www.plantservices.com
Get It
Back
Recover the energy
invested in powering
compressors
A Puzzling Gear Tooth Failure
p.40
Fly Ash in Concrete Causes Concerns
p.44
m ay 2 0 1 0
Use the CMMS to Handle
Service Requests
p.27
Energy Strategy: Is Board-Level
Management on Board?
p.58
PS1005_01_Cover.indd 1
5/7/10 8:48 AM
Get high-quality AC drives and
motors at AutomationDirect prices!
Variable speed drives can improve your bottom line by reducing
your AC motors’ energy consumption. An investment of as
little as $99 can start paying off immediately.
• GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz
control for general purpose applications. Built-in I/O,
Modbus communications capability and programmable
preset speeds increase its flexibility.
• GS2 AC drives (0.5 to 10 hp) feature built-in PID control,
dynamic braking and Modbus communications.
• DuraPULSE AC drives (1 to 100 hp) add sensorless vector
control, a removable keypad that stores up to four
different application programs, and built-in discrete
and analog I/O. Communicate via built-in Modbus or
an optional Ethernet connection.
www.automationdirect.com/drives
Marathon Electric NEMA Premium Efficiency XRI
series motors are compliant with the Energy
Independence and Security Act of 2007, giving you
both a low purchase prices and long-term energy
savings. Our line of Marathon motors includes:
• NEMA Premium Efficiency XRI (1 - 10 hp), starting at $310
• Blue Chip XRI Ultra High Efficiency (15 - 100 hp), for
high-cycle or long-run applications, starting at $993
• Inverter-duty (1/4 to 100 hp) standard efficiency,
starting at $129
www.automationdirect.com/motors
www.automationdirect.com
Go online or call to get complete information,
request your free catalog, or place an order.
1-800-633-0405
PS1005_FPA.indd 2
5/7/10 10:27 AM
Over 900,000 products for the ones who get it done.
Call. Click. Stop By.® www.grainger.com
PS1005_FPA.indd 3
5/7/10 10:35 AM
Atlas Copco Compressors: The Air Auditing Specialists.
Puzzled by rising energy costs?
Atlas Copco has a full range of compressed air auditing services available - from simple system
diagnostics all the way to ultrasonic leak detection. These services are available for any
compressed air system.
A compressed air audit from Atlas Copco will:
Show your compressor’s energy usage.
Highlight areas where savings could be made.
Provide you with a payback analysis on any new investments.
Provide you with a professional audit report.
Text: Audit and your Zip Code to 79274
Call Us: 866-688-9611
Log On: www.atlascopco.us/mboxusa
PS1005_FPA.indd April
4
Audit_Ad_BestPractices
13.indd 1
5/7/10
10:36
AM PM
4/13/2010
2:02:00
table of contents
may 2010 / Vol. 31, No. 5
features
32 / COVER STORY
Get It Back
Recover the energy invested in powering compressors
40 / Power Transmission
Extracting the Root of a Puzzling Gear Tooth Failure
How we resolved a problem in a power generation drivetrain
44 / Flooring
The Fly in the Concrete
Exclusives
Why return condensate to the boiler?
The best reasons are intertwined with process economics.
www.PlantServices.com/articles/2010/04ReturnCondensate
ToBoiler.html
Abrasion-resistant pipe exhibits dual personality
Induction-hardened steel pipe is hard on the inside, soft on
the outside.
www.PlantServices.com/articles/2010/04AbrasionResistant
Pipe.html
Best practices for installing safety valves
Follow these common sense guidelines to ensure your steam
system is safe.
www.PlantServices.com/articles/2010/04InstallSafety
Valves.html
Coal fly ash in cement brings green value – and flooring
challenges
47 / Power Distribution
The Electrical Tester’s Toolkit
Accurate troubleshooting relies on using the proper tool for the job
specialists
25 / Human Capital
31 / Technology Toolbox
Integrity
Emission Controls
Doing what’s right because
it’s the right thing to do
New technologies are advancing our abilities to contain
unsavory emissions
27 / Asset Manager
Handling Service
Requests
58 / Energy Expert
Are We There Yet?
It’s evolved way beyond the
primitive telephone help desk
How board-level management
can get onboard
columns and departments
7 / FROM THE EDITOR
23 / Your Space
Training with a purpose
Oil and Water
Eight steps to cash-positive education.
www.PlantServices.com/articles/2010/04RoadTo
Reliability.html
The balance of risk and
responsibility
Find Those Golden
Production Nuggets
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, except the September and December issues which are
$36. Canadian and foreign annual subscriptions are accepted at $145 (Foreign airmail $200/yr). Single copies
are $81. © 2010 by Putman Media, Inc. All rights reserved. The contents of this publication August 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 August 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.
8 / UP AND RUNNING
• LEDs Get Serious Attention
• ASHRAE Rescinds Assessment of Non-Chemical Devices
• Screws vs. Lobes
Speed reductions and routine
stops can cost more than you
realize
51 / IN THE TRENCHES
When Johnny Comes
Marching Home
Acme tries to outmaneuver
the Army
17 / CRISIS CORNER
Say What?
Overcoming stigmas and
communication challenges
53 / PRODUCT FOCUS
57 / CLASSIFIEDS
19 / WHAT WORKS
w w w .PLANTSERVICES.co m may 2 010 5
PS1005_05_TOC.indd 5
5/7/10 1:46 PM
The First Name in
Power Transmission
DODGE® power transmission products offer reliable
service and low maintenance to help reduce your
total cost of ownership. Our innovative bearings,
gearing and power transmission products have
solved the toughest applications for over 125 years.
Our technical sales team can help you with the
most challenging applications, and our worldwide
distributor network ensures immediate delivery.
• Unmatched Quality
• Superior Reliability
• Improved Uptime
When it comes to PT solutions, DODGE is the first
name in power transmission.
dodge-pt.com
baldor.com
• Quick Delivery
©2008 Baldor Electric Company
PS1005_FPA.indd 6
5/7/10 10:37 AM
from the editor
Putman media, inc.
555 W. Pierce Rd., Ste.
301, Itasca, IL 60143
Phone: (630) 467-1300,
Fax: (630) 467-1120
mike brenner
Group Publisher
mbrenner@putman.net
editorial staff
paul studebaker, cmrp
Oil and Water
paul studebaker, cmrp
Editor in Chief
pstudebaker@putman.net
The balance of risk and responsibility
russell l. kratowicz, p.e. cmrp
Executive Editor
russk@putman.net
There’s no doubt the 11 presumed
deaths and millions of gallons of spilled
oil from the Deepwater Horizon oil rig
explosion on April 20 will merit a place
on the long list of man-made disasters.
Fingers will be pointed, journalists will
write, and lawyers will sue, but if past
experience is a guide, little will be said
about how we decided to take on the risk,
and who met the responsibility.
We took on the risk because, just like
building windmills, reacting uranium,
and mining coal, we have the technology
and the experience to do it as safely as is
humanly possible, and the track record
to prove it. We took on the risk because,
like driving a car, living in a fault zone,
or taking a big bite of steak, just because
something awful could happen, and eventually will happen somewhere, sometime,
doesn’t mean we shouldn’t. And above all,
with oil speculators paying $80-plus dollars per barrel and the enormous financial
and human costs of U.S. energy insecurity,
we decided this oil is worth the risks.
As we rush to assign blame, let’s pause
to appreciate not only the 11 dead, but
the hundred others who were doing
hard work on our behalf when the rig
exploded. Let’s marvel at the technology
that allows thousands of oil platforms
around the world to extract and deliver
safely the oil we rely on to go get our
lattes. And let’s support the engineers,
ironworkers, and mariners who, as we
go to press, are working day and night to
contain and collect the oil as it spills.
The Deepwater Horizon was tapping
an oil well containing large amounts of
gas at very high pressures. Gas apparently
escaped, was ignited, and exploded. We
might need better gas handling equipment
on oil platforms, and we’ll build it.
Oil apparently is leaking in several
places from the riser pipe that folded
Alexis Gajewski
Associate Editor, Digital Media
agajewski@putman.net
stephen c. herner
V.P., Creative Services
sherner@putman.net
jennifer dakas
Art Director
jdakas@putman.net
david berger, p.eng.
Contributing Editor
peter garforth
Contributing Editor
sheila kennedy
Contributing Editor
joel leonard
Contributing Editor
bob sperber
Editor at Large
publication services
carmela kappel
Assistant to the Publisher
ckappel@putman.net
jerry clark
V.P., Circulation
jclark@putman.net
jack jones
Circulation Director
jjones@putman.net
rita fitzgerald
Production Manager
rfitzgerald@putman.net
Jill Kaletha
Reprints Marketing Manager
Foster Reprints
(866) 879-9144 ext.168
jillk@fosterprinting.com
administrative staff
john m. cappelletti
President/CEO
julie cappelletti-lange
Vice President
keith larson
V.P., Content
rose southard
V.P., Technology and Web Development
PS1005_07_Edit.indd 7
and fell as the rig sank. Platforms are designed with multiple water-tight flotation
chambers, and almost never sink. Maybe
some chamber doors were open, and
water used to fight the fire sank the rig.
We’ll be sure that can’t happen again.
The blowout preventer on the sea floor
is designed to seal the well at the push of a
We decided this oil is
worth the risks that
come with drilling a
mile below the surface
of the ocean.
button. It’s a highly evolved, robust device
that is tested repeatedly before and during
operation. If it or its procedures need to be
improved, we’ll improve them.
We keep aircraft carriers in the Middle
East and ambulances at NASCAR races.
A field of oil rigs so close to our precious Gulf of Mexico shoreline should
probably be attended by a more comprehensive set of containment and collection equipment, and a solid strategy for
deploying it. We’ll do that, too.
But ultimately, we set our priorities,
we take our chances, and we pay our
dues. Our best efforts haven’t prevented
horrendous consequences of levee failures, aircraft hijackings, or even bridge
corrosion from ordinary road salt, much
less the confluence of two or three uncommon events or mistakes.
Let’s thank the dead, their families,
the responders, and the engineers and
managers who will try to prevent a recurrence. It won’t be the last time.
PAUL STUDEBAKER, CMRP, Editor in Chief
pstudebaker@putman.net, (630) 467-1300 x433
w w w .PLANTSERVICES.co m may 2 010 7
5/7/10 8:50 AM
up & Running
LEDs Get serious Attention
Solid-state technology is proving practical for general illumination
General illumination by light-emitting diodes (LEDs)
is beginning to come to industrial facilities as manufacturers overcome problems with initial cost, lumen levels,
and power factors; governments and utilities increase
energy conservation incentives; and energy cost concerns
remain high.
On April 6, U.S. Congresswoman Judy Chu met with
executives and engineers of solid-state lighting company
LEDtronics to discuss and gain insight into the technological advances in LEDs and the contributions LED lighting applications might bring to energy conservation on a
national level.
During the two-hour gathering, Pervaiz Lodhie, LEDtronics
president and CEO, and other company executives explained
the technology’s latest innovations and its potential to become
a major contributor not only to energy efficiency but also to
reducing greenhouse gases and generating green jobs. “The
solid-state lighting and solar energy industries are the top job
creators in the United States today,” said Lodhie. “In addition,
these cutting-edge technologies spur innovation, boost domestic manufacturing and reaffirm the United States as the leader
in technological ingenuity around the world.”
LEDs are well known to be compact, energy-efficient,
LEDs say Hi to hi-bays
The first costeffective generalillumination LED
applications were
where reduced heat
load or maintenance contributed
critical economic
benefits. Now
LEDs compete with
fluorescents and
other high-efficiency technologies for general application in warehouses
and factories. A typical LED hi-bay fixture uses 1/3
to 1/2 the wattage of a fluorescent, metal halide, or
high-pressure sodium fixture of equivalent illumination,
and lasts two to three times as long. (Source: Dialight)
8
U.S. Congresswoman Judy Chu and Pervaiz Lodhie, CEO and
president, LEDtronics
durable, mercury-free, and white-bright light generating sources that produce little heat and last 10 times as
long as compact fluorescents. These properties well suit
them to be used with alternative energy sources such as
solar and wind. But until recently, they were limited to
single-bulb use in applications such as instrument panels,
electronics, pen lights, and strings of indoor and outdoor
Christmas lights.
Manufacturers expanded LED applications by clustering
the small bulbs, first as battery-powered items such as flashlights and headlamps, and now with standard bases to fit
common light fixtures. The first cost-effective applications
have been where reducing heat load and maintenance contribute economic benefits. Now they’re competing with fluorescents and other high-efficiency technologies for general
application in warehouses and factories. Analysts predict
that by the end of the decade, LEDs will be the dominant
source for commercial and residential lighting.
LEDtronics described a wide range of projects around the
world, including a group of street lights abutting a local public school; the South Capitol Street Bridge in Washington,
D.C., that Rep. Chou traverses every day; and a U.S. Army
garrison in South Korea.
“Considering the number of major energy-saving LED
bulbs we supply to U.S. industry, we’re helping save two to
three megawatts of energy each year, over and above the
continued energy savings of the past 26 years,” Lodhie said.
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_08_14_UpRun.indd 8
5/7/10 8:53 AM
For the
price of this
ASHRAE Rescinds
Assessment of
Non-Chemical
Devices
On May 5, ASHRAE announced that
it has received numerous comments
and questions concerning its April 7,
2010, press release relating to research
project no. RP 1361, Biological Control in Cooling Towers Using NonChemical Water Treatment Devices.
After careful consideration, ASHRAE
has decided to rescind that release
pending further review. The cognizant
ASHRAE Technical Committee, TC 3.6
Water Treatment, which sponsored and
is responsible for the project, has not
yet reviewed the final report. TC 3.6
expects to complete its review, including voting on whether to recommend
approval of the final report, within the
next 30 to 60 days.
The rescinded release announced
that the two-year research project,
recently completed by Dr. Radisav
Vidic at the University of Pittsburgh,
evaluated five non-chemical devices
using different technologies to control
biological activity in a model coolingtower system. The devices studied
included a hydrodynamic cavitation
device, pulsed and static electric field
devices, an ultrasonic device, and a
magnetic device.
ASHRAE has rescinded its statement that, in Vidic’s research, none of
the non-chemical devices measurably
reduced planktonic or sessile microbial
populations in comparison to notreatment tests and to a conventional
chemical microbial control treatment
protocol. The findings appear to be
inconsistent with previous research by
non-chemical device manufacturers
and some independent researchers on
some of the same devices tested in the
Resources
DO BE$T ON iPHONE
The BE$T desktop program calculates a motor’s annual electricity usage based on its nominal
efficiency, and compares it to
Baldor Standard-E and Super-E
premium-efficiency motors. It then
recommends, by catalog number,
the appropriate Baldor motor
for the application, and notes
the payback period, in months,
for replacing the existing motor.
It also is capable of calculating
savings for using a variable-speed
drive, and annual carbon footprint
reductions. BE$T is available on
CD-ROM, downloadable from www.
baldor.com, and now as an iPhone
app by visiting iTunes and searching on the keyword “Baldor.”
ProSmart®
gives you these,
plus 17 more.
GET A GRIP ON TEMPERATURES
The 7th edition of Omega’s Temperature Measurement Handbook
offers detailed information and
specifications on more than
40,000 products for process
measurement and control. It adds
the latest technology and new
products in sanitary temperature
sensors and devices, wireless
connectors and instruments,
profile temperature labels, thermal
imagers and infrared temperature
products, automation products,
new technical books, and updated
technical references and data. Also
included are traditional products
such as thermocouples, RTD
probes and elements, thermistors,
calibration equipment, handheld
instruments, meters, controllers,
timers, transmitters, process
controllers and power switching
devices, data acquisition, recorders, cryogenics temperature
measurement, and heaters. Visit
www.omega.com/literature.
Think about ITT.
ITT ProSmart condition monitoring
checks and analyzes not one but
up to 22 critical conditions of your
rotating equipment. Including
vibration, temperature, pressure,
and rpm, every five seconds.
It’s the kind of data that can make
the difference between catching a
problem early—and catastrophic
failure. Visit itt.com/prosmart.html,
or call 1-800-734-7867.
w w w .PLANTSERVICES.co m May 2 010 9
PS1005_08_14_UpRun.indd 9
5/7/10 8:53 AM
up & Running
ASHRAE study. Those other studies reported measurable
degrees of biological control.
Vidic had said that, “These results suggest that equipment operators, building owners, and engineers should
consider taking more frequent water sample tests for their
a very small Plexiglas model of a cooling tower, fully
complying with the proposal submitted by the researcher
and approved by TC. 3.6. There are significant variances
between the preliminary results of the study and actual
field results recorded by non-chemical device manufactur-
Regardless of the type of water treatment used,
ashrae recommends that owners of cooling and refrigeration
systems conduct routine testing.
systems that rely on NCDs for biological control. If the
testing reveals a problem, one possible measure is to add
chemical treatment capability to the system to prevent a
potential health hazard from developing until additional
research and field testing can resolve this question.”
In its May 5 announcement, ASHRAE says that RP
1361, as is typical of experimental research projects, did
not involve actual full-scale cooling towers operating in a
working cooling system. Rather, researchers constructed
CRC Capabilities 7x4.875
2/15/10
10:42 AM
Page 1
ers. This is one aspect of the study that will be reviewed by
TC 3.6 and may indicate the need for further research.
In addition, the rescinded press release referenced
Legionella though the project Statement of Work did not
include protocols for testing for Legionella.
Regardless of the type of water treatment used,
ASHRAE recommends that owners of cooling and refrigeration systems conduct routine testing to evaluate
whether the water treatment is working effectively.
Your Best Solution
TM
Whether you are looking for a precision cleaner, degreaser, lubricant, or sealant product, CRC will always
provide solutions that work. CRC has been the brand of choice in the Industrial market for over 50 years!
Go online to www.crcindustries.com/ei to see our entire product offering of MRO maintenance chemicals.
Use our online product selector guide to easily find the perfect solution for your individual application needs.
CRC’s Breadth of Line
Patented MSDL™
Factory Trained
Sales Force
On-line Educational
Resources
www.crcindustries.com/ei
10
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_08_14_UpRun.indd 10
5/7/10 8:55 AM
With experience comes cleaner air.
Without a doubt,
UltraWebisAlwaysBetter.com
25 YEARS OF PROOF
Ultra-Web ® technology is the world standard for advanced nanofiber air filtration.
Ultra-Web filter cartridges, only from Donaldson ® Torit ®, are the preferred filter
for cleaner air, longer filter life and greater energy savings.
LONGEST LIFE
Performing in the field for 25 years and counting.
PROOF IS IN THE PATENTS
Ultra-Web technology is backed by 80 issued and pending patents worldwide.
THE ENGINEERS’ FILTER
More than 1 billion square feet of filter media used.
FOR ALL POPULAR COLLECTORS
Ultra-Web replacement filters ship in 24 hours.
IMPROVES LIVES
Ultra-Web technology is also used in the production of medical products,
M1 Abrams tanks and more.
Donaldson Company, Inc.
Minneapolis, MN
55440-1299
The winning combination for cleaner air is Downflo ®
Oval dust collectors and Ultra-Web filters available
with MERV 13, 14 and 15 efficiency ratings.
Learn more.
UltraWebisAlwaysBetter.com
800.365.1331
donaldsontorit@donaldson.com
donaldsontorit.com
© 2007 Donaldson Company, Inc. All Rights Reserved.
PS1005_FPA.indd 11
5/7/10 10:37 AM
CCOMP-430_Compression_rev.indd
1
PS1005_FPA.indd 12
4/28/10
4:38:56
5/7/10
10:38PM
AM
SCREWS VS. LOBES
Calling the technology both new and
proven, Atlas Copco has replaced its Rootstype blower offerings with screw technology adapted from its oil-free compressors.
The resulting ZS Series blowers offer an
average of 30% lower power consumption,
lower maintenance, and quieter operation at
directly comparable initial cost for applications at pressures as high as about 17 psig.
The new ZS screw blower was tested by
TÜV against a tri-lobe blower in accordance with ISO 1217, edition 4. The tests,
detailed at www.efficiencyblowers.com,
found the ZS to be 23.8% more energy
efficient than a tri-lobe blower at 0.5 bar (7
psig) and 39.7% 0.9 bar (13 psig). The improvement is mainly due to the compression characteristics of the screw technology, though an integrated gearbox and the
lubrication system contribute.
The technology targets low-pressure
applications such as wastewater aeration.
Treatment plants use about 3% of the electric
power generated in the United States, and
blowers consume about 70% of that. Cutting
that consumption is an example of “sustainable productivity,” says John Conover, a business line manager at Atlas Copco.
Companies are on a global quest to
reduce energy consumption and costs, and
once the low-hanging fruit, such as lighting, compressed air leaks, motor/pump
sizing, etc., is gone, they’ll be looking for
new ways to achieve their annual goals.
“Efficiency and productivity are fundamental,” says Ronnie Leten, president and CEO,
Atlas Copco. At his company, “No project
goes forward unless it improves efficiency
without jeopardizing reliability.”
In the United States, about 56 billion
kilowatt hours are used for drinking water
and wastewater services, according to
the EPA. “Just 10% energy savings in this
sector could collectively save about $400
million annually,” says Stephen Kuhn,
president, Compressor Technique Business,
Atlas Copco.
.
nds e.
a
h
l
r
you e peop
n
i
er
luke
o th
te, F on
a
Pow ision t ion.
r
u
ac c 9 e d i t i I / I V
t
c
I
hly
Pre the Na
oug he 200 C AT I uch
r
o
ted ile m
n
d th w ith t
ss,
a
i
n
r
a
o
h
,
oc e
re
J
t
3409980_02333_PlantSvcs.indd 1
PS1005_08_14_UpRun.indd 13
r
w
a
le
lian
nd
nd
he p ted
liab
, re y c o m p dard a ions . A rt of t
s
d
e
t
e
a
t
g
n
d
ll
Rug are fu 0E sta pplica all or p ed, an
a
7
r
s
t
l
l
u
F PA u s t r i a rms ou nufact
too
d
a
a
he N
of t e in i n tition f ned, m
s
e
u
p
sig
m
e
ke.*
for
o
d
r Flu
he c ls are ers .
e
t
f
e
f
r
o
o
p
e to
g ine
ians
Fluk uke en
hnic
c
e
l
t
0
by F
of 1
out ou?
9
it:
y
y
l
r
ip k
Nea t about
ersh
b
a
m
h
W
me
rm
ree
ch fi
sear
taf
e
y re
.
g
part notice
d
n
n
d
a
io
out
t thir
tion
den ge with
nat
pen
n
e Na . c o m /
inde to cha
h
t
n
a
t
e
by ubjec
Join . f l u k
s
ted
duc ations
w
con
c
ww
rvey . Specifi
u
s
e
n
atio
renc
refe Corpor
e
nd p
*Bra 08 Fluk
©20 2333
Ad 0
12/11/08 10:15:06 AM
5/7/10 8:57 AM
up & Running
Resources
OWN A DMM TECHNICAL LIBRARY ON CD
Keithley Instruments published a digital multimeter (DMM)
technical library for engineers and researchers who use
DMMs for a wide range of applications. The CD-based
library houses more than 100 documents, including measurement tips, application notes, and product selection
guides. To request a free copy of the CD, visit www.ggcomm.
com/Keithley/Mar10_NewsRelease_DMM-CD.html.
REFURBISH AND RECERTIFY LIFT MAGNETS
The six-page “Lift Magnet Certification/Refurbishment
Program” brochure describes how Eriez inspection, exchange, and refurbishment ensures continual compliance
with ASME B30.20 standards. Eriez’ procedure includes
inspection of lift magnet surface and resurfacing of poles
(if needed); inspection, repair, and replacement of missing or damaged parts; new warning labels and capacity
markings; load testing; and certification. Every magnet is
14
returned with a Certificate of Compliance and a one-year
“as new” warranty. Download the brochure at http://service.
eriez.com or contact Eriez and request brochure B-103.
GROK THE BENEFITS OF OPC UA
Sorry for the long URL, but if you need or want to know
more about the technology underlying connectivity
and communications among disparate systems, this
might be the best hidden, best place to get started:
www.opcfoundation.org/Default.aspx/UASDK/Files/
The%20Benefits%20of%20UA.htm?MID=AboutOPC
CONTROL CABINET CLIMATES
In industrial enclosures, high temperatures reduce reliability
while overcooling degrades energy efficiency. Simply enter data
relevant to your application and, by completing a series of calculations, Therm 6.0 determines the cooling capacity required
to provide the best solution. See www.rittal-corp.com/software.
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_08_14_UpRun.indd 14
5/7/10 8:57 AM
New from WD-40 Company: BLUE WORKS™ Industrial Grade, specialty maintenance
products. Ask your distributor for details on how you can experience outstanding
performance from a line that meets your rigorous technical requirements.
For a free sample,* visit BlueWorksBrand.com/sample and enter Offer Code PSP
*Whilesupplieslast.OfferavailabletoIndustrialProfessionalsonly.OffernotavailableinAlaskaorHawaii.
PleaseseeonlineSampleRequestFormforfulldetails. ©2010WD-40Company
PS1005_FPA.indd 15
50-StateVOCcompliant
5/7/10 10:39 AM
FLIR’s Mission
Catching problems before they turn
into nightmares
Know what elite warfighters and plant engineers have in
common? No room for error.
The #1 manufacturer of infrared cameras in the world,
FLIR has been helping engineers and technicians keep
aging production lines moving during the worst economy
in decades; the cost of failure is catastrophic to families
and businesses alike.
It’s no surpise that FLIR is the #1 manufacturer of
infrared cameras in the world.
FLIR provides the same
powerful technology
that special operations
forces use in battle.
There are over 250,000
FLIR cameras in the field
and on factory floors, all
supported by the world’s
largest Thermography
training organization.
i-Series
Point and Shoot
T-Series
Professional
P-Series
Expert
Visit www.flir.com or call 800.464.6372 to schedule your free demo and find out why
FLIR has been the most trusted name in thermal imaging for 45 years.
PS1005_FPA.indd 16
5/7/10 10:40 AM
Crisis corner
Joel Leonard
Say What?
Overcoming stigmas and communication challenges
Right now, I’m a little concerned about the com-
munication problems and stereotypical misperceptions
that inhibit productive conversation. I’m about to depart
on a worldwide crusade to fight the skilled labor shortage by speaking at the PIRM Conference in Atlanta;
the Euromaintenance Conference in Verona, Italy; the
Engineering Management Congress in Dubai, UAE; and
the ICOMS Asset Management Council in Adelaide,
Australia. It’s a 60,000 air-mile journey to communicate
with people around the globe, but I can’t seem to even
understand the corner grocery clerk.
My better half was enduring the change of seasons and
battling various forms of colds, cruds, flus, etc. At midnight,
she demanded that I go to the store to fetch a bottle of Nyquil. OK, dear, whatever it takes to make you happy.
So, I traveled through the eeriness of darkness to the
24-hour supermarket, where the night shift was at work.
After gathering the medicine and some other items, I
walked up to the only cashier. He barked out one word:
“Eight!” I didn’t know if he was limiting the number of
items I could purchase, wondering if I’d had dinner, or
expressing how little he loved me. Since it was midnight
on April 7th, was he saying it was now April 8th?
He said it again: “Eight!”
I waited and looked at him with bewilderment until he
finally explained, “Sir, I will check you out on checkout line
8 after I finish cleaning checkout line 6.”
How was I to know that was what his “Eight!” meant? Was
he so tired, lazy, or involved in his own world that he could
not make the effort to provide the communication needed to
close the sale?
Because I had nowhere to be at midnight, I informed him
of the various interpretations, permutations, and possibilities I could have derived from his exclamation. I explained
my bewildered experience loudly and voluminously, embarrassing him as his late-night colleagues bit their lips trying
not to burst into laughter.
When I left, instead of saying “Good night” or “Goodbye,” I barked out, “Petunia!” He looked at me with the same
bewildered look I must have given him. I said, “See how it
feels?” and walked out the door. I think he’ll make a little
more effort to communicate more effectively.
In this twitterful, 140-character and acronym-saturated
world, people are no longer communicating, but barking
out the briefest form of expression and expecting others to
understand. As Foster Martin so eloquently stated in the
classic movie, Cool Hand Luke, “What we have here is a
failure to communicate.”
Do you have similar problems in your facilities? Do
your departments work cohesively, or do they bark out
abbreviated commands that diminish understanding and
performance?
As soon as I open my mouth and
expose my southern drawl, many
attendees obviously mentally
subtract 40 IQ points.
My communications outside the Southeastern United
States generally require multiple steps. I get a warm
reception after the moderator introduces me, but as soon
as I open my mouth and expose my southern drawl,
many attendees obviously mentally subtract 40 IQ points
from me. They equate my dialect to episodes of “Cops”
or someone who just walked in from the cornfields of
Hooterville.
That used to upset me, because they were focused on
the way I communicated and missed my message. But
more companies are experiencing the maintenance crisis,
and I’ve learned proven techniques and developed new
methods to mitigate these serious business challenges.
Where they used to discount me, now it’s gratifying to
see their eyes bug out and jaws drop as they learn about
the potential power to be gained by developing interactive 3-D training tools, implementing the Reliability
Vortex, or setting up Break Through Training programs
in their area.
Do you have communication challenges, stigmas, and
stereotypes to overcome? How do you confront these issues? Please share. And stay tuned to future Crisis Corner
columns and episodes of SkillTV, where I will share the
interesting interactions captured on this worldwide journey
to fight the maintenance crisis.
E-mail Contributing Editor Joel Leonard at joel@skilltv.net.
w w w .PLANTSERVICES.co m May 2 010 17
PS1005_17_Crisis.indd 17
5/7/10 9:03 AM
Fast and Easy Installation
W
hen your plant’s compressed air system leaks, more than just air
is getting out. You’re losing money in the form of wasted energy,
wear and tear on your compressors and increased operating and
maintenance costs. Duratec Airline, a unique time and money-saving piping
system, is designed to reduce leaks and costs.
A tough piping system that meets ASME codes and OSHA safety requirements,
Duratec Airline requires less time, labor and money to install and maintain
than traditional systems. Its long, lightweight coils cut down on the number of
potential leak points in your system. Duratec fittings are quick and easy to
install and feature double O-ring seals that ensure maximum joint integrity.
Duratec requires no special tools or installation training and eliminates the
need for soldering and threading. And because Duratec is so quickly and
easily installed, modified, and adapted to existing metal systems, it can reduce
your plant’s downtime. So stop your compressed air system’s problems before
they become big news — Install Duratec.
5 Sec.
25 Sec.
To find out more call us or visit: www.ipexamerica.com
Total Time: 55 Sec.
HDPE
Aluminum
HDPE
AirLine System
U . S . To l l F r e e : 1 - 8 0 0 - 4 6 3 - 9 5 7 2
Products manufactured by IPEX Inc. and distributed in the United States by IPEX USA LLC.
Duratec® is a registered trademark of IPEX Branding Inc.
PS1005_FPA.indd 18
5/7/10 10:42 AM
what works
Boiler Controls Save Mega BTUs
Emissions project provides one-year payback in improved efficiency
The University of Texas at Austin’s 424-acre campus
(UT) is the academic home to 50,000 students. Boilers and
gas turbines at the Hal C. Weaver Power Plant provide yearround power, steam, chilled water, demineralized water, and
compressed air to approximately 200 campus buildings. In
satisfying state air-quality compliance requirements, the
plant reaped an unexpected $500,000 annual energy savings
by retrofitting one 150,000-lb. boiler with an innovative
system that reduced NOx emissions from 158 tons per year
to 21 tons per year.
“Our objective as we began the boiler retrofit was to reduce NOx emissions, but the process resulted in us producing more energy with less gas by improving our combustion efficiency,” says Juan Ontiveros, director of utility and
energy management at the school. “This allowed us to bank
our standby boilers, saving us hundreds of thousands of
dollars per year.”
The emissions-control system is Compu-NOx by Benz
Air Engineering, Las Vegas (www.compunox.com). “We
chose Benz Air to bring us into compliance because of its
innovative and less expensive solution to the boiler retrofit,”
says Kevin Kuretich, associate director, Utilities and Energy
Management Department, UT. “Other vendors proposed
similar solutions that involved flue gas recirculation (FGR)
to cut down on NOx, but Benz was able to do the job
without burner replacement. Burner replacement – four on
Boiler 3 and eight on Boiler 7 – was estimated to cost $2 million. We also chose Benz Air because we thought it had the
most knowledge of the system and the expertise to upgrade
our PLC/PC interface system.”
The control platform controls airflows for precise metering
by means of variable-frequency-drive (VFD) on fans instead of
dampers. “The Compu-NOx control system uses the absolute
linear relationship of fan speed to fan airflow as the basis of
combustion control,” explains Robert Benz, president of Benz
Air Engineering. “The system measures fuel flow and interpolates the correct fan speed to give the desired flow.”
Less horsepower is used to drive the fans, which results in
significant cost savings from not running them continuously
at full speed. “We have very precise airflow control, which
makes all the difference in the world in fuel efficiencies and
emissions,” says Ryan Thompson, project engineer, Utilities
and Energy Management Department, UT. “We took Boiler 3
from 175 ppm NOx to less than 25 ppm without installing new
Variable-frequency drives precisely adjust fan speeds to provide
controlled flows of recirculated exhaust gas and air for combustion
control.
burners, which would have been very expensive and required
the boiler to be offline for several months. With Benz Air and
Compu-NOx, all we had to do was change the fan power supply
by using variable-frequency-drives to cut our emissions.”
The modification also included a separate recirculation
fan and ductwork between the exhaust flue and the burner
intake for FGR, which extracts flue gas from the boiler outlet
duct upstream of the air heater and returns it through a
separate duct to the combustion air duct that feeds the wind
box. The slightly cooled combustion gas from the boiler
exit is mixed back with the burner flame to reduce the peak
flame temperatures, which reduces NOx.
The installation supports boiler banking: keeping the
auxiliary boilers in a hot standby mode. “It allows us to
keep one boiler at the ready, without using any measurable
amount of gas,” Ontiveros says. “It’s a big advantage, saving
us 30,000 pounds of steam per hour.” Turndown is in excess
of 100:1 because of the VFD’s stable operating characteristic.
Benz Air relies exclusively on ABB AC drives for its
Compu-NOx system. The ACS800 uses ABB’s exclusive
motor control algorithm called Direct Torque Control. “The
ACS800 has a lot of communication flexibility that allows us
to enjoy direct control of the AC drive digitally through the
Ethernet back-up connection,” says Benz. “In the case of this
university, we had to support several back-up systems to its
communications and we were able to do that.”
Payback on the system will be less than 12 months.
w w w .PLANTSERVICES.co m May 2 010 19
PS1005_19_Works_drives.indd 19
5/7/10 9:08 AM
Get new performance
out of your old fans.
ISO 9001 Certified Quality
Management System
Anthony DiNunzio, Aftermarket and Repair Sales Manager
At Robinson Fans, we pride ourselves on being your trusted source for new fans. But we also have a
dedicated team of repair specialists who can fix and rebuild any worn fan–even upgrade a competitor’s–to
deliver new fan performance, all at the price of a repair. We’ll even come to you to diagnose and evaluate.
Robinson Fans. The name behind what’s ahead.
Black
|
2 Color 186 (Red) & Black
|
Spot Red - PMS 186
|
2 Color 186 (Red) & White
|
Reverse
|
Find out how to keep your fans moving.
PS1005_FPA.indd
PS1003_FPA.indd
11 20
RobinsonFans.com
|
724-452-6121
5/7/102:11
10:43
3/2/10
PMAM
what works
Equipment Easily Unplugged in Columbus
Fast, safe reconfiguration boosts flexibility and efficiency
Edison Welding Institute (EWI) in Columbus, Ohio, is
dedicated to applied research and development of materials
joining and welding. It provides expert materials joining
assistance, as well as research, consulting, and training to
its members in the aerospace, automotive, energy, chemical,
heavy manufacturing, medical, and electronics industries.
Its 40,000-sq.ft. high-bay laboratory provides space to set
up individual work stations for a large number of projects
simultaneously. Three 1,600 A bus bars provide 480 V power
throughout the laboratory, with more than 100 separate
power drops for welding power supplies.
Workspace layouts and equipment are constantly being
rearranged. “We have nearly every one of the recognized
welding processes commonly used today, and they all
require electricity,” says Andy Joseph, manager, welding and
testing labs at EWI. “The equipment for these different procedures takes space, but we’re not using them all at the same
time, so we need to be able to change them out.”
Previously, fused disconnects were attached directly to
the overhead bus bars, with pin-and-sleeve connectors at
the work stations. Safety was a concern because the disconnects were located at the ceiling level. Joseph explains, “We
had to use a 20-foot pole with a hook on the end to turn off
the power to a plug. Disconnecting live would have been an
unsafe option.” From a safety standpoint, he adds, there was
no way to disconnect quickly if someone was getting hurt.
As a remedy, EWI first considered installing disconnect
switches at ground level. This still would have required the
pin-and-sleeve plugs to connect the equipment, and the
switch boxes would have taken up valuable space. Joseph
notes, “We would have had to buy 120 disconnect boxes that
would have required extra wiring.”
Instead, Joseph selected Decontactor Series switch-rated
plugs and receptacles from Meltric (www.meltric.com),
which combine the two functions. The decontactors were
ordered from Johnson Electric Supply in Columbus. The
decontactors make disconnecting power a simple and safe
operation. Pressing a pushbutton off-switch on the decontactor receptacle breaks the circuit and ejects the plug to
its rest position. Then the plug can be withdrawn from the
receptacle in complete safety, because the circuit is already
dead. When the plug and receptacle are separated, deenergization can be verified visually, and a safety shutter on the
receptacle prevents access to live contacts.
Switch-rated plugs and receptacles make it safe and easy to
connect and disconnect equipment such as the energy chain and
mechanized welding system of this side-beam workstation.
Safety was the key factor in the decision. According to
Joseph, simplified compliance to the NFPA 70E Standard for
Employee Workplaces was an additional benefit. He says,
“With the disconnects overhead, we would have had to suit
up with personal protective equipment [PPE] because there
was no way to verify that the power was disconnected without someone going up in a manlift. Having the disconnect
switch right in the plug eliminates the need for an arc flash
hazard assessment or suiting up.”
Another benefit, according to Joseph, is the easier installation of the decontactors compared to the pin-and-sleeve
connectors. “They required soldering,” Joseph says, “and
we’re constantly swapping equipment in and out. Changing
the decontactors is a timesaver by comparison.”
In addition to the welding power supplies, EWI uses
auxiliary equipment such as hoists, wire feeders, fume extractors, welding positioners, robotics, and travel carriages.
Joseph says he purchased 20 each of Meltric’s 20-A and 30-A
decontactors, rated for 480 V, for these applications.
“Probably the biggest benefit for us has come from efficiency improvements,” Joseph says. “Previously, we would
leave workstations set up because it was hard to take them
apart and put them back together. This made floor space
hard to come by. Now, changeouts are easier to accomplish,
we have a more presentable area, and the engineers and
technicians don’t have to worry about someone else tearing
down their workstation because it is easy to set up again.”
w w w .PLANTSERVICES.co m May 2 010 21
PS1005_21_Works_pwr.indd 21
5/7/10 9:06 AM
Safety7”
HERTZ PLANT SERVICES
YOUR EQUIPMENT RENTAL SOURCE.
Safety10”
DEDICATED INDUSTRIAL PLANT SERVICES PERSONNEL. CUSTOMIZED RENTAL PROGRAMS.
SPECIALIZED EQUIPMENT AND TOOLS. TURNAROUND PLANNING SERVICES.
TECHNOLOGICALLY ADVANCED ASSET MANAGEMENT PROGRAMS.
PLANT SERVICES. READY TO HELP.
Rentals. Sales. Service.
1-888-777-2700 www.hertzequip.com
® U.S. Pat. Off. © Hertz System, Inc. All rights reserved. All other trademarks are the property of their respective owners.
PS1005_FPA.indd 22
5/7/10 10:44 AM
your space
Find Those Golden Production Nuggets
Speed reductions and routine stops can cost more than you realize
By Herb Lichtenberg
Whistles are blowing, phones are ringing, and people
are scrambling all over the factory floor. There has just been a
major equipment breakdown and it looks like it will take days
to repair and get the plant running again. Just think of the lost
production, the late orders, and the unhappy customers.
When this happens, it gets a lot of attention from all levels
in the organization. It’s happened to me on several occasions
and these can be gut-wrenching times. For instance, I once
managed a blooming and rolling mill complex. The blooming mill was powered by a 10,000-hp steam engine and
everything had to go through that one mill. One of the two
piston rods failed from fatigue. The piston blew through the
cylinder head and was found 80 feet down the motor room.
Luckily, no one was in the room at the time, but we ended
up losing two and a half days (61 hours, actually) repairing
the engine, its foundation, and gearing. The incident got a
lot of attention with an investigation, root cause analysis,
and a new procedure so it wouldn’t happen again.
Sound familiar? These things happen in every plant, and,
if dealt with properly (investigation, root cause analysis,
implementation of countermeasures), won’t happen again.
But these single-event losses are not the real killers of production unless they occur frequently or are the result of a
systemic problem such as an ineffective preventive maintenance program. The real killers of productivity are small
events we take for granted or consider part of the process.
In the same complex, we experienced a delay that occurred
on an average of twice per shift, three shifts per day, 365 days
per year. Changing the “hot saw” was a routine, seven-minute
delay and was considered a necessary part of the process. It
was hardly ever mentioned in our daily meetings, even though
it cost us an average of 255 production hours each year. Now,
that’s something everyone, including the brass, should have
gotten excited about. But a seven-minute delay in production
just didn’t generate much concern.
However, the guy whose job it was to sharpen the saws saw
the waste. Working with tool steel and carbide insert vendors,
he came up with a new saw design that lasted twice as long,
adding 127 hours of production time per year to the mill’s output. As this example illustrates, repetitive short-duration delays
that are considered part of the process, or are considered minor
issues, can be a gold mine of productivity improvements.
Another gold mine can be found when production speeds
are reduced because of equipment, process, or procedural matters. Speed is the second factor in the OEE calculation. In my
experience, both from managing plants and assessing them as
a consultant, speed often can cause a major loss of productivity. In fact, in many of the plants I’ve assessed, speed losses
were higher and eliminated more production than unplanned
When a plant goes down, people
notice, but when it slows down,
there isn’t a big sense of urgency.
downtime. When a plant goes down, people notice, but when it
slows down, there isn’t a big sense of urgency.
For example, we were asked to assess a crushing and
conveying operation. Management was concerned about lost
production equipment downtime caused. The assessment,
however, showed that 15,000 tons per day were lost through
planned and unplanned downtime, and that more than
16,000 tons were lost because of speed loss each day. Our
investigation pointed out two primary reasons for the speed
loss. The first was low load factors on the belts attributable
to several operating factors, and the second was that the
setpoint on the feeder belt was reduced manually whenever
material was flowing to a particular stock pile.
The control system captured load factors and setpoint,
but the causes for the reduced production rates weren’t
captured. While all production stoppages were routinely reviewed, slowdowns weren’t part of the daily review process.
“Gold is where you find it.” But successful miners know
where to look and have the proper tools. So, in your search
for improved productivity, calculate your plant’s OEE and
map the losses. Dig into the data to uncover those nuggets
hidden in repetitive small delays and production slowdowns.
At the same time build a better foundation by improving the
business process for equipment maintenance, process control, and data capture. You’ll be rewarded with more golden
nuggets of productivity than even Midas could imagine.
Contact Herb Lichtenberg, senior vice president and practice
director for production, SAMI Corp. (www.samicorp.com), at
hlichtenberg@samicorp.com.
w w w .PLANTSERVICES.co m May 2 010 23
PS1005_23_Yours.indd 23
5/7/10 9:24 AM
3 models
to choose from
mIT 510/2, 520/2
and 1020/2
For over 100 years, Megger has been
the world recognized leader in the area of insulation testing.
Our 5 and 10-kV insulation testers meet the requirements for use in CATIV 600 V
applications, in line with IEC61010-1. Some of the features of the units include:
n
n
n
n
n
n
n
Free! Distributor catalog
Contact us now for the 2010 Megger Distributor Catalog.
Request your free copy today at vfmarcom@megger.com or
contact us at 1-866-254-0962
PS1005_FPA.indd 24
www.megger.com/us
n
Extremely high measurement sensitivity
(15 TΩ @ 5 kV; 35 TΩ @ 10 kV)
3 mA test current
2 mA noise immunity
High performance guard terminal
Battery or line operated
IP65 case rating
Result storage capability (MIT520/2 and MIT1020/2)
Automatic performance of five industry-standard tests
5/7/10 10:45 AM
HUMAN CAPITAL
Tom Moriarty, P.E., CMRP
Integrity
Doing what’s right because it’s the right thing to do
Many years ago, I saw a poster on a wall in one of
the buildings on a military base where I was posted as a
junior enlisted person. The poster’s message stuck with
me. It showed a picture of a person stretching his reach
to paint an obscure area of a machine foundation. It
was a location that nobody would ever see, even if one
was looking for it. The caption under the picture read,
“Integrity means doing your best even when no one else
will know.”
In my mind, this message conveyed the essence of the
meaning of integrity: Doing what’s right because it is the
right thing to do.
What made me think about this? As I write this
column, the Arnold Palmer Bay Hill Invitational golf
tournament was airing on television. The event was
rained out the previous Sunday, so I switched to the Golf
Channel. A Ladies Professional Golf Association (LPGA)
tournament was on.
The first action I saw was that of media darling Michelle Wie trying to hit a golf ball out of a water hazard.
Ms. Wie had one foot in the water and another foot on
the bank of the pond. She took a mighty swing, a huge
spray of water shot into the air, but the ball barely got out
of the water. After she finished swinging at the ball, she
relaxed her grip and her club touched the ground inside
the hazard line. In golf parlance, she “grounded” her club
inside the hazard line; a two stroke penalty.
The tournament rules officials notified Ms. Wie that
she was, in fact, given a two stroke penalty. This made a
tournament win very unlikely, and a significantly lower
paycheck highly likely.
The rules of golf can be difficult to understand, and
some of the rules might seem ridiculous to those who
don’t embrace the game. But when you make your living
as a professional, you’d better know the rules of the game
you play. Few people would argue that point, but Ms. Wie
was apparently one of them.
The integrity issue first appeared when Ms. Wie didn’t
charge herself a two stroke penalty for grounding her
club, which would have been consistent with the character of the game of golf.
The second integrity issue surfaced at the end of her
round when she tried to argue the point with rules officials.
Ms. Wie stated that she was off-balance, which is the only
allowable reason to ground a club inside a hazard line.
Repeated viewing of the video made it hard for an
unbiased observer to be convinced she was off-balance.
It looked more like she was disappointed with the fact
that the ball barely made it out of the water hazard; she
When you make your living as a
professional, you’d better know
the rules of the game you play.
appeared to relax her arms and her grip on the club. She
seemed to not be thinking about the rules related to her
actions.
Now, contrast Ms. Wie’s actions with those of an icon
in the world of golf. His name was Bobby Jones, and he
was famous as a superior golfer and gentleman. His integrity was unquestioned.
At one well-documented event, the 1925 U.S. Open, Mr.
Jones was in contention. During the tournament, he was
getting ready to hit a shot and he grazed the grass near
his ball. He wasn’t certain, but he thought he saw his ball
move. No one else saw it move, no one else thought he
should penalize himself for something he was not certain
of. As a consequence of taking the penalty, he did not win
that tournament.
Later, as Mr. Jones was being praised for his integrity, he
was quoted as saying, “You’d as well praise me for not breaking into banks.” He did what was right because he believed
it was right. Over his career, Bobby Jones won 13 major
tournaments and to this day is revered within the sport.
Whether you’re a tradesman, an athlete, or a supervisor, integrity has a way of balancing the scorecard over
time. Take responsibility and be accountable for your actions, whether others see it or not. It’s the entirety of your
work that defines who you are and how others perceive
you. Do what’s right because it’s the right thing to do.
Tom Moriarty, P.E., CMRP, is president of Alidade MER Inc.
Contact him at tjmpe@alidade-mer.com and (321) 773-3356.
w w w .PLANTSERVICES.co m May 2 010 25
PS1005_25_HumanCap.indd 25
5/7/10 9:26 AM
“Our business changes
every six months.
Our systems take a year
to catch up.”
Customer mandates, regulation and
market conditions are changing faster
than ever. How do you keep pace? By the
time you implement most enterprise
applications your needs have already
changed. The answer is IFS.
IFS – first in enterprise agility
• The first software package built from
the ground-up on a Ser vice-Oriented
Component Architecture (SOCA), combining the agility of ser vice orientation
with the proven benefits of components
• IFS’ seventh generation of components
and second generation of SOA -- the
most stable platform on the market
• Roll out functionality in stages,
addressing your needs in priority order
• Easily integrate with legacy systems
or other third-par ty software
• ERP, EAM, SCM, CRM, PLM
Read our white paper on how to take your organization to the Next
Generation of Maximum Overall Equipment Efficiency! Call 1.888.437.4968
today to get your copy.
SEE US ON PLANT SERVICES’ ONLINE CMMS COMPARISON TOOL.
I F S – T H E G L O B A L E N T E R P R I S E A P P L I C AT I O N S C O M PA N Y
w w w. I F S W O R L D . c o m
PS1005_FPA.indd 26
5/7/10 10:46 AM
asset manager
david berger, P.Eng.
Handling Service Requests
It’s evolved way beyond the primitive telephone help desk
Industries that deal with the public rely on a service center
to handle requests for maintenance. Property management
companies developed a centralized call center for taking maintenance requests and dispatching someone to take corrective
action. They were among the first to benefit from a Web-based
product, where tenants completed a Web-based form to request
maintenance. This reduced labor costs through automation and
self-service. For tenants, the Web-based process provides an
audit trail, and allows online tracking of request status.
Other industries have adopted this model, or at least Webbased service/work requests. CMMS vendors responded
with features and functions that facilitate the process.
Work initiation: Even a basic CMMS package has the
ability to generate a work request via the Web. Some vendors
sell this capability separately from the main CMMS package
at a fraction of the base package price. The fact recognizes
that users are typically internal or external customers of the
maintenance service provider and, as such, are interested
only in a very small portion of the CMMS functionality.
Alternatively, service providers can establish a service center
to deal with phone calls or e-mail requests. Many municipalities have a centralized call center that takes requests by telephone. Requests by citizens, local businesses, or city employees
for maintenance of roads, parks, facilities, and transit vehicles
are handled by a call center representative.
No matter what your industry, each demand for maintenance, however received, eventually funnels into the CMMS
and becomes a work request. In some cases, the CMMS vendor offers a separate module to track customers and service
requests - customer relationship management (CRM) software. In other cases, a company purchases CRM software
separately and integrates it with its CMMS package. The
simplest approach, of course, is for the person answering the
call to enter the work request directly into the CMMS.
Once work requests are in the CMMS, they’re evaluated,
approved, and scheduled. Suppose several telephone complaints indicate that one area of your building is too hot and,
at the same time, complaints are received that an area at the
other end of your building is too cold. It could be that of the
dozen or so complaints received, there’s really only one root
cause – the HVAC system is out of balance. Thus, a single
work order to fix the HVAC system is issued, approved, and
scheduled. The work order is cross-linked to all of the work
requests that relate to it to facilitate status tracking.
Status tracking: Most people who initiate a service request
expect to be kept abreast of service status. Most CMMS packages have notification capability and the sophisticated ones
have workflow engines, both of which allow requestors to re-
The expectation of most people
who initiate a service request
is that they will be kept abreast
of service status.
ceive notification whenever there’s a change in status. Examples
of status changes that might be of interest to requestors are:
• Work request received
• Work order approved
• Work order scheduled
• Percent completion or estimated date of completion
• Work completed
Every status change should be date- and time-stamped so
that time info can be analyzed and improved over time.
Pareto analysis: This is a simple but powerful tool for
analyzing service history . It’s especially useful for identifying recurring problems, the root cause, and the most
cost-effective remedy. Most CMMS work requests identify
relevant problem codes associated with a given asset. The
most common Pareto analysis of problem codes is a bar
chart showing the number of occurrences or dollars spent
for each problem code. Focus on reducing the frequency and
cost of the tallest bars on the Pareto graph. Similarly, Pareto
analysis can be conducted for cause and action codes.
Once an asset is identified on the work request, likely
problem codes associated with it are found on a table lookup. When a service person troubleshoots a problem, codes
for the root cause and action taken are then entered onto the
work order. The latter two coded fields are tied to the problem code and asset type to generate a nested and hierarchical tree structure for problem, cause, and action codes. Most
of the high-end CMMS packages have this feature.
It might be helpful to conduct Pareto analysis daily, summarized for the week, and consolidated for the month and
year-to-date. This increases the availability, performance, and
reliability of your key assets over time, as well as the overall cost
of maintaining them.
w w w .PLANTSERVICES.co m May 2 010 27
PS1005_27_28_AssetMgr.indd 27
5/7/10 9:27 AM
asset manager
Service level agreement: Another useful feature of the
more advanced CMMS packages is the ability to record and
monitor service level expectations. The CMMS might track
the interval between when a service request is made, when
someone is dispatched, and when the problem is solved. The
CMMS can record a service catalog, i.e. all of the services
provided, service level expectations, and the standard cost
of providing each. The CMMS can track costs and service
levels for comparison to your standard.
IT specialization: There are five asset classes, namely
plant equipment, facilities, mobile equipment, infrastructure, and IT assets. Although the service model can be
applied to each asset class, IT assets are most relevant.
For decades, help desks have been taking calls from users
experiencing problems with desktop computers, laptops,
printers, and so on. Service level agreements are established
with internal IT departments or external service providers,
and service requests are typically taken by phone or via the
internet using CMMS or IT help desk software.
Chargebacks: Some CMMS packages can accommodate
chargebacks to internal departments or external customers
to cover labor, spare parts, and overhead charges. This is accomplished by turning work orders into third-party invoices
for services rendered. A number of CMMS vendors are quite
sophisticated in this area, offering advanced features:
• Mark-up of labor, material, and other costs
• Rounding of time and cost values
• Establishing a min and max labor time or dollar charge
• Distinguishing billable work from non-billable work
• Configuring billing templates with rate information for
a specific job type
• Associating billing templates to specific customers, customer class, or on a one-off basis, including appropriate
rates, mark-ups, and charges
• Handling split charges (e.g. for multiple accounts)
• A llowing customer access to only their own service level
and billing information
E-mail Contributing Editor David Berger, P.Eng., partner,
Western Management Consultants, at david@wmc.on.ca.
Vertical Motion Arms
Vertical Motion Arms that field-adjust to any load.
Any workspace. And any operator.
Hoffman® Brand SYSPEND™ Vertical Motion Arms quickly field-adjust for different
control panels and operators. Only SYSPEND Vertical Motion Arms let you easily field-adjust
and recalibrate the lifting force without special tools or service calls. Operators enjoy easy
vertical travel and swivel. Available in a monitor/keyboard model plus three models for HMI
enclosures, touchscreens and control panels.
Contact your local Hoffman distributor, or locate your sales office at hoffmanonline.com
Hoffman® SYSPEND™ offers:
• Adjustable vertical travel up to
30.5 cm (12"), swivel to 340 degrees
• Weight capacity up to 46 kg
(125 lbs.)
• Integrated cable management
• NEMA Type 4, 4X and 12 rated
solutions
• Available stainless steel arms for
use in washdown environments
©2010 Pentair Technical Products
PTPA-156 Temporary Syspend Ad_PlantServices.indd 1
PS1005_27_28_AssetMgr.indd 28
4/16/10 9:26 AM
5/7/10 9:27 AM
NOT ALL IRON
IS CREATED EQUAL.
WE PITY THE STUFF THAT ENDS UP AS REBAR.
The best ore goes on to become members of the Hyster team, a full line of trucks that
derives their exceptional power to perform from 80 years of integrity, engineering
excellence and quality design. Throw in durability and reliability, and the end result is
lift trucks that are as tough as nails and as dependable as all get-out, day in and day out.
© 2010 Copyright Hyster Company. Hyster and
2765_HST2368_FortisPS.indd
1
PS1005_FPA.indd
29
are registered trademarks of Hyster Company.
HYSTERAMERICAS.COM
3/9/10
11:07:27
AM
5/7/10
10:46 AM
Surround
yourself with
confidence.
Plus 70 years of measurement
expertise built into every product.
Agilent’s new family of award-winning handhelds puts a
wealth of important features and capabilities into your hands.
Like vivid displays, dual-temperature measurements and more.
Along with world-class accuracy and
Digital multimeters
Digital oscilloscopes
ease-of-use you can depend on for
Capacitance meter
better results from the world’s largest
LCR meters
Multi-function calibrator/meter
Clamp meters
test and measurement company.
That’s confidence. That’s Agilent.
For a free application note
and product information
www.agilent.com/find/confidence
Agilent and our Distributor Network
Right Instrument. Right Expertise. Delivered Right Now.
© 2010 Agilent Technologies, Inc.
PS1005_FPA.indd 30
Buy from an Authorized Distributor
www.agilent.com/find/distributors
5/7/10 10:47 AM
Technology Toolbox
Sheila Kennedy
Emission Controls
New technologies are advancing our abilities to contain unsavory emissions
Modern biofilters and scrubbers have capabilities and
cost efficiencies that exceed their predecessors’. Integrated
tools slash emissions and portable diesel engine filters and
green fuel emission controls are satisfying unique requirements. Meanwhile, researchers are developing approaches to
managing hazardous releases from coal-fired power plants.
Advanced biotreatment: When released, volatile organic
compounds pose a threat to health and the environment.
New VOC controls improve regenerative thermal oxidizers
and conventional biotreatment alternatives. An example is
Tri-mer’s MultiPhase BioSystem, a combined biofilter and
bioscrubber of synthetic ceramic biomedia that tolerates
higher gas temperatures and doesn’t degrade.
The company’s bioremediation treats multiple VOC emission types in liquid and gas phases with as much as 98%
efficiency, producing only clean, non-hazardous solids for
disposal or burning. The system doesn’t generate NOx byproducts typical of older combustion approaches. Much less
carbon dioxide is released because natural gas isn’t burned.
The self-cleaning, clog-free system also is more compact and
less expensive to install and operate.
Fast start: One way for power plants to reduce emissions
is to achieve faster start-ups. The Siemens Flex-Plant 30
power island is designed to start up within 30 minutes and
reduce carbon monoxide release by more than 200 tons per
year compared to standard F-class combined-cycle plants.
Fast-start features include a three-pressure heat recovery
steam generator (HRSG) with Benson once-through technology, high-capacity steam attemperation and full capacity
steam bypass systems, piping warm-up capabilities, Siemens’
steam turbine stress controller, modern water treatment
system, and optimized plant standby using auxiliary steam
to maintain vacuum. These integrated technologies result in
50% shorter plant start-up times.
Mobile control: Diesel soot is carcinogenic and highly
regulated. Mobile diesel power users who require portable
filtering technology can consider a trailer-mounted Mobile
Power Emissions Control System from Rypos. It connects to
diesel power generators ranging from 100 kW to 500 kW to
reduce soot by as much as 95%.
While passive diesel particulate filters need high exhaust
temperatures and are prone to soot accumulation and
clogging, Rypos’ active diesel particulate filters offer active
regeneration and operation that is essentially maintenance-
free. The system uses no more than 1% of the energy output
to regenerate so there’s is virtually no increase in fuel use.
Mercury management: Coal-fired power plants represent
the greatest share of human-generated atmospheric mercury
emissions. National Energy Technology Laboratory (NETL)
researchers developed a TOXECON process for coal-based
Mobile diesel power users who
require portable filtering
technology have an alternative
power generators to reduce mercury emissions significantly,
increase particulate matter collection efficiency, and maximize the use of coal combustion byproducts. The process
injects sorbents between existing particulate control devices
and captures pollutants in a pulsed-jet baghouse.
A recently-completed three-year demonstration project in
Michigan resulted in removing more than 90% of the mercury in the flue gas. NETL estimates approximately 97 lbs. of
mercury and 250 tons of particulate matter will be captured
at the plant annually.
Gas scrubber: Sulfur dioxide and carbon dioxide also are
hazardous byproducts of coal-fired power plants. Pacific
Northwest National Laboratory (PNNL) researchers working to capture sulfur dioxide and other acid gases developed
a Reversible Acid Gas Capture process that binds oil-like
organic liquids with acid gases in power plant emissions.
The liquid is then heated to recover the gases for disposal.
This technique reportedly captures twice as much pollutants as water-based scrubbers, and is more energy-efficient
because water requires more energy to pump and heat. The
PNNL technology is anticipated to be an easy retrofit for
existing coal-fired plants.
E-mail Contributing Editor Sheila Kennedy, managing director of
Additive Communications, at Sheila@addcomm.com.
Reference Web sites:
www.tri-mer.com
www.energy.siemens.com
www.rypos.com
www.cemtrex.com
www.netl.doe.gov
www.pnl.gov
w w w .PLANTSERVICES.co m May 2 010 31
PS1005_31_TechTool.indd 31
5/7/10 9:28 AM
Get It
Bac k
Recover the energy
invested in powering
compressors
By Paul Studebaker, cmr p
Editor in C hief
It’s common knowledge (and the Ideal Gas Law) that
compressing a gas raises is temperature. Compressors must
be air- or water-cooled, and compressed gases are commonly cooled to condition them for use.
Less well known is the fact that all of the energy required
to compress a gas is theoretically available for recovery as
heat: the compressed gas leaving the compressor system at
room temperature contains no more energy than the roomtemperature air entering the compressor.
“It’s possible to extract, by heat transfer, an amount of
energy from the compressed air that is equivalent to the
amount of energy the electric motor placed into the com-
32
pressed air,” says Bill Scales, P.E., CEO, Scales Industrial
Technologies (www.scalesair.com). “This might appear to
be a paradox, but confirms the first law of thermodynamics and the principle of the conservation of energy, which
states that energy can neither be created nor destroyed; it
can only change form.”
So how can compressed air perform work to power plant
equipment? “When the compressed air expands, it draws
energy from its surroundings equivalent to 20% to 25% of
the energy we put in,” says Wayne Perry, technical director,
Kaeser (www.kaeser.com). “It robs it from the atmosphere
or the devices where it expands.”
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_32_38.indd 32
5/7/10 11:11 AM
Efficiency / Compressors
Compressor manufacturers and savvy system
engineers are well aware of the potential for
energy recovery, and have increased their offerings of equipment, accessories, and know-how to
maximize energy recovery ROI. “One of the better methods to improve the overall efficiency of a
compressed air system is to recover this rejected
heat,” says Scales. “However, the availability of
the heat and the opportunity to recover and use
it are two different matters.”
Gather it up
Recovery: Practical versus possible
Figure 1. The challenge is to recover energy from as many as possible
For a sense of how much energy might be
of the compressor’s heat-producing components, including compression
available, consider that one horsepower equals
elements, oil cooler, intercooler, and aftercooler.
2,545 BTU/hr. “Although most rotary screw
and reciprocating air compressors are sold in
The most common industrial compressor is the
nominal horsepower sizes, they generally operate at
lubricant-injected rotary screw supplied as a packaged
loads that are 10% higher than their motor nameplate
compressor, which makes it easier to recover the heat. “In
rating at rated compressor discharge pressure and full
this type of compressor, approximately 80% of the heat is
capacity output,” Scales says. “Therefore, a 100-hp air
rejected in the lubricant cooler,” Scales says. “Most of the
compressor (110 brake hp) generates almost 280,000
remaining heat is rejected in the aftercooler with a small
BTU/hr at full load. In addition, the electric motor
percentage in the form of radiated heat from the compreswith an assumed efficiency of 93% will dissipate an adsor housing and lubricant separator receiver.
ditional 19,600 BTU/hr.”
“In a two-stage lubricant-free rotary screw compressor,
The potential to recover this energy was recently driven
almost all the rejected heat is evenly divided between the
home by TÜV’s certification of Atlas Copco’s “Carbon
aftercooler and intercooler,” Scales says. “In two-stage,
Zero” compressor as capable of recovering 100% of the
water-cooled reciprocating compressors, the intercooler
input electrical energy. The challenge is to recover energy
and aftercooler might each reject 40% of the heat, and the
from as many as possible of the compressor’s heat-procylinders a total of 20%. A centrifugal compressor might
ducing components, including compression elements, oil
have each intercooler and aftercooler share almost equally
cooler, intercooler, and aftercooler (Figure 1).
in the heat load.”
Recoveries nearing 100% are possible only under rather
Ingersoll Rand has engineered heat recovery systems for
ideal conditions. “We’re recovering 100% only under very
more than 20 years. “Sometimes the hype is more than realspecific conditions: 40°C, 70% RH, 20°C inlet water,” says
ity,” says Ian MacLeod, global portfolio manager, centrifugal,
Dave Hebert, product marketing manager, oil-free, Atlas
Ingersoll Rand (www.irco.com). “It’s application-driven,
Copco (www.atlascopco.us). “Typical recoveries are in the
because you need both the demand for heat and the matchmid-90s.” The TÜV test results depend on extracting heat
ing supply.”
of condensation from input air humidity to compensate
Recovered energy is delivered as hot air or warm water,
motor losses.
typically about 180°F maximum but sometimes higher.
“If you have a need for the heat, you can recover 90% to
It’s produced only when the compressor is running, and
95% of it,” says Perry “It takes about $50,000 per year to
can be recovered only if there is a use for it. Common
power a 100 hp compressor, so a $10,000 heat exchanger
uses include process heating, supplemental space heating,
can pay back in 3 months.”
making hot water, or preheating boiler make-up water.
Real-world project paybacks depend on the cost of
“The biggest opportunity is with centrifugals because
alternative energy sources (typically natural gas), how well
they tend to be larger and offer hotter discharge temperayou can match energy supply and demand, the type(s) of
tures compared with contact-cooled compressors, and
compressors, and the complexity of the project.
they’re usually applied on steady loads,” says MacLeod.
“Depending upon the type of compressor, method of
“Positive-displacement compressors are more often
cooling, and radiant heat losses, it is possible to recover
smaller and cycling, with run times that might not corenergy in the form of heat transfer that is equivalent to
relate with the need for heat.”
50% to 90% of the total energy input,” says Scales.
w w w .PLANTSERVICES.co m May 2 010 33
PS1005_32_38.indd 33
5/7/10 11:18 AM
Efficiency / Compressors
ROI is delayed by partial-year
operation of space heating, and mismatch of supply and demand times in
intermittent operations. Energy storage adds cost, complexity, and maintenance. “However, the applications
are limited only by the imagination
and possible opportunities, and are
not limited to the northern or colder
environments,” Scales adds.
Paybacks vary depending on the
alternate heat source, but even when it’s
gas, they can be “Less than two years –
and that can include the cost of the new
compressor on larger installations,” says
Hebert. “They’re much faster when the
alternative energy source is electricity
than when it’s gas, and faster when the
energy demand is constant. But even on
smaller installations, you can recover
70% with a retrofit, and recover that cost
in less than two years.”
Lots of hot air
Advanced Performance.
Advanced Protection.
A proven performer just got better!
Like all Sprayon® products, the New Sprayon® Insulating Varnish line helps to preserve and
protect your equipment to prevent costly damage and downtime. The Sprayon® Insulating
Varnish program features excellent adhesion to metals, windings, coils and armatures.
It has been developed to penetrate old and new windings. This great performer is
now offered in bulk for use in dip applications and can be baked for faster cure rates and
maximum hardness. Sprayon® Insulating Varnish meets performance standards of ASTM
D 115-07 and Temperature Class F requirements. The New Sprayon® Insulating Varnish
line has been reformulated to improve performance including:
Improved dIeletrIc Strength ......60% improvement in dielectric strength
FaSter dry ....................................67% reduction in dry-times
FaSter BuIld ..................................50% higher film build
Improved FIlm IntegrIty ............... Improved durability against harsh
chemicals & environments
IncreaSed comFort ....................... Equipped with our Dan-Vern™ spray button
for faster coverage with less finger fatigue.
dIp applIcatIonS ...........................Now available in bulk for dipping applications
For more information please visit
sprayon-insulatingvarnish.com
34
The simplest way to recover heat on
air-cooled compressors is to add
ductwork and blow the warm air into
a room. “A lot of space heating projects
are just on the compressor room, to
keep it from freezing,” says Perry.
“Cooler [denser] inlet air temperatures have little effect on efficiency of
positive-displacement compressors
– they just use more power to deliver
more compressed air when the inlet
air is cool. You want to keep inlet air
density up on dynamic compressors
such as centrifugals.”
Most facilities have positive-displacement (PD) rather than centrifugal
compressors. “Approximately 80% to
90% of PD compressors are air-cooled,”
says George Mankos, global portfolio
manager, high-pressure, Ingersoll Rand.
It’s a simple matter to duct the heat from
those compressors into conditioned
space when heat is needed. “It’s very
low-capital,” Mankos says. “We made
the discharge out the top of our units to
make it easier for our customers.”
Cameron air-cooled centrifugal
compressors facilitate energy recovery
by delivering the hot air at the exit of
the air/air exchangers, which can then
be efficiently ducted for space heating (Figure 2). “In Buffalo winters,
we need no outside source to heat our
assembly plant; we use the heat of
compression from the compressor that
supplies the utility air to our plant, for
efficient space heating,” says Sandeep
Gadkary, general manager, operations,
Cameron (www.c-a-m.com).
The apparent simplicity of such
systems is seductive, but beware. “It’s
fine for a short length, but as distance
increases or if the ductwork is under-
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_32_38.indd 34
5/7/10 11:19 AM
Efficiency
/ Compressors
Simple system
A company operates two 100 hp
air-cooled rotary-screw compressors at full capacity for 8,000
hours per year. The brake horsepower measured at the compressor shaft is 110 and the motor
efficiency is 0.93; the fan motor
has an efficiency of 0.90 and
requires 5 bhp. The conversion
factor is 2,545 BTU per hour
per bhp. The total heat is:
110
5
+
x 2,545=
0.93 0.90
315,160 BTU per hour
Assuming only 80% of the heat
is recoverable, the two compressors offer about 504,000 BTU/
hr. At a natural gas cost of $0.50
per therm (100,000 BTU), and a
heating season of 4,000 hours
per year, the annual savings is:
$0.50
504,000 x
x 4,000 hours
100,000
= $10,080 per year
Summer
RF
e
us
a
are
ho
re
Wa
D
C
ter
n
Wi
er
T
WF
d
ate
L
ng
Co
flo olin
Su w in g ai
r
mm
er
ow
r fl er
Ai Wint
in
fa
nu
Ma
ri
ctu
e
ah
are
nt
Wi
in
fan:
WF Wall
near ceiling / on in Winter
L Outside louver: open in summer
D Doors: open in winter / closed in summer
RF Roof fan: on in Summer
C Compressors
T Thermostat: controls fans and louver
Note that the compressors were
purchased air-cooled and the fan
horsepower was necessary for operation, so in this case, the cost of fan
operation isn’t deducted from the
savings. The general arrangement of
the compressors within the plant and
warehouse area is depicted in the
drawing. Plant air is further heated in
winter and discharged to the warehouse; during the warmer months the
heat is rejected outside the building.
The outside louver and wall fan
prevent potential problems with
elevated compressor room tempera-
tures. “The plant personnel did the
installation and, as you can see, it
was done without any ductwork,” says
Bill Scales, P.E., CEO, Scales Industrial Technologies (www.scalesair.
com). “For many applications, the
energy cost of operating any additional
ventilating or booster fans should
be deducted from the savings.”
sized, the compressor overheats,” says
Chris Wagner, president and CEO,
CAM Technologies (www.compressedairmanagement.com). “This is a very,
very common problem, so they boost
it with a VFD or separate blower and
starve the compressor inlet.”
Large systems call for large ductwork. “You might have to insulate the
duct, which can be 6-ft.-square on a
200 hp compressor. That’s a very expensive duct,” Wagner adds. “It works
if the room is nearby. If it’s boosted,
engineer it to maintain ¼-in. WC in
the housing.”
Scales Industrial Technologies offers
these cautions:
• Louvers and ductwork constitute
restrictions to the flow of ventilat-
ing air and might decrease the
necessary fan airflow to effect
proper cooling. In some cases
booster fans might be necessary
and the cost of operation should
be considered.
• Size louvers for minimum restriction and to maintain the air velocity at a maximum of 10 ft/sec to 15
ft/sec. Follow the compressor and
dryer manufacturer’s recommendation for the maximum allowable
static pressure.
• Bring inlet cooling air in at a
relatively low point, but don’t pick
up dirt or dust. In a dusty environment, a generously sized air panel
filter is necessary. Keep the panel
inlet filters, louvers and cooler
surfaces clean for best compressor
performance and reduced maintenance costs.
• Direct the cooling air towards
the compressor and/or dryer
fan inlet(s), through the cooling
surfaces across the compressor
and dryer. Exhaust the warm air
from the room at a level above the
compressor or other air-cooled
equipment.
• In multiple compressor installations, don’t allow the warm
discharge cooling air from one
compressor or dryer to be directed
towards the inlet of the fan of
another compressor or dryer.
• In most rotary screw compressors,
the cooling air leaving the coolers
w w w .PLANTSERVICES.co m May 2 010 35
PS1005_32_38.indd 35
5/7/10 11:20 AM
Efficiency / Compressors
Heat Recovery System Schematic - Typical
Sophisticated system
A manufacturer of mining equipment, tools, and specialty materials
preheats boiler feedwater using heat
recovered from a 5,500 cfm, threestage centrifugal compressor (796
kW at the compressor input shaft).
The boiler and compressor both run
24/7/365. Boiler feed water nominal
flow is 70 gpm, entering at 45°F and
heated to 188°F to enter the boiler.
“Dual pumps and coolers
provide 100% backup,” says Ian
MacLeod, global portfolio manager,
centrifugal, Ingersoll Rand (www.
irco.com). “Higher water temperatures could be achieved, but this
customer opted for volume over
temperature.” The energy recovery
system captures 753 kW, or 95%
of the motor shaft horsepower.
Compressor Centac C950 MODEL C155MX3
(3 stages, standard coolers)
90°F, 5544 cfm @ 100psig
118°F, 70.4 gpm
Heat Exchanger
86°F, 227
gpm
108°F, 206 gpm
158°F,
21 gpm
108°F, 21 gpm
104°F, 73.4 gpm
Pump-skid wired
to compressor
Dual Pumps
108°F,
227 gpm
Cooler 1
Air
Compressor Cooling Water
Hot Water to Boiler
Raw Water to Heat Recovery Cooler
45°F, 81 gpm
Boiler feed
water
To drain
Cooler 2
can be 20°F to 40°F warmer than the inlet air. Therefore,
recirculated plant air can be used for supplemental heating. Don’t take in sub-freezing air and expect to use the
air compressor to heat it to a temperature where it will
reduce heating fuel costs.
• Improper ventilation can result in elevated air compressor
and dryer operating temperatures. This can lead to reduced
Take it off the top
External Aftercooler
Total Power Recovered = (500 x 70.4gpm x 73F)/3413 = 753kW
equipment life, increased maintenance and repair costs,
and an unreliable air compressor system. The initial price
of a good ventilation system usually is far less than the
resulting cost of a hot operating environment.
If ducting is daunting, consider an air-to-water heat
exchanger. “With an air-to-water heat exchanger or a watercooled compressor, you can heat a room some distance
away,” says Wagner. “Run a 2-in. to 3-in. pipe to and
from a fan-cooled heat exchanger. Take water at
110°F and return it at 85°F. You only have to insulate
a 3-in. pipe.”
Gallons of warm water
Figure 2. Ducting warm air can be easier when it is delivered from the top of
the compressor package.
36
Water-cooled compressors offer warm water that
can be directed through a liquid-to-liquid heat
exchanger to heat water or process fluid, or through
a water-to-air heat exchanger for space heating.
“These heat recovery units are available as packaged units, and include the pumps and controls for
simplified installation and economic operation,”
says Scales.
The aforementioned Carbon Zero oil-free compressor relies on routing water through its heat-producing components to maximize the potential heat
recovery, and yields hot water at up to 194°F. Small
amounts of heat are lost and can’t be recovered,
such as inefficiency of the drive motor, radiation
into the room, and heat that remains in the outlet
compressed air. However, the air drawn into the
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_32_38.indd 36
5/7/10 11:20 AM
more resources at www.plantservices.com
Topic
Search
Scales Air projects
“Heat recovery hot topic”
Blow molding energy recovery
“PET project”
Dryer technologies
“Four untruths compressed air”
Compressed air audit
“Compressed air audit”
THE RIGHT TOOL FOR
EVERY JOB
For more, search www.PlantServices.com using the terms
compressed air, energy and recovery.
compressor normally contains humidity. During compression,
this humidity condenses and releases latent heat.
Heat also can be taken at the oil cooler of oil-flooded equipment,
but recovery percentages are typically in the mid-70s, to avoid
overcooling the oil. “Compressors want oil at 140°F, so you can’t
take a lot of that heat,” says Wagner. “Replace the cooling tower
with a heat exchanger, but return the water at higher than 70°F or
water will be pulled out of the air into the oil.”
Make it a drying heat
Another way to use otherwise wasted heat is for regenerating
desiccant dryers. A typical dryer uses two desiccant beds – one
is in operation while the other is in regeneration. “These dryers
often are regenerated using an electric heater and blower system, or by purging them with clean, dry compressed air,” says
MacLeod. “The former uses additional energy and the latter
consumes about 15% of the compressor’s output.”
Instead, the heat of compression can be used to desorb the water.
“We route the hot discharge air from the compressor first through
the wet bed to regenerate it, then through the cooler to cool the
air and condense out much of the moisture, then through the dry
bed to bring the dew point down, typically to -20°F to -40°F,” says
Mankos. “The energy consumption of the system is about 60 watts
to run the controls,” Mankos says. “It’s a cost-effective retrofit,
even at electricity prices as low as two cents per kilowatt-hour.”
The discharge air temperature from a three-stage centrifugal
compressor is typically 235°F to 260°F; from a two-stage it’s
about 350°F. Hotter air gives a lower dew point by more complete regeneration of the desiccant, so it’s more effective to take
the energy after the second stage, then route the air through an
intercooler and back to the third stage (Figure 3).
“After heating, the regenerating tower is depressurized,” says
Gadkary. “From the outlet, a small portion of dry air is blown
into the regenerating tower and vented. This stripping can
remove the last bit of moisture from the desiccant, allowing the
package to deliver dewpoints of -40°F and lower.”
After stripping, the desiccant bed is cooled to eliminate moisture spikes. Some of the dry, cool air from the outlet is directed
through the bed, then rejoins the processed air at the outlet so
no compressed air is lost.
w w w .PLANTSERVICES.co m May 2 010 37
PS1005_32_38.indd 37
• Energysaving
compressors
• Pointofuse
compressors
• Oil-freecompressors
• Auditingservicesthat
identifywaste
• Compressormonitoring
capabilities
• Airtreatmentproducts
Don’t get stuck with the wrong solution.
To find out more, visit
GardnerDenverProducts.com/Solutions.aspx
5/7/10 11:21 AM
PS March 2010 ad.qxp
2/26/2010
Summit Industrial
Products
Your Best
Choice for
Synthetic
Lubricants
Increase reliability and
reduce down time of your
critical rotating equipment
with synthetic lubricants
from Summit Industrial
Products. Our lubricants
keep your equipment
running cooler, smoother,
longer and more efficient.
A Complete Line Of Full
Synthetic Lubricants:
Air, Gas & Refrigeration
Compressor Fluids
Gear & Bearing Lubricants
Hydraulic Oils
R&O Lubricants
Blower Lubricants
Turbine Oils
Barrier Fluids
High Temperature Chain Oils
Oven Conveyor Chain Oils
Vacuum Pump Oils
Air Tool Oils
NSF ISO 21469 Certified
ISO 9001 : 2008 Certified
SUMMIT
INDUSTRIAL PRODUCTS
4:24 PM
Efficiency / Compressors
How It Works
Hot and dry
IC
IC
TDP
arrangement
AC
Dryer
skid
Dry
-40˚F
DP
Figure 3. Hotter air does a more thorough regeneration of the desiccant dryer adsorption
bed, so on a three-stage centrifugal compressor it’s best to route the air from the second
stage through the bed and back to the third stage.
Expansive opportunities
Water, space, condensate, and dryer heating are the most common ways to recover
energy, but specific facilities might offer
other opportunities. Recovered energy
has been used to replace gas or electric
heaters to melt wax, liquefy chocolate and
sugar, and power parts-drying systems.
“Hot air from the compressor discharge, prior to the aftercooler, also can
be used to reheat compressed air after
initial cooling or drying,” says Scales.
“This adds energy to the air.” However,
care must be taken to ensure the end
users can accept the elevated temperature. Insulate the piping to reduce
heat lost through radiation and, more
importantly, to protect personnel who
might touch exposed pipes.
Gas expansion is an often overlooked opportunity to recover energy.
“In process compression, one often
can integrate an expander stage in a
compressor, making it a compander,”
says Gadkary. The process gas is
expanded in the expander stage to
recover energy and increase compressor efficiency. “The savings can range
up to 20%, and it is successfully employed in air separation applications,”
he says. “This technology also offers
a great opportunity in industrial air
applications that experience significant pressure drops and involve large
volumes of air.”
When it comes to compressor energy
recovery, “The opportunities are excellent,” Scales says. “Use your imagination to recover the heat from your air
compressors and reap the benefits of
reduced energy consumption and lower
operating costs.”
Why energy is so seldom recovered
Many facilities are candidates for
compressor energy recovery projects
with attractive ROI, but have accounting structures that prohibit them. “The
problem is, people don’t take a systems
approach,” says Wayne Perry, technical
director, Kaeser (www.kaeser.com).
Maintenance has a broken compressor and just needs to replace it,
or the plant operations people need
more air, so they buy a compressor. They aren’t graded by energy or
carbon. The purchasing department is
graded on performance to budget, and
buys the least expensive machine.
“In the accounting department, capital
goes in one bucket, and utilities in another. The people who buy the compressors
are below the level where they can be
put together,” says Perry. “They tell us
they can’t spend to save energy because
it will actually hurt their performance
measurements by increasing their cost
per ton. At a large company with an
energy policy, or at small company
where it’s essentially one guy with left
and right pockets, we can get it done.”
Perry sees some improvement with
more attention to carbon footprint.
“The emerging ISO 500001 standard
will help,” he says. “It’s an energy
management standard along the lines
of ISO 9000 and ISO 14000: plan, do,
check.” A draft standard is expected
late this year (see www.iso.org/iso/
pressrelease.htm?refid=Ref1157).
www.klsummit.com
800.749.5823
PS1005_32_38.indd 38
38
May 2 010 w w w .PLA NTSERVICES.co m
5/7/10 11:22 AM
Any motor. Any voltage.
Any application.
Now test up to 10 kV with the
Fluke 1555/1550C insulation
resistance testers
From motors and generators, to cables and
switchgear, Fluke now takes you all the way
to 10 kV. With automatic data storage and PC
interface, the new Fluke 1555 (10 kV) and
redesigned Fluke 1550C (5 kV) fit right into
your preventative maintenance program.
• CAT III 1000 V, CAT IV 600 V safety rated
• Voltage breakdown detection alerts
you when voltage is present for increased
user safety
• Best in class, 3-year warranty
For details visit www.fluke.com/insulation
Tired of cranking your meter?
Trade up to a Fluke digital
insulation tester and save!
For details on how you can save up
to $75 on a new Fluke insulation tester,,
visit www.fluke.com/insulationtradein today!
Fluke. Keeping your world
up and running.®
©2010 Fluke Corporation.
Specifications are subject to change without notice. Ad 3782055A
PS1005_FPA.indd 39
3782055A_PE_PS.indd 1
5/7/10 10:48 AM
4/15/10 12:56 PM
Reliability / Power Transmission
A 37-MW electrical power generation system driven by
an aeroderivative gas turbine (Figure 1) suffered a puzzling
failure in its parallel-shaft gearbox (Figure 2). After only
several thousand hours of operation under typical service
conditions, the teeth broke on the pinion of a double helical
gear set (Figures 3 and 4).
The original equipment manufacturer (OEM) asked us to
theory didn’t explain the gear tooth failures completely. At the
time, however, a better explanation wasn’t apparent.
Testing and analysis
We performed a comprehensive on-site evaluation of the
drivetrain to capture data that potentially could suggest a
better explanation for the failures. This mechanical testing
The axial vibration was intensified by the excitation of the pinion’s axial
vibration frequency. The pinion’s radial vibration rose when the gearbox
was operated at synchronous speed but under no load.
uncover the underlying cause of the failed gear teeth. Previous studies of this matter proposed gear mesh misalignment
as the root cause of the failure. The basis for this conclusion
was founded primarily on bluing patterns observed on the
pinion’s turbine-end helix.
Because the gear tooth failures were attributed to misalignment, the OEM had begun to redesign the gear tooth profile on
the replacement gear to better tolerate misalignment. Nonetheless, the OEM suspected that the gear mesh misalignment
40
included operating forced response and impact modal testing, vibration monitoring during partial and transient load
events, and measuring critical dimensions in the gearbox
and shaft position as load and temperature varied. Accelerometers, velocity transducers, and a multi-channel data
acquisition system captured structural and rotor vibration
measurements. Radial proximity probes at each end of both
gearbox shafts and an axial proximity probe measured
movement of the input (pinion) shaft (Figure 2).
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_40_43_pwrtrans.indd 40
5/7/10 9:31 AM
Reliability / Power Transmission
Big equipment, big problem
Figure 1. The serious malfunction, which consisted of broken
pinion teeth in the gearbox, took the entire system out of service.
The root cause of the failures was a mystery to both the unit’s
owner and the gearbox OEM.
The evidence
Watching the details
Figure 2. The drivetrain’s gearbox was instrumented with
accelerometers, velocity transducers, and proximity probes to
record the response during the routine operating conditions.
Secondary damage
Figure 3. The gear tooth failures were severe enough that sizeable
fragments of the pinion not only fractured, but had broken
completely free from the gear during routine operating conditions.
Figure 4. Additional scratches in the gear teeth occurred as broken
gear tooth fragments dispersed through the gearbox.
An Essinger Bar system measured the movement of each
gearbox bearing housing. Temperature mapping across
the gearbox at each operating condition identified possible
anomalies in the temperature distributions, which could
have been related to distortion and gear misalignment.
Ā e recorded test data showed that structural vibration
occurring in the gearbox during different test load conditions was inconclusive. Ā e motion of the gearbox bearing
housings relative to the baseplate was inadequate to cause
the misalignment that others suggested, again based on an
interpretation of the bluing pattern.
Moreover, gear analysis tools failed to predict magnitudes of
mechanical stress that would have caused gear tooth failures at
the location where they had occurred (apex edge of the double
helix chevron, always on the same side of the apex), even when
mesh misalignment was considered in the analysis.
On the other hand, we saw considerable pinion rotor radial
and axial vibration, particularly when the gearbox was operated
at low loads or at idle speed. Significant shifts in the pinion’s
axial position and relatively high-amplitude axial vibration
were apparent while the drivetrain operated at idle speed.
The axial vibration was intensified by the excitation of
the pinion’s axial vibration frequency. The pinion’s radial
vibration rose when the gearbox was operated at synchronous speed but under no load. The primary component
of this vibration mode occurred at 43% of running speed,
the result of bounded rotordynamic instability. These
conditions could have contributed to gear tooth failures,
w w w .PLANTSERVICES.co m May 2 010 41
PS1005_40_43_pwrtrans.indd 41
5/7/10 9:32 AM
Reliability / Power Transmission
Unexpected movement
Fundamental theory says…
Axial load
from
coupling
9 10
768
2
4&5
1
x
79
42 810
56
3
Pinion (Turbine End)
x
FB1=-FR1
-FA1
FR1
Pinion (Alternator End)
Figure 5. The pinion shaft centerline position is depicted relative
to the pinion bearing centerline, both at the turbine end (left)
and at the alternator end (right). The two large circles represent
bearing clearances, and the arrows indicate the directions the
rotor centerline moved with increasing load during testing. The
substantial difference in the responses at the two ends of the
pinion also is evident.
but were insufficient to provide a complete explanation of
the high stresses at the failure location.
Measurements recorded at the gearbox bearings indicated
that radial loading on the pinion rotor wasn’t balanced between
FA2
FB2=-FR2
FR2
Figure 6. A free body diagram of the helical gear set illustrates the
unbalanced forces on the pinion that arise when an external axial
force is applied.
the turbine end and the alternator end. The bearing temperatures and eccentricities at the rotor ends differed considerably,
and the data indicated that radial loading was skewed to the
turbine end. The measurements also showed that the gearbox
leaned towards the alternator when under load. This was in
conflict with the “axial centering” and side-to-side load sharing
nature of a double helical gear. Interestingly, the average location of the pinion’s radial centerline shifted in an unexpected
manner as the load increased (Figure 5).
As the load increased, movement in the turbine end
followed a crescent-shaped trajectory, while the alternator
Axial load
from
coupling
FB1=-FR1
-FA1
FR1
42
FA2
FB2=-FR2
FR2
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_40_43_pwrtrans.indd 42
5/7/10 9:33 AM
Reliability / Power Transmission
end gradually moved toward the bearing centerline along
a relatively straight path. In the absence of external forces,
a double helical gear moves axially until the torque load
is balanced between the helices. Gear symmetry results in
identical radial loads, which the bearings on the turbine and
generator end must carry. Symmetric loading implies both
bearings should operate similarly, which was what drivetrain testing didn’t reveal.
Axial thermal growth
exceeded the maximum axial
travel that this particular
flexible coupling
could tolerate.
The rotor centerline trajectories indicated that the radial
load on the turbine-end bearing increased while the radial
load on the alternator-end bearing decreased as the overall
transmitted torque rose.
For this situation to exist, an external axial force must be
acting on the pinion rotor to make one helix carry significantly more load than the other. A free body diagram of the
helical gear set illustrates how helix loading can be asymmetric when an external axial force is applied to the pinion
(Figure 6).
more resources at www.plantservices.com
TOPIC
Gear MOC Powder metal gears Gear problem diagnostics Powertrain PdM Design limits Gears Gears and vibration SEARCH
“The Barkhausen effect”
“The power of powder”
“Gearing: care and feeding”
“Avoid the rolling thunder”
“Destined to fail”
“Gearbox essentials”
“Understanding and minimizing
industrial noise”
For more, search www.PlantServices.com using the
keywords gearbox, misalignment, vibration.
The additional testing and analysis identified the root cause
of the equipment malfunction, saved the OEM money, and
potentially prevented additional costly gearbox failures.
Eric Olson is a principal engineer and Chris Hurrell is manager of
test facilities at Mechanical Solutions, Inc., Whippany, New Jersey.
Contact them at MSI@MechSol.com and (973) 326-9920.
Diagnosis and solution
The source of the external force, and cause of the failures,
was thermal growth in the high-speed rotor system (pinion
and the power turbine). To be transmitted to the pinion,
such an external axial force also had to have passed through
the disk-pack type mechanical coupling connecting the
turbine and gearbox.
In general, disk-pack couplings are flexible in the axial
direction. However, test data showed that drivetrain axial
thermal growth exceeded the maximum axial travel that
this particular flexible coupling could tolerate.
The drivetrain’s axial growth pushed on the bull gear rotor thrust bearing, which then transmitted the unbalanced
axial load to the gear teeth. The turbine-end helix carried
significantly more load than did the alternator-end helix,
and this load imbalance led to pinion geartooth failures well
within the equipment’s expected operating life.
A modification of the coupling to include additional axial
clearance corrected the machinery problem. The coupling
then accommodated thermal growth between the power
turbine and gearbox pinion at the operating conditions
of the high-speed rotor system. Gear-mesh misalignment
wasn’t the primary factor causing gear tooth failures, which
suggested that gear tooth profile modifications the OEM was
devising at a cost of $300,000 weren’t necessary, and might
even be harmful.
w w w .PLANTSERVICES.co m May 2 010 43
PS1005_40_43_pwrtrans.indd 43
5/7/10 10:57 AM
Using ash in concrete is nothing new. The Romans
used volcanic ash in their spectacular construction
projects long before the introduction of Portland cement,
having discovered its value as a hardening agent when
mixed with lime. The ancient Romans used volcanic ash
as an admix to erect buildings such as the Pantheon and
Coliseum, roads, and aqueducts. Remember, these structures are more than 2,000 years old.
Fly ash concrete was first used in the U.S. in the
1920s for dam construction, when engineers found
that it reduced the total cement requirement. Today, as
more projects seek LEED certification, ash is resurfacing as a popular environmentally-friendly alternative
to Portland cement. No longer are we using volcanic
ash, of course, but coal fly ash is gaining ground as the
green alternative of choice for LEED projects. Many of
the projects and the millions of square yards of LEED
flooring we’ve installed in recent years used ash in the
cement mixture. While fly ash holds benefit as a recycled component, it also presents flooring contractors
with unique challenges.
What is fly ash?
To understand the green benefit and challenges that fly
ash brings to the flooring process, you must understand fly ash. It’s a byproduct of coal power plants,
which account for more than half of the electricity we
consume in the United States, according to Headwaters
Resources in South Jordan, Utah, which supplies mate-
44
rials derived from coal combustion products, including fly ash, nationwide.
“Fly ash is composed of the non-combustible mineral
portion of coal. When coal is consumed in a power plant,
it’s first ground to the fineness of powder. Blown into
the power plant’s boiler, the carbon is consumed – leaving molten particles rich in silica, alumina, and calcium.
These particles solidify as microscopic, glassy spheres
that are collected from the power plant’s exhaust before
We now know that the
maximum level that avoids
complications in adhering floor
covering is 15% fly ash.
they can “fly” away – hence the product’s name: fly ash,”
according to a Headwaters report.
Fly ash is considered the modern-day “Pozzolan,” a
word that comes from the Italian city, Pozzuoli, which
most consider the birthplace of ash concrete technology.
Pozzolan is a siliceous material that by itself possesses
no cementitious value. However, with the presence of
moisture, it reacts with calcium hydroxide to form a compound with cementitious properties.
Concrete made with fly ash is strong, durable, and resistant to chemical attack, as evidenced by the many early
Roman buildings still standing.
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_44_46_Floor.indd 44
5/7/10 9:39 AM
Why fly ash is popular
Traditionally-produced Portland cement, while extremely
versatile and strong, is not environmentally friendly. According to the Green Resource Center, the manufacture of Portland
cement accounts for 6% to 7% of the total carbon dioxide (CO2)
humans produce. That equates to the greenhouse-gas equivalent of 330 million cars, each driving 12,500 miles per year.
Coal fly ash is a coal-fired power plant waste byproduct,
which otherwise would end up in a landfill. Its use in cement
reduces the energy demands of manufacturing other concrete ingredients, reducing energy consumption, costs, and
greenhouse emissions, and slowing the depletion of natural
resources. In fact, according to Headwaters research, more
than 12 million tons of coal fly ash are used in American
concrete products each year.
Because of coal fly ash’s green qualities, its use in concrete
can generate points toward LEED certification by the U.S.
Green Building Council:
• Materials & Resources
• MR Credit 4.1 Recycled Content
• MR Credit 4.2 Recycled Content
Effect on flooring installation
In the past several years, we’ve gained extensive experience in
commercial LEED projects, many of which used fly ash in the
concrete. We found that, while fly ash benefits concrete durability and strength, makes it more workable, and is the green
thing to do, its use as an additive in concrete can generate some
fairly challenging bonding issues with flooring. Here’s why:
Fly ash is one of the residues generated in coal combustion.
Depending on the source and type of coal being burned, fly ash
makeup varies considerably, but all fly ash contains substantial
amounts of silicon dioxide and calcium oxide.
If you’ve ever tried to attach anything to a silicon-based
product, you know firsthand that it won’t stick. Similarly, calcium oxide, also known as quicklime or burnt lime, is a caustic,
alkaline crystalline byproduct – and like other high-alkalinity
products, plays havoc with flooring adhesives. “The fly in the
ointment, or in this matter, the fly ash, is that nothing will stick
to this type of concrete regardless of what you do,” wrote Lew
Migliore, president and owner of The Commercial Flooring
Report in March 2008. He advised flooring contractors to get
involved early in the specification process to prevent specifying
or trying to install products that simply won’t stick.
The American Coal Ash Association and the flooring
industry have been working to address this problem since
2008. In response to issues raised in that 2008 article, ACAA
Executive Director David Goss said, “There have been many
successful projects in which coal fly ash (CFA) has replaced
more than the typical 20% to 30% replacement levels. However, as the replacement levels are increased, a change in the
typical concrete placement and curing process should be
observed. In other words, more can be better, provided the
Read the flooring specs carefully
Figure 1. Installing a fine floor on a substrate of concrete laced
with fly ash might be problematic, but it can be done.
unique characteristics of fly ash are accounted for during the
engineering phase of the program.
“To this end,” he continued, “it has been noted while the
bonding characteristics of certain flooring compounds are
acceptable in applications where typical CFA replacement
levels are used, very little is known about these characteristics when higher levels of CFA are utilized. The historical
mechanisms of concrete failure (pH, moisture, and type of
finish) need to be evaluated as a function of CFA loading to
determine if the loading levels are relevant. We believe that
sound research evaluating various mix designs under simulated operating conditions will help identify any precautions or finishing processes that will enable your industry to
provide high quality flooring for any application.”
While the ACAA and flooring industry collaborate to
research the optimum fly ash concentration levels, flooring
installers are left to face the challenges.
On the ground: Dell Children’s
The Dell Children’s Medical Center in Austin is a great
example of the value, and challenges, encountered with fly
ash in concrete. Built in 2007, Dell Children’s was the first
Platinum LEED hospital in the world. To achieve the highest
LEED designation demanded that the project incorporate every possible opportunity to gain LEED points. This
500,000-sq.ft.project had about 40,000 sq.yds. of linoleum
and 175,000 ft. of hand-cut seams just for inset patterns. One
of the project team’s goals was to reduce cement use, carbon
dioxide, and greenhouse effects. So, the team substituted fly
ash for a portion of the cement, pouring 41,000 cu.yd. of the
fly-ash concrete in the foundation and walls.
According to Roger Vokt, superintendent of Greater
Austin Development, which poured the concrete on this
w w w .PLANTSERVICES.co m May 2 010 45
PS1005_44_46_Floor.indd 45
5/7/10 9:40 AM
Reliability / Flooring
project, the pilings for Dell Children’s job had as much as
50% fly ash content. Ā e slab on which we installed flooring
contained between 30% and 35% fly ash.
A white paper published a few years after we completed
the project documented that high concentrations of fly
ash in concrete used in new LEED projects across the
country was failing. But, at the time of the Dell Children’s
construction, we were learning on the fly, so to speak.
Very quickly into the installation project our teams
began experiencing significant challenges attaching the
linoleum to the slab, even though all normal readings
(moisture and alkaline) were within the manufacturer’s
recommended tolerances.
We stopped the job for about 30 days, attempting to
resolve the issue. During this time, we did an enormous
amount of testing and explored a variety of methods we
thought might cure the problem. We even called on concrete
experts to core the slab to determine the cause of this nonadhesion. We couldn’t determine the cause, but did come up
with a solution. We found that a very aggressive scarifying
of the surface of the concrete (just less than bead blasting),
was the best way to get the linoleum to stick. Ā e additional
In anticipation of those situations, expect
to see exclusion clauses in your flooring
contractor’s proposal and contract.
floor preparation ultimately enabled us to install the flooring
successfully, but at significant additional cost to us.
We also performed mechanical bond testing throughout
the project to verify that our solution was working. Ā is is a
tried-but-true test that tells the story as far as material being
bonded to the subfloor. We conducted this test in addition to
the moisture and alkalinity testing that we perform on each
of our projects.
Lessons learned
Since the Dell project, we now routinely encounter fly ash in
cement in LEED projects – and in fact, we approach the bid
process for those jobs expecting that we will be dealing with
high concentrations of fly ash. We now know that the maximum level that avoids complications in adhering floor covering
is 15% fly ash. We know that projects with concentrations in
the 30% to 35% range should expect and plan for significant additional costs in prepping the floor to install materials. Having
encountered this situation routinely now on LEED installations, we know what to look for and adjust, including changes
to the flooring adhesive itself, if necessary.
As Migliore advised in 2008, savvy flooring contractors
should ask the general or concrete contractor about the con46
more resources at www.plantservices.com
TOPIC
SEARCH
Terrazzo flooring
“Tough but beautiful”
Slab-on-grade floors
“Solid cures for concrete floors”
Moisture problems “You shouldn’t have to walk
on water”
Moisture and pH problems “Caustic comments”
Epoxy/cleaner compatibility “Between the tiles”
Concrete restoration “Quality at your feet”
Leeds certification
“Sustain a house of green”
For more, search www.PlantServices.com using the keywords
concrete, flooring, and LEED.
crete composition at the outset of the project. If your project
contains fly ash, make sure you have an experienced flooring
contractor who knows how to respond:
• Shot blast the floor to open it up to allow sealants to adhere
• Use a cementitious or polymeric sealer
• Specify products with the most likelihood of adhering.
While stretch-in carpet, laminated flooring and freefloating floors might be the best flooring options in these
cases, those solutions might not be practical for commercial
surfaces. Ā e fact is that almost any flooring surface might
be used, but additional preparation might be required and
probably will represent an additional expense to the owner.
Like the saying, “buyer beware.” When it comes to LEED
projects, architects, contractors, and owners should ensure
they choose a flooring contractor that keeps up with the
latest technology and that can troubleshoot problems to find
a solution – or better yet, circumvent problems before they
occur. Be sure to choose a flooring partner that is aware of
fly ash and its challenges, and one that will be vigilant and
cautious early on in researching the concrete on which it
will be expected to install product.
In anticipation of those situations, expect to see exclusion
clauses in your flooring contractor’s proposal and contract. We
now include a clause in our proposals that, along with moisture
and alkalinity issues typically associated with concrete slabs,
excludes “floor preparation required to adhere floor coverings
if a high concentration of fly ash or other additives that impede
the adhesion of flooring materials” is present on these projects.
No doubt, fly ash will continue to grow in popularity as
LEED projects become the norm in commercial construction. By doing your research early in the project, being
aware of the effect of fly ash on flooring installation and
planning for extra floor prep, and choosing an experienced
LEED flooring expert, you can meet these green demands
without ruining your project’s bottom line.
Bill Imhoff is CEO of Intertech Flooring, Austin, Texas. Contact
him at wei@intertechflooring.com and (512) 385-4574.
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_44_46_Floor.indd 46
5/7/10 9:40 AM
Accurate troubleshooting
relies on using the proper
tool for the job
Keeping the facility’s power system operating safely and
reliably requires a variety of electrical tests. Do you have the
right tools for the job? Here’s a rundown of some of the more
common equipment that you might need.
Digital multimeter
Digital multimeters (Figure 1) are the most common type of
electrical test equipment, and are the workhorses for electrical testing. Applications for multimeters are numerous, and
include testing voltages at both power and control levels,
measuring the current to various loads, checking the resistance of motors and transformers and other components,
and testing continuity of switch contacts and wiring.
Almost every multimeter measures AC and DC voltage
and current, and resistance. Voltage measurements generally
range from millivolts to 1,000 volts. Current ranges generally run from milliamps to as much as 10 amps. Resistance
measurements typically are from less than one ohm to tens
of megohms. Many models have additional functions such
as continuity buzzers, temperature, capacitance, frequency,
and diode testing. More advanced models include peak hold,
inrush current, max/min recording, data logging, and PC
communication for setup and data storage.
Meters that measure true RMS (TRMS) values are more
accurate than average-responding meters when waveforms
contain harmonics,
such as the voltages and
currents in motor drives and power supplies.
Non-contact voltage detector
These instruments are simple and effective for quickly determining whether voltage is present on a circuit or in a panel
(Figure 2). However, you must verify that they’re working
properly if you want to rely on them for confirming voltage
absence (see sidebar, “Safety takes three steps”). A followup test with a multimeter is recommended to confirm that
conductors are deenergized before performing work on the
circuit. Various models use lights, buzzers, or both as the
indicating signal.
Solenoid voltage detector (Wiggy)
These instruments have been around for many years, and are
still popular with many electricians. The original design uses
a solenoid to move a pointer, which indicates the nominal
system voltage level. They don’t give precise readings of actual
voltage. In addition to the pointer, solenoid vibration provides
an audible indication of voltage presence. They require no batw w w .PLANTSERVICES.co m May 2 010 47
ps1005_47_50_pwrdist.indd 47
5/7/10 9:42 AM
Safety / Electrical
the meter and allowing convenient current
teries, and are rugged enough to bounce
Handful of power
measurements on almost any circuit.
around in a tool box without damage.
Historically, current clamps operated on
Now for the bad news. While
the transformer principle and were limited
many of these units are still in
to AC measurements. Today, however,
service, they don’t comply with
many use electronic devices, such as Hallcontemporary test equipment
effect sensors, and can measure both AC
safety standards. Also, the solenoids
and DC current.
consume significant power from
Current clamps are rated from several
the circuit under test, and produce
amps to thousands of amps, and there
a voltage transient when makare flexible probes available that install
ing and breaking the connection.
around large conductors or multiple
As a result, they can damage any
bus bars (Figure 3). These allow current
sensitive solid-state devices on the
measurements at any location in a power
circuit. They also can overheat if endistribution system from the main service
ergized for longer than the recomto the smallest branch circuit.
mended duty cycle marked on the
instrument, and they are subject to
Figure 1. The hand-held digital multimeter
mechanical wear that might render
Clamp meter
is the workhorse of the circuit testing tools
them inaccurate. I don’t recommend available.
These are becoming popular, with a wide
using them.
selection available from a number of manNewer designs mimic the original style instrument, but
ufacturers (Figure 4). They combine the functions of a muluse indicator lights rather than the solenoid. Some of them
timeter with a built-in current clamp, eliminating the need
actually include a vibrator to provide the feedback of the
for a separate adapter and the interconnecting wires. The
solenoid. These instruments have acceptable safety ratings,
only function missing from many of them is DC current,
and don’t damage the circuit under test.
although there are some AC/DC models. Current measuring
ratings can be as high as 1,000 amps. Consider one of these
if you make many current measurements routinely and don’t
Current clamp
need the flexibility of the larger current probes.
While almost every multimeter has a current measuring
function, it’s only usable for relatively low currents. In addition, the need to break into the circuit to connect the meter
Insulation tester/megohmmeter
in series with the load makes many measurements inconveAlthough multimeters measure resistance, they’re not
nient or impossible. Most industrial current testing is done
capable of making the very high resistance measurements
with a spring-loaded current clamp adapter that is clamped
needed for testing insulation on components such as bus
around a conductor temporarily, extending the amp range of
bars, panels, motors, and transformers. For this task you
Confirm without touching
Figure 2. The non-contact tester indicates whether a circuit or
component is deenergized.
48
Size doesn’t matter
Figure 3. The measuring loop on a flexible current probe
attachment for a multimeter is capable of being opened up to
encircle large conductors or bus bars.
May 2 010 w w w .PLA NTSERVICES.co m
ps1005_47_50_pwrdist.indd 48
5/7/10 9:42 AM
Safety / Electrical
Current without breaking a circuit
more resources at www.plantservices.com
TOPIC
Search
Hi-pot testing “Diagnostic insulation testing”
“Making the workplace safe”
Safety attitude Lightning “Lightning on a stick”
Test equip “Testing, testing”
Electrical distribution “Matching the standards”
Power distribution “Reliable distribution”
“Caution: High voltage”
Safety NFPA70e “Revised NFPA 70E clarifies
electrical safety”
Arc flash “The Electrical Barrier”
For more, search www.PlantServices.com using the key­words analyzer, harmonic, and solenoid.
Figure 4. The clamp meter measures the current flowing through
smaller conductors.
need an instrument that measures tens or hundreds of gigohms (1 gigohm = 1,000 megohms) at test voltages from 500
to several thousand volts (Figure 5). Insulation testers apply
the test voltage between the conductors or windings and the
metal frame of the equipment under test, measure the very
small current that flows through the insulation, and display
the result as resistance.
Modern digital testers automatically run insulation tests dielectric absorption ratio, polarization index, step voltage,
and dielectric discharge. These non-destructive tests involve
calculations based on changes in the insulation resistance
during a measurement period of several minutes. When
performed regularly, megohm tests can indicate insulation
deterioration long before it becomes a problem.
Hi-pot tester
Like megohmmeters, hi-pots measure insulation integrity by applying a high voltage
across the insulation. Unlike megohmmeters, however, hi-pots don’t measure insulation resistance. They measure the resulting
leakage current and sense the presence of
breakdown (arcing) either across a surface
or through air. As a result, hi-pots not only
determine insulation effectiveness, but they
also can detect reduced spacing or crimped
wires. Manufacturers often used them for
production line testing, or in the field for
component-acceptance testing.
Hi-pots are available for both AC and
DC testing, with voltage ranges from
2.5 kV to more than 100 kV. Because
the hi-pot can deliver enough current
to produce arcing, improper testing can
be destructive to the device under test. Therefore, it’s important to follow OEM recommendations for the device
being tested, or use standard industry practice. While AC
tests are used for many applications, DC tests are necessary if high capacitance to ground exists, such as filters
or long cables that would cause excessive leakage current
with an AC tester.
While some testers are controlled manually with analog
meters, available microprocessor-controlled digital testers
automatically control the voltage ramp-up, test voltage, and
test duration. They also log the results in memory for later
uploading to a PC.
Low-resistance ohmmeter/milliohmmeter
Testing the resistance of switch or relay contacts, large motor
or transformer windings, or bonding jumpers and connections
requires an instrument that can measure accurately down to
micro-ohms (1/1,000,000 of an ohm). Multimeters simply can’t
measure such small resistances, and
Points to high resistance
the test leads and clips typically have a
resistance of several tenths of an ohm,
which would make any such low-resistance readings meaningless.
A low-resistance ohmmeter uses a
four-wire Kelvin connection to the
device under test. Two wires inject
a test current, while the other two
measure the resulting voltage across
the device, which is then converted
to ohms and displayed (Figure 6).
Because the test leads aren’t included
in the voltage reading, their resistance
has no effect. Test currents can vary
from 1 A to 100 A or more, dependFigure 5. The insulation tester monitors
ing on the instrument design and
the current flowing through the insulation
measurement range.
between a conductor and its environment.
w w w .PLANTSERVICES.co m May 2 010 49
ps1005_47_50_pwrdist.indd 49
5/7/10 9:43 AM
Safety / Electrical
Measuring low resistance
Safety takes three steps
When checking for the absence of voltage with any type
of testing instrument, always use this three-step process:
1. Verify that the instrument reads correctly on
another energized circuit.
2. Check the system of interest.
3. Verify that the instrument still reads correctly on an
energized circuit.
This will ensure that a reading of “no voltage” isn’t a
result of an instrument failure.
Safety
Figure 6. A low resistance ohmmeter can accurately measure
winding resistance in transformers and motors.
Loop impedance tester
Loop impedance testers are useful for verifying the integrity of branch circuits and equipment grounds. They draw a
current through the circuit (in short pulses to minimize the
power dissipation) and measure the resulting voltage drop to
calculate the total circuit impedance. This impedance reading can be used to determine what the short-circuit current
is at that location or conĀrm that protective devices will trip
properly. Bad connections in a series of receptacles can be
located by identifying the point where the loop impedance
changes signiĀcantly.
Any test equipment, test leads, or accessories that connect
to energized conductors must meet the IEC category rating
appropriate for the test location, and must carry an independent third-party agency approval, such as UL, ETL, or CSA.
Industrial electrical testing requires a minimum 600 V CAT
III rating, although some measurements will require a CAT
IV rating (main service bus bars or outdoor circuits, for
example). Many new instruments are 600 V CAT IV/1000 V
CAT III, making them suitable for virtually any measure-
Hi-pots don’t measure insulation
resistance. They measure the
resulting leakage current and
sense the presence of breakdown.
ment within their voltage rating. To ensure safety while
making measurements, replace older test equipment that
doesn’t carry these ratings.
Power quality analyzer
Anyone who works on or near energized systems must be
For those who need to take their power system measurequaliĀed on those systems by virtue of training and knowledge,
ments to the next level, a power quality analyzer Āts the
in accordance with the OSHA deĀnition,
bill (Figure 7). Measurement capabiliWatch for harmonics
must wear appropriate personal protective
ties include most multimeter functions
equipment, and must follow appropriate
such as voltage, current, and resistance,
work practices for the tasks performed as
plus power, power factor, and energy.
deĀned in NFPA 70E.
They also display voltage or current
This discussion has covered the more
waveforms on an oscilloscope screen,
common pieces of test equipment for
capture and display transients, and
industrial power system testing. There
calculate and display harmonic levels
are other more specialized test instruand total harmonic distortion. This can
ments as well. Having the appropriate
provide information that is simply not
equipment for the type of testing you do
available on a multimeter, and makes
will make your tasks safer, more effecthe devices indispensable for troubletive, and more efficient.
shooting motor drives, transformer
overheating problems, or just general
power quality analysis. Harmonic meaBen Miller is an electrical consultant
surements, for example, can indicate
and safety trainer, and president of
Figure 7. The power quality monitor is
transformer saturation or loads that
B. Miller Engineering. E-mail him at
valuable when troubleshooting equipment
need Āltering to reduce harmonic heatinformation@bmillerengineering.com
that is sensitive to harmonic distortion of
ing of upstream equipment.
or call (847) 948-7746.
the electrical waveform.
50
May 2 010 w w w .PLA NTSERVICES.co m
ps1005_47_50_pwrdist.indd 50
5/7/10 9:44 AM
in the trenches
When Johnny Comes Marching Home
Acme tries to outmaneuver the Army
Jerry Kahn was the senior security officer at Acme’s precious metal processing facility located a few miles from the
company’s mining operations in the Rockies. He was a 34-yearold, no-nonsense kind of guy. This attitude could be attributed
to being a veteran officer in the Army Reserve who participated
in military training exercises that occurred throughout the
year. In each case, Jerry notified Anne Emmony in Acme’s HR
department of the dates he’d be off from work.
While on active duty last fall, Jerry and a few members of
his military team were injured in an accident during a particularly hazardous training exercise. The Army extended
his deployment to cover the prolonged out-of-state hospital
stay and nearly two months of physical rehab the injury
required. As soon as he was able, he contacted Anne from
his hospital bed and was informed that he’d need to file an
Acme form to request unpaid leave.
When the Army released him from active duty, Jerry still
experienced some difficulty walking, had limited range of
motion in one shoulder, and couldn’t stand or sit very long.
He told Anne about his upcoming discharge before returning home to request reemployment with Acme’s security
department and to give Anne the medical documentation
that confirmed his physical limitations.
Anne told Jerry that his physician would need to submit
an ADA accommodation information form. Because there
were no forms in the office, Anne promised to send him one
at home.
But Anne delayed sending the form for several weeks.
When Jerry received it, he gave it to his doctor to complete
and send directly to Acme.
A few weeks later, Jerry contacted Anne, who told him
the doctor never sent the form. Jerry repeated the exercise,
despite the doctor’s insistence that he sent the first form
as requested. Jerry tried to meet with Anne to get things
straightened out, but Anne kept postponing the meeting.
When the meeting finally took place, Anne was accompanied by Acme’s risk management consultant. After half
an hour of discussion, Anne offered Jerry an entry-level
position in the security department with no supervisory
duties at about half the pay he received before the accident.
Jerry refused the deal, and Anne suggested he apply for a
junior security officer position at a pay rate slightly below his
former rate, providing he was the chosen candidate following a competitive interview process.
Jerry applied, was interviewed, and selected for the junior
job. Two weeks after he accepted the junior position, Jerry
filed a complaint against Acme under USERRA with the
Veterans’ Employment and Training Services at the U.S.
Department of Labor.
How could this situation have been avoided? Should
employers be wary of hiring military reservists? Should
Jerry be grateful that he has a job in this economy? Is Acme
showing insufficient respect for the military? What should
an employer do when faced with a disabled veteran who
seeks reemployment?
A plant engineer says:
This is a terrible situation made worse by an HR associate
who isn’t doing her best. Not knowing if Jerry’s difficulties
would be long-term or not makes this a more difficult situation. Anne should have been on top of this from the first call
she received from Jerry. HR “lives” by forms and it would
seem to me that Anne could have gone the extra mile to find
out from Jerry where his forms were when she didn’t receive
them in a timely manner. Then, the delay in sending the
necessary forms seems to indicate that maybe Anne should
be offered a “junior position.”
What’s important here isn’t the delay in forms being sent
but whether Jerry could perform his duties as a security supervisor with the disabilities he had as a result of his training accident. It would appear that because he could perform
the duties of a “junior” security officer, that he might be able
to perform the duties of the senior security officer. If that’s
the case, then shame on Acme and Anne.
w w w .PLANTSERVICES.co m May 2 010 51
PS1005_51_52_Trenches.indd 51
5/7/10 9:44 AM
in the trenches
I don’t believe employers should be wary of hiring military reservists. The number of reservists in an organization might be important only if too many are out at the
same time. I believe Acme (through the action and nonaction of Anne) has shown disrespect for the role military
reservists play in our country. Respect for a wounded
soldier would have dictated better follow-up and response
to the necessary forms.
An attorney says:
The USERRA requirements are quite specific and basically
say that the company should make “reasonable efforts” to
return the veteran to the job they had left, and if that’s not
possible, to offer the veteran a job that is the nearest approximation in terms of seniority, status, and pay. There are
several caveats to this general statement, the most important
being whether the veteran is able to perform the duties of
the previous job or the job with the “nearest approximation.”
As to the Acme situation, Anne should have gotten right
on it after Jerry was released and gotten the forms to Jerry.
She could have contacted the physician directly, or, as some
companies do, sent Jerry to be evaluated by Acme’s physician. Not all physicians are expert at assessing what the
returning worker can or can’t do, and finding one that is
competent in that area might be very useful. Some companies also have tests that they administer to assess job competency for specific positions.
What Acme seems not to have done is provide a basis as
to why Jerry could not be reemployed at his previous job. If
Acme could provide a good reason why Jerry couldn’t have
the supervisor position, and if they could demonstrate that
the job offered Jerry was the “nearest approximation,” they
would have done their duty in complying with USERRA.
As to being wary of army reservists, that would open a
discrimination case that Acme doesn’t want to get into.
Given our alphabet soup of employment laws – ADA,
FMLA, USERRA - it’s little wonder that Acme was confused
and apparently stalling Jerry’s return to work. In this case,
Jerry’s rights and Acme’s obligations are dictated by both the
Americans with Disabilities Act and USERRA.
The basic rule under USERRA is that a covered employee
must be reinstated to employment following military service
provided that the employee has given the employer notice
of the military service and reapplies for employment within
certain time limits. If an employee is hospitalized or convalescing from a military-incurred injury, the period within
which the individual must reapply for employment runs
from the date the employee has recovered from the injury.
Generally, an employee must be reinstated to his former
position or the position he would have had if he had not
been on military duty. One exception to this rule is if the
employee can no longer perform the duties of his former
position. In that case, the employer is required to help the
employee become qualified for reemployment unless that
would cause an undue hardship for the employer. This is the
same “undue hardship” that is an exception to the accommodation requirement under the ADA.
An example might make this clearer. If the senior security
officer position required an employee to be on his feet for
the entire work shift and Jerry’s injury precluded him from
standing for eight straight hours, Acme could help Jerry
become requalified for his former job by allowing him to sit
down periodically. Acme would be required to do this if it
did not pose an undue hardship.
While the facts here don’t provide any detail about the
duties of the senior security officer, it seems likely that an
individual with limited range of motion in one shoulder and
the inability to either stand or sit for long periods of time
wouldn’t be able to perform in the position of senior security
officer. Because it would pose an undue hardship for Acme
to modify that job to fit Jerry’s restrictions, Acme appears to
have been correct in not reinstating Jerry to that position.
Acme had an obligation, however, to employ Jerry in a
position as close to the position he left as he was capable
of performing given his service-incurred injury. And that
appears to be what Acme did by placing Jerry in a junior
security officer position at a slightly lower pay rate. And to
make things even simpler, this accommodation is precisely
what is required under the ADA for a disabled employee,
which Jerry surely is because of his physical limitations.
Just for the record, an employer who refuses to hire an applicant because he is a military reservist violates the law.
Professor Homer H. Johnson, Ph.D., Loyola University Chicago
(312) 915-6682, hjohnso@luc.edu
Julie Badel, partner, Epstein Becker & Green, P.C.
(312) 499-1418, jbadel@ebglaw.com
The number of reservists in an
organization might be important only
if too many are out at the same time.
When faced with a disabled veteran who seeks reemployment, a company should try to accommodate them if possible. In this case, we don’t know if it was possible for Jerry
to perform his duties as a Senior Security Supervisor or not.
Jeffrey L. Strasser, Bacova Guild
(540) 863-2656, Strasser.Jeff@bacova.com
An academician says:
52
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_51_52_Trenches.indd 52
5/7/10 9:45 AM
product focus
Eliminate Roof Fluttering
If rooftop fluttering is a concern, the
RhinoBond System offers a non-penetrating mechanical fastening solution
that distributes the wind load across
the roof. This membrane attachment
system uses the same fastener
and plate to secure the membrane and the insulation without penetrating the roofing material. The system leaves no potential point of entry for moisture,
requires fewer fasteners, and provides improved wind-uplift
performance. An electromagnetic induction welder bonds
the underside of the membrane to a specially coated plate that
holds the insulation and membrane in place.
OMG
(800) 633-3800 / www.olyfast.com
Seal and Protect Bearings
from Shaft Currents
The AEGIS 841 SGR bearing
isolator protects severe-duty
motor bearings with a shaft
grounding ring and an IP56
non-contact seal. It’s well
suited for IEEE 841 motors
controlled by variable-frequency drives. The bearing
isolator features an anti-clog
slinger drain system to
prevent dirt and debris from
plugging up the drain and compromising performance.
Electro Static Technology
(207) 998-5140 / www.est-aegis.com
Put Inventory in Order
Variable-speed compressors save energy
The QGV family of variable-speed compressors range from 20
hp to 200 hp. They can operate continuously at full speed, or
as a trim machine where they maintain the pressure within 2
psi. The QGV can supply as little as 15% of full-load capacity,
providing energy savings over start/stop or modulating compressors. Features include 68 dB(A)sound level, touchscreen
control, 75 to 150 psig operation, and automatic sequencing.
CribMaster9 inventory management software is designed for
custom configuration and easy navigation. New programming methods reconstruct the application, enabling the
benefits of a modern interface to speed navigation through
the system, true N-tier deployment capabilities to satisfy
most IT requirements, and business object integration
capabilities to enhance integration capabilities with other
applications. Custom views can be configured for individual
users, and connectivity includes Web Services, WCF, .NET
Remoting, and Enterprise Services Hosting.
WinWare
(888) 419-1399 / www.cribmaster.com
Monitor standstill status
on hazardous machines
Lock Saver produces a nearly invisible, semi-dry lubrication barrier on lock parts so locks work smoothly, keys don’t
get greasy, and lock mechanisms don’t “bleed” or spill onto
floors. Features include anti-corrosion protection, no sticky
mechanism, won’t freeze or gum up, works in all climates
and conditions from from -65°F to +450°F, nontoxic, and
environmentally friendly.
The G9SX-SM Standstill Safety Monitoring Unit shows status for machines
with varied hazardous part stop times,
with no sensors required. The system
operates out of the box without sensitivity adjustments, or users can adjust
system sensitivity manually to the specific needs of each machine. It can be
used with inverter-controlled systems
without threat of malfunction because
of the inverter’s dynamic brake or
auto-tuning functions. It improves
productivity by sensing zero motion instead of waiting for a
countdown timer to expire. The system operates on 24 VDC,
but can monitor motors up to 480 VAC.
Mil-Comm Products Company
(888) 947-3273 / sales@mil-comm.com
Omron Scientific Technologies Inc.
(800) 479-3658 / sales@sti.com
Quincy Compressor
(251) 239-2784 / www.quincycompressor.com
Lock Lube Leaves Parts Clean and
Corrosion-Resistant
w w w .PLANTSERVICES.co m May 2 010 53
PS1005_53_54_Products.indd 53
5/7/10 9:51 AM
PRODUCT FOCUS
Torque Tester Combines Meter,
Transducer, and Bracket
Precision grout transfers loads
effectively and safely
The 588-10K construction-grade grout is designed to transfer a load effectively and safely. It’s a non-corrosive, nonmetallic, mineral-based precision material with high initial
and ultimate flexural and compressive strengths. It can be
mixed quickly, as needed, on the jobsite. It offers improved
workability and is placed by pouring or pumping in both
interior and exterior applications.
W. R. Meadows
(847) 214-2100 / wrmil@wrmeadows.com
Explosion-proof motor starter sports
modular trip blocks
These motor control enclosures and systems use Moeller’s
PKZ2 plug-in trip modules and universal enclosures in sizes 0
through 3 to control 30 hp at 480 V or 25 hp at 600 V. Eleven
plug-in modules range from fractional to 30 hp. Exchanging
trip modules requires no tools or rewiring. Units are available
in both AC and DC, full-voltage non-reversing and full-voltage
reversing models up to 42 amps continuous current rating.
They include a through-the-door disconnect handle, mechanical reset button, start and stop pushbuttons, watertight gasket,
hinged cover, and standard conduit entries.
Adalet
(216) 267-9000 / www.adalet.com
Rechargeable LED uses C4 Technology.
The E-Flood uses six LEDs and wide-pattern reflectors for a
uniform pattern. Provides 4,000 candela peak intensity and
615 lumens at 400 feet on high. The low setting provides 2,150
candela and 330 lumens. Run time either eight or 18 hours.
They have a 50,000-hr lifespan. The LiteBox models features
a pushbutton switch and shoulder strap, and are available in
international safety orange or high-visibility yellow.
Streamlight
(800) 523-7488 / cs@streamlight.com
54
Testing and calibrating a torque
wrench usually requires a transducer,
a bracket, and a meter. The
Stanley Proto Torque Tester
combines them in one tool
that can test torque wrenches
of all types when full-scale
calibration is needed or when
a quick pass/fail check is
required. They’re available
for 5 in-lbs to 600 ft-lbs with
an accuracy of 1% of indicated value in
both directions from 10% to 100% of full
scale. An LCD displays output and rotates for easy viewing.
Red/green/yellow lights, as well as an audible buzzer, signal
when torque target zones are approaching and met. They
conform to ASME B107.29.
Stanley Proto
(800) 800-8665 / www.stanleyproto.com
Spill-Control Pallets Have UL Validation
EcoPolyBlend spill-control pallets protects against groundwater contamination to meet EPA standards and further
support green initiatives because they are made from 100%
recycled polyethylene. The pallet is the first of its kind to
have green claims validated by an independent, third party
— UL Environment, a wholly owned subsidiary of Underwriters Laboratories.
Justrite Manufacturing Co.
(800) 798-9250 / www.justritemfg.com
Noise Analyzer Is Fast and Accurate
Casella offers the smallest ⅓ octave-band noise
analyzer, the CEL-621. It’s the first to incorporate
statistical (Ln%) values to perform short-term,
environmental noise assessments. From simple
baseline surveys to full ⅓ octave-band analysis,
all measurements are performed through a
simple, intuitive, menu-driven system.
The high-resolution display presents
results in a simple, color-coded
format to minimize the risk of
misinterpreting. Data can be
downloaded to reports without
any special software.
Casella
(800) 366-2966
info@casellausa.com
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_53_54_Products.indd 54
5/7/10 9:52 AM
mro marketplace
Oil Skimming Applications Sourcebook
Coxreels Catalog
Abanaki’s 29-page handbook offers application notes on 29 real-world implementations of oil skimming, the lowest cost way to
remove oil from water. Indexed by industry
and application, readers quickly find case
studies for their situation. Sections include consulting engineering, machining,
manufacturing, utilities, coolant, grease/
water separation, groundwater remediation, oil/water separation, and wastewater.
Call (800) 358-7546 (SKIM) or visit www.abanaki.com/008.
Abanaki
Coxreels full-color catalog showcases the
expanding line of Coxreels high-quality professional grade hose, cord, and cable reels.
The catalog’s clean format navigates easily
and makes ordering options and accessories
for your reel a snap. Choose from a variety
of mounting brackets, roller guide options,
motor speed controllers, and so much more.
www.coxreels.com
AIR SAVING BLOWOFF IS SUPER QUIET
self-closing safety gate
The low-cost Super Air Knife™ dramatically
reduces compressed air usage and noise when
compared to other blowoffs. It delivers a uniform
sheet of laminar airflow with hard-hitting force
across the entire length. Energy use is comparable to a blower without the maintenance
or downtime. Applications include blowing off
liquid, chips, and contaminant, cooling hot
parts, and air screening. Call (800) 903-9247
or visit www.exair.com/85/123.htm.
EXAIR Corporation
The FabEnCo Self-Closing Safety Gate is
an adjustable swinging gate for fall protection at your ladder, platform, and stair openings. It can be clamped on either side of the
handrail, at different levels, and mounts on
channel, angle, flatbar, or pipe. Our adjustment bolts provide positive stop without
handrail contact. Available in galvanized steel
(Safety Yellow optional), aluminum, and stainless steel.
Call (713) 686-6620 or see www.safetygate.com/psv.
FabEnCo
InfraMation 2010
Pocket Guide to Gears
Coxreels
The world’s largest infrared camera applications
conference is in Las Vegas, Nov. 8 -12, 2010.
Learn new infrared applications, network
with other infrared camera professionals, and
sharpen your infrared camera skills at InfraMation 2010! Hosted annually by the Infrared
Training Center, the world’s largest infrared camera training provider, InfraMation is the premier
opportunity to learn how infrared technology is used in the word today.
Register online at www.inframation.org or call (866) 872-4647.
When it comes to gears, come to the experts.
And who knows more about gears, than Martin. After all we’ve been manufacturing gears
for over 50 years. If you purchase or specify
gears, this handy pocket sized guide is for
you. Filled with product descriptions, formulas and more, you will find it indispensable.
(817) 258-3000, www.martinsprocket.com
FLIR
Martin Sprocket & Gear, Inc.
The World’s Largest Infrared Camera Applications Conference
Nov 8-12, 2010 // Bally’s Hotel on the Las Vegas Strip, Las Vegas
Register online now at www.inframation.org
or call us at 866 872 4647
Register Today for the
Best Early Bird Special!
Learn new infrared applications, network with other infrared camera professionals, and
sharpen your infrared camera skills at InfraMation 2010! Hosted annually by the Infrared
Training Center, the world’s largest infrared camera training provider, InfraMation is the premier opportunity to learn how infrared technology is used in the word today. InfraMation
is highly-rated as an extremely efficient way to stay up to date in the field whether you are
new to infrared or have years of experience, Register now for our best early bird offer.
EaRly BiRd OFFERS
 aMaZiNG dEal
Expires May 14th
Conference Price w/Spouse Pass - $1,745
* 5 Free Hotel Nights - Save $345
* 1 Free Spouse Pass - Save $350
HERE aRE tHE tOP tEN REaSON’S wHy yOU
SHOUld REGiStER NOw FOR tHE wORld’S
laRGESt tHERMal iMaGiNG cONFERENcE:
1. View over 60 thermal imaging presentations
2. Learn at expert-led training workshops
3. Network with industry professionals
your Price: $1,050 - Save $695!
4. Gain ITC renewal certification credits
 ExcEllENt dEal Expires June 30th
Conference Price /Spouse Pass - $1,745
5. Bring your spouse – FREE (includes meals)!
* 3 Free Hotel Nights - Save $207
* 1 Free Spouse Pass - Save $350
6. See how others in your field are growing
and expanding
your Price: $1,188 - Save $557!
7. Ask questions and get help for your needs
 GREat dEal
Expires August 31st
Conference Price w/Spouse Pass - $1,745
* 2 Free Hotel Nights - Save $138
* 1 Free Spouse Pass - Save $350
your Price: $1,257 - Save $488!
8. Profit by getting 5 FREE Hotel Nights
immediately
9. Have your IR camera inspected by expert
technicians FREE
10. Enjoy Las Vegas – while you advance
your career!
 NicE dEal Expires November 1st
Conference Price w/Spouse Pass - $1,745
* 1 Free Hotel Night - Save $69
* 50% Off Spouse Pass - Save $175
your Price: $1,501 - Save $244!
REGiStER By PHONE, ONliNE
or use the Fax BacK FORM
on the reverse side!
cONFERENcE FEatURES
 4 ½ days of presentations and events
 3 hour clinics each day
 Exhibits
 Log the required hours to renew your ITC
certification
 Spouse pass includes all daily breakfasts
and lunches as well as the wel come Gala
Dinner and cocktail party provided on
Tuesday evening
Don’t miss InfraMation 2010 -- the only
one-stop educational event for thermal
imaging innovations and practical
applications in predictive maintenance,
energy auditing, building diagnostics,
condition monitoring, machine vision
and automation, optical gas imaging and
gas detection, R&D, thermal dynamics in
engineering design ... and much more!
OPTIONAL PRICING WITHOUT SPOUSE PASS
Conference price is $1,395 without a spouse pass. Free hotel nights are calculated at $69 per night. Simply deduct the FREE
Hotel Night savings from $1,395 if you do not want to take advantage of the Free Spouse Pass.
866 872 4647
iwww.inframation.org
*Guests/spouses fee includes all conference
meals and activities, but does not include
admission to technical sessions, admission
to IR Clinics, and the conference proceedings.
MIT400 SERIES 1-kV INSULATION
AND CONTINUITY TESTERS
Online video demonstrates end-over-end
drum tumbler
The Megger MIT400 Series meet the most
stringent requirements and are ideal for Category IV 600V applications. The units feature
adjustable voltages providing 250V to 1000V
or 50V to 1000V. The top-of-the-range models
can store and download data. The instruments
are sealed to IP54, lessening the chance of water ingress. Contact us at (866) 254-0962.
Megger
Morse unveils an online demonstrational video, complete
with detailed literature, that
describes its end-over-end drum
tumbler. For more information
visit www.MorseMfgco.com.
Morse Mfg. Co., Inc.
w w w .PLANTSERVICES.co m may 2 010 55
PS1005_55_56_AdLits.indd 55
5/7/10 12:32 PM
mro marketplace
handbook HIGHLIGHTS WIRELESS TECHNOLOGY
Low-cost color display shaft alignment
The Blue Cat® New Horizons® in Wireless handbook contains 68
full-color pages of cutting-edge technology showcasing wireless sensors,
transmitters and receivers, and Ethernet
Web-based measurement and control
devices. Solutions include temperature,
pressure, pH, humidity, flow, and process
applications for test & measurement, automation, and industrial manufacturing.
www.omega.com/literature/wireless26/
Omega
LUDECA, INC.
print and electronic training products
SOLENOID VALVES Catalog
We publish a broad range of products featuring content in Electrical, Construction,
Maintenance, Mechanical, and Alternative
Energy. Many new and updated editions
are included to help keep your skills current, including Welding Skills, Fluid Power
Systems, Rigging and Lifting Principles,
and Instrumentation. Visit www.go2atp.
com to browse our materials.
American Technical Publishers
Avoid costly downtime with new Low-cost
color display shaft alignment. Align your
machines with SHAFTALIGN in 3 easy
steps: Enter dimensions, measure, then view
results —with 3D graphics and centerlines
to scale. Upgradable, keeps up with your
needs! Call (305) 591-8935 or visit www.
ludeca.com/prod_shaftalign.php.
This new catalog details two-way bronze
and stainless steel solenoid valves, 1/4-in.
to 3-in. to control flow of water, ammonias, fuel oil, gas, steam, brine, solvents,
cryogenics and oxygen. Available in NC/
NO, packless construction, continuous-duty
coils for all voltages, no differential pressure required to open and two-way straight
through design. For more information, call
(973) 427-4341 or visit www.magnatrol.com.
Magnatrol Valve Corp.
Stainless Steel Pickling Gel
Pumps for Industry
Easy to use and store, Wonder Gel
safely cleans the toughest slag, weld
scale, black oxides and discoloration
from stainless steel surfaces economically, without damaging sound
metal surfaces. It restores the
Before
After
protective chromium oxide layer
to resist new corrosion and leaves a
silvery finish. Call (877) 899-5315 or visit www.derustit.com.
Gorman-Rupp’s products include self–priming centrifugal pumps, standard centrifugals
pumps, submersible pumps, trash pumps,
priming assisted pumps, and rotary gear
pumps. A complete line of packaged lift stations and booster stations that include pumps,
motors, controls, piping, accessories, and
enclosures are also available. Call (419) 7551011 or visit www.GRpumps.com.
The Gorman-Rupp Company
Bradford Derustit Corp.
Electric Heaters, Controls, and Sensors
Tempco’s 864-page 35th Anniversary
catalog offers electric heaters, temperature
sensors, TEC Temperature controls, turnkey process heating systems, and related
accessory Items. New products include
PPR-1800 video graphic data recorders.
Select from stock items or have Tempco
custom design and manufacture for your
application. Visit www.tempco.com.
Tempco Electric Heater Corp.
56
Custom reprints strengthen brand value
Custom reprint products of articles and
features from Plant Services create powerful marketing tools that serve as instantly
credible endorsements. Reprints are a simple
way to put information directly into the
hands of your target audience. Having been
featured in a well-respected publication adds
the credibility of a third-party endorsement
to your message. Call 866.879.9144 x168
or e-mail sales@fosterprinting.com.
Foster Printing Service
may 2 009 w w w .PLA NTSERVICES.co m
PS1005_55_56_AdLits.indd 56
5/7/10 12:33 PM
classifieds
Products and services
HOT & DIRTY
CoNtrol
ENClosurEs?
Electra
Kool
HOT & DIRTY
CoNtrol
ENClosurEs?
Electra
Kool
tm
Filter/Ventilators forcefully
blow out hot air & cool with
finely filtered ambient air!
Less $$ than AC or Vortex
Tubes! Five models for any
size enclosure! Since 1980!
info@wayneproducts.com
www.wayneproducts.com
FrEE Catalog!
1 800 255-5665
TUBE TYPE OIL SKIMMERS
tm
Filter/Ventilators forcefully
blow out hot air & cool with
finely filtered ambient air!
Less $$ than AC or Vortex
Tubes! Five models for any
size enclosure! Since 1980!
OILY WATER?
• Skim Oils, Fats, And Grease 24/7
• TigerTube® Collector Tubing
• Model 6V Skimmer Tubes
Save 30% On New Collector Tubes
Contact Brian - sales@skimtech.com
330-774-5044
330-757-7606 Fax
www.skimtech.com
Mini & MAXI-SkimmersTM
Collect economically! Several
types with 1 qt - 100 gph rates!
Reach from 5” to 100 ft. down!
Also use with coolants & parts
wash fluids! Thousands in use
since 1990!
View product info at
www.wayneproducts.com
call 800 255-5665 or email to
info@wayneproducts.com
ENVIRONMENTAL BIRD CONTROL
RONIN AIR
FALCONRY SERVICE
805-698-5757 | www.roninair.com
OIL MIST & SMOKE
IN YOUR SHOP?
www.mistcollectors.com
Tel: 1-800-645-4174
Place a Classified Ad!
Contact Polly at
(630) 467-1300, ext. 396
Advertiser index
Control Connection
The Best Place to Find
the
PerfectConnection
Job For You
Control
is Just a Click Away!
THE CAREER RESOURCE FOR PROCESS AUTOMATION PROFESSIONALS
THE CAREER RESOURCE FOR MACHINE AUTOMATION PROFESSIONALS
Job search today at
ChemConnection
jobs.plantservices.com
THE CAREER RESOURCE FOR CHEMICAL PROCESSING PROFESSIONALS
Plant Connection
THE CAREER RESOURCE FOR PLANT ENGINEERING PROFESSIONALS
Pharma Careers
THE CAREER RESOURCE FOR PHARMACEUTICAL PROFESSIONALS
Al w ays u p an d Ru n n in g
Food
Connection
• Digital Edition
• Blogs
RESOURCE FOR FOOD PROCESSING PROFESSIONALS
•THEECAREER
-newsletters
• W ebcasts
• W hite Papers
• Much more!
PharmaQbD Careers
CompanyPAGE
Abanaki . . . . . . . . . . . . . . . . . 55
Agilent Technologies. . . . . . . . . 30
American Technical Publishers. . 56
Atlas Copco Compressors. . . . . . . 4
AutomationDirect.com. . . . . . . . . 2
Baldor Electric Co.. . . . . . . . . . . 6
Bradford Derusit . . . . . . . . . . . 56
Cameron Compression. . . . . . . . 12
Cox Reels. . . . . . . . . . . . . . . 43,55
CRC Industries. . . . . . . . . . . . . 10
Donaldson Company,
Inc.Ultrafilter. . . . . . . . . . . . . . 11
EXAIR . . . . . . . . . . . . . . . . . . 55
FabEnCo. . . . . . . . . . . . . . . . . 55
Flir Systems-Imaging . . . . . . 16,55
Fluke . . . . . . . . . . . . . . . . . 13,39
Gardner Denver . . . . . . . . . . . . 37
Gorman-Rupp Co.. . . . . . . . . . . 56
2
GouldsRoninAir.indd
Pumps / ITT
Industries. . . 9
Grainger. . . . . . . . . . . . . . . . . . .3
CompanyPAGE
Hertz. . . . . . . . . . . . . . . . . . . . 22
Hyster . . . . . . . . . . . . . . . . . . 29
IFS North America . . . . . . . . . . 26
Inpro/Seal . . . 1/13/09
. . . . .9:40
. . AM
. . . . . . 60
Ipex. . . . . . . . . . . . . . . . . . . . .18
Kaeser Compressors. . . . . . . . . 59
Ludeca . . . . . . . . . . . . . . . . . . 56
MacroAir Technologies. . . . . . . .42
Magnatrol Valve . . . . . . . . . . . . 56
Martin Sprocket & Gear. . . . . . . 55
Megger . . . . . . . . . . . . . . . . 24,55
Morse Manufacturing . . . . . . . . 55
Omega Engineering. . . . . . . . . . 56
Pentair Technical Products . . . . 28
Robinson Fans. . . . . . . . . . . . . 20
Sprayon Products. . . . . . . . . . . 34
Summit Industrial Products. . . . 38
Tempco Electric Heater . . . . . . 56
Tri Tool . . . . . . . . . . . . . . . . . . 14
WD-40. . . . . . . . . . . . . . . . . . .15
PROOF
THE CAREER RESOURCE FOR PHARMACEUTICAL PROFESSIONALS
w w w .PLANTSERVICES.co m may 2 010 57
PS1005_57_Classified.indd 57
5/7/10 11:38 AM
energy expert
peter garforth
Are We There Yet?
How board-level management can get onboard
When I started this monthly column in 2005, the first one
was titled, “Where is the Business Leadership?” It explored
the paradox of the obvious gap between the proven benefits
of effective energy management and the relative lack of senior
management attention to the topic. In the past months, the Pew
Center on Global Climate Change has supported a study of the
energy management practices of major companies. I was flattered to be invited to be on the study’s advisory committee. As
the report findings came together, I was again reminded of this
Many projects to enhance America’s
energy efficiency and funded by
stimulus monies can only be met
with non-U.S. products and services.
paradox. The question is still on the table: “Is American senior
management there yet?” when it comes to embracing energy
and climate change management as a strategic business issue.
Companies participating in the Pew study were Dow Chemical, Toyota, United Technologies, IBM, PepsiCo, and Best Buy,
leaders in their business sectors. The study findings were simple
and predictable. For each, energy efficiency is a core strategy
and a part of the company’s aspirations and metrics. Leadership and support is real, planned, and sustained. Energy goals
are company-wide, specific, and kept updated. Energy data is
current, robust, comparable, and available when and where
needed. The resources assigned are significant and related
to the value of the returns in terms of both cash and human
capital. Benefits are measurable, sustained, and usually greater
than expected. Last, but not least, successes are celebrated and
communicated. To these companies, effective energy management is a non-negotiable part of their overall competitiveness.
The final report was unveiled at a recent meeting in
Chicago. A number of us were asked to join a panel on “The
Changing Paradigm: What’s Next for Corporate Energy
Efficiency?” Speaker after speaker underlined the growing
challenge of being ready for future energy uncertainties. The
consistency of this message was impressive, coming from
industry, utilities, and politicians from across the spectrum.
This column has often commented on the unpredictability
of our energy future. Pricing is unpredictable and likely to be
significantly affected by climate change legislation. Supply reli58
ability and quality are less certain as a result of policy, supply
infrastructure, and accelerating demand. The recent drilling
rig accident in the Gulf of Mexico underlines how uncertainties can manifest themselves. Events like this can stall policy
for years, in turn affecting potential new supplies. The recent
deaths of miners in West Virginia are another tragic marker in
a long story of the human price we pay for electricity. It’s hard
to see how safety and climate change concerns won’t have far
reaching effects in this part of the energy value chain.
Another drum beat around clean energy and climate change
is getting more attention. As the global focus grows, businesses
are repositioning their offerings to serve the market needs.
Increasingly, these businesses are from outside the United
States, often supported by clear national and regional policies
that pursue clean and renewable energy supplies and strategic
energy efficiency. Again, as I have often pointed out, energy
productivity isn’t just about judicious management of operational performance; it’s also about new opportunities in the
market. The flip side of this statement is that it’s also about new
competitive risks for those who choose to ignore it.
This competitive reality was highlighted with the recent
awareness that many projects to enhance America’s energy
efficiency and funded by stimulus monies can only be met with
non-U.S. products and services. The political outrage, real or
simulated, doesn’t really disguise the fact that in many cases,
local industry is ill-prepared to respond to the needs.
The changing paradigm the panel members saw in Chicago
was clear. Energy and climate change risks are board-level
issues demanding a global perspective and quality management attention. Best practices, so well summarized in the Pew
Report, are a given. Companies must be flexible to handle multiple energy future scenarios, and teaming on energy issues up
and down the value chain and with local communities will be
required. Stakeholders, customers, and competitors will reward
effective players or expose the weaknesses of the others.
Given the sheer weight of the evidence of the growing
strategic importance of energy and the competitive risks of
ignoring it, I’m still amazed by how low it is on many companies’ management agendas. My question from the first column
in 2005 still stands. Where is the business leadership…are we
there yet?
Peter Garforth is principal of Garforth International LLC, Toledo, Ohio.
He can be reached at peter@garforthint.com.
May 2 010 w w w .PLA NTSERVICES.co m
PS1005_58_Energy.indd 58
5/7/10 9:54 AM
“In a business where every
hundredth-second counts, we
can’t settle for second-best.”
— J. D. Gibbs
Team President – Joe Gibbs Racing,
technology partner with Kaeser Compressors since 1998
N
obody knows a winner better than Joe Gibbs Racing. That’s why
they’ve installed Kaeser compressed air systems in their state-of-theart raceshop.
Reliable air is the lifeblood of Joe Gibbs’ operation – just as it is in
yours. From CNC milling centers to the fab shop and everywhere else
in your plant, Kaeser provides all the clean air you require to keep you
running at peak performance, 24/7.
Available in any size you need, our units are engineered for easy maintenance and energy efficiency ... but most of all, for reliability. So, when
you want a winner, choose Kaeser.
&2035(66256
(866) 516-6888
www.kaeser.com/sigma
Kaeser Compressors, Inc., P.O. Box 946, Fredericksburg, VA 22404 USA
Built for a lifetime is a trademark of Kaeser Compressors, Inc. ©2009 Kaeser Compressors, Inc.
Nose2Nose - 0507.indd 1
PS1005_FPA.indd 59
6/5/2009 8:35:12 AM
5/7/10 10:49 AM
Inpro/Seal Company has been in the business of bearing
protection for rotating equipment for 32 years and counting.
We have been supplying bearing protection for the IEEE841 motors since they were first introduced. It is only logical
that we would expand into the field of motor shaft current
mitigation to protect motor bearings. The CDR is:
ROBUST
Machined entirely out of solid corrosion resistant
and highly conductive bronze, the CDR/MGS is
capable of carrying 12+ continuous amps. They
are made exclusively by the Inpro/Seal Company
in Rock Island, IL, to ensure consistent quality
and same-day shipments when required.
RELIABLE
The CDR and MGS (Motor Grounding Seal)
products were developed in our own Research and
Experimentation Laboratory and then extensively
tested and evaluated by professional motor
manufacturing personnel. Our standard guarantee
of unconditional customer satisfaction of product
performance applies. We stand behind our products.
REALISTIC
When you order a CDR or MGS from Inpro/Seal,
you are assured of the complete responsibility
for technology and performance from a single
source. We want to earn the right to be your first
choice for complete bearing protection.
For more information visit www.inpro-seal.com/CDR or contact
800-447-0524 for your Inpro/Seal Representative.
PS1005_FPA.indd 60
5/7/10 10:50 AM