parts
INBREIF
80%
of OSHA refinery citations are related to operating procedures, mechanical integrity, process hazard analysis, process safety information, and management of change.
Source: OSHA
y all accounts it had been an accident; still others, the quiet majority perhaps, might have described it as having been an accident waiting to happen. It really didnt matter. Not at the moment when there were 28 bodies, 28 funerals to arrange, 28 lives to contemplate. Of the 36 injured, some clung to life; certainly all would be scarred physically or emotionally from the tragic event. Flixborough, England, June 1, 1974: A Nypro UK facility was about to be ground zero for another type of industrial revolution, one that would span the globe and forever link safety to engineering, plant maintenance to plant operations, and supervisors to employees. This was an accident that had everything: a highly sought after chemicalcaprolactam (a precursor chemical used in the manufacture of nylon), the rupture of a temporary bypass valve, a fire on an adjacent pipeline that had been burning for an hour, a vapor cloud, an explosion, a plant destroyed, and 1,800 neighboring buildings severely damaged. It was this event, almost 30 years ago, that some call the genesis of what we in the United States know as Process Safety Management. More likely, the Flixborough incident was just one more in a string of horrific and catastrophic incidents that marred industrial processes and left scores dead and injured. In fact, since that fateful afternoon an ocean away, weve had other major industrial accidents around the globeBhopal, India (1984) and Texas City (2005), just to name a few. It takes significant causes to lead to significant effects. Sometimes, having many bad things happen (causes) can force us to take positive and preventive steps for change (effects). Such has been the charge with the Department of Labors efforts to field, through OSHA, a formal Process Safety Management (PSM)
program, and a more focused National Emphasis Program (NEP). Three years into the second decade of the 21st century, both PSM and NEP are relatively new to U.S. manufacturing. While PSM-NEP makes sense, we must begin to make sense of it.
History and purpose

OSHA promulgated the PSM standard (CFR 1910.119) in 1992 as a way to address and combat a number of catastrophic incidents that occurred throughout the world. Several aspects of the process safety discipline itself were already being used by some larger petroleum refiners and petrochemical companies since before 1992. In the fall of 1994, OSHA issued its compliance guidelines and enforcement procedures. Instruction CPL 02-02-045 established the policies and procedures for enforcement and provided clarification and general guidance. This instruction also provided a first glimpse into what can now be described as PSM and its ineffectual bureaucracy. Because the initial inspections under what was then called the Program Quality Verification (PQV) were so resource intensive, this ultimately meant that very few inspections would be conducted. The well-intended program was mired under its own weight and could hardly deliver the desired safety results. In 2007, after a decade and a half of continual horrendous incidents in the petroleum refining industry involving highly hazardous chemicals (HHCs), OSHA initiated a refinery NEP. OSHA had hoped that by taking a more in-depth and more frequent look at certain aspects of PSM, the hazards involving HHCs in the petroleum workplace would be greatly reduced or even eliminated. This effort moved the organization from resource-extreme inspections to nimble audits.
54 March 2013
PLANT ENGINEERING
This laser focus provided just the positive results OSHA was looking to find. In the first year alone, OSHA completed inspections in 14 refineries in six of OSHAs 10 regions. This was an exceptional volume of inspections when compared to the few inspections accomplished with the initial PSM audit team prior to NEP. The new NEP was applicable to all federal, non-voluntary protection program (VPP) refineries. All state plans had to adopt the NEP or develop an equivalent program. Twenty-five states, Puerto Rico, and the Virgin Islands adopted OSHAapproved state plans. Many are identical to the federal guidelines, but sometimes they have different enforcement policies. The states that chose the state plans are mandated to communicate with the federal OSHA on the details of their plan and additions to and changes from the original intent of the federal guidelines. With the refinery NEP, inspectors were better able to get to the heart of process safety issues quickly by asking questions from a prepared list of 100 static and 15 dynamic questions. The list of 100 static questions is available on the OSHA website. The 15 dynamic questions are not published and change from time to time. The findings from those initial 14 refinery inspections were heavily technical, involving faults with operators, engineering, and maintenance. In fact, 80% of the 348 resulting citations were related to operating procedures, mechanical integrity, process hazard analysis, process safety information, and management of change. Recent statistics indicate that this was no fluke. In 65 inspections conducted through March 2011, 53% of the citations were written for engineering and maintenance categories: mechanical integrity, process safety information, and process hazard analysis. In August, 2009, OSHA issued Instruction CPL 03-00-010, Petroleum Refinery Process Safety Management National Emphasis Program, its most recent guideline on the subject of refinery NEP. Like all its predecessors, this instruction describes policies and procedures for implementing a National Emphasis Program (NEP) to reduce or eliminate the
workplace hazards associated with the catastrophic release of highly hazardous chemicals at petroleum refineries. As a result of the success in reducing catastrophic incidents, loss of life, and loss of property in the refinery industry, OSHA initiated a pilot program in mid2009 to cover other plants making or using HHCs in their process. Through experiences gained in the refinery industry, OSHA was able to improve its approach for inspecting PSM-covered facilities that allowed for a greater number of inspections using better allocation of OSHA resources. The pilot program was superseded in late 2011 with an OSHA instruction, directive CPL-03-00-014, PSM Covered Facilities National Emphasis Program. This made the pilot program official and nationwide, with mandates that state plans adopt a similar program. The nations refineries were now covered under one National Emphasis Program, and other, nonrefinery facilities making or using HHCs were covered under the CHEMNEP (Chemical National Emphasis Program). Refineries are pretty self-explanatory; other facilities were broken down into three types to ensure all types of facilities were covered: ammonia, chlorine, and all others. CPL-03-00-014 gave direction for how plants would be targeted for inspection: n U.S. Environmental Protection Agencys Chemical Accident Prevention Provisions, Program 3 Risk Management n Explosives manufacturing NAICS codes n OSHAs IMIS database n OSHA Area Office knowledge of local facilities. The guideline also gave OSHA authorization to conduct a full NEP inspection if it happened to be in a facility for another cause. Also, if a facility had an accident or catastrophe that required action from OSHA, it could take advantage and perform a full NEP at that time. OSHA already had an aggressive schedule requirement to complete three to five programmed inspections per Area Office per year; these nonprogrammed inspections presented other opportunities to test process safety.
NEP program guidelines should apply to any plant
t stands to reason that if youre in a facility that is not PSM mandated, you might not be too concerned with the National Emphasis Program. If you are in a PSM organization, you might have made the mistake of thinking its a safety program. The fact is, as identified above, much of the process safety centers around engineering and maintenance. In a sampling of the results of 98 CHEMNEP inspections, 44% were found to be traditional engineering and maintenance related: mechanical integrity and process safety information. Here are the 14 elements that make up the NEP. Review them and see how many can and should apply to your facility and how your company works:
n Employee participation n Process safety information n Process hazard analysis n Operating procedures n Training n Contractors n Pre start-up review n Mechanical integrity n Hot work permit n Management of change n Incident investigation n Emergency planning and
response
n Compliance audits n Trade secrets The CHEMNEP relied on dynamic questions. The questioning was streamlined in the CHEMNEP to cover more ground with limited resources. Also, through its work in refineries, OSHA found a better method to uncover the problem areas. OSHA found that refineries had extensive written process safety management programs but insufficient implementation. In other words, what refineries said they did was not what they did. A short riff of questioning could quickly point to the troubled processes E in a plant. P
plant engineering
March 2013 55
IN NOVATIONS
Case packer
The 939EZ Versatron Case Packer is equipped with an air-over-oil lift table, which controls the descent of product into the case, and a simple indexing case feed that maintains design simplicity without sacrificing control and speed. The 939EZ can operate at speeds of up to 30 cases per minute. It is also equipped with a variety of rugged and durable case packer change parts, all designed for safe, easy, and consistent 15-minute changeover. Optional equipment and features include a pneumatically controlled flap opener for RSC cases.
Standard-Knapp www.standard-knapp.com
Input #200 at www.plantengineering.com/information
Thermal imaging camera kit

The thermal imaging camera kit is an economically priced, compact, rugged, and lightweight product. It features plug-and-play compatibility, fast data transfer and a wide temperature range and a high sensitivity of <50 mK. This camera kit includes everything needed for a quick out of box deployment and is designed specifically for thermal bench top testing applications. Thermal Imaging Systems are now bringing the advantages of thermal imaging to the test bench of every R&D engineer.
Omega Engineering www.omega.com
Personal air conditioner

The Dual Action PAC is coupled with a lightweight vest, which delivers either cool or warm air to the wearers torso and neck. By wearing the vest and PAC, industrial employees working in extreme temperatures can avoid the negative impact of low temperatures in winter as well as heat stress and fatigue in the summer. Workers can adjust the Dual Action PAC to provide either heating or cooling. Thanks to vortex tube technology, the Dual Action PAC provides air temperatures ranging from 30 F to 120 F.
Vortec www.vortec.com
Input #202 at www.plantengineering.com/ information
Proximity sensor
The W27 MultiPac photoelectric proximity sensor uses two redundant receiver arrays to detect difficult targets such as bundled bottles in the packaging and food and beverage industries. The W27 MultiPac provides overhead counting and indexing to ensure bundles are both created and transported properly. With two independent receiver arrays, the W27 MultiPac ensures continuous detection when diffused light is misdirected from bundled surfaces.
SICK www.sickusa.com
56 March 2013
PLANT ENGINEERING
Send new product releases to: peproducts@cfemedia.com
Connector system for OEMs

The SpeedStack Mezzanine Connector System is a highdensity, low-profile solution that supports data rates of up to 40 Gbps per differential pair. The system is designed for OEMs that contend with limited PCB real estate. The mated stack heights of 4 mm to 10 mm along with a 0.80 mm pitch provide design engineers with the ultimate in flexibility to address space constraints without sacrificing performance. The SpeedStack Connector System comes in multiple circuit sizes of 22, 44, 60, 82, 104, and 120.
Molex, www.molex.com
Machine-mountable remote display

The Machine-Mountable Remote Display enables users to view the iVu sensor image remotely and serves as a constant monitoring and user-programming interface, without interference from electrical noise. The rugged, noise immune, stationary remote display features an 89-mm (3.5-in), diagonal, color LCD flat-panel touchscreen display and an exceptionally wide viewing angle.
Banner Engineering www.bannerengineering.com
Temperature compensating refractometer

The HydroFlow Automatic Temperature Compensating Refractometer allows plant operators to quickly determine the concentration of metalworking coolants and cleaners, heattreating fluids, water-based hydraulic fluids, and even plating baths. This simple yet rugged device is portable and requires no batteries. Its large, easy-to-read scale is available in two ranges: 0- to 10-deg Brix and 0- to 32-deg Brix. These handy fluid recycling instruments are designed for most metalworking operations.
ErieZ, www.eriez.com
Curved pump pliers

The Klaw Pump Pliers are available in two styles: Quick-Adjust and Classic. The Quick-Adjust has a pushbutton, quick ratchet feature that allows the user to easily adjust the pliers to any position. Both styles of Klaw Pump Pliers are compact and narrow for better access in small or hard-to-reach spaces. The gripping surfaces of the jaw also have specially hardened teeth for positive gripping and reduced wear. In addition, a special groove at the tip of the jaw is designed for holding nails.
Klein Tools, www.kleintools.com
PLANT ENGINEERING
March 2013 57
IN NOVATIONS
Wireless pump control application
Grundfos North America has launched the Grundfos GO, an app that provides wireless pump control and full access to Grundfos online tools. The GO app is a combination of a mobile interface and a free app available in the App Store and Google Play. Once the app is installed to a mobile interface, users can copy profiles to new pumps, generate installation reports, request status data, adjust pump settings, and receive alarms and warnings. The app also provides a live data feed from the pumps onto the screen.
Grundfos, www.grundfos.com
Pneumatic cylinder switches

The Nitra line of pneumatics products includes nine styles of position switches for pneumatic cylinders, including round, dovetail, T-slot, square, and D-shaped; additional dovetail accessories are available to accommodate larger dovetail slots. The new styles are solid-state electronic switches available in normallyopen 3-wire dc PNP and NPN configurations, and can be purchased with an M8 wiring connector or 3-meter integral cable with wire leads. Mounting bands with adapters for round body cylinders are available ranging from 1/8 in. to 4 in. sizes.
AutomationDirect, www.automationdirect.com
Butterfly valves
The High Performance Butterfly Valves Series offers Class VI shut-off and an advanced seat design, which provides a bi-directional interference and pressure-assisted seal. These valves are available in sizes from 2 in. through 12 in. with a pressure rating up to 285 psi for 150 class and 740 psi for 300 class valves. The HP Series disc is engineered for a quick release from the seat, which reduces torque and seat wear. Machined position stops on the body locate the disc in the seat to achieve maximum seat and seal life.
Assured Automation www.assuredautomation.com
Heavy-duty dry vacuum

The 110-gal Premium Heavy Duty Dry Vac System is a rugged, industrial duty vacuum cleaner that has been engineered to rapidly vacuum high volumes of dry material. The higher capacity drum means that fewer drum changes will be required during cleanup. It has no motor or impeller to clog or wear out, making it ideal for cleaning abrasive materials like steel shot, garnet, metal chips, and sand, yet it can also be used for general purpose applications.
Exair, www.exair.com
58 March 2013
PLANT ENGINEERING
Compressed air dryers

The D-EC Energy-Saving Refrigerated Compressed Air Dryer series are available in eight models, ranging in capacities from 10 to 125 standard cubic feet per minute (SCFM). The D-EC dryers are ideal for small commercial compressed air users such as machine shops, automotive repair and refinishing businesses, and light manufacturing applications. The D-EC cycling dryers incorporate a thermal mass that stores cold energy, providing enhanced operating efficiency.
Ingersoll Rand, www.ingersollrand.com
Diode arrays
The 450W SD05 (unidirectional) and SD05C (bidirectional) Series General-purpose TVS Diode Arrays (SPA Devices) are designed to protect electronic equipment from damage due to electrostatic discharge (ESD) and other transient events. SD05 and SD05C Series devices are made of silicon diodes, which allow them to absorb repetitive ESD strikes or surge transients safely without performance degradation. Their low dynamic resistance (0.5 for SD05, 0.6 for SD05C) provides up to a 50% reduction in clamping voltage when compared with competing technologies, and can safely dissipate induced surge currents up to 30 A.
Littelfuse, Inc. www.littelfuse.com
Pump for multi-gas detector

The Ventis Slide-on Pump (Model VSP), available in black or safety orange, allows for convenient sampling of up to 50 ft in a wide range of applications. It is ideally suited for gas monitors for personal protection throughout the day. No tools are required to attach or remove the pump to and from the Ventis monitor. Since the pump is powered by its own battery pack, as is the Ventis, the battery packs can be easily exchanged between instruments as needed. There are three available battery pack options including standard lithium-ion, extended runtime lithium-ion, and alkaline, which make the pump extremely flexible in the field.
Industrial Scientific, www.indsci.com
Liquid paddlewheel flow meters

The IC-LPM series of paddlewheel meters provides accurate flow rate monitoring over the range of 0.5 to 1200 l/min with standard nominal sizes up to 50 mm. Its stainless steel construction offers corrosion resistance and a versatile design with custom options to meet varying flow monitoring requirements. The IC-LPM paddlewheel meter features a supported paddlewheel impeller mounted on a bearing and pin assembly.
Icenta Controls Ltd., www.icenta.co.uk
PLANT ENGINEERING
March 2013 59
IN NOVATIONS
ITW Warehouse Automation www.itwwa.com
Warehousing solution
ITW Warehouse Automation introduced its StorFast cart-based, ultra-high-density AS/RS solution. The cart-based AS/RS maximizes storage capacity with higher density and throughput. The designs are modular and can easily be expanded as capacity requirements and SKUs increase. The carts operate on each level of the system and have the ability to change levels, which gives the StorFast built-in redundancy, resulting in greater efficiency.
Mounted ball bearings

Emersons Sealmaster material handling mounted ball bearings feature cast iron housings and an extended inner race insert bearing with ball riding nylon retainer. The insert features a rivet to prevent outer ring rotation and is available with setscrew or SKWEZLOC concentric locking collar. The contact seal provides balance between contaminant resistance, grease loss, and friction. The bearings are available in common unit material handling industry bore sizes and housing configurations.
Sealmaster www.emerson-ept.com
Pressure reducing valve

Tacos 3350 valve is used to automatically feed water to a hydronic system when pressure in the system drops below the pressure setting of the valve. The 3350 is suitable for systems with fill pressure requirements of 10 to 50 psi and features a fast-fill button with automatic reset. All cartridge-style reducing valve parts are contained in a one-piece cartridge that can easily be removed and serviced. The 3350s dial-in pressure setting allows for easy adjustment throughout the 10 to 50 psi range, without the need for an external gauge. The design of the valve features a stainless steel coaxial strainer, preventing system debris from affecting the valves performance.
Taco www.taco-hvac.com
Centrifugal pump
Xylem Inc.s Bell & Gossett series e-90 line centrifugal pump is specifically designed for the commercial HVAC market. The pump features a high hydraulic efficiency and closed-coupled design and can be mounted either vertically or horizontally for a wide range of applications. The e-90 line centrifugal pump also features a vacuum cast bronze impeller and a robust silicon-carbide mechanical seal to deliver reliable operation in demanding environments. The pump is available in eight sizes, providing wide hydraulic coverage up to 300 gpm flow. The pump uses an industry standard 56J motor in 1/3 - 3 hp 4-pole speed and 1/2 - 5 hp 2-pole speed.
Xylem Inc., www.xyleminc.com
60 March 2013
PLANT ENGINEERING
PRODUCTMART
Why Should You Filter Your Water?
Scale formation reduces the heat transfer rate and increases the water pressure drop through the heat exchanger and pipes. In fact, one study has shown that .002" fouling will increase pumping needs by 20%.
The Best Engineered Water Filtering Solution Always Costs Less

2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A ( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8 w w w. t e k l e e n . c o m info@tekleen.com
Input #100 at plantengineering.hotims.com Input #101 at plantengineering.hotims.com
e-newslet ters
Plant Engineerings
electronic newsletters
deliver news and information on the latest trends in manufacturing in every corner of the plant oor. Plant engineers and managers refer to these sources of information for the up-to-the-minute news and trends that impact their business.
PlantMail: HotWire: HotWire on MES: HotWire on Automation: Maintenance Connection: Product Showcase: Weekly Monthly Monthly Monthly Monthly Monthly
OIL MIST & SMOKE IN YOUR SHOP?

www.mistcollectors.com Tel: 1-800-645-4174
3.5" wide x 4.5" high

Set In Place Pantone 382c and Walk Away!
Input #102 at plantengineering.hotims.com
Need CEUs?
Visit the PLANT ENGINEERING Media Library and view our on-demand Webcasts. Pass the CEU exams after viewing and earn your CEUs!
www.plantengineering.com/webcasts
I Freestanding. I No
Patent Pending
Mechanical Attachment to Roof or Skylight! I Complies with OSHA 1910.23(e)(8). I Powder Coated or Galvanized.
763-694-2614 www.railguard.net
Input #103 at plantengineering.hotims.com
Sustainable Manufacturing: Monthly
Get your plant ahead of the curve. Subscribe today by going to
Reach your Audience! Place your Ad in PLANT ENGINEERINGS Product Mart or Classieds section, call today and get results!
www.plantengineering.com/newsletters
ple1003jh_enewslttrs.indd 1 3/1/2010 2:56:53 PM
630-571-4070
PLANT ENGINEERING
March 2013 61
For more information on how to advertise in Plant EnginEErings Internet Connection, call Jim Langhenry at 630-571-4070 x2203
aitkenproducts.com
Aitken Products manufacturers and distributes high-quality industrial heaters. Aitkens products are for a variety of industrial applications and are available when needed. Aitken Products Inc.
exair.com
Exairs product line includes Vortex Tubes and products utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination. Exair Corp.
rosler.us
The Rosler group is the leading supplier of surface finishing equipment and consumables. Products include mass finishing and show blast equipment, wastewater treatment systems, and compounds for mass finishing. Rosler Metal Finishing USA
alliedelec.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical products with over 50 sales offices across the United States and Canada. Allied Electronics
flexicon.com
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.
schneider-electric.com
Schneider Electric delivers solutions for electrical distribution, machine and process control and automation, power and lighting management, and engineering services. Schneider Electric
atlascopco.us
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco
fluke.com
Fluke is the world leader in the manufacture, distribution, and service of electronic test tools and software. Fluke Corp.
seweurodrive.com
One of the largest global suppliers of drive technology, SEW-EURODRIVE specializes in gear reducers, motors and electronic motor controls. SEW-EURODRIVE
idc-usa.com
IDC-USA is a growing cooperative with a rich history of helping independent distributors remain competitive on a national level within a free enterprise system. IDC-USA
automationdirect.com
AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including PLCs, operator interfaces, sensors, and more. AutomationDirect
tnb.com
Thomas & Betts supplies over 70% of the items used in a typical electrical application and provides market-leading commercial heating and ventilation products, supplying over 70% of the items used in a typical electrical application. Thomas & Betts Corp.
ingersollrand.com
Ingersoll Rands diverse and innovative products range from complete air compressor systems, tools, ARO pumps, material handling systems and more. Ingersoll-Rand plc
baldor.com
Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.
ustsubaki.com
U.S. Tsubaki is a leading manufacturer and supplier of power transmission and motion control products and is the worlds market share leader in roller chains. U.S. Tsubaki Inc.
lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.
binsfeld.com
Binsfeld Engineering specializes in creating leading technology for transmitting data from rotating sensors. Binsfeld Engineering Inc.
vaisala.com
Vaisalas core business is environmental measurement, especially weather measurement and chosen industrial measurements. Vaisala
brushart.com
Brush Art Corporation is a full-service advertising agency and custom publishing firm. Brush Art Corp.
motionindustries.com
Motion Industries is a leading distributor of industrial MRO supplies with more than 500 operations, including nine distribution centers. Motion Industries
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.
camfilfarr.com
Camfil Farr is the worlds largest and leading manufacturer of filters and clean air solutions. Camfil Farr
omega.com
Omega offers more than 100,000 state-of-the-art products for measurement and control of temperature, humidity, pressure, strain, force, flow, level, pH, and more. Omega Engineering Inc.
donaldson.com
Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.
rittal-corp.com
Rittal manufactures the worlds leading industrial and IT enclosures, racks and accessories, including high-efficiency, highdensity climate control and power management systems. Rittal Corp.
62 March 2013
plant engineering
Place next to your computer or go online to plantengineering.com for hot links to these companies.
Remove at Line
3 h 201 c r a M
CONTACTS
Advertiser
Aitken Products, Inc 800-569-9341 Allied Reliability 843-414-5760 Atlas Copco Compressors 866-688-9611 AutomationDirect 800-633-0405 Baldor Electric Company 800-828-4920 Binsfeld Engineering Inc. 800-524-3327 Camfil Air Pollution Control 800-479-6801 Caterpillar - Northeast CFE Media LLC 630-571-4070 Donaldson Co., Inc 800-365-1331 Exair Corp 800-903-9247 Flexicon Corp 888-353-9426 Fluke Corp 888-443-5853 IDC-USA 866-575-2025 Ingersoll-Rand 704-655-4000
Page Number RSC Number
Advertiser Contacts for plant engineers
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Plant Engineering.
Send Info
Advertiser
Lubriplate Lubricants Co 800-733-4755
Page Number
RSC Number
Send Info
10 16 24 Gate C-2 C-4 22 4 23 33 12 7 8 11, 28 14, 15
8 www.aitkenproducts.com 13 www.alliedreliability.com 18 www.atlascopco.us/mboxusa 2 www.automationdirect.com 27 16 5 www.baldor.com www.binsfeld.com www.camfilapc.com
50
25
www.lubriplate.com
Motion Industries, Inc Gate C-1, 16A-16P, 21 800-523-9328 Omega Engineering, Inc 888-556-6342 Plant Engineerings Electronic Newsletters 630-571-4070 Rittal Corporation 800-477-4000 Rosler Metal Finishing USA 269-441-3000 Schneider Electric 847-397-2600 SEW-Eurodrive, Inc. 1
1, 15 www.MotionIndustries.com 3 www.omega.com
37 www.plantengineering.com/newsletters 18, 19 26 13 2 40 27 45 14 19 www.rittal-corp.com www.rosler.us
17 www.NECatDealers.com/power www.cfemedia.com 10 6 7 9,21 www.donaldson.com www.exair.com www.flexicon.com www.fluke.com
11 www.schneider-electric.com 4 www.seweurodrive.com
Solutions For Engineers 630-571-4070 Thomas & Betts Corporation 901-252-8000 U.S. Tsubaki 800-323-7790 Vaisala, Inc. 888-824-7252
www.PlantEngineering.com 20 24 www.tnb.com www.ustsubaki.com/pe
29 22 www.vaisala.com/dewpointsensor 26
12 www.IDC-USA.coop/difference
Yaskawa America, Inc C-3 800-927-5292 www.yaskawa.com
43 23 www.ingersollrandproducts.com
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
Need More Info? FAX this page to: 630-214-4504

Title Address State e-mail
Name Company City Telephone
Zip
Fax
PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.
PLANT ENGINEERING
March 2013 63
INCONCLUSION
The self-evident truths about maintenance
s a writer by trade, I appreciate a good turn of a phrase. One of my favorite documents is the Declaration of Independence, and one of the better lines in that document begins, We hold these truths to be self-evident... Of course, if those truths really were selfevident, Thomas Jefferson and the other framers of the Declaration of Independence probably wouldnt have needed to make them more evident. In reality, it was a not-too-subtle dig at the British monarchy at the time, and they responded by taking considerable umbrage at the cheeky nature of the colonists, and thus the Revolutionary War began. In modern manufacturing, there is one truth that needs to be held as self-evident, one not-too-subtle point that needs to be made, and one revolution that needs to begin as a result:
Bob Vavra
Content Manager
Youre no longer talking about the cost of maintenance. Youre talking, in real dollars, about a return on your investment in maintenance. You can make a case with anyone that maintenance pays.
Plant maintenance is not a cost center. Maintenance is a profit center.

This simple manifesto changes the dynamic of your thinking about the role maintenance plays in your operation. It changes the math. It changes the operational emphasis. It changes the responsibility of production from a product-centric metrics to a capacity-centric metrics. The math part is pretty simple. Better maintenance increases equipment availability. Better equipment availability increases capacity. Better capacity increases throughput. More throughput suddenly gives you more things to sell without having to increase staff, change production schedules, or add additional shifts. It does require a greater respect for the idea of planned maintenance. Everything we ownfrom our bodies to our cars to the grips on our golf clubsrequire attention, a proactive plan of regular maintenance, and an analysis of the cost of doing nothing versus the cost of maintaining or replacing parts. Having gone through each of these scenarios over the last year, I can tell you that making the right expenditure at the right time makes a world of difference. If you view maintenance as the cost of replacing a part when it breaks, youre missing the larger mathematics here. If a motor
fails, it shuts down a line. If you have the motor in your parts crib, you can probably get a replacement up and running in half a day or so. Of course, the workers on that line are idled and they are being paid without producing anything, no new product is running through the line, and the product that was ruined when the line went down has to be accounted for. Add up all those costs, and hope your supply chain isnt too disrupted by this. Oh, and did you have a motor in the crib? Was anyone hurt when the line went down? Run to failure, as weve suggested in the past, is not a maintenance strategy. It leaves you vulnerable to whim and fate, and the last time I checked, those two words arent part of any accepted Lean maintenance practice. The only advantage of run to failure is that it has a straight-line cost to it. A part breaks, you replace the part, and that is the cost of that failure. Only, as we see above, its far from the only cost, or even the largest cost. The hardest part about a maintenance strategy is getting the budget to do it right. Good maintenance isnt prohibitively expensive, but it requires constant funding and constant attention. Like a sound, employeecentric safety program, maintenance is seen as a cost center because in and of itself, it cannot produce additional revenue. It is a way to spend $1 today to avoid spending $5 tomorrow. Its that initial $1 expenditure that is getting harder and harder to justify. Thats where treating maintenance like a profit center has its greatest impact. Youre no longer talking about the cost of maintenance. Youre talking, in real dollars, about a return on your investment in maintenance. You can make a case with anyone that maintenance pays in increased capacity, less waste of raw materials, less waste of staff time, and greater productivity from workers. This is true whether your maintenance plan is in-house or given to a third-party vendor. The only time its not true is when you have no maintenance plan at all. Maintenance is a profit center. We at Plant Engineering hold that truth to be self-evident. But like Thomas Jefferson, it makes the E point to also put it down on paper. P
64 March 2013
PLANT ENGINEERING
NOTHING GOOD HAPPENS AFTER MIDNIGHT
Nobody wants that middle-of-the-night-call telling you systems are down. Not you. Not us. And, certainly not the guy with the problem. Thats one of the reasons you should turn to Yaskawa for drives and motion control. Trust your operations to Yaskawa and the phone wont ring at night. The boss wont be in your ofce. And, maintenance wont be breathing down your neck with another re to put out. Trust Yaskawa and youll get a good nights sleep. Rest easy tonight. Call Yaskawa today.
YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M

Follow us: For more info:
http://Ez.com/yai439
2013 Yaskawa America Inc.
The new Baldor RPM AC Cooling Tower Direct Drive Motor sets a new standard in cooling tower motors. Designed exclusively for cooling tower applications, the RPM AC motor mounts directly to the cooling tower fan, eliminating high-maintenance gearboxes, drive shafts and couplings. Combined with Baldors VS1CTD proprietary adjustable frequency drive, this slow speed, high torque combination operates at variable speeds to maximize system efficiency and minimize noise. Perfect for new installations or for retrofitting older, less efficient cooling tower
systems, the RPM AC Cooling Tower motor and VS1CTD Cooling Tower drive offers improved reliability while greatly reducing maintenance costs and energy consumption. Check out our website for case studies, installation photos and additional information about the revolutionary new RPM AC Cooling Tower technology from Baldor. We are truly changing the future of cooling tower technology! baldor.com 479-646-4711
Energy Efficient Unmatched Quality Superior Reliability Low Maintenance Quiet Operation Made in the USA
2011 Baldor Electric Company

Plant Engineering April 2013

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Plant Engineering April 2013

Uploaded by

Copyright:

Available Formats

41 Selective coordination

47 Pipe joining systems

54 Fall arrest solutions

Brands You Count On,

People You Trust

Representing North Americas Leading Brands In MRO Replacement Parts

sMore Than Bearings

Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 550 Locations

Best prices on pneumatics

All Stainless Steel Pneumatic Cylinders - F Series

More cylinder series also interchangeable with popular brands

Plant Maintenance and Operations

Compact Thermal Imager

*OSXL-I Series Starts at $ 1195

HHB-ISCOPE Starts at $ 299

COPYRIGHT 2013 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

Dont get torqued off. Get TorqLOC!

Maintenance as a pro t center

Courtesy: Rockwell Automation

Weld Smoke Collector

Paper Scrap Handling Systems

Abrasive Blast Dust Collectors

Laser Cutting Smoke

Looks Like a Safe Because Its

Food Processing Dust

Dust From Thermal Spraying

Dust From Chop Saw

Plasma Cutting Smoke Collector

Plant Engineers, the Camfil APC Farr Gold Series

Call us about NFPA and ATEX Explosive Dust compliance issues.

Follow. Connect. Watch. Learn.

Virtual ride and fly through a Farr Gold Series

25 Benchmark your manufacturing

performance to deliver results

selective coordination design

47 Pipe joining systems

get in the groove

51 Fall arrest solutions require

attention to detail, not scale

53 Making sense of process safety

Is your plant a Top Plant?

Connect with us!

Exclusive blogs at www.plantengineering.com/blogs

LinkedIn: Plant Engineering Professionals

Point, click, watch

System Integrator Guide

The Truth About Compressed Air!

Compare these Blowoffs

Facts about Blowers

Blower Air Knife

Flat Air Nozzles

EXAIR Super Air Knife

See the Super Air Knife in action. www.exair.com/79/akvideo.htm

USA sales@flexicon.com 1 888 FLEXICON

CHILE UK AUSTRALIA SOUTH AFRICA

+56 +44 +61 +27

Checklist for robotics survival

Watch how ScopeMeter was created:

Putin to open Hannover Messe 2013 on April 7

input #10 at www.plantengineering.com/information

Equipment de-energized during upgrade

Spending too much time and money on aging equipment?

Square D Services is now Schneider Electric Services!

Make the most of your energy