OCTOBER 2011
www.plantservices.com
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ANALOG MODULE LCD **
CPU LCD*
Time-saving troubleshooting tools
at your fingertips
Use the technology built into the Productivity3000 programmable controller
to make your job easier. These integrated diagnostic tools in the FREE
software save you time and headaches:
HISTOGRAM
PS1110_FPA.indd 2
• Run-time editing lets you make program changes to
the CPU without pausing I/O updates or stopping/
restarting the program.
• * The built-in display on the CPU can show system
alarms and information, or it can be configured to
display user-defined messages triggered by the
program.
• ** The patent-pending LCD on all analog modules
gives you quick access to actual field signal values no need to drag out a multimeter. Also see module
and signal faults, such as range errors.
• Module Status Bits (MST), automatically created for
each I/O module, can be used for error checking
and reporting, and to simplify the troubleshooting
process.
• Create powerful graphs with Bit and Word Histogram
tools and see your data like never before. Isolate
chase conditions, make sense of rapidly changing
numbers or visualize intricate processes.
9/27/11 4:42 PM
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
Facts About Blowers
There 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
different blowoff methods: drilled pipe, flat 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. The following comparison proves that
the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application.
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 filters,
belts and bearings.
Here are some important facts:
The goal for each of the blowoff choices was to use the least amount of air possible to get the
job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG
which provided adequate velocity to blow the water off. The blower used had a ten horsepower
motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page
summarizes the overall performance. Since your actual part may have an odd configuration,
holes or sharp edges, we took sound level measurements in free air (no impinging surface).
Filters must be replaced every one
to three months.
Belts must be replaced every three
to six months.
Drilled Pipe
Blower Air Knife
This common blowoff 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. The initial cost of the drilled
pipe is overshadowed by its high energy
use. The 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.
The 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 flat air nozzle, but
was comparable to EXAIR’s Super
Air Knife. The large blower with its
two 3" (8cm) diameter hoses requires
significant mounting space compared
to the others. Noise level was high
at 90 dBA. There was no option for
cycling it on and off to conserve energy
like the other blowoffs. Costly bearing
and filter maintenance along with
downtime were also negative factors.
Flat Air Nozzles
EXAIR Super Air Knife
As shown below, this inexpensive
air nozzle was the worst performer.
It is available in plastic, aluminum
and stainless steel from several
manufacturers. The flat air nozzle
provides some entrainment, but suffers
from many of the same problems
as the drilled pipe. Operating cost
and noise level are both high. Some
manufacturers offer flat air nozzles
where the holes can be blocked an OSHA violation. Velocity was
inconsistent with spikes of air.
The Super Air Knife did an exceptional
job of removing the moisture on one
pass due to the uniformity of the laminar
airflow. The 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 off
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.
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 effective airflows.
• Poorly designed seals that allow dirt and
moisture infiltration and environments above
125°F decrease the one year bearing life.
• Many bearings can not be replaced in the
field, 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 difficult to
control since mechanical adjustments are
required.
To discuss an application, contact:
EXAIR Corporation
11510 Goldcoast Drive
Cincinnati, Ohio 45249-1621
(800) 903-9247
Fax: (513) 671-3363
email: techelp@exair.com
www.exair.com/85/423.htm
The Super Air Knife is the low cost way to blowoff, dry, clean and cool.
Blowoff Comparison
Comp. Air
Type of blowoff
PSIG
BAR
SCFM
SLPM
Horsepower
Required
Sound
Level
dBA
Annual
Purchase
Approx. Annual First Year
Electrical
Price
Maintenance Cost
Cost
Cost*
Drilled Pipes
60
4.1
174
4,924
35
91
$50
$4,508
$920
$5,478
Flat Air Nozzles
60
4.1
257
7,273
51
102
$168
$6,569
$1,450
$8,187
Blower Air Knife
3
0.2
N/A
N/A
10
90
$5,500
$1,288
$1,500
$8,288
Super Air Knife
60
4.1
55
1,557
11
69
$494
$1,417
$300
$2,211
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.
PS1110_FPA.indd 3
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table of contents
OCtOBer 2011 / VOL. 32, NO. 10
features
24 / COVER STORY
Symptom Administrator
Production automation and control networks provide diagnostic
data to get to the root of the cause
33 / mOTORS And dRIVES
drive Away Harmonics
Currents and voltages can take away capacity
39 / pumpS
positive displacement — part V
Fundamentals, design, and applications for metering pumps
44 / pROduCT ROundup
Tough Enough to Handle Fluids
Pumps, switches, valves, nozzles, and flowmeters are ready for
liquid launch
specialists
Smart buildings for the smart grid
Facility uses 60,000 sensors and meters to achieve energy
efficiency, water savings, and optimized operations.
http://www.plantservices.com/articles/2011/09-intelligentbuilding-solutions-smart-grid.html
Optimization of energy usage
energy consumption statistics for industry are eye-popping.
http://www.plantservices.com/whitepapers/2011/optimizationof-energy-usage.html
manufacturing leaders at imx discuss the workforce crisis
Mark tomlinson talks about the Interactive Manufacturing
experience event and the future of American industry.
http://www.plantservices.com/multimedia/2011/manufacturingleaders-fight-the-workforce-crisis.html
How to balance steam loads efficiently
Understand the finer characteristics of boilers and heat recovery
steam generators.
http://www.plantservices.com/articles/2011/09-how-to-balancesteam-loads-efficiently.html
PLANt SerVICeS (ISSN 0199-8013) is published monthly by Putman Media, Inc., 555 West Pierce road,
Suite 301, Itasca, IL 60143. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals Postage paid at Itasca,
IL and additional mailing offices. Canada Post International Publications Mail Product Sales Agreement No.
40028661. Canadian Mail Distributor Information: Frontier/BWI,PO Box 1051, Fort erie, Ontario, Canada, L2A
5N8. Printed in U.S.A. POStMASter: Send address changes to PLANt SerVICeS, Putman Media, Inc., PO
Box 3435, Northbrook, IL 60065-3435. SUBSCrIPtIONS: Qualified reader subscriptions are accepted from
PLANt SerVICeS managers, supervisors and engineers in manufacturing plants in the U.S. and Canada. to
apply for qualified-reader subscriptions, please go to www.plantservices.com. to non-qualified subscribers in
the U.S., subscriptions are $96 per year. Single copies are $15. Subscription to Canada and other international
are accepted at $200 (Airmail only) © 2011 by Putman Media, Inc. All rights reserved. the contents of this
publication may not be reproduced in whole or in part without consent of the copyright owner. In an effort to
more closely align with our business partners in a manner that provides the most value to our readers, content
published in PLANt SerVICeS magazine appears on the public domain of PLANt SerVICeS’ Website, and may
also appear on Websites that apply to our growing marketplace. Putman Media, Inc. also publishes CHeMICAL
PrOCeSSING, CONtrOL, CONtrOL DeSIGN, FOOD PrOCeSSING, INDUStrIAL NetWOrKING, tHe
JOUrNAL, PHArMACeUtICAL MANUFACtUrING and WeLLNeSS FOODS. PLANt SerVICeS assumes no
responsibility for validity of claims in items published.
9 / CRISIS CORnER
23 / TECHnOlOgY TOOlbOx
Reliability Rescue
non-invasive Surgery
for Equipment
Better inventory management
frees up training funds
11 / mR. SuSTAInAbIlITY
The profession personified
Ultrasonic, vibration, and
pressure analysis can be done
without disruption
Let yourself be inspired by
ISSP’s Hall of Fame inductees
43 / bIg pICTuRE
17 / HumAn CApITAl
High-performance work
system integrates
maintenance, engineering,
and operations
let Them Own the Solution
Give employees the
opportunity to succeed when
you delegate
global Competence,
local Operations
50 / EnERgY ExpERT
19 / ASSET mAnAgER
Too much Information
Answers to CMMS questions
are a click away, but which
are accurate and relevant?
loading Order and
balanced Energy
Listen to more than energy
sound bites
columns and departments
7 / FROm THE EdITOR
15 / YOuR SpACE
Towers of power
bear down on
Counterfeits
Industrial plants harvest the
wind
13 / WHAT WORKS
• Switch to propane translates
to maintenance savings and
increased productivity
Fake bearings can create
safety risks and cause
equipment downtime
49 / ClASSIFIEdS / Ad IndEx
www.PLANTSERVICES.Com oCTobER 2011 5
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Atlas Service Ad 7 7/8 x 10.5:Layout 2
9/28/11
12:11 PM
Page 1
Keeping your production on track
Hi, I'm Daniel and I’ve been a service technician working with Atlas Copco products for
over 26 years. I’ve seen technology race ahead over that time, but the one thing always
setting the pace is our commitment to keep your productivity on track.
The key behind Atlas Copco’s service offering is that it’s fully customizable, with a
selection of plans and programs that put you in the driver’s seat. We understand how
important compressed air is within your workplace and keeping your production fine
tuned is our number one priority. Looking after your processes and applications is part
of every Atlas Copco employee’s mission and this goes far beyond the compressor room.
Inspecting your piping system for leaks, assessing pressure drops, and checking
condensate drains is all in a day’s work for our service teams.
Our driving force is to continue to bring sustainable productivity through safer, cleaner,
more energy-efficient and cost-effective compressed air technology. Simply log onto
www.atlascopco.us/danielusa or call 866-688-9611 to learn more about us, our products,
and how we have earned and will continue to earn our reputation.
© Copyright 2011 Atlas Copco Compressors LLC. All rights reserved.
PS1110_FPA.indd 6
9/28/11 12:15 PM
PUTMAN MEDIA, INC.
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(630) 467-1300 Fax: (630) 467-1120
FROM THE EDITOR
MIKE BACIDORE, EDITOR IN CHIEF
MIKE BRENNER
Group Publisher
mbrenner@putman.net
EDITORIAL STAFF
MIKE BACIDORE
Editor in Chief
mbacidore@putman.net
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Associate Editor, Digital Media
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V.P., Creative Services
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Art Director
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DAVID BERGER, P.ENG.
Contributing Editor
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Contributing Editor
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Contributing Editor
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Contributing Editor
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PUBLICATION SERVICES
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Vice President
KEITH LARSON
V.P., Content
ROSE SOUTHARD
V.P., Technology
TOWERS OF POWER
Industrial plants find opportunities to harvest the wind
Three years ago, I predicted more
industrial plants would begin harnessing alternative energy supplies and using
them to create their own power, and even
sending power back to the grid. I wrote
about an existing industrial plant that
has been harvesting the energy of the
wind to generate electricity for almost
10 years now. BP’s Netherlands Refining (Nerefco) was utilizing power from
a nine-turbine, 22.5-MW wind farm
near Rotterdam, which displaced 20,000
tons of greenhouse gas emissions. The oil
refinery not only uses the energy to run
its own operations, but also contributes
power to the Dutch grid.
Now, as more industrial plants begin
adding wind turbines to their electricity supplies, the very idea seems almost
worthy of a why-didn’t-we-think-of-thisearlier palm smack to the forehead. Estimated wind energy costs hover around
$0.05/kWh, but the real issue is with the
energy’s intermittency and the tricky
details involved in contributing power
back to the grid. Additionally, typical
annual maintenance costs run about 5%
of the installation cost. That’s significant
but can be cut in half with proactive
maintenance or reliability practices.
Recently, Wago (www.wago.us) tipped
up a 100-ft-tall, 32-ft-diameter windmill
using portable hydraulics at its North
American headquarters in Germantown,
Wisconsin. The ability to raise and lower
the unit in around 20 minutes will help
to alleviate a considerable amount of
those maintenance costs. This particular system, built by Renewegy (www.
renewegy.com) in Oskkosh, Wisconsin,
includes power supplies, cables, connectors, fuse blocks, and a backup capacitor
module manufactured by Wago and can
generate 20 kW of power, or about 8-10%
of the facility’s electricity demand.
The $80,000 price tag was more than
halved by various energy incentives, but
it’s the VP-20 wind turbine’s hydraulic
tip-up capability, along with the internal
CANbus communication, which is converted to Ethernet for remote monitoring, that differentiate it.
And now, Lincoln Electric (www.
lincolnelectric.com) has erected a 443-fttall wind tower at its world headquarters
in Euclid, Ohio.
ANNUAL MAINTENANCE
COSTS RUN ABOUT 5% OF
THE INSTALLATION COST.
The tower project, which was dedicated in late August, is a global endeavor,
with the tower’s can sections coming
from Katana Summit (www.katanasummit.com) in Columbus, Nebraska,
the glass fiber reinforced polymer blades
produced by LM Wind Power (www.
lmwindpower.com) in Poland, and the
Synderdrive synergetic drive train in the
turbine coming from Kenersys (www.
kenersys.com) in Germany.
Even more impressive than the 220
tons of steel that comprise the wind tower is the 2.5 MW of electricity it has the
capability to generate. It can supply up to
10% of the power needed at the Lincoln
Electric campus. The company calls the
wind tower a symbol of its commitment
to the wind tower fabrication industry.
Neither company has immediate
plans to send power back to the grid, but
harvest-your-own energy is growing.
Mike Bacidore, Editor in Chief
mbacidore@putman.net, (630) 467-1300 x444
WWW.PLANTSERVICES.COM OCTOBER 2011 7
PS1110_07_Edit.indd 7
9/26/11 2:29 PM
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PS1110_FPA.indd 8
9/27/11 4:42 PM
cRisis coRneR
Joel leonard
Reliability Rescue
better inventory management frees up training funds
Recently, Mike eisenbise, SMRP past president, of-
fered the simplest way to describe equipment lifecycle. He
calls it, “from lust to rust to dust.” When newly acquired,
buyers have a yearning to have equipment because they’re
in the lust phase. As equipment ages, it begins to rust. And
finally, when it no longer works or dies, it becomes dust.
There’s no more need to explain with statistics or bathtub
charts; that analogy makes it simple enough for even the
newest employee to grasp. And it also can help convince
management that true profitability needs a reliability rescue
if we’re going to have a resurrection of U.S. manufacturing
and avoid a double-dip recession. We need to explain to top
leaders the need to invest in condition monitoring systems
and have an adequate, efficient MRO inventory level.
I interviewed Robert Holmes, marketing director at CribMaster (www.cribmaster.com), to uncover more insight on
what more can be done to fight the maintenance crisis and
provide a reliability rescue by extending equipment life.
JL: From your industry exposure, do you believe that we’re
in fact having a maintenance crisis?
RH: We see a different side of things. Because we make solutions to help with maintenance and indirect material processes, we’re usually highly engaged with forward-thinking
clients who know the importance of continuous improvement and lean processes. With this said, we work with
the maintenance elite, the superstars of the industry. The
interest for our technology has been and continues to be of
great interest to many maintenance and shop-floor professionals with a very small percentage of those people willing
to implement a system. I guess this might be a sign of a crisis
not having the leadership skill to sell projects internally or
to control budgets.
JL: How can strong inventory management and control
systems help mitigate the maintenance crisis?
RH: Inventory management and tool control is critical to
smooth maintenance. Having parts on hand without carrying too much has a positive effect on working capital. Inventory management is critical to any business. From developing lean process flow to reducing inventory cost, inventory
management is critical to a business.
JL: How does spare-parts vending help operations?
RH: Having spare parts on hand greatly reduces downtime
and improves maintenance productivity. Issuing spare parts
in a dispensing device at the point of use or in proximity to
where the work is done drastically reduces the walk-andwait time to and from the tool crib or where the spare parts
typically are stored. Vending also ensures that the right part
tRue pRofitability needs a Reliability
Rescue if we’Re going to have a
ResuRRection of u.s. ManufactuRing
and avoid a double-dip Recession.
is available at the right time, regardless of the shift or the
time of day. Items can be made readily available 24/7 in a
controlled but user-friendly environment. This allows maintenance professionals to focus on the work at hand rather
than doing unproductive activities.
JL: What else can be done to fight the maintenance crisis?
RH: More can be done by building an awareness on the need
to control maintenance costs through an effective inventory
management system. This can be done simply by writing
informative articles such as this one. Maintenance professionals and decision-makers are now more educated on the
benefits of vending. In fact, many maintenance facilities are
requesting a vending solution to manage inventory. It’s no
longer a novelty. The key from this point forward is to help
others understand there’s more to an inventory management
system than just vending. RFID technology combined with
robust software has made tremendous strides in tracking tools, spare parts, and other mobile assets. Dispensing
devices with highly sensitive scales allow maintenance
facilities to track bench stock or bulk inventory accurately
one piece or one fistful at a time. These types of technologies allow the maintenance professional to get the products
needed in the shortest amount of time possible while the
software tracks the critical information.
email contributing editor Joel leonard at joel@skilltv.net.
www.PLANTSERVICES.Com oCTobER 2011 9
PS1110_09_CrisisCorner.indd 9
9/26/11 2:30 PM
Manually verifying every flowmeter
wastes time and money.
I wish I could just tell which ones
need attention.
You CAN Do THAT
Monitor flowmeter integrity dynamically, automatically and on your schedule.
Emerson’s Smart Meter Verification for Micro Motion Coriolis meters is the only automatic
diagnostic tool that checks the entire meter’s performance and integrity — in line. This allows you to trend data,
confirm on-spec performance and forecast calibration needs without interrupting your process. It’s time you had
control of your operation with a clear picture of every flowmeter’s health, go to EmersonProcess.com/Verification
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.
PS1110_FPA.indd 10
9/27/11 4:42 PM
Mr. susTainabiLiTy
paul studebaker, cmrp
The Profession Personified
Let yourself be inspired by issP’s hall of fame inductees
When sustainability professionals from around the
world convened in Portland, Oregon, in September for
ISSP Conference 2011, the inaugural on-the-ground event
of the International Society of Sustainability Professionals
(ISSP, www.sustainabilityprofessionals.org), they spoke of
many things — from measuring water footprints and social
fingerprints to supply chain analysis, the emerging UL 880
standard for manufacturing, and how to gain greater support and understanding of sustainability by governments,
businesses, and, above all, the general population.
“Sustainability” means different things to different people,
and attendees strove to help each other and the association define the terminology, their individual roles, and the
qualifications needed for the wide variety of jobs and careers
related to sustainability.
One of the most inspiring and meaningful events of this
extraordinary conference was the induction of the first five
members of the ISSP Sustainability Hall of Fame. ISSP established its Hall of Fame to formally recognize individuals
who made significant contributions to the field of sustainability and to the professionals who serve it. With the first
five members, the organization has established a benchmark
for the profession: Sustainability Hall of Fame members
personify the range and depth of the profession’s skills,
activities, and potential impacts.
The ISSP board of directors selected the five industry
leaders who most closely met criteria for service, research,
innovation, advancement of the case for sustainability,
participation in the adoption of sustainability in sectors or regions, and contribution to the definition of the
profession. In future years, the ISSP board might choose to
induct any number of people at once into the ISSP Sustainability Hall of Fame, including just one in a given year.
Let me introduce the five founding members of the ISSP
Sustainability Hall of Fame.
Ray Anderson is founder and chairman of carpet manufacturer Interface (www.interfaceglobal.com) and one of
sustainability’s earliest pioneers. After experiencing a “spear
in the chest” epiphany more than 17 years ago, Ray altered
the direction of his petro-intensive company forever. Inspired
by his vision, Mission Zero is Interface’s promise to eliminate
by 2020 any negative effect its companies might have on the
environment. At the conference, Ray’s award was accepted by
his daughter because of his untimely passing in August.
Gil Friend, president and CEO of Natural Logic (www.
natlogic.com), a sustainability strategy firm, has been a central figure in the sustainability movement for 40 years and
has helped establish and expand the sustainability consulting profession during the past 20 years. He’s the author of
“The Truth About Green Business,” which was ranked as a
must-read sustainability book in a recent survey by Triple
Pundit (www.triplepundit.com).
susTainabiLiTy haLL of faMe MeMbers
Personify The range and dePTh of
The Profession’s skiLLs, acTiviTies,
and PoTenTiaL iMPacTs.
Amory B. Lovins, chairman and chief scientist of Rocky
Mountain Institute (www.rmi.org), has been active at the
nexus of energy, resources, security, environment, development, and economy in more than 50 countries for 40 years.
Karl Henrik Robert is a Swedish cancer researcher and
founder of The Natural Step (www.thenaturalstep.org)
framework for sustainable development. In recent years,
he focused his scientific research through the Real Change
Program, an international initiative linking university
research specialization in real world application using The
Natural Step framework.
Bob Willard is an expert on quantifying and selling the
business case for sustainability. He’s a teacher, speaker, and
author whose books include “The Sustainability Advantage,”
“The Next Sustainability Wave,” and “The Sustainability
Champion’s Guidebook.”
As visionaries, activists, writers, teachers and, above
all, doers, these five individuals serve as an inspirational
guide to the history and principles of the sustainability
movement. Whether your role is to guide a global corporation or, at least as important, to cut your facility’s energy
consumption by a few percent, you’ll benefit from exposure
to their lives and works.
“The individuals we have chosen as our founding members for the ISSP Sustainability Hall of Fame are among the
giants in the field of sustainability,” said Marsha Willard,
executive director of ISSP.
www.PLANTSERVICES.Com oCTobER 2011 11
PS1110_11_MrSustain.indd 11
9/27/11 9:44 AM
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PS1110_FPA.indd 12
9/27/11 4:43 PM
wHaT works
move more maTerial
switch to propane translates to maintenance savings and increased productivity
The Chicago-area facility of Marietta (www.mariet-
tacorp.com), manufacturer of hotel amenities and consumer
goods, relies on forklifts for material handling, including
shipping, production, and receiving. Before its forklift lease
was to expire, Logistic Distribution Manager Jesse Gomez
encouraged his team to investigate propane-fueled forklifts.
After an analysis of propane-fueled forklifts, the company
leased 14 propane units from Toyota Material Handling
(www.toyotaforklift.com) and gained improved forklift
performance, space availability, and operating costs. “My
staff is completing more work in fewer hours and everyone is
excited about that,” says Gomez.
HigH performanCe
The forklifts always maintain 100% power and are faster
than electric forklifts, explains Brian Feehan, vice president of the Propane Education & Research Council (www.
propanecouncil.org). “Before 2007, the facility used electric
forklifts, which could run only one shift before requiring a
battery recharge,” says Feehan. “That entailed heavy-lifting
equipment to move the 4,000-lb batteries.”
Propane-fueled forklifts streamline refueling. “Replacing
propane cylinders doesn’t require heavy lifting and is less
time- and labor-intensive than refueling with other technologies,” explains Feehan. “Plus, it takes less time to fill a
propane cylinder than to switch a battery, and less time to
fill or switch a propane cylinder than to charge a battery.”
easy refueling
There’s an established infrastructure for propane. The facility buys it from Atlas Mid-America, which delivers to the
alTernaTive moTor fuel Tax CrediT
available for 2011 forklifT propane use
The Tax Relief, Unemployment Insurance Reauthorization, and Job Creation Act of 2010 passed by
the U.S. Congress in December 2010, extended a
50-cent-per-gallon alternative fuel tax credit through
Dec. 31, 2011, which includes propane. Facility
owners can apply for a tax credit for propane used
in 2011 to fuel forklifts. For further information
about the 50-cent-per-gallon tax credit, visit http://
npga.org/i4a/pages/index.cfm?pageid=1717.
A local propane provider can deliver propane directly to facilities, refill
empty propane cylinders on-site, and then store them outdoors.
plant, refills cylinders on-site, and stores them outdoors.
That opened space on the production floor, which had
been able to run only two production lines per day. Since the
transition, it consistently runs four to five lines per day for
20 hr/day, four days/week. If demand requires, the facility
can run as much as 24 hr/day, seven days/week.
The lease for the propane-fueled forklifts, including required maintenance, was $105,000, about $25,000 less than
the lease for the electric forklifts. Reduced maintenance in
the first three months saved more than $15,000, explains
Gomez. And the facility can lock in six-month propane contract pricing, making propane fuel costs more predictable.
THe fuTure
Gomez points out that Marietta’s facility saves money by no
longer sending dead batteries to a landfill. Eliminating that
allows the facility to be more environmentally focused.
The Propane Education & Research Council was authorized by the U.S. Congress with the 1996 passage of Public
Law 104-284, the Propane Education and Research Act
(PERA). The mission of the Propane Education & Research
Council is to promote the safe, efficient use of odorized propane gas as a preferred energy source through research and
development, training, and safety initiatives.
www.PLANTSERVICES.Com oCTobER 2011 13
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your spaCe
Bear Down on Counterfeits
fake bearings can create safety risks and cause equipment downtime
By randy L. Bowen, sKf usa
true story: a steel mill suspected an unauthorized dealer
had supplied counterfeit bearings. The mill reported that,
after only hours of operation, the maintenance team had
to shut down the machinery, dismount the bearings, and
remount the older bearings. Close inspection concluded that
more than 1,000 bearings were, in fact, fakes.
Counterfeit bearings are everywhere along the supply
chain, and they’re not limited by size or type. While the
perception might be that smaller bearings for automotive or
consumer products are the most prevalent targets, large-size
counterfeits have become common in the industrial aftermarket, especially if the true product is in short supply.
Fake bearings can pose potential safety risks or unplanned and costly equipment downtime. For one petrochemical processor, it took an emergency shutdown to reveal
the counterfeit bearings. Following two days of operation,
bearings failed in a critical application, forcing an unscheduled stoppage. Analysis confirmed the counterfeits, which
were replaced, but not before they had exacted a heavy price
in cost and lost productivity.
Illegal bearing manufacturers have devious techniques to
fool customers, and it’s becoming difficult to distinguish the
real deal from counterfeits. Fake bearings won’t have “fake
bearings” written on them. They won’t be scratched, rusty,
or dirty. They won’t necessarily be less expensive. They appear to be genuine, premium products and are marketed as
such. And they might take several forms.
• Low-quality bearings might have false brand markings.
• Bearings can be remanufactured and sold as new.
• Old, used bearings might be cleaned and polished.
Graphics technologies aid and abet unscrupulous manufacturers, who can produce good copies of product boxes.
The bottom line is that operations might end up purchasing
a product with unpredictable quality for a high price.
Most fakes look so much like the real thing that only a
trained technician can tell them apart. Risks include damage to capital equipment or injury to machine operators
and other plant personnel. When a fake bearing fails, there
might be financial and legal consequences for the buyer.
The bearings also might fail early because of inadequate
or incorrect lubricants or defective lubrication grooves in
the outer raceways. Others might suffer from poor sealing,
non-hardened or poorly ground raceways, or improper cage
designs. Problems might include inappropriate packaging of
the bearing or incorrect storage before use.
How can plant operations across industries protect
against counterfeits? The best protection is sourcing through
authorized distributors or buying directly from the manufacturer. Authorized distributors should be able to produce
documents or signage affirming the manufacturer’s support.
The counterfeit-bearing problem has grown so much that
the World Bearing Assn. (WBA, www.stopfakebearings.
the Best proteCtion is sourCing
through authorizeD DistriButors
or Buying DireCtLy from the
manufaCturer.
com) launched a counterfeit awareness campaign to make
premium-brand customers aware of the risks and problems
with counterfeits. Major manufacturers understand what’s
at stake and are taking steps to combat counterfeiting.
In our case, a full-time, global team is involved in efforts
to stem the tide. Law enforcement authorities make raids
that choke off sources and close the illegal businesses.
Special anti-counterfeit marking has been developed to help
trained personnel spot fakes.
The overall issue of counterfeit bearings should immediately raise a red flag for maintenance personnel. Be aware of
the situation, understand the risks, and establish processes
to verify that a bearing is genuine.
For those who use counterfeit bearings knowingly, the
risks are much greater than any short-term savings they
might realize. They have no redress to the product manufacturer, warranty claims are out the window, and related costs,
liability, and claims must be assumed when the bearings fail.
Using fake bearings on high-value capital machinery
almost certainly affects operating reliability, because they’ll
have been manufactured to inferior quality standards.
The unquestionable conclusion is that, while maintenance
and reliability personnel might not be able to detect readily
whether a bearing is real or fake, the machinery will tell the
story soon enough.
randy L. Bowen is vice president-distributor sales at sKf usa
(www.skfusa.com). email him at randy.l.bowen@skf.com.
www.PLANTSERVICES.Com oCTobER 2011 15
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YOU’RE MOVING 600 PALLETS PER HOUR.
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hysteramericas.com
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2/7/11 10:39 AM
humAn CAPitAL
Tom moriarTy, P.E., CmrP
Let them own the soLution
Give employees the opportunity to succeed when you delegate
sometimes, it seems that getting through the day is
like playing two ends of a ping pong table by yourself. Sure,
you might be able to hit a lob shot and run to the other end
of the table in time to return a volley, but try to hit 10 shots
back and forth consecutively. Unless you’re a cartoon mouse
named Speedy Gonzalez, you’ll probably not be able to do it.
There are countless people working by means of iPhones
from their kids’ soccer practice fields or from their homes at
10:00 at night. Why? Having observed this in many environments, I’d say it boils down to three situations.
First, some people are truly overwhelmed because the organization is grossly understaffed and totally out of control;
they’re simply doing the best that can be done. This might
include as many as 30% of the managers out there. If you’re
in this situation, you’re probably contemplating alternatives;
it might not be a safe working environment, and it probably
has an effect on personal health and home life.
Second, there are the 10% of people who simply thrive on
feeling self-important; they can’t be saved.
The third group is perhaps 60% of the managers; people
who are overwhelmed because they don’t know how not to
be overwhelmed. These people need to be able to manage
their situations better.
The required skills are prioritization, time management,
and delegation. Prioritization is doing what you’re responsible for personally. Time management means not doing the
things for which others can be responsible. Delegation is
transferring responsibility while retaining accountability.
There are hundreds of things that can be prioritized —
moved off of your plate and onto the plate of people who
are closer to the problem. Doing this not only lightens your
daily workload, but, if done right, it also provides an opportunity for your crew to grow professionally, to have a voice
in how things can get done, and to have ownership over the
matters that affect their work environments. It’s what we
consultant-types call a win-win situation.
Many supervisors were promoted to their positions because they were excellent at their former level of responsibility. They know they can do most, if not all, tasks assigned to
their crews or solve any problems their crews experience. As
a supervisor, don’t spend time doing the jobs your crew has
been hired to do. Moreover, when you do your crew’s work,
you take away their opportunities to learn, to gain experience, and to feel valued.
You must get comfortable with the fact that some of your
crew members can’t do the job with your level of quality
or as efficiently as you can. Just remember that you weren’t
born with the skills you have; someone gave you an opportunity to become proficient. This is what you now need to
provide for your crew.
What can you delegate? You can delegate as much as your
crew can handle, but you always will be accountable if they
Just RemembeR thAt you weRen’t
boRn with the skiLLs you hAve;
someone GAve you An oPPoRtunity
to beCome PRofiCient.
screw up. This means you’d better interact with your crew
and understand their capabilities. It requires balance and
sometimes encouragement. Give them some opportunities
slightly beyond what they’ve already demonstrated.
How do you know what people can handle? By listening.
Suppose your organization just implemented a new work
management process. Hundreds of thousands of dollars
have been spent on designing the process and training
people to use the process; even the software was upgraded.
Six weeks into the new process, one of your crew members
walks by and says, “This sucks. The way the scheduler is assigning craftsmen to the jobs is idiotic.” You should immediately think this is an opportunity. If someone is passionate
about the problem, let them take part in the solution. They’ll
see the bigger picture more clearly and bring a customer
perspective to the solution. Allocate time for a focus team to
study and solve the problem.
The supervisor’s job is to let them own the solution. Give
them the information and resources they need to be successful. Let them know what the limits of the outcome will
be and let them work on the solution. If it works, don’t pick
it apart. If they were unsuccessful, it’s because you didn’t
provide them with something they needed to be successful.
Figure out how to do better on the next opportunity, but
keep at it.
tom moriarty, P.e., CmRP, is president of Alidade meR. Contact
him at tjmpe@alidade-mer.com and (321) 773-3356.
www.PLANTSERVICES.Com oCTobER 2011 17
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ReoUiReD
FoR PaS-55
ComPliaNCe.
agile eam.
Senior executives, corporate boards and stock holders need the biggest bang for their buck,
and are already asking about PAS-55, the new standard for asset lifecycle management.
But only the most agile enterprise asset management (EAM) software will let you comply with
this mandate. Only IFS Applications is comprehensive enough for PAS-55 but agile enough to
implement and reconfigure with minimal business disruption. So your energy assets can be
as agile as your thinking.
iFS—FoR agile BUSiNeSS
www.youragilePAS55.com
Plant_services_7_875x10_5.indd
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11-02-15
16.33.09
9/27/11 4:43
PM
MOL-3
aSSeT Manager
david berger, P.eng.
Too Much InforMaTIon
answers to cMMS questions are a click away, but which are accurate and relevant?
Where do you get help if you need information about
which CMMS to buy, getting the most out of an upgrade, or
how many planners you need? Some argue there are more
options than there ever were for finding free information.
After all, the Web, social media, webinars, e-newsletters,
and other offerings give us a range of low-cost, alternatives
when looking for answers. But the explosion of knowledge
readily available through these channels has produced a new
problem. It has become increasingly difficult to:
• find the right information quickly and easily
• determine its accuracy and relevancy
• get the level of detail required
• apply the information to your specific situation.
Is this a matter of “you get what you pay for”? After all,
much of the new media is free after you purchase servers,
Internet service, operating system, browsers, and video
equipment. Let’s look at some old-fashioned ways to seek
advice, as well as emerging trends in knowledge sharing.
InTerneT-baSed Search
Many users turn to a search engine instinctively when they
need solid information. Are you unclear on how a planner
can help with a new CMMS? Key “planner” into the search
engine and voila! Oops, that brought up organizations with
“planner” in their titles, or details on time management
software. What about keying in the “role of a planner”? Alas,
that search provides links to sites that advance your thinking on the planner’s role, but these are wedding planners,
urban planners, and other planners. How about entering
“role of a maintenance planner”? Finally, up come only 1.4
million possible links that might be relevant.
So, you search through articles, advertorials, blogs, discussion boards, scholarly works, white papers, and videos that
don’t seem to quite answer your question, even though they all
provide pieces of the puzzle. You want to know how a planner
can extract more from a CMMS. What do they actually do with
the CMMS? So, you try “role of a maintenance planner in optimizing a CMMS.” This cuts the number of links down to about
110,000. More importantly, references on the first page suggest
you’ve taken the search in the wrong direction.
You see that 45 minutes have passed and you still struggle
with why your lead hand, supervisor, or maintenance manager can’t play the planner role. After all, you run a mine,
which isn’t as complex as those in the search results.
So, you try other searches to pin down an answer, but
time keeps ticking. Sometimes, you get lucky and find a big,
thick, free June 2000 report titled “Why a mine site could
use a planner after purchasing a CMMS — a detailed guide
to justifying and setting up a planning function.” Given its
age, the article might be outdated. There’s no mention of
the sophisticated reliability management tools and mobile
solution that came with your CMMS. Thus, in terms of currency, a dark cloud of doubt hovers over this wonderful find.
Perhaps finding another source can confirm its relevance.
Many uSerS Turn To a Search
engIne InSTIncTIvely When They
need SolId InforMaTIon.
WIkIS and oTher elecTronIc coMMunITIeS
A wiki is a community of sorts with a common purpose,
where users share knowledge on a website set up for that
purpose. The most famous of these is Wikipedia, a user-generated encyclopedia. A wiki might be a source of information, but it has the same inherent problems described above.
A community of interest (COI) is a more general term
that refers to people who share information on a certain
topic. COIs can be face-to-face at a monthly meeting of likeminded people or a trade show with a theme. COIs also are
available online. Some large multinational companies establish their own COIs to share best practices across multiple
plants and business units. COIs also are an excellent forum
for raising a question to invoke discussion among your peers
who probably struggle with the same questions and can help
you through them. That’s why some CMMS vendors build
COIs for customers to help each other solve or avoid problems, exploit opportunities, benchmark, and use the CMMS.
blogS
A blog is a Web-based, frequently updated posting of personal
content, typically written by an individual. A blog can follow
someone’s African vacation or describe the woes of a project
manager struggling to implement a CMMS. In either case,
pictures and links to relevant websites of product and service
companies referenced in the text can be posted. You can post
comments and ask questions of the blogger. Many industry
www.PLANTSERVICES.Com oCTobER 2011 19
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ASSET MANAGER
gurus have blogs, allowing you to get
useful information and even answer or
debate questions.
Many companies monitor online,
and employees should be cautious of
off-the-cuff remarks, such as, “My
manager is such a jerk; he tells me I
should just get the work done, rather
than him paying a planner to tell me
what work to get done.”
#1 IN BEARING ISOlATORS
www.inpro-seal.com
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ILA
AVA
YOUR PARTNER
FOR CUSTOM ENGINEERED
BEARING PROTECTION
When you work with Inpro/Seal, you can be
assured that you’ll receive the responsive,
localized support you deserve – every time.
Our global sales network works alongside
customers, applying years of experience in
rotating equipment to design the right
solution for each unique application.
But it doesn’t end there; you can expect
that level of knowledgeable, personalized
service every time you contact Inpro/Seal.
With an installed base of over
4,000,000 bearing isolators…
you won’t be our only customer,
but you’ll certainly feel like it.
PUSH SYSTEMS
There are pull systems and push systems for information exchange. When
you demand information from your
CMMS or perform an online search,
you’re pulling information. Information such as a newsletter, email
notification, or technical bulletin sent
to you without your specific request
is pushed to you. Because of privacy
restrictions, you might be asked to
sign up for an electronic subscription,
Many push systems can be turned into
pull systems by requesting that any
new entry be emailed to you. Unwanted push media is called “spam.” and
we’ve all experienced our fair share of
this 21st century nuisance.
SOCIAL MEDIA
All the rage are social platforms such
as Facebook, Twitter, LinkedIn, and
YouTube. Companies struggle with
finding useful applications for these
and preventing abuse by employees,
such as personal use or industrial
espionage. Vendors are exploring
how to use it. What if each asset had a
Facebook page? What if you could tie
condition-based monitoring to that
page, and send “tweets” that provided
any critical change in condition status? CMMS vendors are just beginning to integrate such functionality
into their applications.
VENDORS AND CONSULTANTS
One of the best alternatives is to consult with someone trusted and knowledgeable in the area for which you
seek advice. They can sift through the
plethora of information quickly and
apply their knowledge to your specific
situation. But good consultants can
be expensive, and it takes time to find
and contract with a good one.
Email Contributing Editor David Berger,
P.Eng., partner, Western Management
Consultants, at david@wmc.on.ca.
PS1110_19_20_AssetMngr.indd 20
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5 16.33.09
THE WOODHEAD ADVANTAGE
Using Woodhead products makes a
statement. It says that you care about
superior quality, outstanding product selection and dependable performance in harsh
or regular environments.
It demonstrates that you don’t simply want
solutions—you want the right solutions for
the maintenance and repair work that you
do. It shows that you place a high priority
on safety, reliability and performance.
IT’S
TO
YOUR
ADVANTAGE.
WIRING DEVICES
POWER DISTRIBUTION
PORTABLE LIGHTING
TOOL SUPPORT
REELS & GRIPS
ADVANTAGE: WOODHEAD.
www. woodhead.com/ps
MOL-302_PlantSrv1.indd 1
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9/27/11 4:43 PM
Using anything other than Sullair replacement parts is
like forcing a square peg into a round hole.
Sullair compressed air systems consist of highly
engineered components, carefully matched for
capacity and pressure and are designed for total
system integration to achieve maximum performance
and energy efficiency.
Maintaining the system
The dependability of a Sullair system relies on proper
maintenance and quality parts. In fact, all Sullair
service parts are designed for Sullair equipment and
are built to exacting standards.
Sullair components must be routinely inspected and
maintained to ensure that you’ll always get the
productivity your Sullair system was designed to
deliver — at the lowest total life-cycle cost.
Lubricant technology leadership
Sullair pioneered the lubricated rotary screw
compressor and today leads in the development of
long-life and biodegradable lubricants that eliminate
environmental pollution, improve economics, and
maximize performance.
Sullair’s name – inside and out
When replacement parts are needed, use only those
from Sullair. Why? Because they are good enough to
earn the Sullair name. Remember, installing anything
other than a Sullair part in your compressed air
system is like forcing a square peg into a round
hole. Is it worth the risk?
TM
www.sullair.com
Sullair Corporation is a subsidiary of Hamilton Sundstrand Corporation. Hamilton Sundstrand is a subsidiary of United Technologies Corp. (NYSE: UTX)
PS1110_FPA.indd 22
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Technology Toolbox
Sheila Kennedy
non-invasive surgery for equipmenT
ultrasonic, vibration, and pressure analysis can be done without disruption
new non-destructive testing tools abound. Physicsbased ultrasonics, faster vibration analyzers, regulatorycompliant leak detectors, digital pressure sensors, and 360°
optical scanning are among the solutions available.
Automated ultrasonic testing: Portable, phased-array
ultrasound inspections simplify weld integrity testing, crack
detection, corrosion surveys, and other maintenance tasks.
Compared to conventional ultrasonics, the physics-based
phased-array system from Olympus NDT focuses the beam
electronically and can conduct tests at multiple angles
from a single probe. OmniScan MX2, the latest iteration of
Olympus NDT’s OmniScan phased-array unit, has a large
touchscreen to ease navigation and data entry and IP66-level
durability. Its Weld Overlay Wizard and faster data transfer
speed expedite weld inspection setup, testing, and analysis.
“Its features provide superior usability, enhanced by an intuitive touchscreen interface,” says François-Côme Beaupré,
Olympus NDT’s OmniScan product manager. “The result is
reduced training and a big increase in productivity.”
Portable vibration analyzer: Vibration meters and analyzers detect and diagnose machinery problems. Portable tools
such as Ludeca’s lightweight VibXpert II can detect and analyze machine vibrations, bearing conditions, and inspection
data. The device expands on the original VibXpert platform
with a large VGA color screen, a rapid data processor, and
IP65-level durability. Options include recording waveforms
by triggering, time delay, or a combination of the two, and
dynamic balancing clarifies if vibration causes imbalance.
Ray Wonderly, owner of Advanced Maintenance Technologies, remarks: “Speed is important when working with big
routes because it cuts down data collection time. I also was
impressed by its crisp, bright color display and recording
functionality.” Other features he noted are accurate, consistent vibration measurements, light weight, long battery life,
route storage capacity, and access to historical information.
Acoustic leak detection: Portable acoustic emission technology detects leaks, their location, and the leak rate. The
VPAC II digital acoustic leak detector from Mistras Group
quantifies valve leakage in conformance with the EPA’s
Greenhouse Gas Reporting Program. Routes can be preloaded into the device. It stores readings and leak rates for
100 valves. Transferring data to a workstation is done using
VPACwin software and a Bluetooth interface.
“Users save money by identifying through-valve product
loss and by optimizing planned maintenance schedules,
identifying bad actors, and prioritizing repairs,” says Ralph
Genesi, group executive vice president of Mistras Group.
Electronic remote sensor: Non-destructive tools for
measuring flow, pressure, and level simplify tank and vessel
maintenance. Emerson Process Management introduced the
Rosemount 3051S electronic remote sensor (ERS) system for
distillation towers and other tall vessels. The ERS calculates
DP in one of two digitally linked sensors and transmits
porTable acousTic emission
Technology deTecTs leaKs,
Their locaTion, and The leaK raTe.
using a standard HART signal. “We have had no lost production and better on-stream operation since installing electronic remote sensors” says Tim Anderson, I&E reliability
team leader for Chevron Phillips Chemical.
3-D optical metrology: Optical metrology is available for
large-scale equipment, components, and structures. The 3-D
type used in Phase Vision’s Quartz scanners is faster and
provides better data resolution than mechanical and laser
metrology. Millions of points can be measured in seconds,
without clamps or contact. The scanners are suited to large
or complex shapes, as well as flexible and non-flexible surfaces, and are immune to ambient light and shiny surfaces.
A scanner accessory from Phase Vision is the fully
programmable rotary table, which provides the ability to
scan 360° in one pass rather than moving the scanner or
object being scanned. “The table can be programmed to turn
through a set number of degrees between scans, enabling a
complete all-round scan to be taken in just a few minutes,”
says Dave Sanderson, product manager for Phase Vision.
email contributing editor sheila Kennedy, managing director of
additive communications, at sheila@addcomm.com.
reference Web siTes:
www.olympus-ims.com
www.ludeca.com
www.amtvibrationanalysis.com
www.mistrasgroup.com
www2.emersonprocess.com
www.phasevision.com
www.PLANTSERVICES.Com oCTobER 2011 23
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For years, medical professionals
have warned us to treat the cause, not the
symptom. That’s sound advice, whether
it applies to a person or manufacturing
equipment. Industrial plants, however,
must first identify the symptoms so they
can intervene proactively to minimize
downtime, or at least conduct a rootcause analysis when failure occurs.
But where does one find a machine doctor who can work 24/7? The answer probably already exists in your system control
network. Smarter equipment means
smarter diagnostics, so the data’s available,
but how you use it is up to you.
New equipmeNt, New iNFormatioN
The Siemens Industry manufacturing
plant in West Chicago, Illinois, implemented new equipment from Prima
Power as it ramps up new production capabilities, and the new integrated production
system also provides highly useful information. The plant is using data from the
Prima Power software for three main areas,
explains John Hayden, manufacturing
engineering manager, control components
and systems engineering, at the plant. “Our
materials organization is using it in real
time to know exactly how much raw material is available for each type and thickness
of material,” he says (Figure 1). “Manufacturing engineering is using the data for information such as sheet utilization, number
of hits, and punch life. And maintenance
uses it for diagnosing troubleshooting, fault
codes, and downtime.”
Siemens’ West Chicago plant has transitioned from a manually loaded coil steel
shear process, which required significant
setup for each different raw material,
where parts were cut to the right part
length, and then transferred manually to a
shearing station, where they were sheared
to the right width, says Hayden. “These
parts would then be transferred manually
to a turret press, where they were manually
24
OctOber 2011 www.PLANtSerVIceS.cOm
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9/27/11 11:29 AM
From paper making …
Based in Alpharetta, Georgia, Cellu Tissue Holdings, a division of Clearwater Paper (www.clearwaterpaper.com), has
a strategic focus on consumer-oriented, private-label tissue
products. The company’s Interlake facility in St. Catharines, Ontario, has two production lines: the PM2 wet crepe
machine, which primarily manufactures coffee filter base
paper, and the TM3 through-air-dried tissue machine, which
primarily manufactures premium kitchen towels.
At the St. Catharines mill, the HP 2002 quality control
system (QCS) on the No. 2 paper machine was contributing to rising maintenance costs. It was increasingly difficult
to obtain technical support and spare parts for the legacy
system, which was originally installed in 1986. Because of
a lack of Ethernet network connectivity, technicians had to
record data manually. Justification for replacing the outdated
QCS was based on the implementation of a modern monitoring and data collection system that would reduce annual
maintenance expenses.
The St. Catharines mill enlisted Honeywell to provide a
new Da Vinci QCS for its No. 2 paper machine, similar to the
system installed on the sister No. 3 tissue machine in 2006.
The QCS’s application server runs the performance machinedirection (MD) and cross-direction (CD) controls, and it
supports precision platform and measurement sensors. Together, these provide supervisory MD controls, supervisory
CD controls, supervisory color control, process information,
historical trending, statistical analysis, and printed reports.
Track WhaT You need
Siemens Industry
loaded for punching, and then finally unloaded manually and
transferred to a brake press, where they were formed, which
required significant setup for each part,” he explains.
The new automated process has raw material stored in a
cassette that’s called down to the turret press at the time it’s
required and loaded automatically, explains Hayden. “Once
it’s punched, it’s retained in a WIP cassette until the automated brake is ready. The WIP cassette is called down and
loaded automatically, squared, and conveyed into the brake
for forming. Setup time is done automatically, as well as
eliminating the time-consuming manual brake setup.”
The plant also has a preventive maintenance system tool,
Mpulse, that maintains the schedule for each piece of equipment. “As part of our Siemens Starpower factory program,
we also review our maintenance activities and the associated
downtime, on a quarterly basis to identify needed additions
or improvements to the system to eliminate unexpected
downtime,” says Hayden.
Lutz Ehrlich, punching/automation product manager, Prima
Power (www.primapower.com), suggests finding a sustainable
maintenance plan that doesn’t conflict with production planning. “Become proactive in the maintenance and cleanliness of
the complete system,” he says. “Treat the system like an airplane.
Don’t attempt to check the engine gearbox oil at 30,000 ft.”
Figure 1: Data management software tracks available raw material,
production parameters, fault codes, and downtime at Siemens
Industry’s plant in West Chicago, Illinois.
Cellu Tissue’s QCS upgrade allowed for implementing Honeywell’s remote monitoring service, too. Ethernet
network connectivity with Da Vinci QCS allows technicians
located in Honeywell’s Houston office to monitor the mill’s
scanner equipment and diagnose problems. Remote monitoring capabilities range from continuously monitoring process
variable data to pulling trend information and providing
recommendations. Technicians can even take control of the
system remotely, if needed.
Honeywell personnel log into the equipment health
monitoring tools daily via a virtual private network (VPN)
connection between the mill and Honeywell to log alerts,
including low-priority ones, and collect trending data.
Monthly reports, including CD power spectrum (machine
signature), reel report overview, shift production report,
and standardized summary report, assist the St. Catharines facility in addressing improvement opportunities.
Periodic meetings are held to review alerts, trending logs,
and recommendations.
“The Ethernet connectivity of the Experion MX QCS, from
the system servers all the way down to individual scanning
sensors, enables data transfer of process and system health
information to local mill-wide systems, local or corporate
data historians, and Honeywell remote service infrastructure,” explains Ross MacHattie, director of product marketing for pulp and paper at Honeywell Process Solutions (www.
honeywell.com). “Quality data is collected from high-speed
scanning to provide a statistical record of the paper as it is
being made. This can be kept in an historian for process troubleshooting or customer complaint analysis. Remote analysis
of the data can be done by process experts in near-real time
to monitor the process for instability or other problems.”
www.PLANTSERVICES.Com oCTobER 2011 25
PS1110_24_30_CvrFeatr.indd 25
9/27/11 11:29 AM
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Production data is sent to manufacturing execution systems for trim
optimization and as-shipped product
records, explains MacHattie. “System
health information can be used by remote service personnel to keep tabs on
the QCS performance without having
to be in the mill every day,” he says.
“They can even talk to the individual
sensors remotely through Ethernet
connections, which results in better
predictive maintenance.”
During 2009, QCS remote monitoring reduced the Honeywell maintenance contract at the St. Catharines
mill by more than 50%.
… To paper prinTing
The RockTenn (www.rocktenn.com)
printing plant in Jacksonville, Florida,
was experiencing gradually increasing
unreliability of its automation systems.
The systems produced too many false
alarms, and there was no feedback
as to where the problem was and no
diagnostic tools.
“The plant had to test each interlock
physically until it located the fault,”
says Andy Banaczyk, head of maintenance at RockTenn. The programmable logic controllers (PLCs) controlling
the printing plant were obsolete and
too expensive for upgrade with the
26
PS1110_24_30_CvrFeatr.indd 26
original manufacturer, so Banaczyk
decided to replace all of them.
The RockTenn plant prints more
than 900 huge rolls of paper each
month. The press is 14 ft wide and
nearly 150 ft long (Figure 2). It was
built by Cobden Chadwick of England,
a firm now out of business.
Banaczyk began the retrofit project
by replacing some of the original PLCs
with new ones from AutomationDirect (www.automationdirect.com),
but he soon realized he needed help.
He called on W.L. Smith Electronics
(www.wlsmithelectronics.com), which
designed, built, and supplied many
of the control enclosures. Smith also
programmed many of the PLCs that
were installed into various recesses
and enclosures around the press.
After some of the controls had been
changed, Banaczyk wanted to add
inter-PLC communications and data
transfers to allow the PLCs to share
status information. He called on Expert
Automation Design (EAD, www.eandatechnical.com), a systems integrator
whose specialty is upgrading older
automation systems.
Banaczyk didn’t have the original
PLC code and had no way to convert
the old code, so EAD had to rewrite the
control and safety code for each new
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PLC, with the help of AutomationDirect’s DirectSoft programming software.
Banaczyk implemented a voice-broadcast system using the audio capabilities
of the C-more touchscreen. He recorded
many messages tied to specific actions or
operations. When the press starts, three
voice messages are heard in succession:
“Caution — stand back. Hands up.
Starting the press.” If a gate is opened,
the voice announces which gate to alert
operators. If the press won’t start, the
voice announces why and where the
problem lies. Banaczyk can change the
messages or the triggers as needed.
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D2-260 and D0-05 models connected to
C-More touchscreens, all from AutomationDirect. The plant also replaced many
of the pushbuttons, selector switches,
and indicator lights. “We set up a communications system, so that all the
PLCs in the building, with a few minor
exceptions, are linked by an Ethernet
network,” explains Glenn Erickson,
president of EAD. “We can call up any
linked PLC and monitor its status or
make changes to the PLC logic, all from
any of several PCs around the plant.”
The entire system also is tied to a PC
running DirectSoft software, which
allows Internet access from Web browsers. Any authorized person can log in
from anywhere in the world and monitor the system or make changes, which
has resulted in reduced downtime and
service calls, says Banaczyk.
Some PLCs control temperature,
safety systems, and press operations.
Some simply monitor operation. The
PLCs pass and exchange data among
themselves as needed over the network
in a peer-to-peer network configuration
with no PLC as a master, eliminating
the single point of failure. To date, there
are 30 new PLCs with nearly 2,500 corresponding I/O points.
The first project, the updated safety
system, reduced unnecessary stoppages dramatically. “I couldn’t count
the number of stoppages we used to
have,” says Banaczyk. “I just know it
was a nightmare before, and we have
no problems now.” And when the rare
stoppage occurs, the new automation
system announces exactly where the
fault is at the main control panel (Figure 3). With fewer safety system faults,
this item has dropped off the charts as
an area of concern, says Banaczyk.
Is there a doctor In the network?
One advantage of using the controls
network for diagnostic information
is that the network already exists,
and often the diagnostic information
is available on the network, explains
Matthias Hofmann, general manager,
factory automation business, industri-
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al automation systems, at Siemens Industry. “This includes
not only system diagnostics, but also diagnostics from the
production process itself,” he says.
Automation systems with diagnostic information that
can be presented in an actionable way can reduce the time it
takes when unplanned downtime stops a machine, continues Hofmann. “With safety integrated in the automation
system, productivity and machine uptime can be improved,”
he says. “Regarding energy efficiency, an automation system
can measure and collect data on machine or process energy
usage and determine which components can be shed if peak
demands are approaching. This information also can be
used to schedule production to minimize energy usage and
avoid exceeding peak demands.”
An enormous amount of data is available on the control
network, confirms Mike Hannah, manager, networks and
infrastructure, at Rockwell Automation (www.rockwellautomation.com). Getting the data to the right person at the right
time is critical for good decision-making in the machinecontrol environment, says Hannah.
“Data can be sent directly to the HMI, which is typically
where the operator or maintenance personnel would go to
view the information, and it would point them in the correct direction for action,” says Hannah. “It also would be
possible to send SMS or email messages to the appropriate
personnel. Ideally, you want the information to be sent as
quickly as possible to the person responsible for getting the
machines back up and running.”
Connecting the control network and the enterprise network requires protection, says Bobby Thornton, HMI and
communications product engineer at AutomationDirect.
“Data needs to be accessible, but proper VPNs and firewalls
need to be used to protect the process.”
30
PS1110_24_30_CvrFeatr.indd 30
OctOber 2011 www.PLANtSerVIceS.cOm
9/27/11 11:29 AM
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3/1/11 1:38 PM
9/27/11 4:44 PM
reliability / motors and drives
Currents and voltages can take up capacity
by Wolfgang Hilmer, Siemens industry
High voltage and current distortion are the topics of primary focus in the IEEE 519 standard, the most commonly
used standard for limiting the harmonics in the electric industry. For purposes of this discussion, we’ll define harmonics as currents or voltages with frequencies that are integer
multiples of the fundamental power frequency. For example,
the 2nd harmonic of a standard 60-Hz frequency would be
120 Hz, and the 3rd would be 180 Hz. Any equipment using
semiconductor switching devices (UPS systems, computers, and variable speed drives) produce harmonic currents.
These harmonic currents produce no real work, but they
take up capacity by inducing heat throughout the electri-
cal distribution system. Harmonics increase operating cost
through extra heating in transformers, motors, and wiring,
and by increasing the air conditioning requirements to
remove heat. The higher the harmonic distortion, the more
problems, simply put. Harmonic mitigation is a key factor in
controlling facility electrical operating costs today and will
be for the foreseeable future.
IEEE 519 limits the total harmonic demand distortion
(THDD) and voltage distortion (THVD) at the point of
common coupling (PCC). The VFD input current distortion
(THID) doesn’t necessarily need to be less than 5% to meet
IEEE 519 at the PCC (Figure 1).
HarMONiC liMitS
isc/iLoad
supply impedance
<11
11<h<17
17<h<23
23<h<35
35<h
tHdd
< 20
>5%
4.0
2.0
1.5
0.6
0.3
5%
20 < 50
5% to 2%
7.0
3.5
2.5
1.0
0.5
8%
> 50
<2%
10.0
4.5
4.0
1.5
0.7
12 %
Figure 1. ieee 519 limits the total demand distortion, in percent of maximum demand load, at the point of common coupling.
www.PLANTSERVICES.Com oCTobER 2011 33
PS1110_33_37_MotorsFeatr.indd 33
9/27/11 11:35 AM
RELIABILITY / MOTORS AND DRIVES
STANDARD SIX-PULSE DRIVE
18-PULSE DRIVE
ACTIVE FRONT END
Figure 2. The input line reactor reduces
line-side harmonics by a limited amount.
Figure 3. The THID for the 18-pulse drive
typically is 5%.
Figure 4. The fully regenerative drive can
feed braking power back to the supply.
Especially in large power distribution systems and installations, in which
the variable frequency drive (VFD)
isn’t the main load, six-pulse drives
can meet IEEE 519 at the PCC, though
sometimes harmonic mitigation is
necessary. A range of solutions is available for this purpose, including passive
and active harmonic filters, typically
connected upstream of the VFD, plus
drive topologies including multi-pulse
rectifiers and active front ends.
On a typical drive, the motor-side
inverter controls the motor, the DC
link capacitor serves as the voltage
source, and the front end charges the
DC link. On the standard six-pulse
drive, the input line reactor reduces
line-side harmonics by only a limited
amount, while the higher impedance
results in lower harmonics (Figure
2). The THID at the input terminals
typically is in the 40% range. Let’s now
take a look at three types of newer,
low-harmonic, VFDs:
• 18-pulse VFD
• active front-end VFD
• six-pulse VFD with integral harmonic fi lter.
The 18-pulse VFD is a robust design
with a good track record and typically is found in municipal water and
waste processing facilities. The typical
18-pulse VFD has a phase-shift ing autotransformer with nine-phase output
and a high-impedance line reactor. It
also includes an 18-pulse rectifier — 3
x 6-pulse (Figure 3). The THID for
such a drive typically is 5%, but some
manufacturers supply a configuration
that achieves a THID of 8%.
For true 18-pulse performance, the
transformer secondary voltages and
impedances must be identical, while
the secondary phase shift must be
perfect. If the line supply is connected
directly to a single six-pulse bridge,
but uses a phase-shifting transformer
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LHF IN CAD
Figure 5. The line-harmonic-filter design features a reactor with zig-zag windings.
for the other two, the impedance imbalance results in a greater THID.
The VFD with an active front end is
fully regenerative, meaning it can feed
braking power back into the supply
system. It has low harmonic distor-
tion, usually less than 3% THID, operates easily on a weaker power supply
having voltage and frequency dips and
sags, plus its control of reactive power
can even assist in stabilizing a weaker
power supply.
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Th is type of VFD has a line-side
IGBT converter/rectifier and clean
power fi lter (Figure 4). A line-side
rectifier of at least the same current
rating as the motor-side inverter
provides a controllable power factor
of 0.8 lead to 0.8 lag. With a smaller
rectifier, the unit can operate at unity
PF. The active front end, by defi nition, is inherently regenerative and
can feed power back into the supply
system when the motor is braking.
The six-pulse VFD with integral
harmonic fi lter is a standard six-pulse
drive with the addition of a line harmonic fi lter integrated into the drive
lineup. This configuration provides
benefits such as a single enclosure and
protection by the drive circuit breaker
and fuses. The short-circuit current
rating applies to the complete enclosed
drive unit, and there’s no need for
external protection upstream of the
fi lter. Nor will you need extra power or
Reliability, durability and longevity are properties
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9/27/11 11:35 AM
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9/27/11 1:49
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PM
8/24/11
relIabIlIty / motors and drives
Head to Head
6-Pulse With
Integral LHF
18-Pulse
Active Front End
all non-regenerative applications (can have
braking unit
and resistor)
all regenerative
industrial applications. non-regenerative applications with special
requirements
all non-regenerative applications (can have
braking unit
& resistor)
all power
systems, also
weak ones
all power systems,
also weak ones
normal supply
systems. Check
details on weak
supply systems
(isC/iL<20)
Generator supplies, including
small emergency
generators
Generator supplies, including
small emergency
generators
Generator supplies, check
details on small
generators
rated < 3-4x
drive rating
• Highest cost
• Largest
• Always meets
footprint
ieee 519
and weight
• Offers unique
• Almost
features for
always meets
stable operation
ieee 519
also on very poor
• Robust &
supply systems
proven solution
•
•
•
•
Least cost
Most compact
Lowest weight
Meets IEEE
519 in most
applications
on regular
supply systems
table 1. Compare options before selecting a drive.
control cabling for overload or temperature protection.
The new line-harmonic-filter (LHF) design features a reactor with zig-zag windings (windings from three phases on a
common core) to provide some degree of harmonic cancellation. The reactor is combined with a small capacitor bank
that results in a compact design, about 16 in. wide for 150 to
400 hp and 24 in. for 500 hp to 800 hp. The THID is approximately 8%, while the PF is unity at full load, capacitive at
partial loads, which might present a difficulty on a weak supply network or with small backup generators less than three
or four times the drive rating. The harmonic limits might be
exceeded with weak supply systems (Figure 5).
In addition to the compact design, these VFD units typically have a lower cost and higher efficiency and are suitable
for safe operation on generator supplies, provided the total
drive load is around 25% to 30% of the generator rating, for
example, on remote applications.
Finally, for direct comparisons, see Table 1.
Wolfgang Hilmer is product manager, motion control business, at
Siemens Industry. Contact him at wolfgang.hilmer@siemens.com.
PS1110_33_37_MotorsFeatr.indd 37
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PERFORMANCE / PUMPS
This is the conclusion of a series of articles based on Hydraulic
Institute’s comprehensive e-learning course, “Positive Displacement Pumps: Fundamentals, Design and Applications.”
for continued advances. Electronics and robotics provide a
significant improvement in the pump’s self-contained flow
management resulting in automatic capacity correction
that’s available and will be further enhanced in the future.
Robert Sheen invented the first pump that
During the past 75 years, there has been
began this branch of the pump family tree. The
more technological advancement related to
By Hydraulic Institute
core of his invention was a method of controlmetering pumps than any other type. Almost
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ling volumetric flow that was actually part of
all of this development has been more focused
the pump itself. It wasn’t dependent on a bypass valve after
on producing a controlled limitation of flow than it has
the discharge or pump speed changes by replacing belts
on improvements in flow inducement. As true controlledand pulleys or even motors. It wasn’t dependent on changvolume metering pumps enter the 21st Century, this minor
ing pump size to limit the amount of chemical dosed to a
branch of the pump family tree will rely on a new platform
APPLICATION SCOPE
Figure 1. The standard array of metering pumps offers a variety of performance and mechanical characteristics.
WWW.PLANTSERVICES.COM OCTOBER 2011 39
PS1110_39_42_PumpsFeatr.indd 39
9/27/11 3:53 PM
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PERFORMANCE / PUMPS
specific application of boiler feed or
cooling tower chemicals and not dependent upon diluting the chemicals
to match the pump’s application rate.
His invention was a means to control
the pump’s output while maintaining
consistent, repeatable flow accuracy
over time. It was a labor-saving device.
The terms “metering pump” and
“dosing pump” have evolved as
popular synonyms. It’s important to
recognize that accuracy is a critical,
value-added element of controlledvolume metering pumps. Different
technologies are used for capacity
control and different pump head arrangements evolved to meet applications for dosing pumps.
Controlled-volume pumps are available in numerous versions and styles,
having entered the market during the
past seven decades. The configuration
variety is primarily the result of the
many industries with specific needs
for sustainable accuracy in chemical
dosing. Accuracy on three levels has
become the primary benefit of this
pump type in the delivery of additives to automated processes, as well
as those with the simple mission of
maintaining accurate constant flow.
Metering pumps fi ll essentially this
same set of process-critical needs in
every industrial niche.
Process pressures can range from
atmospheric to 50,000 psig (3,500 Bar).
Pump capacities per head vary from 10
ml/hr to 5,000 gal/hr. Several types of
metering pumps have evolved to best
suit each application. Drives, control
methods, and liquid-end combinations
have been designed to handle the full
scope of applications (Figure 1).
Unlike other pumps, cost of ownership usually isn’t heavily influenced by
power consumption and repair costs.
A more likely case for savings often
can be made from high-level accuracy
in the cost of chemicals metered or
quality of a final product. These factors
first drive the decision to the family
of controlled-volume metering pumps
and then to the appropriate model and
version. Since the invention of these
pumps, the value of such technology
can be found in the confidence that an
operator has in the pump delivering
liquid at the precise desired rate.
While metering pumps are an easy
choice for the original invention’s intent,
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PS1110_39_42_PumpsFeatr.indd 40
Figure 2. The earliest metering pumps were driven by electric motors.
40
OCTOBER 2011 WWW.PLANTSERVICES.COM
9/27/11 3:53 PM
ROTARY MOTION TO FLOW
Figure 3. Contemporary metering pump
flow can be adjusted from outside the
pump body.
factors such as steady-state accuracy, repeatability, and linearity represent even
greater value in the majority of applications. Controlled-volume accuracy gives
the confidence one can dispense the
desired amount of liquid over extended
periods of time. Many processes require
pump discharge capacity to be varied by
as much as 1,000-to-1.
While convenience of flow rate
adjustment might cause an engineer
to consider variable-capacity pump
systems, the value of doing so diminishes if one can’t depend on the pump
to meter the chemical at the predetermined settings repeatedly. The costs
of compensating for variable-capacity
pumps that have low accuracy can be
extremely high in the form of extra
components or in poor quality results
from the process.
Controlled-volume pumps are
almost immune to changes in the system conditions, and the newest metering pump technologies automatically
adjust to maintain the set point, even
when the discharge pressure changes.
Nearly every innovation makes it
easier to set the desired discharge
rate with minimum effort. There’s no
need to calculate the capacity change
caused by stroke-length change.
The first controlled-volume metering pumps had an electric motor with
a belt and pulley drive. The commonly
used drive types still include standard
AC motors (Figure 2).
PS1110_39_42_PumpsFeatr.indd 41
Solenoid drive systems are probably
the most popular because of competitive pricing. AC and DC variable
speed motors are used in conjunction
with stroke length control in some
types. Pneumatic and hydraulic power
sources are found in specialty applications. Advanced electric motors, such
as stepper motors, taken from the
robotic industry, eliminate the need
for stroke length control, simplifying
setup and operation.
The capacity in the original metering pump was changed by adjusting
piston stroke length from outside
the pump (Figure 3). But its adjust-
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The hydraulic insTiTuTe
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belong to HI, and engineering consulting firms affiliate as “standards partners.” For more information about the Hydraulic Institute,
its member companies and standards partners visit www.pumps.
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Along with e-learning courses, HI also offers ANsI/HI Web-based
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One of the most widespread trends covered in the course, metering pumps, is the subject of the fifth module, a fact-filled, basic
training. It takes a student from the very clear points of what distinguishes a pump as a controlled-volume metering pump to how the
evolution of this branch of pumps is fulfilling the inventor’s vision that
these pumps were always more akin to instruments than pumps.
During this e-learning course, participants will be introduced to the versions and forms of pumps that actually have sustainable, accurate capacity control inherent to the pumps themselves, thus distinguishable from
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PS1110_39_42_PumpsFeatr.indd 42
ment via an internal, oil-bathed gear
system was introduced 30 years after
the first metering pump. This drive
type is readily available today.
The choice of drive system is
important as it relates to durability,
accuracy, automation levels, maintenance availability, and cost.
From the simplest timed triggering of a solenoid to electric motor versions as depicted above, all
incorporate some capacity change.
While speed initially was a secondary control method that extended
the turndown ratios from the 2-to-1
or 3-to-1 limits to 10-to-1, speed was
seen as a preferred capacity control
in some applications. Speed brought
accuracy problems.
42
Many controlled-volume pumps
today incorporate both stroke length
and stroke frequency/speed adjustments to provide as much as 100-to-1
capacity variation. Electronics, however, enable both wider speed variation
and extreme accuracy to the point of
eliminating the need to vary the stroke
length and avoiding the hydraulic difficulties inherent to running pumps at
less than full stroke length.
Matching of the correct liquid end
to the correct drive mechanism is how
this class of pumps delivers peace of
mind to operators who need precise
liquid delivery, from the original
packed-plunger heads to diaphragmliquid ends that incorporate sensors to
monitor operation and accuracy.
OctOber 2011 www.PLANtSerVIceS.cOm
9/27/11 3:53 PM
tHe biG piCture
Bill WeBer, dupont
Global CompetenCe, loCal operations
High-performance work system integrates maintenance, engineering, and operations
now in his 30th year with DuPont, Bill Weber is overseeing startup of the company’s newest production facility in
Cooper River, South Carolina. This $500 million plant will
produce 25% of the company’s Kevlar portfolio, the largest product line in its Protection Technologies business, of
which Weber is vice president. He recently spoke with Plant
Services about maintenance and reliability in a new facility
with global resources.
PS: How do you manage the maintenance and reliability of
so many varied physical assets across North America, not
to mention globally?
BW: We have a wide variety of physical assets. Many of
them are high hazard. We understand hazards and come up
with the right designs and procedures to try to make sure
we address them after doing the right kind of process hazard
analysis. To build, operate, and maintain — those are global
functional capabilities. Whether it’s project engineering or
predictive maintenance, there’s a level of functional training
to ensure we’re leading-edge. We have a small percentage of
the total workforce in our Global Competency Center who
might be deployed in those functions. We want to ensure
we’re standardizing across best practices. The majority of the
work that gets done will be done at the given plant site.
PS: What is DuPont’s strategy for maintenance as a core
competency of the organization?
BW: It starts with trying to understand the degree of importance and uniqueness of the given skill set for that maintenance activity. Predictive maintenance involves sophisticated,
next-generation tools to do it, so our Global Competency
Center scans for those advances. We can deploy for all sites
from our core group. If it becomes so standardized that it’s
easy to contract on a variable basis, we will consider outsourcing it. If it’s something that requires a special skill, we’ll bring
it in-house. Our global headquarters is in Bloomington, Delaware. There will be similar groups that act as hubs in other
geographic areas. For example, there are high hazards in the
area of metallurgy. We’ll have a core group of those specialists
helping in preventive maintenance and in troubleshooting.
The Global Competency Center isn’t a physical building. It’s
more of a human network.
PS: How is DuPont recruiting and hiring individuals with
the necessary skills to fill positions at Cooper River?
BW: A key part of hiring is using progressive approaches
to be sure we brought people into that operation who can
realize what we call a high-performance work system.
It includes planning and execution of maintenance and
operations. We brought the people in many months before
the facility started up. There were layers of training and
tHink beyond maintenanCe and
address tHinGs in a Continuous
improvement approaCH.
orientation. In the high-performance work system environment, you actually think beyond maintenance and address
things in a continuous improvement approach. It’s flipping
180° and saying you’re on the front line and thinking about
the next predictive step. It starts with bringing in the right
people, and then it builds with attitude, and it’s supplemented by never-ending expectations and never-ending training.
It starts with team-based behaviors. Operator-based maintenance is an expectation out of that. Predictive maintenance
is a journey, so it’s layered in with the group.
PS: How does DuPont address the relationship between
its manufacturing technical organization and the maintenance organization?
BW: We like to think we’re getting better at this every
decade. The manufacturing technical organization and the
maintenance organization and the operations organization
all report to the same person. We try to be sure they view
themselves as codependent. If you look at DuPont, versus
our peers, we’re a fairly conservative company. We make
some of the highest hazard products in the world. We’re
used to dealing with risk management. I’m always trying to
balance things as a general manager. In this plant, there was
a lot of forethought given to things like redundant sensors
and critical parts on-hand, so a fair amount of engineering
was put in place from the start. If our plants are going to pay
off, we require extraordinary uptime.
www.PLANTSERVICES.Com oCTobER 2011 43
PS1110_43_BigPicture.indd 43
9/27/11 9:40 AM
proDuct rounDup
tough enough to hanDle FluiDS
pumps, switches, valves, nozzles, and flowmeters are ready for liquid launch
Standards for the pump industry typically come from
the American National Standards Institute (ANSI, www.
ansi.org) and the Hydraulic Institute (HI, www.pumps.org),
which has been developing and updating standards for almost 100 years. In February, HI updated the 2004 edition of
the ANSI/HI standard on viscosity correction and published
the Effects of Liquid Viscosity on Rotodynamic (Centrifugal
and Vertical) Pump Performance ANSI/HI 9.6.7-2010. It
also updated the 2004 edition of the ANSI/HI standard on
air-operated pumps and published Air-Operated Pumps
ANSI/HI 10.1-10.5-2010.
HI released a new standard and updated another in September 2011.
First, the Centrifugal Pump Test Standard (ANSI/HI 1.6
— 2000) and the Vertical Pump Test Standard (ANSI/HI 2.6
— 2000) were superseded by the newly released Standard for
Rotodynamic Pumps for Hydraulic Performance Acceptance Tests, (ANSI/HI 14.6 − 2011). The new test standard
contains significant updates from the 2000 versions is are
considered the new global reference for testing centrifugal
and vertical pumps.
ANSI/HI 14.6 − 2011 includes six acceptance grades
instead of two that were included in the 2000 versions.
Tolerance bands have been developed that will be of interest to those concerned with energy efficiency. Acceptance
grades with bilateral tolerances and acceptance grades with
unilateral tolerances are defined. Default acceptance grades
based on the purchaser’s application are available to guide
the pump community. The standard also contains tolerances
for pumps with low-horsepower input.
The standard features an updated layout of the test arrangement and appendices containing information regarding measuring equipment, string tests, and discrete test
variables. New graphics and content provide readers with
insight into NPSH testing. In addition, it contains special
test techniques related to model testing to predict performance of pumps too large to test by conventional means.
The Applied Nozzleloads Standard (ANSI/HI 9.6.2 − 2011)
was updated by HI. The new applied nozzle loads standard
includes recommendations for assessment of applied nozzle
loads for horizontal end suction single-stage pumps (ANSI/
ASME B73.1, B73.3, and B73.5M), vertical in-line singlestage pumps (ANSI/ASME B73.2), axial split-case single and
two-stage pumps, and vertical turbine short set pumps.
44
ValVeleSS pumpS
These valveless, ceramic pumps are
engineered for pilot plant fluid control.
The internal components are designed to
eliminate accuracy drift typical of pumping
systems that rely on elastomers (flexible tubing and diaphragms) to move fluid through
the pump. The valveless rotating and
reciprocating piston design is engineered to eliminate the need
for check valves. Flow rates can be controlled mechanically or
electronically via standard industrial control protocols.
Fluid metering
(800) 223-3388 / www.fmipump.com
pump protection Flow Switch
The FlexSwitch FLT Pump Protection Flow Switch is designed
to add an extra margin of safety. It monitors the flow and
temperature of the process stream and indicates flow and
temperature, or level. A single switch monitors both variables simultaneously. Dual 6A relay outputs are standard and
are assignable to flow, level, or
temperature. It is pressure tested
to 3,500 psig at 70 °F. The maximum service is 2,350 psig at 500
°F. Higher ratings are available.
Agency approvals include FM,
ATEX, CSA, CRN, and CE.
Fluid components
(800) 854-1993 / www.fluidcomponents.com
cake pumpS
The Seepex BTH cake pump design allows flow rates up to
220 gpm at differential pressures of 540 psi. An auger pushes
the cake into the pumping element. The pitch, diameter,
and speed of the auger can be adjusted to match
the application. A customizable open hopper
and system controls are engineered for a
non-intrusive cake pump solution. The
control panel is designed to control
dry running protection sensors,
load cell sensors, pressure gauge,
and boundary layer injection.
Seepex
(937) 864-7150 / www.seepex.com
OctOber 2011 www.PLANtSerVIceS.cOm
PS1110_44_47_Roundup.indd 44
9/28/11 10:24 AM
SubmerSible SolidShandling pumpS
The Infinity submersible solids-handling pumps are available in 3-, 4-, 6-,
and 8-in. flanged discharge sizes and
horsepower ranging from 2 hp to 75
hp. These combinations can provide
flows to 3,100 gpm and heads to 190 ft.
They use NEMA Premium Efficiency
motors and pass a 3-in. spherical solid.
The finned motor housing is designed
for optimal heat dissipation. Pumps
are available with channel or vortex
impellers. The line of submersible
solids-handling pumps is available in
slide rail, construction/trash, and dry
pit versions.
gorman-rupp
(419) 755-1011 / www.grpumps.com
double-diaphragm pump
The Model 2500 electric-powered,
self-priming, double diaphragm
plastic pump is rated for 25 gpm and
can pass solids to 1 in. Self-contained,
it has a push-button start/stop and a
programmable variable-speed drive.
One piston drives both pumps, each
with its own check valves. It runs on
single- and three-phase and can be
operated remotely or integrated into
a process system. It has a PVC body,
polypropylene wetted parts, and the
two diaphragms can be reconfigured
to operate independently.
edson
(508) 995-9711 / www.edsonpumps.com
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PS1110_44_47_Roundup.indd 45
9/28/11 10:24 AM
produCt roundup
Centrifugal pump
level sWitCh
These Flojet magnetically coupled centrifugal
pumps are designed
for reliability, leak-free
transfer, and purity of
the medium. The drive includes
a motor driving a set of magnets
engineered to eliminate the need for
motor shaft seals. The temperature barrier between the motor and the media reduces heat transfer to the media. The
polypropylene and Ryton housings and ceramic spindles are
designed for chemical resistance. Models are available with
flow rates from 4.6 gpm to 14.5 gpm, and with motors in AC
and DC voltages.
The Series FSW2 Free-Floating Level Switch is
a mercury-free self-counter-weighted floating
switch. The polypropylene body has a double
airtight chamber with high-pressure melted
polypropylene re-injection sealing. Cable
hangers are available to suit a variety of
mounting applications. The position of
the float changes, depending on the liquid
level, determining the microswitch position,
which in turn controls pump operation.
itt
(914) 641-2000 / www.itt.com
sealed drive train
The 2000 CC pump is designed for industrial applications
where close-coupled configurations are preferred, but the
robustness of a gear-joint drive is needed. This pump features a sealed gear-type
universal joint drive train
and rotor/stator pumping element geometry.
It’s designed to transfer
abrasive, high-solids
content materials. The
pump handles radial and
thrust loads. Rotor/stator pumping elements are engineered
to require less energy consumption and reduce the potential
for plugging and downtime.
dwyer instruments
(800) 872-9141 / www.dwyer-inst.com
pump monitoring
The Pump Health Monitoring solution is designed to detect and predict problems, including cavitation, excessive
temperature, vibration,
process leakage, seal pot
level, and differential
pressure imbalance.
The instruments are
engineered to monitor
continuously. An asset
management interface
gives maintenance technicians, operators, and
managers a view of all
conditions, with alerts for situations requiring attention.
emerson process management
(800) 999-9307 / www.emersonprocess.com
valve interloCks
The 605 series of water jet pump units can
convert to a variety of operating
pressures. The range has been
expanded to include
eight operating
pressures from
4,000 psi to
40,000 psi (275
bar to 2,800 bar),
with engines to 600 hp (447 kW). Diesel and electric models
are available. They offer flows as low as 20 gpm (83 lpm).
These mechanical valve
interlocks are operated with
color-coded keys, which control
the valve position and communicate its state. When the
green key is released, the valve
is locked in the open position.
For the red key to be released,
the valve must be locked in the
closed position. If a valve is left
in a midway position between
open and closed, both keys are
trapped in the device. The interlocks need no electronic wiring. They are designed for retrofitting older installations. All
components are made of 316 stainless steel.
nlB
(248) 624-5555 / www.nlbcorp.com
netherlocks
(713) 681-1792 / www.netherlocks.com
moyno
(877) 486-6966 / www.moyno.com
Water jet pump
46
OctOber 2011 www.PLANtSerVIceS.cOm
PS1110_44_47_Roundup.indd 46
9/28/11 10:24 AM
Atomizing nozzle
UltrAsoniC Flowmeter
The XAER air atomizing nozzle
enables spraying of viscous
fluids at fine atomization and
low flow rates. The spray nozzle
provides a full cone round pattern
engineered for liquids with a high
viscosity (100+ cP). Atomization
takes place outside the nozzle, so the flow rate is independent of air pressure. It is available for ⅛-in. and ¼-in. pipe
sizes and can be specified in a choice of standard materials,
including nickel-plated brass, 303 or 316 stainless steel.
The Optisonic 6400 portable ultrasonic flowmeter measures flow velocity, current volumetric flow, and a variety
of diagnostic values. The device stores readings in the
integrated memory for data logging. It has an evaluation
unit and one or
two rails, each
equipped with
two ultrasonic
sensors. The rails
accommodate
different tube
diameters from ½
in. to 160 in. The
rail attaches to
the pipe using belts or steel straps. A second rail is used
for dual measurements on the same pipe or measurements on a second pipe.
Bete Fog nozzle
(413) 772-0846 / www.bete.com
metAl-seAt BAll vAlves
The M-series valves are engineered to withstand a temperature
range of -20 °F to 661 °F, pressures to ANSI Class 600, and abrasive materials in pipe size from 0.5 to 8.0 in. Ball and seat materials include stainless steel, stellite welded, and hard chromeplated steel. Other coatings are available. An Inconel seat spring
maintains contact between the ball and seat. Connections are
flanged, threaded, socket weld, or butt
weld, and body material options include WCB, CF8 and
CF8M. A uni-directional
shutoff is standard,
with a bi-directional shutoff available.
A-t Controls
(513) 247-5465 /
www.a-tcontrols.com
Coriolis Flowmeter
The Cubemass Coriolis flowmeter
measures mass flow, volumetric
flow, temperature, and density, and
communicates to controllers via
pulse, frequency, 4-20 mA current
with HART, and Modbus RS485.
Available in pipe sizes from 1/24
in. to ¼ in. (DIN 1 to DIN 6), it
measures flow from a few drops
to 2,200 lb/hr with mass flow
accuracy of 0.10% of reading, and
repeatability of 0.05% for liquids. It measures liquid density
with accuracy to 0.001 g/cc with repeatability of 0.0005 g/cc. It
withstands pressures to 5,800 psi and temperatures to 392 °F.
endress+Hauser
(317) 535-1329 / www.us.endress.com
Krohne
(800) 356-9464 / www.krohne.com
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9/28/11 10:24 AM
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Fax: (630) 467-1120
e-mail: mconnaughton@putman.net
POLLY DICKSON,
INSIDE SALES MANAGER
Classifieds
Phone: (630) 467-1300, ext.396
Fax: (630) 364-4175
e-mail: pdickson@putman.net
NORM KLIEMAN,
INSIDE SALES MANAGER
Digital Sales
Phone: (630) 467-1300, ext.344
Fax: (630) 467-1120
e-mail: nklieman@putman.net
SUBSCRIPTION INFORMATION
(888) 644-1803 or (847) 5597360
REPRINTS
JILL KALETHA
Reprints Marketing Manager
Foster Reprints
(866) 879-9144 ext.168
jillk@fosterprinting.com
PUTMAN MEDIA, INC.
555 W. Pierce Rd., Ste. 301,
Itasca, IL 60143
Phone: (630) 467-1300,
Fax: (630) 467-1120
Course Includes:
Complimentary Best Practices Manual ($125 value) and discounts
are available for sponsor organizations.
ADVERTISER INDEX
Course Dates
Agilent Technologies . . . . . . . . 31
Inpro/Seal . . . . . . . . . . . . . . . 20
(Four 2-hour sessions)
Allied Electronics . . . . . . . . . . . 38
Kaeser Compressors . . . . . . . . 52
American Trainco . . . . . . . . . . 47
Lubriplate Lubricants . . . . . . . . . 8
Aramark Uniform Services . . . . 29
Ludeca . . . . . . . . . . . . . . . . . . 26
Atlas Copco Compressors . . . . . 6
Lutz Pumps . . . . . . . . . . . . . . . 37
AutomationDirect.com . . . . . . . . 2
Micro Motion . . . . . . . . . . . . . . 10
Azima . . . . . . . . . . . . . . . . . . . 51
Molex/Woodhead . . . . . . . . . . . 21
Baker Instrument Company . . . 35
Noren Products . . . . . . . . . . . . 37
Baldor Electric Co. . . . . . . . . . . 12
Opto 22 . . . . . . . . . . . . . . . . . . 4
Clayton Industries . . . . . . . . . . 42
Productivity Press . . . . . . . . . . 45
Compressed Air Challenge . . . . 48
Robinson Fans . . . . . . . . . . . . . 14
Diamond Chain . . . . . . . . . . . . 34
SPX Flow Technology . . . . . . . . 30
EXAIR . . . . . . . . . . . . . . . . . . . 3
Sullair Corporation . . . . . . . . . . 22
Flir Commercial Systems . . . . . 36
Summit Industrial Products . . . 40
Gorman-Rupp . . . . . . . . . . . . . 41
Testo . . . . . . . . . . . . . . . . . . . . 27
Hyster Company . . . . . . . . . . . 16
U.S. Tsubaki . . . . . . . . . . . . . . 28
IFS North America . . . . . . . . . 18
Xcel Energy . . . . . . . . . . . . . . . 32
Nov 9
Nov 16
Nov 30
Dec 7
Look for future courses coming soon!
Seats are limited so register now!
Visit the on-line registration today:
www.compressedairchallenge.org/ps
or email us at info@compressedairchallenge.org
Need help improving your air system and can’t make
our course? Try our Best Practices for Compressed Air
Systems Manual. This 325-page manual is available at
our bookstore.
The Compressed Air Challenge is a partner
of the U.S. Department of Energy
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9/28/11 10:28 AM
energy expert
peter garforth
Loading order and baLanced energy
Listen to more than energy sound bites
affordable, reliable, and clean energy services are the
goal of communities and utilities around the world. Achieving a balance between these conflicting targets is challenging and complex. It requires the clear understanding that
competitive energy services are the result of an interconnected system in which policy, business, and technical choices
interact all the way from fuel and supply options to final decisions over energy-consuming equipment. To be frank, this is
a statement of the obvious. But, if it’s so obvious, why do we
tHe energy cHaLLenges of tHe next
decades are HigHLy interconnected
and far from simpLe.
so often fail to take a systemic approach and resort to onedimensional sound bites and single-issue decision making?
This interconnectedness was brought home to me in a
recent analysis for a community energy plan looking at electric vehicles (EVs). Using the assumption that 7% of vehicles
would be electric by 2030, the easy part was to evaluate
the effect on the city’s carbon footprint. The passionate EV
enthusiast would compare a gasoline vehicle with an EV and
come to the obvious answer that the EV gave a net reduction in greenhouse gas emissions. When viewed systemically
for this community, the emissions aspect was found to be
neutral, even with changes in the local electricity supply
to much lower emissions levels. The details of this example
aren’t important. What’s important is that the obvious
answer failed to meet the larger energy goal. This is so often
the case. From a systemic viewpoint, Energy Star refrigerators in the kitchen or efficient motors in a factory might not
be optimal if the power is coming from a 50-year-old plant.
The picture is further complicated by time. Energy-consuming and energy-supply infrastructures stay around for
decades. Depending on the assumptions used for legislation,
costs, and technology, almost any investment can be justified
when viewed alone. When viewed as part of a community-wide
system aimed at cost, reliability, and environmental breakthroughs, the number of choices shrinks dramatically.
This might not always be the answer that market players
want to hear. The windmill salesperson wants to sell windmills. The politician and community leaders want the green
50
photo opportunity the windmill presents. All too often within
a hundred feet of the windmills are hundreds of inefficient
buildings where modest investments in controls, windows,
and insulation would reduce the need for electricity more
cheaply than building windmills. This is another example of a
systemic question: Is it cheaper to supply clean electricity with
windmills or windows? Nothing against windmills — as part
of the energy system, they have a valuable role to play.
The basic approach to systemic thinking has been around
for a long time. It’s encapsulated in the loading order. The
first and cheapest priority is efficiency — increase energy
supply by destroying the need for unnecessary energy. The
second priority, consistently neglected, is to recover heat
from inefficient processes. The third priority is to add renewable energy supplies where they clearly make sense, and
only after the preceding priorities have been fully explored.
Last, but not least, invest in the traditional network systems
to serve the now restructured demand in an optimal way.
Despite overwhelming evidence that systematically implementing the loading order is effective, U.S. energy policy
discussion is still predominantly built on sound bites and
single topics. This applies equally to the protagonists and
antagonists of topics such as domestic prospecting, renewable
or fossil supplies, regulation or liberalization of environmental
standards, free markets or regulated pricing, and technology
and efficiency incentives. These are discussed narrowly without
framing them in overall economic, security, and environmental
targets. This approach won’t get us where we need to be.
The energy challenges of the next decades are highly
interconnected and far from simple. Worldwide, we have to
supply the growing needs of billions of new consumers for
high-quality energy services. We have to revamp existing
systems in the industrialized world to bring them to acceptable efficiencies. We have to slow down and ultimately
reverse the production of greenhouse gases. All this has to
be done over time spans consistently well beyond the tenure
of any CEO, electoral cycle, or politician’s career.
This can happen only with policies and decision-making
processes that deliver the loading order priorities aimed at
balanced energy targets that don’t change with the sound
bite of the day.
peter garforth is principal of garforth international LLc, toledo,
ohio. He can be reached at peter@garforthint.com.
OctOber 2011 www.PLANtSerVIceS.cOm
PS1110_50_EnergyExpert.indd 50
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Consulting Services • Compressor Products • Clean Air Treatment Products • Control Products
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Built for a lifetime is a trademark of Kaeser Compressors, Inc. ©2010 Kaeser Compressors, Inc.
PS1110_FPA.indd 52
9/27/11 4:44 PM