REVOLUTIONARY VIBRATION AND BEARING ANALYSIS
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Contents
NOVEMBER 2012 • VOL 25, NO 11 • www.MT-ONLINE.com
YOUR SOURCE FOR CAPACITY ASSURANCE SOLUTIONS
FEATURES CAPACITY ASSURANCE SOLUTIONS 16
Harnessing The Power Of PMI In Reliability Investigations ©ANDREI MERKULOV — FOTOLIA.COM
Positive material identification can quickly reveal the root causes of bad welds, parts failures and more. It also can help verify on-spec conditions. Greg Mann and Michael Porfilio, Anderson Laboratories, Inc.
UTILITIES MANAGER 25
■ Big Money Talks William C. Livoti, Contributing Editor
26
34
■ Using KPIs To Monitor And Improve Pump Performance Monitoring and tracking pump-system performance can be highly profitable. Just how profitable often hinges on which KPIs are followed. Gunnar Hovstadius, Ph.D.
6
My Take
CAPACITY ASSURANCE SOLUTIONS
8
Stuff Happens
Listen For Machine Faults: Let Sounds Verify Vibration Data
10 13 14
Uptime
23
Automation Insider
40
Technology Showcase
47
Solution Spotlight
48
Marketplace
54
Information Highway
The Maintenance & Reliability Technology Summit is:
54
Classified
An annual, four-day educational experience and professional-development opportunity
55
Supplier Index
Created for plant and facility managers, maintenance leaders and crew members, reliability engineers, industrial technicians and all other capacity-assurance professionals
56
Viewpoint
This vibration analyst explains how audio replay capabilities have enhanced his toolkit (and could be doing the same for yours). Jim Crowe, Jim Crowe Vibration Technologies
SUPPLY CHAIN LINKS 43
DEPARTMENTS
Making It Real A virtual-reality solution is now training clean-coal power plant operators. Special To MT From Invensys Process Management
®
Motor Decisions Matter Don’t Procrastinate… Innovate!
Composed of two days of Conferences (60-minute sessions) and two days of Workshops (full-day sessions) presented by industry experts. Scheduled for April 30-May 3, 2013 at the Hyatt Regency O’Hare, Rosemont, IL.
For more information, visit www.MARTSConference.com today! NOVEMBER 2012
MT-ONLINE.COM | 3
November 2012 Volume 25, No. 11 Your Source For CAPACITY ASSURANCE SOLUTIONS
ARTHUR L. RICE President/CEO arice@atpnetwork.com
BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com
JANE ALEXANDER
Editor-In-Chief jalexander@atpnetwork.com
RICK CARTER
Executive Editor rcarter@atpnetwork.com
ROBERT “BOB” WILLIAMSON KENNETH E. BANNISTER Contributing Editors
RANDY BUTTSTADT
Director of Creative Services rbuttstadt@atpnetwork.com
GREG PIETRAS
Editorial/Production Assistant gpietras@atpnetwork.com
ELLEN SANDKAM
Direct Mail 800-223-3423, ext. 110 esandkam@atplists.com
JILL KALETHA
Reprint Manager 866-879-9144, ext. 168 jillk@fosterprinting.com
Editorial Office:
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1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 WWW.MT-ONLINE.COM
“Visual systems, when applied to equipment, can reduce training time by 60 to 70% and eliminate errors.”
Subscriptions: FOR INQUIRIES OR CHANGES CONTACT JEFFREY HEINE, 630-739-0900 EXT. 204 / FAX 630-739-7967
—Robert Williamson, lean equipment specialist
Our Visual Supplies Can Improve Your Equipment’s Performance! Colored gauge marking labels Problem and Opportunity Tags in English or Spanish Red Move Tags Colored paint pens Colored grease fitting caps and lube point labels Vibration analysis pickup discs and labels Proven Tips for Equipment Troubleshooting handbook Lean Machines instructional book for applying visuals Temperature indicating strips and more
Visual systems supplies that deliver results...fast! To view and order from our complete line of Visual Systems Products, go to...
www.swspitcrew.com To order by phone or fax, call (864)862-0446 Strategic Work Systems, Inc. PO Box 70 Columbus, NC 28722
Maintenance Technology® (ISSN 0899-5729) is published monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Barrington, IL 60010. Periodicals postage paid at Barrington, Illinois and additional offices. Arthur L. Rice, III, President. Circulation records are maintained at Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Maintenance Technology® copyright 2012 by Applied Technology Publications, Inc. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@ wdsmail.com. Submissions Policy: Maintenance Technology® gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc. permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. “Maintenance Technology®” is a registered trademark of Applied Technology Publications, Inc. Printed in U.S.A.
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MAINTENANCE TECHNOLOGY
NOVEMBER 2012
Scheduled maintenance, inspections, emergency response…Team delivers
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T
eam is a world-class service company with the right people, technology and experience needed to keep your plants online and in production. Our highly skilled technicians work to earn your continued trust and conf idence one job at a time. Å… 6DWLVI\LQJ FXVWRPHU QHHGV VLQFH Å… 7UXH DYDLODELOLW\ Å… 0RUH WKDQ ZRUOGZLGH ORFDWLRQV Å… WUDLQHG DQG FHUWLI LHG VHUYLFH VSHFLDOLVWV Å… :RUOGZLGH VWRFN RI LQ KRXVH VHUYLFH HTXLSPHQW Å… %XQGOHG DSSURDFK KHOSV \RX UHDOL]H FRVW VDYLQJV Å… ,PSURYHG SURGXFWLYLW\ PHHWV RU H[FHHGV \RXU JRDOV
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MY TAKE
Jane Alexander, Editor-In-Chief
On The Road With An All-Star Team Of Experts
C
old winds have already begun blowing across Chicagoland—early and often, like they always do. About this time each year, my thoughts start wandering off to warmer places. While Texas and Alabama typically get my nod, I currently have Florida on my mind. You should, too. That’s because Applied Technology Publications is sponsoring three great 2-day workshops, January 14-15, 2013, at the Lake Buena Vista Resort in Orlando. Presented by several members of our All-Star Team of industry experts, these workshops offer a cost-effective and convenient professional-development avenue for you and/or members of your own All-Star Teams. Check them out, then sign up for the one of your choice:
Workshop #1: “Introduction To Planning & Scheduling” Instructor: Ken Bannister, Contributing Editor, Maintenance Technology and Lubrication Management & Technology
Workshop #2: “Pump System Optimization: Uptime, Reliability, Efficiency” Instructor: Bill Livoti, Contributing Editor, Maintenance Technology and Lubrication Management & Technology
Workshop #3: “Oil Monitoring Analyst Preparation Class” Instructor: Ray Thibault, CLS, OMA I, OMA II, Contributing Editor, Lubrication Management & Technology
You know these instructors. You read them. You respect them. Their Orlando workshops provide a wonderful opportunity to learn from and network with them and—let’s just say it—pick their brains. The practical information and techniques that workshop attendees take away from these classes will be invaluable to their respective operations. For details on the content of these in-depth workshops, along with pricing lodging and registration info, please visit www.mt-online.com/wintertraining13. Or call Kathleen Jaros at 847.382.8100 x 117. Please take note: Our January All-Star Team Workshops will be held at the same venue as the 2013 IR/Info Conference, presented by our good friends at Infraspection Institute. Paid attendees at our workshops will be able to network with the exhibitors and attendees of IR/Info, at no charge. I urge you to begin planning your January trip to Florida, ASAP. Registration for our All-Star Team Workshops is open, but space is limited. Don’t let this early-winter opportunity get away from you and your team. Ken, Bill and Ray look forward to seeing you in Orlando. MT jalexander@atpnetwork.com
PS: For information on Infraspection Institute’s 2013 IR/Info event, go to: www.irinfoconference.com
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maintenance technology
NOVEMBER 2012
WHAT VIBRATION PENS WANT TO BE WHEN THEY
GROW UP. The new Fluke 805 Vibration Meter is more than a pen. It’s a Fluke meter that gives you results you can trust, time after time. t Checks overall vibration, bearings and temperature t Ability to export and trend data t Four-level scale quickly assesses problem severity t Unique sensor design ensures accurate and repeatable measurements
Forget the pens. Think METER: fluke.com/VibrationMeter ©2012 Fluke Corporation AD 4151036A_EN
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NEWS STUFF HAPPENS
New Certification For Professional Energy Managers Online, On Your Schedule, At Your Pace Schneider Electric has launched a Professional Energy Manager (PEM)™ certification for its online, vendor-neutral Energy University™ program. Developed with the Institute of Energy Professionals (IEP), the longest-running energy-education program in the U.S., the initiative gives energy-focused individuals a new professional-development avenue toward earning a highly marketable credential in the growing field of energy management. According to the company, this online PEM certification program offers conveniences that aren’t typically available through traditional classroom environments, including flexible schedules, free tuition and a self-paced curriculum that can reduce the program learning length. Additionally, participants may complete and purchase the PEM certification exam online through Energy University. The program prepares students for the exam via a proprietary learning path comprised of free, self-paced, on-demand courses offered in 12 languages. Topics include identifying efficiency opportunities; prioritizing opportunities through the qualification of data; and assembling the resources needed to define, sell and implement an efficiency program. (EDITOR’S NOTE: Schneider Electric reports that since its introduction in 2009, Energy University has trained more than 130,000 professionals worldwide by way of more than 150 courses. The newly launched online PEM certification initiative represents just one part of a significantly expanded investment by the company toward advancing education that prepares current and future workers to manage increasingly intelligent energy infrastructures and processes. Among other things, this aggressive investment strategy includes integrating Energy University with the Schneider Electric Data Center University™, a move that reflects the importance of an ever-busier intersection of energy, IT and data-center facilities.)
QUESTION OF THE MONTH SOUND-OFF: Tell us what you think. . . Really. . .
What was your biggest work-related challenge in 2012 and how did you overcome it? Go to MT-online.com/question with your answer. 8|
MAINTENANCE TECHNOLOGY
PEOPLE PEOPLE... UK-based Smiths Group plc has announced the recent appointment of Duncan Gillis as President & CEO of John Crane. A U.S. national, Gillis formerly held senior posts in a number of countries for Procter & Gamble, McKinsey and United Technologies. He comes to his new position from Algeco Scotsman, where he was serving as President & CEO. During its formal 20th Anniversary Celebration in Orlando, FL, last month, the Society for Maintenance & Reliability Professionals (SMRP) took some time to toast a number of the individuals who played key roles in the organization’s two decades of resounding success. Among those so honored were Bob Baldwin, the Founding and long-serving Editor of Maintenance Technology magazine. Baldwin also was one of the two original founders of SMRP. Another of those receiving shout-outs was Jackie Inglis, otherwise known (affectionately) as “Mama SMRP.” Inglis ran the association during its first five years, keeping membership records, spearheading annual meetings, serving as a liason between the members and staff and driving growth. For more on SMRP’s great past and bright future, see Bob Williamson’s November “Uptime” column (pg. 10).
NOVEMBER 2012
STUFF HAPPENS NEWS
BIZ BUZZ
NOVEMBER 2012
ITT Corporation has signed an agreement to acquire Bornemann Pumps, a global provider of highly engineered pumps and systems for the oil and gas industry. According to Bob Pagano, President of ITT’s Industrial Process business, “Bornemann’s twinscrew technology and multiphase applications experience would align strategically with the Industrial Process business, complement our Goulds Pumps brand and expand ITT’s presence in upstream oil and gas production.” He also emphasized that the acquisition would be bringing together two companies with strong aftermarket and emerging-market focus, as well as management teams and employees with shared values and commitments to quality, performance and customer satisfaction. In addition to its international installed base of multiphase systems for the oil and gas industry, Bornemann also serves the industrial, food and pharmaceutical sectors. Founded in 1853 and headquartered in Germany, Inspiration For Those Battling The Enemies Bornemann’s operations are supported by more Of Reliability & Productivity than 550 employees around the world.
FFIGIHGTINH’ TIN’ WWOORDRSDS
Emerson Process Management has embarked on a program to strengthen its support-service capabilities for customers everywhere. In 2012, Emerson extended its current footprint of 374 global service locations by opening eight fullservice facilities staffed by trained, certified personnel. Going forward, it plans to increase that number by nine per year, while expanding its support staff “at a pace roughly double the underlying automation market growth rate.” Within a year, the company expects to open two new service centers in Asia, two in the Middle East and Africa, one in Latin America and three in Europe. It’s also adding new capabilities to meet customer needs. For example, its Certified Repair and Quick Ship product manufacturing and service centers provide machining, manufacturing, fabrication, actuation, instrumentation and quality assurance services, and are designed to operate at speeds faster than factory lead-time KPI Responsiveness Standards. These include service-center sites less than two hours from customer plants; 24-hour replacement-parts delivery; 24/7 repair availability (onsite and depot) to customer timeline requests; and new-product delivery in five days (10 days for systems).
Digging deep into our mailbag this month, we discovered two quotes that seemed to complement each other nicely. The first, attributed to Charles Darwin, came from a previous contributor to this section, W.C. “Pete” Peterson, a Contract Reliability Engineer at the W.R. Grace Curtis Bay Works.
“Ignorance more frequently begets confidence than does knowledge.” The second was provided by Mitchell Howard, Senior HEP Operator at the Mojave Power Plant, Devils Canyon Power Plant, East Branch Extension. He wrote that one of his site’s mechanics, Jay Holdaway, made this keen observation years ago, “and it is still true!”
“No job is too hard for the guy not doing it!”
!
We just had to run these thought-provokers in tandem. Thanks much, Pete and Mitch! Have you read, heard, seen, thought or written down something that falls into the realm of “fightin’ words” for the maintenance and reliability community?
Send your favorites to quotes@atpnetwork.com. We’ll be selecting one or two (maybe even three) to feature each month. Be sure to give full credit to the individual (dead, alive, real or fictional) that uttered or wrote the words, and why those words inspire you. Don’t forget to include your complete contact info.
MT-ONLINE.COM | 9
UPTIME
Bob Williamson, Contributing Editor
SMRP: Make it Personal And Prepare For The Future SMRP, the Society for Maintenance & Reliability Professionals (“by professionals for professionals”) has been celebrating its 20th Anniversary throughout 2012. Held in Orlando, FL, last month, this year’s annual conference wasn’t just a nod to two great decades, it was among the best of the best SMRP events ever. It also offered one of the most revealing looks into the future of “maintenance and reliability” and our role in helping maintenance and reliability professionals prepare for that future. But first, let’s look at who/what made this year’s annual event a success: n 918 attendees (351 first-time attendees) n 167 exhibitors n 42 guests n 46 states represented
(Texas, South Carolina, Florida, Ohio and Minnesota, in that order, sent the most attendees) n 23 foreign countries represented n Top-five participating companies: Hormel (30),
Michelin (26), Agrium (24), CBRE (15), Freeport McMoran Copper & Gold (13), Georgia Pacific (13) and Mundy Companies (13) Attendees reflected a cross-section of industry types. Their companies represented the full spectrum of manufacturing and assembly, petro-chemical, specialty chemicals, fertilizers, foods, pharmaceuticals, primary metals, cement, mining, pulp and paper, healthcare, wood products, auto automotive manufacturing, pipelines, building materials, engineering services, power generation, public utilities and more. The attendees’ job roles included senior executives, management, supervision, team leads, technicians of all types, maintenance mechanics and electricians, planners, schedulers, storeroom specialists and engineers of all types, from both union and non-union companies. While the audience was made up primarily by individuals in maintenance and reliability roles, it was punctuated with a number of others in production-operations and business-administration roles. 10 |
MAINTENANCE TECHNOLOGY
Many skilled and knowledgeable attendees of all ages proudly sported their Certified Maintenance & Reliability Professional (CMRP) and their Certified Maintenance and Reliability Technician (CMRT) badge ribbons for all to see. Certification exams were also offered to those who had not yet achieved these globally recognized and respected distinctions. This year’s annual conference offered 24 day-long workshops, 60 conference sessions and five outstanding local facility tours for intensive learning, plus networking with special interest groups, task forces and committees. Beyond that, one of the most valuable benefits came from networking with others from diverse groups and industries and exploring what new tools and technologies the nearly 70 vendor displays had to offer. This is the place where the serious maintenance and reliability professionals meet, learn, share and develop life-long professional friendships. Thinking back to the beginnings of SMRP Of course, there were those of us who attended the very first SMRP conference in Nashville, TN, in 1993. That one was a truly memorable event, with over 250 in attendance—well up from the hoped-for number of 160 to break even! From that point on, the organizers and their followers continued to bring on dozens of like-thinking volunteers, recruits and kindred souls to spread the word and grow the unparalleled benefits of the SMRP. It took passion and action to build this association to attract and develop true professionals in maintenance and reliability across countless business and industry sectors. It took a powerful vision among SMRP‘s founders to set the stage for professional development and growth in workplace disciplines that were not always among the most appreciated: maintenance and reliability. Discussions about future trends and roles of maintenance and reliability pros started with gusto at that first SMRP conference in Nashville. On the technical discipline side, we were learning about Reliability Centered Maintenance from the late John Moubray— who had launched his RCM-II book in the USA in 1992. Fresh from the UK and hot off the press, the passion NOVEMBER 2012
n
UPTIME
It took great vision for SMRP’s founders to build an organization around maintenance and reliability, disciplines that weren’t always appreciated. reflected in Moubray’s book on the subject of RCM was unbounded. At the same time, Total Productive Maintenance (TPM), with its focus on both the people and technical sides of maintenance, was gaining momentum. My own passion was for TPM, having learned the principles several years earlier through Seiichi Nakajima, the father of this methodology, as well as through ongoing work with several clients on their transformations. We had many a debate at SMRP (often fueled by Maintenance Technology’s Founding (and longserving) Editor Bob Baldwin) in panel discussions and over beverages: “So, will it be RCM or TPM, Engineering-technical solutions or culture change?” Baldwin would ask. While John Moubray’s emphasis was clearly “RCM,” we would eventually agree that the answer to both questions was “YES.” (BTW: John Moubray passed away in January 2004, leaving with us huge legacy and his great passion for RCM-II). Let the generational shift begin… From my perspective, the 2012 SMRP conference served as a real window to our future. The “old guard” (Sorry guys… I’m one too) rubbed shoulders with rapidly growing numbers of young, bright-eyed, hungry-for-learning professionals and soon-to-be leaders in their industries and the SMRP. The gray hairs were teaching the new guard, and the new guard was telling stories of early successes from their own maintenance and reliability journeys. In some cases, long-time attendees had already passed the torch to their younger counterparts or were teaming at this year’s event as mentors and coaches. But, it’s not just a human generational shift that’s taking place: There’s more—much more—shifting in our profession. Maintenance and reliability is rapidly becoming a bigger competitive business advantage. The new maintenance and reliability The spectrum of “maintenance and reliability” is being expanded at a rapid pace. In many cases, this expansion is being accelerated because of a grossly underestimated skills shortage coupled with the demands for longer-lived, more reliable, more profitable, safer and sustainable plants and facilities. NOVEMBER 2012
On one end of the spectrum are the technicians and maintainers: These are the folks that are graduating from turning wrenches to operating the new-tech tools of our trade. Their social networking and instant access to information on the World Wide Web easily surpasses anything that existed 20 years ago. On the other end of the spectrum is the emerging field of “strategic asset management”—powerful concepts for the future of physical capital-intensive businesses —represented by PAS 55 and ISO 55000. These global best practices are starting to show significant results in cost savings, performance and reliability improvements associated with the hard assets we’re used to dealing with: equipment, process systems and facilities. Maintenance and reliability technicians are hungry for knowledge and skills. They want to hit the ground running in their roles—if they’re not already in the race. Their needs are often different from what was traditionally offered through the SMRP. Basic maintenance skills refreshers and best practices for the plant-floor level are sorely needed due to failing public schools and decades of decline in trade and technical schools. Yes, some of these schools may be coming back. But there’s a generation of maintainers who have missed out on the skill sets needed in industry today (and tomorrow). They’ve learned on the job, from vendors and suppliers and from workshops and short courses. They’re hungry for so much more. We need to figure out the best ways of delivering to them. Strategic asset management is a whole new field on our horizon. But, it is much more than merely complying with PAS 55 and IS0 55000 for Asset Management. These new asset-management specifications and standards will require a whole new set of skills and knowledge beyond the technical reliability skills we’ve honed and fine-tuned for the past 20 years. Asset management as codified in PAS 55 and ISO 55000 will require the skills of understanding strategic business cases, collaboration with others who are not typically part of the maintenance and reliability scope of work, and much more. People skills as well as technical skills will be in demand in our profession. Why? Maintenance and reliability management is a very small, but essential, subset of mt-online.com | 11
UPTIME
Now is the time to take charge of our future. New frontiers are waiting for us. asset lifecycle management. We must master a variety of interdependent relationships and partnerships for the future of our assets and to be successful as maintenance and reliability professionals. Now is the time to begin learning what is embodied in the new Asset Management specifications and standards. Because when it comes, it will likely be aimed at our businesses by business outsiders, launched by senior executives and sweep across our plants and facilities much like ISO-9000 Quality Management did a few decades ago. Insurance companies, investors and owners will likely demand it—and plant leadership will respond accordingly. Maintenance and reliability professionals have a considerable body of knowledge and best practices to apply to Asset Management, but we must learn how to engage ourselves in the process without trying to use the technical jargon of our trade.
Conquering new frontiers The new frontiers for maintenance and reliability professionals will include—but extend well beyond—the foundations of maintenance and maintenance-management best practices. These frontiers will reach much further than reliability and maintainability, RCM and TPM and the latest EAM software. Strategic advantage will go to those businesses that can demonstrate better than bestin-class asset performance and reliability throughout the entire lifecycle of their equipment and facilities. The Society for Maintenance and Reliability Professionals is a leading-edge organization with access to tens of thousands of members’ experiences that we can harness in taking charge of our future. New frontiers are ready and waiting for us. Now is the time to learn, to grow and to challenge the traditional paradigms of maintenance and reliability. Now is the time for a whole new body of knowledge. Make it personal and prepare for the future. Thank you, SMRP, for 20 inspiring and wonderful years. MT Robertmw2@cs.com
A Leader in Electric Motor Testing
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MAINTENANCE TECHNOLOGY
NOVEMBER 2012
BOOSTING YOUR BOTTOM LINE
Are You Asking The Right Questions?
N
ow is probably as good time as any to take our motor management quiz. That’s because it’s true: An ounce of prevention is worth a pound of cure. By answering a few simple and timely questions, you can improve the operating efficiency of important motor-driven equipment such as pumps, fans, conveyors, blowers and air compressors. Even more importantly, addressing these issues early can improve system reliability, preventing system failure and costly downtime. The following three questions (along with your responses to them) will go a long way in helping you assess the state of your facility’s motor system management. Remember, planning for efficiency and reliability is easier than managing unexpected equipment failure and downtime. #1. Does your facility have a current motor inventory? A motor inventory is a list of every motor in a facility, its size, nameplate efficiency, operation, load factor, run-hours and maintenance history. With an up-to-date motor inventory, you can ensure that the most efficient motors are the most often used, track “problem” motors (those with histories of repeated failure), identify candidates for cost-effective replacement and keep these motors in stock to minimize downtime. Ask a vendor or service provider in your area for assistance, or use the simple inventory feature in DOE’s Motor Master+ [Ref 1]. #2. Does your facility have guidelines for repair-replace decisions? It is easier to manage a plan than a crisis. Know what will be done with every motor upon failure by creating repair-replace decision guidelines. The information in your motor inventory, along with local motor repair prices, purchase prices and electricity rates, will assist you in determining the cost-effective choice. (A free MDM calculation spreadsheet, the 1*2*3 Approach [Ref. 2] can help you do this in three easy steps.)
| MAINTENANCE NOVEMBER 2012 32 TECHNOLOGY
#3. Does your facility specify best-practice repair? Best-practice rewinds, as defined by the ANSI/EASA AR 100 standard [Ref. 3], return a motor to its nameplate efficiency. Without this type of specification, a repair could result in a unit that operates less efficiently and, in the event that this motor has significant damage, could compromise reliability. Take the time to check out the best practice repair resources available through the Motor Decisions Matter Website, and contact your motor service provider to develop a specification for your facility. If you answered “yes” to all three questions here, you are on your way to preventing unexpected downtime through motor system management. Fortunately, many organizations can help you plan for reliability, including your local electric utility, motor distributor, motor service center, and government agencies. Additionally, the MDM Website (www.motorsmatter.org) has resources specifically designed to help you get started. Why wait for a crisis? Prevent it with proactive motor system management. (BTW: Visit the MDM site for a bonus question on variable speed drives.) MT 1. http://www1.eere.energy.gov/manufacturing/ tech_deployment/software_motormaster.html 2. http://www.motorsmatter.org/tools/123approach.html 3. http://www.easa.com/sites/default/files/AR1002010_1010-2.pdf For more info, enter 01 at www.MT-freeinfo.com
The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energysaving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org or (617) 589-3949.
| 13 MT-ONLINE .COM2007 OCTOBER
DON’T PROCRASTINATE…INNOVATE!
Ken Bannister, Contributing Editor
Dollars & Cents Vs. Dollars & Sense Championing maintenance-improvement projects in tough economic times isn’t easy. Many will recall the infamous 1990s downsizing era, when countless maintenance departments suffered deep cuts in their capital and operating budgets, which, in turn, lead to a crippling deferred maintenance approach. The subsequent recovery period brought about a better understanding of how to defend against future indiscriminate cutting back of programs through improved setup and use of the CMMS (computerized maintenance management system asset management reporting tools). In the early 1990s, the maintenance department that was able to articulate in “bottom-line” terms the economic consequence of deferred maintenance as a direct result of budget slashing was the maintenance department that not only saved its existing budget, it often was able to capture additional funding for further cost-saving initiatives. Articulating the consequences of deferred maintenance was typically accomplished through a simple Cost/Benefit Analysis report. Such reports position maintenance as an investment in corporate well-being and depict the financial impact of a new or existing initiative or a proposed maintenance budget cut. The Cost/Benefit Analysis provides a statement of record, usually for an accounting department, which likes to review costs and benefits in terms of “dollars and cents”. To invest in something is to dedicate funds and/ or time to a project that’s expected to yield a profit or income. In the case of maintenance initiatives, the profit or income almost always was categorized in the past through the ability to increase operation throughput productivity/quality as a result of increased asset availability and reliability. Those gains would then be translated into dollars-andcents monetary terms. Moving forward 20 years, not every business decision is now fiscal-based, and today’s maintenance department finds itself in a much more sophisticated
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MAINTENANCE TECHNOLOGY
corporate environment: That means competing against every other department for a slice of an everdecreasing investment pie. Remuneration success is still awarded to those departments whose programs return a quick economic benefit, but it’s the innovative program—one that delivers both “dollars and sense”—that now takes the biggest slice of pie! In other words, today’s maintenance departments must be innovative in categorizing their programs’ benefits, not simply in fiscal returns, but in different “currencies” that make sense to the corporation. Available ‘currencies’ Delivering dollars and sense requires homework—and that often commences with the corporate mission and vision. Delivering programs that dovetail directly into the corporate direction is a powerful benefit. Most companies spell out their missions and visions for the world to see in their annual corporate reports or on the home pages of their corporate Websites. Making sense of a project is often a matter of better understanding your company’s business and the impact the corporation strives to make on its investors, customers and the world at large. The ability to put forth programs and initiatives that tangibly categorize additional benefits that make sense to the corporation are more likely to achieve project approval. The following examples show how a maintenance department can be innovative in positioning its Cost/Benefit reports: Meeting and exceeding regulation requirements. If you work in a regulated industry like power generation, food processing or pharmaceutical, you are subjected to regulatory audits that you must pass in order to keep your business-operating license. Due diligence through effective maintenance tracking and performance is a MUST in regulated industries and often speeds up the audit process, reducing the impact of the audit process to the organization. Investigate the ramifications of a license suspension or loss, and the impact to your corporation if such an event were to occur.
NOVEMBER 2012
DON’T PROCRASTINATE…INNOVATE!
Making sense of what you do in tangible terms can get you the dollars every time. Standards accreditation and award programs. Being accredited to specific standards such as ISO 9000 (quality), ISO 14000 (environmental) and PAS 55/ISO 55000 (maintenance) can be a mandated customer requirement for bidding on and performing work. Along with award programs such as the NAME (North American Maintenance Excellence) Award, accreditation serves to project a trustworthy corporate image that can be capitalized on with new customers and help increase corporate/workforce self-esteem. Increased safety. Everyone wants to feel as safe as possible in their workplace. Companies that can demonstrate a good safety record are rewarded handsomely by substantial reductions in their workman’s compensation insurance costs and having staff that turns up for work every day. Working-capital reductions. Reducing MRO inventories through lifecycle costing initiatives and use of just-in-time (JIT) and “pay as you go” vendor-managed inventories significantly decreases (or eliminates) operating capital tied up on inventory shelves. Environmental sustainability via reduced energy. Effective lubrication programs can cut electricity consumption 4-18% by putting the right lubricant, in the right amount, in the right place, at the right time. Effective condition-monitoring programs can deliver energy reduction in a number of ways (i.e., by helping identify and plug simple air leaks in compressed-air systems; by helping eliminate mechanical-drive transmission power losses with laser alignment of driver/driven components; by helping eliminate electrical energy loss to ground through infrared detection of loose connections; and by helping eliminate converted steam losses due to faulty steam traps and poor line insulation with the aid of ultrasonic and infrared technology). Energy consumption also tracked on the basis of natural gas used in heating systems and gasoline/ diesel fuels in fleets. When looking to monitor energy use, try to work with suppliers who have equipment that can be utilized for free—and who may offer rebate credits you can take advantage of.
NOVEMBER 2012
Sustainability through a reduced carbon footprint. In many parts of the world, carbon credits have become trading commodities worth millions of dollars to corporations—whether buying or selling. In July 2012, Australia became the latest country to impose a carbon tax on industry. North America could impose a carbon tax in the future as well, and companies need to be ready. Improved energy management, along with improved maintenance practices, can play an important role in reducing a corporation’s CO2 impact. For every kWh hr of energy we save, we reduce our carbon footprint by 0.000537 tons of CO2. To put that in perspective, finding a simple loose connection in a 400 hp, 480v, 3-phase motor is the equivalent of saving $11,875 in electrical energy per year at 9.5c/kW—and an amazing 67 ton of CO2! Many of these benefits often can be compounded (i.e., a single program or initiative can deliver a two, three or even four times the benefits). For example, an engineered lubrication program can increase bearing life, reduce downtime, reduce energy, reduce carbon footprint and increase safety while meeting regulation and a standards requirement (all for very little capital outlay). Making sense of what you do in tangible terms can get you the dollars every time! A call to action Do you have an innovation story that has yielded dollars and sense? Tell us and others about it by entering our “2012 Maintenance & Reliability Innovator of the Year Award” program. You have nothing to lose and plenty to gain, including some great prizes and bragging rights! Procrastination gets zip. Visit www.reliabilityinnovator.com for full details and entry forms. The deadline is December 31, 2012. Good Luck! Ken Bannister is a world-class asset management consultant and best-selling author of Energy Reduction Through Improved Maintenance Management Practices. Telephone: (519) 469-9173; or email: kbannister@engtechindustries.com.
MT-ONLINE.COM | 15
CAPACITY ASSURANCE SOLUTIONS
When good stuff goes bad (or not)...
Harnessing The Power Of
PMI
In Reliability Investigations 16 |
MAINTENANCE TECHNOLOGY
NOVEMBER 2012
CAPACITY ASSURANCE SOLUTIONS
A non-destructive form of positive material identification can be a shortcut to uncovering the root cause of bad welds, parts failure and more. It also can be an effective way to verify on-spec conditions in your equipment and systems. Greg Mann and Michael Porfilio Anderson Laboratories, Inc.
W
hen the maintenance manager at a Midwestern water treatment plant was confronted with a wet floor in the facility’s pump room, his crew was perplexed. The team could see that a cracked pump housing was the culprit and knew they could repair it with weld filler material. What they didn’t know was the type of material that had been used in the manufacturing of the pump's housing— key information that would let them select the proper weld filler. After a brief discussion, the next step was obvious: Contact a materials testing laboratory to determine the material used in the pump.
MT-ONLINE.COM | 17
CAPACITY ASSURANCE SOLUTIONS
Defining PMI Materials testing labs use a process called “positive material identification” (PMI) to determine the makeup of metallic alloys. As in crime-scene investigations, where a number of tools are used to help unravel mysteries, PMI is one means of tracing a material back to its original Material Test Report (MTR), which is a certified chemical analysis that identifies metallic components. Originally, PMI was a destructive technique performed using wet chemical analysis methods for comparison to material-grade compositional requirements. The process was highly accurate—but labor-intensive, time-consuming and costly. As technology has progressed, advances in technology and electronics have led to portable, handheld X-ray analyzers that are capable of providing valuable chemical information that was previously only available using fixed laboratory equipment. Portable X-ray fluorescence (XRF), for example, provides a fast, easy, non-destructive analysis with minimal capital investment (see Sidebar below). Originally designed as a means of identifying high-alloyed corrosion-resistant materials used in the petroleum industry, this technology has demonstrated the ability to provide analysis for most metallic engineering materials used across industry today.
Fig. 1. Positive material identification using X-ray fluorescence (XRF) analysis can provide material validation at any point in the manufacture of a finished product.
A Look Inside X-Ray Fluorescence X-ray fluorescence (XRF) spectrometry is a technique for the analysis of elements that has broad application in both science and industry. It’s based on the principle that individual atoms, when excited by an external energy source, emit X-ray photons of a characteristic energy or wavelength. By counting the number of photons of each energy emitted from a sample, an element may be identified. XRF technology is an outgrowth of Wilhelm Röntgen’s discovery of highenergy radiation, which he dubbed X-rays, in 1895. In 1913, English physicist Henry Moseley advanced the concept when he constructed an X-ray spectrometer to measure the frequency of certain types of X-rays produced from tubes with different electrode materials. Moseley's results showed that the ordering of the wavelengths of the X-ray emissions of the elements happened to coincide with the ordering of the elements
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MAINTENANCE TECHNOLOGY
by atomic number. This relationship is now known as Moseley's Law. X-rays can be used to identify elements because of the characteristic radiation emitted from the inner electronic shells of the atoms. This radiation is comprised of X-ray photons whose specific energies permit the identification of their source atoms. The X-ray photons are emitted during fluorescence, which is the emission of an X-ray photon that occurs when atoms in a tested material are rearranged by the external energy source. By detecting this photon and measuring its energy, an element can be determined. While the first commercially produced X-ray spectrometer was developed in the 1950s, modern, handheld XRF instruments have revolutionized the field. Capable of analyzing solid, liquid, and thin-film samples for major and trace components, the analysis is rapid and sample preparation is usually minimal or not required. As noted in
the accompanying article, handheld analyzers allow XRF technology to be used onsite to quickly gather key information, offering a low-cost alternative to the more detailed, but time-consuming laboratory techniques that involve fixed machinery and sample destruction. In the industrial maintenance and reliability arena, XRF technology is used most often on metals—to determine components of alloys in parts, equipment and raw stock—and on chemicals, especially petrochemicals. Growth opportunities for these systems were advanced significantly with passage of the European Union’s Regulation of Hazardous Substances (RoHS) directive and the Waste Electrical and Electronic Equipment (WEEE) directive, which restrict the use of certain metals in products. Sources: University of Missouri, National Science Foundation, Northern Arizona University
NOVEMBER 2012
CAPACITY ASSURANCE SOLUTIONS
XRF techniques can also be used to recreate lost information, such as stock-traceability paperwork. The instruments used in this type of PMI can provide comparison to hundreds of alloy grades and families. Industry-accepted procedures and work instructions for PMI using portable XRF devices define acceptance and rejection criteria and aspects to the testing requirements. These considerations include minimum required radiation safety training and safe practices to be used when operating this equipment.
Fig. 2. Handheld XRF devices offer a fast, easy way to conduct a non-destructive analysis with minimal capital investment.
XRF analyzers work by exposing a material sample to a beam of X-rays generated from an internal source. The X-rays interact with the sample surface, locally exciting atoms that emit energy after excitation. This emitted energy is characteristic of the elements present in the sample and is identifiable as a characteristic energy level. The intensity of these unique energy levels represents the relative concentration of each element of interest that is collected on a solid-state detector. This approach can gather qualitative and often quantitative information. Modern software packages have the ability to identify hundreds of commercially recognizable alloy grades. PMI using XRF analysis has become an important tool for quality-assurance applications in nearly all areas of industry, but especially in petroleum processing, nuclear building materials, foundry and scrap. Quality systems are increasingly demanding complete traceability for all materials used in production. This can mean that at any point in the design, manufacture or assembly of components into a final product, material traceability may be required on demand. When traceability for production machinery is required and not available, material validation using portable XRF may be indicated to provide a PMI link to an original MTR. Most modern instruments are designed to permit spot analysis for applications. This is ideal for limited-access areas and for inventory control and material-sorting processes that are based on differences in chemistry. Material validation of incoming stock and final assemblies demonstrate that proper materials are being used. And while the XRF-PMI technique is best suited for high-alloy carbon steel, stainless steel, nickel and cobalt materials, it can analyze other materials. Rapid quantification with reliable results is possible with minimum sample preparation, such as a light surface abrasion. NOVEMBER 2012For more info, enter 71 at www.MT-freeinfo.com
XRF limitations and successes PMI using portable XRF has broad applications—but also some limitations. These include the inability to provide analysis of light elements such as carbon. This is an issue in analysis of carbon steel, where carbon may be the only element separating grades of material, allowing for identification of the alloy family or materials. Other light elements, including Mg, Al, Si, P and S, suffer from poor limits of quantification, which may impose further restrictions on the effective application of the technique for some materials. Still, XRF-PMI remains a highly effective way to verify most materials, as its many successes prove. Here are a few of the many mysteries that have been solved by XRF-PMI: The case of the leaky water pump… Let’s return to the water treatment plant’s pump problem. In this case, the crew removed the pump and took it to the materials testing laboratory to verify the weld material around the footing and the inner surface of the cover for filler-material compatibility to the base material. PMI testing techniques showed the housing to be nickel-based Inconel 825. The analysis also showed the wrong weld filler had been used originally, which caused corrosion and the subsequent leak after just a few years of service. Because the characteristics of Inconel 825 prevented making a repair weld without heat-treating—which the crew couldn't perform—the plant had to purchase a replacement pump.
Fig. 3. PMI analysis of a leaky water-treatment plant pump verified that the wrong weld filler had been used around the footing and inner surface of the cover, thus preventing the maintenance crew from making a repair weld without heat-treating (which the crew couldn't do). Verdict: The plant had to replace the pump. MT-ONLINE.COM | 19
CAPACITY ASSURANCE SOLUTIONS
Fig. 4. Before going online, a new coal plant needed to ensure that its critical components had been built to specified requirements (which included verification of base materials and weld fillers). Quick, onsite PMI analyses of each panel of a 30-section fabricated meterhousing body and every six inches of weld material confirmed that this component passed with flying colors. The unit went into service immediately.
The case of the critical pressure vessel… In preparation to go online, a new coal plant needed to ensure that its critical components had been built/fabricated to specified requirements—which included verification of base materials and weld fillers. Of particular interest was a fabricated meter housing body with more than 30 fabrication sections and welds. Because this critical component would be in daily operation in severe conditions, management ordered a quick, onsite PMI analysis. Each panel and every six inches of weld material was verified to ensure compliance. After the analyses confirmed that the unit passed all requirements, the plant was able to put it into service immediately.
The case of the suspected mixed-material flat stock… When an aftermarket performance-motorcycle fabrication shop was having trouble making bends in formed metal components, a lab was called in to check for mixed material in the stock room. The lab assisted by restoring traceability of two mixed lots of steel. The material intended for the work was alloy steel 4130 (UNS G41300), which contains numerous elements, including 0.80% to 1.10% chromium. Because XRF analysis can detect chromium, as well as nickel and molybdenum, in significant quantities, the process enabled the lab to sort the shop’s materials using this element alone. It determined that some stock contained lower levels of chromium than required (0.03% to 0.05%), and was set aside for other uses. Fig. 5. When an aftermarket performance-motorcycle fabrication shop had trouble making bends in formed metal components, PMI analysis helped trace the problem back to two mixed lots of steel in the shop’s stock room.
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NOVEMBER 2012
Putting PMI to work in your operations Whether monitoring incoming and outgoing materials, reverse engineering, contract satisfaction or product repair, portable XRF provides the ability to quickly verify material-grade composition using non-destructive testing. As an indisputable value-add in an era of high-quality expectations, counterfeit parts and product traceability, this type of PMI could easily become one of your favorite investigative tools. MT
Greg Mann is Chemical Analysis Group Leader/Materials Specialist, for Anderson Laboratories, Inc., in Greendale, WI. Telephone: (414) 421-7600; or email: gregm@andersonlabs.com. Michael Porfilio is Director of Operations at Anderson Laboratories. Telephone: (414) 421-7600; email: mikep@anderson labs.com.
More About Anderson Laboratories, Inc. Established in 1939, Anderson Laboratories is an independent materials testing facility located in Greendale, WI. Specialties include chemical analysis, mechanical testing, welding procedure and performance qualification, failure analysis, environmental and corrosion testing, as well as on-site evaluations. Analyses are performed by skilled personnel with a combined experience of more than 70 years, and instrumentation is programmed for the majority of engineering alloys used in modern manufacturing. Anderson’s tensile capabilities range from several grams to 200,000 pounds force, both in tension and compression. Computer-controlled testing equipment can determine many properties in both English and Metric units. Compliance to the appropriate ASTM, ASME, EN, JIS and other applicable specifications is considered of vital importance in obtaining accurate mechanical testing results. Anderson Laboratories is accredited to the International Organization for Standardization (ISO) 17025 through the American Association for Laboratory Accreditation (A2LA) and Det Norske Veritas (DNV). Learn more at www. andersonlabs.com. For more info, enter 02 at www.MT-freeinfo.com For more info, enter 69 at www.MT-freeinfo.com
NOVEMBER 2012
For more info, enter 72 at www.MT-freeinfo.com
MT-ONLINE.COM | 21
Register Now For The Extraordinary. . .
RCM FOR THE LAYPERSON
! 6ERY 3PECIAL 7ORKSHOP 0RESENTED "Y 4HE -AN 7HO 7ROTE 4HE "OOK
NEIL BLOOM
0IONEERING 2#- %XPERT AND !UTHOR /F -C'RAW (ILL S Reliability Centered Maintenance (RCM) Made Simple
Due to high demand, the dates for this workshop have been changed:
November 27-29, 2012
Chicago Marriott O’Hare | Chicago, IL AT THIS WORKSHOP, ATTENDEES WILL LEARN: s 7HY OVER OF ALL ATTEMPTED 2#- PROGRAMS RESULT IN FAILURE s (OW TO SUCCESSFULLY IMPLEMENT A COMPREHENSIVE CLASSICAL 2#- PROGRAM WITHOUT THE NEED FOR OUTSIDE EXPERTISE s (OW TO SIMPLIFY NOT STREAMLINE AN 2#- PROGRAM USING IN HOUSE RESOURCES s 7HAT THE PITFALLS OF 2#- ARE AND HOW TO AVOID THEM s 7HY THE #ONSEQUENCE OF &AILURE !NALYSIS #/&! IS MORE COMPREHENSIVE AND EASIER TO UNDERSTAND THAN THE &AILURE -ODES AND %FFECTS !NALYSIS &-%! At no extra charge, Neil Bloom will be available on Friday, Nov. 30 to mentor attendees on how to implement his RCM process on specific systems and equipment. For personal attention, bring your own plant-specific P&IDs, plant schematics or design drawings.
s )MPORTANT DIFFERENCES BETWEEN hFUNCTIONAL FAILURESv AND hFAILURE MODES v AND BETWEEN hFAILURE MODESv AND hFAILURE CAUSES v s (OW TO ESTABLISH SYNERGISTIC STRATEGIES FOR THE INTEGRATION OF PREVENTIVE AND CORRECTIVE MAINTENANCE s 4HE FUNDAMENTAL CONCEPTS OF hHIDDEN FAILURESv AND THE h#ANON ,AWv OF RUN TO FAILURE WHICH ARE A VITAL BUT GROSSLY MISUNDERSTOOD PART OF 2#- s (OW TO DEVELOP AN 2#- h,IVING 0ROGRAM v s (OW TO MONITOR AND TREND THE 2#- RELIABILITY PERFORMANCE OF AN ENTIRE PLANT
For Full Course Details, Lodging Info And Online Registration, Go To: www.mt-online.com/rcm For more info, enter 70 at www.MT-freeinfo.com
AUTOMATION INSIDER
Diagnostics Mark The (Trouble) Spot
By Gary Mintchell
Y
ears ago, many of us took part in the “Great Fieldbus Wars” that raged across the automation side of manufacturing. If you worked on the maintenance and reliability side of an operation, you were either a bystander—essentially kept in the dark—or some type of “collateral damage” in these wars. Debates about the technical merits of different “fieldbus” technologies and discussions of the benefits to be realized for manufacturers of all types seemed to be never-ending. Things eventually settled down (as they usually do). The many digital fieldbuses that were proposed in the 1990s gradually coalesced into two main ones—Foundation Fieldbus, promulgated by the Fieldbus Foundation, and Profibus PA, promulgated by Profibus International. Although the initial benefits were touted as labor cost savings due to wiring reductions, the real benefits involved enhanced diagnostics. If maintenance and operations could devise ways to capture and use that information, many additional benefits would ensue. These included better information about the status of processes and the ability to react more quickly to problems. Going digital Larry O’Brien, Marketing Director for the Fieldbus Foundation, recently engaged me in a discussion about the benefits of digital networks. “The diagnostics issue is really an information management problem that can be solved with the technology we have today,” he observed. “NAMUR NE 107 diagnostics have been part of our specification since 2010. NAMUR NE 107 is extremely valuable because it not only creates standard symbols and terms for reporting diagnostic conditions, it makes it a lot easier to classify diagnostics in terms of severity and root cause.” O’Brien continued, “When you go completely digital, the volume and type of diagnostics that are available to you increase exponentially, as does the bandwidth to report these diagnostic conditions. All of a sudden, you find yourself able to access thousands of diagnostic parameters at a time from many different devices across your fieldbus network.” Think about the “exponential increase” O’Brien describes: This takes diagnostics into a whole new dimension, where it becomes part of your overall plant optimization strategy. MT Gary Mintchell, gmintchell@automationworld.com, is Co-Founder and Editor in Chief of Automation World magazine and blogs at www.garymintchellsfeedforward.com. For more info, enter 03 at www.MT-freeinfo.com
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NOVEMBER 2012
MT-ONLINE.COM | 23
Go For It!
Are your innovative juices flowing? Are your light bulbs going off? They better be!
Categories: Š
For more info, enter 72 at www.MT-freeinfo.com
Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources
Presented By
Applied Technology Publications
Details & Entry Forms Available At www.reliabilityinnovator.com
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BIG MONEY TALKS XX UM UM William C. Livoti, Contributing Editor
The Power Industry At A Glance: Redux
T
his topic may seem repetitious (I’ve written about it several times). But as the Power Generation sector continues to evolve, a discussion of its current state at a given point— and its future as far as we can see—needs to be revisited from time to time. So I’m bringing it up again: What’s the state of the Power Industry today, where is it going and what will it look like over the next decade? As I monitor developments in Power Generation, I’m fascinated by the changes and—in my opinion— some of the knee-jerk decisions the industry makes these days. In many cases, those reactions are driven by proposed legislation; in others, public sentiment and the media are doing the driving. One can’t begin to speculate on the future of Power Generation without factoring in the economy. Here we are: at the very threshold of the second decade of the 21st century and we are STILL struggling to recover from the recession/ depression (depending on whom you ask or what you’re reading, hearing or seeing). And, now, with the recent devastation wrought by Hurricane Sandy, that struggle to recover probably won’t be getting much easier or moving much faster for a while. Even before Sandy made landfall, though, most economists felt that 2013 wouldn’t be very pretty. Current state Let’s look at the state of the Power Industry from the perspective of Fall 2012 (pre-Hurricane Sandy): • The U.S. coal industry is bracing for tighter— and more costly—regulation of its waste. The associated costs, of course, will be passed on to the coal industry’s customers (i.e., the power generators). • Natural gas seems to be the fuel of choice—for now. The power companies have had little control over this matter due to legislation and public sentiment.
• Renewable energy seems to be moving forward— and should continue to do so as long as the incentives for it remain in place. So much for the big power producers…For the rest of us—end-user consumers—the primary concern should be how to cost-effectively run, protect and ensure the sustainability of our power-using operations. Fortunately for us, there is (finally) renewed interest in Combined Heat and Power (CHP). Leveraging available technologies CHP is an efficient, clean and reliable approach to generating decentralized power (DE) and thermal energy from a single fuel source. CHP can increase operational efficiency and decrease energy costs, while reducing emissions. Makes sense to me. Let’s look at a few more advantages to CHP and DE. Centralized electric power is produced at large generation facilities and shipped over transmission and distribution grids to end-users. DE and CHP offer several advantages over centralized power: • Distributed-generation power is produced near its point of use, minimizing the risk of power loss. • CHP’s multiple energy sources (steam, electricity, hot water) maximize energy (fuel) usage. • Control of electrical cost reduces impact of peakdemand charges, power-factor correction, etc. Future state Like other industries, the Power-Gen sector is evolving. As I have often written, though, all industries need to adapt to the times, be proactive, avoid knee-jerk reactions and leverage all available technology. That said, it may also be beneficial to look into the past for solutions today. UM wclivoti@atpnetwork.com For more info, enter 261 at www.MT-freeinfo.com
VOLUME 72 / NO. 42
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UM MT was proud to publish this article by one of the most recognized and respected technical experts in the pump world as part of our very first Utilities Manager supplement in February 2006. Almost seven years later, its recommendations are as relevant as ever for reliability- and efficiency-focused users of pumping systems.
Using KPIs To Monitor And Improve Pump Performance Savvy energy staffers know that monitoring and tracking the performance of their pumping systems can be a very profitable undertaking. Just how profitable, though, often hinges on which key performance indicators are followed over time. A noted expert suggests a combined approach. Gunnar Hovstadius, Ph.D. Consultant
P
ump systems in industry often are connected to various types of monitoring and control systems. Typically, end users will only monitor one or several parameters, such as flow rate, pressure, power and/or current. That rather limited type of monitoring, though, really doesn’t provide a full view of a pump’s performance. By just monitoring a few individual parameters, a company risks overlooking important information about system performance as a whole. It is difficult to find useful key performance indicators (KPIs) to track in the quest for improved efficiencies in a pumping system. Tracking maintenance costs by themselves certainly can provide good data on the health of a system. But, in many cases, better information can be obtained by combining several parameters into a one KPI and following it over time. One way to do this is to relate flow and power, rather than to simply measure them independently. Let’s examine how this can be done. Fluid system relationships For pump systems, the relationship between fluid power, flow rate, pressure (head) and specific gravity of the fluid can be expressed in the following equations: Fluid Power (bhp) = Head (ft) * Flow (gpm) * specific gravity (Equation 1) 3960 In order to determine the electrical power used by the system it is necessary to divide the fluid power by the efficiencies of the different components that produce it: i.e. motor, drive and pump efficiencies. Specific energy Specific energy (Es) is good measure to use for calculating the cost of pumping. This is the energy used to move a certain volume through the system. It is measured as Watt hours/gallon, or any other suitable units, and it has the advantage of being a direct measurement of the cost of pumping once you know the cost of energy. (This is the same as measuring the miles per gallon for a car.) Energy Used = Pumped Volume Es = Pin * Time = V
26 | utilities manager
Specific Energy (Equation 2) Pin Q
(Equation 3)
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Fig. 1. Specific energy as a function of head for different overall efficiencies
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Pump Operation When Throttling Discharge Valve
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Reduction in Pressure Loss Using a vsd
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Pump Operation When Using a Variable Speed Drive
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As seen in equation (3), the instantaneous value of the specific energy equals the input power divided by the flow rate. Using the equation for Fluid Power and dividing by the various efficiencies we get Equation 4: Input Power (kW) = Head (ft) * flow (gpm) * Sp. gravity* 0.75 ηdrive * ηmotor * ηpump * 3960 From this we get Equation 5: Es = Head (ft) * Sp. gravity * 0.75 ηdrive * ηmotor * ηpump * 3960 If there is no drive in the system, the corresponding term is replaced by 1. Specific energy is a useful measure for comparing different system solutions and the cost of pumping. In systems where the flow is constant, this is a simple task by using the equations above. In systems with varying flow rates, it becomes a little more complicated. First, Es needs to be calculated as a function of flow rate, which requires information from pump, motor and drive manufacturers. The pump manufacturer has to provide pump curves for variable speed operation, while the motor and drive suppliers have to provide efficiency curves as a function of load and speed. Specific energy (Es) is a linear function of the head if the other factors are constant. We can, therefore, plot it as a function of head for different overall efficiencies. See Fig. 1 where the overall efficiency is the product of the different component efficiencies from Equation 5. The lowest line in the diagram represents 100% efficiency, which, of course, is not reachable. If input power, flow rate and head are available at a specific duty point, it is relatively easy to mark the value of Es as a point in Fig. 1, and then interpolate the overall efficiency. Using a program such as the U.S. Department of Energy’s (DOE’s) Pump System Assessment Tool (PSAT), the best available pump and motor efficiencies for a specific duty point can be found and a lowest possible specific energy can be calculated for the duty point in question, if there is no VSD involved. It is harder to find out what the efficiency of a motor/drive combination is, as it varies depending on how well these two components fit together. The drive, if present, introduces additional losses in the motor that should be accounted for. (Fig. 2 gives an idea about the combined efficiency of a drive and motor. Motors react differently to different drives. It is, therefore, a good idea to buy a drive and motor
from the same manufacturer to assure a combination that is well matched. Modern drives have improved considerably compared to those available some years ago.) After using the PSAT, a new point below the first can be plotted in the specific energy diagram. (See Fig. 4, where this has been done.) Potential savings from using better-matched equipment at the upper duty point can be calculated from the difference in specific energy. PSAT does it automatically. Pump control methods In many applications, pump flow is routinely controlled by throttling a control valve on the pump discharge. The throttled valve can be controlled to maintain a designated flow rate, pressure or any other parameter to satisfy system needs. When a valve is used to control flow, the flow rate is decreased by increasing resistance in the pipe system and moving the operating point up the pump head curve as shown in Fig. 3. From the information in Fig. 3, it is possible to estimate the head necessary to produce a certain flow in the system if there were no throttling. (One way of getting the pump to operate at such an unthrottled duty point would be to use a variable speed drive to reduce pump output.) Head requirement without throttling can be read on the original unthrottled curve below the throttled operating point. Using PSAT, the best motor and pump efficiencies for this unthrottled operating point can be found and Es can be calculated and plotted in the specific energy diagram. The result is a good graphical representation of where the system is operated from a cost point of view and where it could operate if optimized and without throttling losses (see Fig. 4). In the Fig. 4 example, the original specific energy is about 4.8 Wh/Gallon at 700 ft. The optimized pump/motor combination is about 2.8, and the specific energy with an optimized pump/motor combination without throttling losses is around 1.2 Wh/Gallon at 300 ft. Avoiding throttling losses is of the utmost importance when it comes to economic pumping. In the case of varying flow rates, Es has to be calculated for different flow rates. The corresponding head is obtained from the pump curve. The total operational cost can be obtained if the flow distribution as a function of time is known.
There is a strong relationship between reliability and efficient operation. Inefficiently operated pumps usually cost more, not only to run, but also to maintain.
28 | utilities manager
Key performance indicators As indicated above, it is very useful to track the performance of a pump system not only to see how efficiently it is operating relative to optimum, but also to be able to easily and quickly discover deviations from the norm. It is, therefore, suggested that power-divided-by-flow rate would be a very useful KPI if flow rate and power are monitored.
Volume 7 / no. 4
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30%
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Fig. 4. Specific energy at different operating points
In many industries, motor current is monitored instead of power. The current is roughly proportional to power and can be used as a substitute for power. In both cases, the quotient will be a very good measure of the system efficiency and also sensitive to system changes. In a recent assessment of a pump station, it was found that one of three parallel pumps was drawing about 100kW, but contributed almost nothing in flow. The pump was practically dead headed by the other two pumps since the wear rings were badly worn and the delivered head, therefore, was lower than for the other pumps. As the system was set up to monitor total flow and motor currents independently, the problem with the pump was hidden. If the current-divided-by-flow rate for the system as a whole had been monitored and tracked, the problem would have caught someone’s attention sooner. Another very valuable performance indicator is the repair record of a pump. Pumps are generally quite reliable. If they are operated close to their best efficiency points (BEPs), they should last for a long time. If a specific pump deviates from the rest of the pumps in a facility, or shows a rising curve for the cost of maintenance, there is good reason to investigate it further. Remember, there is a very strong relationship between reliability and efficient operation. Thus, an inefficiently operated pump usually costs more all the way around– not only to run, but also to maintain.
Conclusion Pump systems should be continuously monitored and tracked using key performance indicators (KPIs) to discover performance improvement possibilities. Maintenance costs are particularly telling. Don’t underestimate the benefits of using maintenance cost records for individual pumps as KPIs. Power divided by flow rate also can be a very useful KPI for the task. This method gives a number that is directly proportional to the cost of pumping and is sensitive to changes in the system. Furthermore, it can easily be demonstrated graphically, so that operators get a visual picture of how efficiently their system is operating. Tracking these types of KPIs will provide crucial clues in your quest for improved efficiency. MT Following a long, distinguished career with ITT, including many years as Director of Technology for the corporation’s Fluid Technology business (i.e., ITT Flygt, Goulds Pumps, etc.), Gunnar Hovstadius went on to build a highly successful consulting practice in the field of pump-system efficiency. When he wrote this article in 2006, he was spending much of his time consulting with the Industrial Efficiency Alliance, based in Portland, OR. These days, Dr. Hovstadius continues to travel for and work with industrial and governmental clients around the globe. Among other things, his busy workload currently includes serving as a Pump System Optimization Expert for the U.S. Department of Energy and UNIDO. Email: gunnarh@msn.com. For more info, enter 262 at www.MT-freeinfo.com
Volume 7 / no. 4
utilities manager | 29
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Lube-Free Chain Reduces Operating Costs
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ccording to U.S. Tsubaki, its Lambda Chain delivers long-term clean operation without additional lubrication. Packaging, food processing or any application that must be lube-free or where manual lubrication is unfavorable are just some of the applications for which this product is suited. The company points to a number of additional features and benefits that Lambda Chain offers, including, among other things:
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◆ Strong, reliable operation, with longer wear life than standard chain ◆ Less downtime and reduced maintenance costs due to the lube-free design ◆ Oil-impregnated bushings that minimize chain elongation ◆ The ability to perform well in temperatures up to 302 F ◆ Smooth roller engagement that cuts sprocket wear and replacement costs ◆ The same maximum allowable loads as U.S. Tsubaki’s standard chains Lambda Chain is available in both drive and conveyor (with attachments) styles. U.S. Tsubaki Power Transmission, LLC Wheeling, IL For more info, enter 04 at www.MT-freeinfo.com
Power-Monitoring Software Optimizes Data-Center Ops
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chneider Electric’s recently released StruxureWare™ Power Monitoring for Data Centers incorporates a full range of capabilities that let facility teams identify, respond to and investigate the root causes of power-system events; measure utility and facility power quality; measure power usage effectiveness (PUE); calculate power distribution losses; understand UPS and generator system power loading; and audit generator system testing. The software actively monitors and analyzes the electrical power distribution infrastructure of a data center, including medium voltage, low voltage and IT floor power. Comprising hardware, software and communication components and integrated with professional services, all elements are modular and interoperable to provide better continuity of supply, enhanced safety and easier installation. In addition to providing deep insight into a data center’s electrical system, this new tool can help trim energy-related operating costs in the facility and boost the ROI of its electrical assets. The software’s compatibility with third-party systems will make it easy for a facility to leverage its existing investments. Schneider Electric Palatine, IL For more info, enter 05 at www.MT-freeinfo.com
30 | UTILITIES MANAGER
VOLUME 7 / NO. 4
UM
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lexEnergy designs and manufactures innovative systems capable of producing continuous energy with near-zero emissions from a broad range of fuel sources, including otherwise unusable low-quality gas, for the combined heat and power, oil and gas production, landfill-gas and digester-gas markets. Its Flex Turbine™ MT250 produces ultra-clean electricity and useful thermal energy via a rugged and efficient turbine system. Capable of running on a variety of fuel gases, including pipeline-quality natural gas, oilfield-associated gas and biogas, it can start 100+ hp loads, on or off the grid, and needs only eight hours of planned maintenance per year. According to the company, its Flex Powerstation™ is the cleanest power plant in the world. It produces electricity from a wide range of fuels, down to as low as 5% methane, with almost undetectable emission levels, and does so without gas compression and prior siloxane removal. FlexEnergy Inc Irvine, CA For more info, enter 06 at www.MT-freeinfo.com
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Efficient Burner-Management Solution Boosts Safety, Efficiency And Compliance
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ccording to Platinum Control Technologies, there’s more to burner management than lighting an ignition. Solutions like the company’s scalable BMS-731 system can help end-users in the oil and gas arena record essential data and safely automate heating processes, thus reducing injury risk, maximizing well production and facilitating environmental compliance. Developed for natural-draft burner applications (natural gas or propane), Platinum’s BMS-731 has the ability to fire, direct or indirect to 10 mmBtu/hour. Its temperature control feature allows for tighter control, while adding redundant shutdown capability. A user-friendly front-panel interface with 4-line display simplifies programming and troubleshooting, and plain-language messaging means no more error code for operators to memorize or reference. A certified Burner Management System, the BMS-731 meets all applicable codes. It incorporates multiple inputs for external safety devices and can be retrofitted to existing systems without draining vessels. Applications include production units, treaters, heated separators, line heaters, tank heaters, dehydrators and VOC combustors. Platinum Control Technologies, Inc. Fort Worth, TX For more info, enter 07 at www.MT-freeinfo.com
VOLUME 7 / NO. 4
UTILITIES MANAGER | 31
It Takes One...
An Innovator That Is!
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The Innovators At Presented By
Applied Technology Publications
Scalewatcher North America, Inc. Oxford, PA www.scalewatcher.com
Developed and patented in the Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher™ technology was introduced to the European market in the 1980s. Based on its immediate market success, Mr. Doelman brought the technology to the United States, whereupon he applied for and received a patent in 1991. From that point on, Scalewatcher North America has been on the forefront of environmentally sensitive water treatment. Scalewatcher’s innovative products are no-maintenance, environmentally friendly descalers that do not change water composition. Scales and stains disappear gradually and completely, without further action required, guaranteed. The units work by way of magnetic and electric fields and a continuously changing frequency. The process forces dissolved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. Scalewatcher technology has been used by more than 250,000 satisfied customers worldwide. These maintenance-free products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cooling; reduce bacterial counts in cooling systems; reduce water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; and last 20+ years.
The Innovators At Scalewatcher will award individual water-treatment units to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 73 at www.MT-freeinfo.com
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Are You One? You Could Win An All-Expense Paid Trip To MARTS 2013 & More
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Dreisilker Electric Motors, Inc. Glen Ellyn, IL www.dreisilker.com
Applied Technology Publications
Henry Dreisilker came to America from Germany in 1954 seeking opportunity and gainful employment. Hard work and integrity landed him his first job in a small motor repair and appliance business. Seven months later, he purchased the business, founded Henry Dreisilker Electric Motors and Appliance Service and began by specializing in commercial motor repair and sales. Combining old-world craftsmanship with advanced technology, the company grew steadily from three employees to over 120. Today, Dreisilker Electric Motors, Inc. provides complete electric motor solutions to commercial, industrial and municipal customers nationwide. It distributes new electric motors, parts, accessories and controls from major OEMs and offers a range of value-added, reliability-related services. Among its many offerings is Dreisilker Total Motor Management (DTM2), a comprehensive program that incorporates expert technical coordination of an operation’s motor database, inventory recommendations, energy analysis, repairversus-replacement decisions, exchange motor options and maintenance training on motor systems. Expert field technicians are available for scheduled maintenance or to respond quickly to emergencies 24/7/365. The company’s innovative and exclusive Motor-Safe™ Repair 2.0 process uses special induction technology stripping, accurate and precise rewinding, advanced varnishing, dynamic balancing and thorough testing. Dreisilker never uses the “burnout oven” methods practiced by other motor shops. Motors repaired by Dreisilker improve reliability, increase uptime and save energy. The reliability of your motors, in turn, translates directly into productivity and profitability.
The Innovators At Dreisilker will award individual iPads to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 74 at www.MT-freeinfo.com
Get Details & Entry Forms At www.ReliabilityInnovator.com
CAPACITY ASSURANCE SOLUTIONS Do you hear what I hear?
Listen For Machine Faults: Let Sounds Verify Vibration Data Audio-replay capabilities have enhanced this author's vibration-analysis toolkit and could be doing the same for yours.
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Jim Crowe Jim Crowe Vibration Technologies
©STOCKSHOPPE - FOTOLIA.COM
ver the years, technicians have listened for sounds made by machines in order to identify evolving problems as early as possible. By the time a fault becomes serious enough to be heard in a noisy plant, however, it could be too late to prevent damage. Now, portable vibration collection devices aid in the early detecting of problems and maintaining the health of rotating machinery. Even so, the use of these devices has not made listening an obsolete art. Sound remains an important element in the early recognition of deteriorating conditions and in validating potential faults in rotating machinery. When used in conjunction with vibration waveform plots, playback of recorded sounds supports the existence of a fault, helping to convince persons who may have difficulty reading graphic plots. Often, analysts must deal with managers who see only meaningless squiggly lines when shown a waveform or spectral plot. Add sound, and the lines suddenly make sense. Put on your headphones The sounds coming from machines provide important clues that may be missed by relying on vibration data alone. That’s why I advocate the wearing of headphones by technicians who are collecting vibration data. I always try to watch the data as it is being acquired to detect abnormalities in amplitude or 34 |
MAINTENANCE TECHNOLOGY
pattern. In most plants, there’s so much noise-making activity (i.e., associated with vehicle traffic, people, machines, etc.) that it can be difficult to watch every reading as it is taken. By listening to the accelerometer signal, it’s possible to instantly recognize a change from the normal hum of a smoothly functioning machine. I’ve been wearing headphones during route collection of vibration data for many years in order to hear unfiltered sounds covering the entire frequency spectrum. Emerson’s portable CSI 2130 Machinery Health Analyzer records the waveform vibrations emanating from a machine. Anytime I hear something abnormal, I make a “note” on the analyzer to take a careful look at the waveform data after uploading it to a computer. When reviewing the data later, I’ll see the note calling attention to the waveform collected from that particular machine. NOVEMBER 2012
CAPACITY ASSURANCE SOLUTIONS
Fig. 1. Waveform audio replay starts by clicking on the Play Audio button.
Fig. 2. Two waveforms are easily compared using the audio replay.
The analyzer generates plots of frequency spectra as well as the waveforms. Analysts look at the waveform to determine the severity or impact of the vibration, and they look at the spectrum to determine the cause—be it imbalance, a bearing defect, a lubrication-related issue or something else. The information can later be uploaded to computer-based software for detailed analysis. That's where the latest version of Emerson's AMS Suite: Machinery Health™ Manager comes in. NOVEMBER 2012
It incorporates the ability to convert the audio portion from waveform data collected periodically or online. Users can actually hear an audible indication of a problem. The easiest way to do this using the Machinery Health Management software is to plot the waveforms to be played, right-click on the waveform, and select “Play Audio” to launch the Waveform Audio Player (Fig. 1). A loop button allows repetition of short-duration audio replays for close study. MT-ONLINE.COM | 35
CAPACITY ASSURANCE SOLUTIONS
Sounds clips can clearly illustrate machinery vibration problems, even for individuals who have had no formal vibration training.
What you’re listening for The sound of a waveform collected from a “problem” machine is distinct from that of a similar machine where no fault is present. Similarly, waveforms collected from one machine at different times can be used to demonstrate a change in performance. In practice, any vibration data obtained during a routine collection can be used as a benchmark, as sound from each machine is obtained at the same time as the physical vibration data. If an abnormal sound is heard on a subsequent round, the audio portion of each waveform can be compared, as in Fig. 2. This can be played back or sent to someone with minimal understanding of vibration data in a format anyone can grasp. Simply put, it’s like listening to the machine at different times with a stethoscope. Some caveats in the use of this technology… ■ Care must be taken to be sure both recordings are set
at the same scale and not to let each file autoscale. The volume on both clips should be the same as when they were generated. This way they will all be set at the same scale. When they are played back with the loop icon selected, the recording will play in an endless loop. ■ Waveforms used for comparison should be acquired using
the same units and same fmax setting. If different fmaxes are used and the energy from a fault is above the lower frequency selected, the abnormal sound on the lower one will not be heard. If the data collection technician thinks he/she is hearing high-frequency energy from a fault that may be the result of poor lubrication, it’s necessary to acquire and analyze a waveform with a much higher fmax than normal route data so it can be heard when
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replayed. Remember: The signal that a technician hears is not filtered, so it could be a lot different than the low-pass filtered data acquired by the portable data collector. ■ Long-term time waveform data can also be taken if the
analyzer has Transient capability. This data can also be stored and played back as a sound file. Any energy that is above a chosen fmax will be filtered out and not heard on replay. A real-world value proposition Data taken recently on a motor with a severe bearing innerrace defect was compared with data from a motor on an identical machine (since no historical data on the faulty bearing was available). These sound clips were attached to a vibration report that was sent to the maintenance manager to illustrate the severity of the defect. This individual had no vibration training, but the sound clips clearly illustrated the difference between the machines in a way he could recognize. As a result, the motor was changed out before the faulty bearing could fail and cause damage to the machine—and possibly disrupt production. An unplanned failure of this particular machine would have resulted in three to four hours of downtime. I maintain that this type of situation—as well as other costly unscheduled events—can be avoided by listening to sounds recorded during vibration collection. MT
Retiring after 30 years in mechanical maintenance at the Alcoa Warrick Operations (including 18 of them spent as a Reliability Technician), Jim Crowe established Jim Crowe Vibration Analysis, based in Rockport, IN, in 1999. Telephone: (812) 430-2457; email: jcrowevt@gmail.com. For more info, enter 08 at www.MT-freeinfo.com
NOVEMBER 2012
99% of Americans have seen combat on TV.
Photo by Petty Officer 2nd Class Sandra M. Palumbo, U.S. Navy - Bahrain, November 6, 2007
1% of Americans have seen combat in Iraq or Afghanistan.
We know where you’re coming from. We’ve got your back. Join the online community at IAVA.org
For more info, enter 75 at www.MT-freeinfo.com
ORLANDO, FLORIDA / JANUARY 13-16, 2013
DON’T MISS THIS OPPORTUNITY: KICK OFF 2013 IN A GREAT WAY
WYNDHAM LAKE BUENA VISTA RESORT
Details & Registration: Call 609.239.4788 or www.IRinfoconference.com
TECHNOLOGY SHOWCASE
Condition-Monitoring Solutions How safe, healthy and productive are your equipment systems?
Faster Machinery Alignment Via Onboard Intelligence
Handheld Multimeter Stands Up To Harsh Temperatures
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Ludeca, Inc. Doral, FL
Agilent Technologies, Inc. Santa Clara, CA
udeca’s sensALIGN tool combines PRUEFTECHNIK’s new, patented intelligent sensor technology with the ROTALIGN ULTRA iS platform. The result is instantaneous data acquisition and realtime displays, with guaranteed 100% accuracy, under even the roughest field conditions. The sensALIGN intelligence automatically considers the effects of ambient vibration, acceleration of rotation, backlash, speed of rotation and other factors in determining the Quality Factor (QF) of alignment. ROTALIGN ULTRA iS, with its userfriendly interface, is now faster than ever, even while collecting thousands of measurement points with its patented Continuous IntelliSWEEP method.
ccording to Agilent Technologies, its U1273AX OLED handheld digital multimeter can operate in temperatures from -40 to 131 F with no warm-up time required. This operating range is coupled with IP54 water and dust resistance, and a CAT IV/600 V safety rating. When paired with the U1583B AC current clamp, the device supports current measurements without breaking the circuit under test. Advanced capabilities include a lowimpedance mode that reduces ghost voltages from capacitive coupling and a low-pass filter that eliminates switching noise from motor-drive measurements.
For more info, enter 09 at www.MT-freeinfo.com
For more info, enter 10 at www.MT-freeinfo.com
Calibration Services For All Industries
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ndress+Hauser offers a full range of calibration services, including providing regular checking, validation, calibration and clear, concise certificates. The company can help establish a metrology plan by fixing calibration specifications per parameter (maximum permissible errors, periodicities) or by defining the right reference tools according to their uncertainty. It also provides a full range of Standard Operating Procedures to support its on-site work. CompuCal™, a high-performance scheduling and electronic software tool, helps control the scheduling activity around your installed base, providing traceable and auditable records. Endress+Hauser, Inc. Greenwood, IN
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MAINTENANCE TECHNOLOGY
For more info, enter 11 at www.MT-freeinfo.com For more info, enter 78 at www.MT-freeinfo.com NOVEMBER 2012
TECHNOLOGY SHOWCASE
Cost-Effective ‘Check-Engine Light’ Technology For Monitoring Semi-Critical Equipment
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KF’s new CMSS 200 Machine Condition Indicator is a low-cost, battery-powered, standalone monitoring solution for semi-critical machines with constant operating conditions that usually aren’t evaluated on a regular basis. Independent and self-sufficient, it periodically measures vibration and velocity, and monitors for problems relating to misalignment, imbalance, etc. It also measures enveloped acceleration to detect bearing degradation and keeps a running check on operating temperatures. Built-in intelligence evaluates data and helps avoid false alarms. Performing like a car’s “check-engine light,” the device indicates alarm status on three LEDs. Individual units can be stud-mounted or epoxied to the monitored equipment. SKF Lansdale, PA For more info, enter 12 at www.MT-freeinfo.com
Robust, Versatile, Handheld Data Collector
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PM Instrument has launched the rugged Leonova Diamond®; its nextgeneration, handheld device for condition measurement in rough industrial surroundings. The first portable instrument offering the SPM HD® measuring technique for monitoring of rolling-element bearings, it enables simultaneous tri-axial vibration measurements with FFT up to 25,600 Lines at 40Khz. According to SPM, other features and capabilities, including a laser tachometer with IR temperature, voice recording, electronic stethoscope, singleand dual plane balancing, laser alignment, run up/coast down, bump-testing and RF measuring point identification, make it well suited for beginners and advanced vibration analysts. SPM Instrument, Inc. Eugene, OR For more info, enter 13 at www.MT-freeinfo.com
NOVEMBER 2012
For more info, enter 76 at www.MT-freeinfo.com MT-ONLINE.COM | 41
You know ‘em. You read ‘em. You respect ‘em...
TRAIN WITH OUR ALL-STAR ROAD TEAM THIS WINTER! January 14 - 15, 2013 • Lake Buena Vista Resort • Orlando, Florida Join These Applied Technology Publications All-Stars For The Value-Added, In-Depth 2-Day Workshop Of Your Choice. Pick Just One. . .
Workshop #1:
Workshop #2:
Workshop #3:
“Introduction to Maintenance “Pump System Optimization: “Oil Monitoring Analyst Planning & Scheduling” Uptime, Reliability, Efficiency” Preparation Class” Instructor: Ken Bannister,
Instructor: Bill Livoti,
Instructor: Ray Thibault,
Contributing Editor, Maintenance Technology and Lubrication Management & Technology
Contributing Editor, Maintenance Technology and Lubrication Management & Technology
CLS, OMA I, OMA II, Contributing Editor, Lubrication Management & Technology
Attendees will come out of this course with a complete basic understanding of the crucial planning & scheduling process, along with a practical toolset of matrices, formats, processes and formulas they can use immediately at their sites.
Optimizing your pumping systems will play a major role in solving the energy and environmental problems of the future, as well as help you cut maintenance costs and improve overall reliability. Learn the real “tricks of the trade” in this course.
This class is excellent preparation for those who seek CLS certification. Moreover, it will give attendees the best possible preparation for their OMA I exam.
Workshop #1 Fee: $1490*
Workshop #2 Fee: $1490*
Workshop #3 Fee: $1490*
* Your Registration Fee Covers 2 Full Days Of Classroom Training And All Course Materials For Your Chosen Workshop + Continental Breakfast, Breaks And Lunch Each Day! BONUS/BONUS! Our All-Star Team Training Workshops Will Be Held At The Same Venue As The 2013 IR/Info Conference. Paid Attendees Of Our Workshops Are Invited To Network With IR/Info Exhibitors And Attendees At No Charge. Go To www.mt-online.com/wintertraining13 For Complete Details On Each Workshop, As Well As Lodging Arrangements And Registration Forms, Or Call : 847.382.8100 x 117
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Training today for tomorrow...
Making It Real Approaches to ensure the sustainability of an industry can come in many forms. This virtual-reality solution is a case in point. It's now helping the USDOE develop and train those clean-coal power-plant operators that we'll need in the future. Special To MT From Invensys Process Management
NOVEMBER 2012
D
esigned for use in integrated gasification combined cycle (IGCC) power plants with carbon capture, Invensys Process Management’s SimSci-Esscor EYESIM immersive training system has been deployed at the U.S. Department of Energy (DOE) National Energy Technology Laboratory’s Advanced Virtual Energy Simulation Training and Research (AVESTAR) Center in Morgantown, WV. Wearing stereoscopic headsets, IGCC field operators are immersed in a virtual environment and given the ability to move throughout the plant, coordinating their activities with control-room operators as if they were in the actual facility. Users can experience and interact with IGCC plant equipment in real-time, activate transparent views of equipment internals, display pop-up trends of key process variables and experience equipment sound effects, malfunctions and visual training scenarios.
Trainees at the AVESTAR Center learn about advanced IGCC plants using realtime simulators, much like those used to train airline pilots. MT-ONLINE.COM | 43
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The EYESIM solution is also fully integrated with plant operating models, using the DYNSIM modeling solution, so actions taken by a field operator affect the plant’s process, and actions performed in the control room change the information visible to the field operator. Fully interactive animations respond and react to the actions of plant personnel, illustrating how various pieces of equipment will operate under almost any scenario and condition. As a result, field and control-room operators learn to collaborate and perform as a team.
A gas-leak training scenario displayed in the IGCC immersive training system at NETL’s AVESTAR Center.
Moving through state-of-the-art The EYESIM solution is the centerpiece of a new state-of-theart training center that will help bring online a new generation of zero-emission IGCC power plants. The formal EYESIM site acceptance test was completed on July 16, 2012, after a complete plant startup, culminating a long-term project that began in 2008, when Invensys was awarded a contract by the DOE to simulate the IGCC process using its DYNSIM process modeling software. “Training IGCC operators require us to simulate the chemical process of coal-gasification with CO2 capture together with combined-cycle power generation,” says Stephen E. Zitney, Ph.D. and Director of NETL's AVESTAR Center. “No one has ever done that before, but now with help from Invensys, we can simulate almost any operating scenario, including disturbances, malfunctions and emergency shutdowns. We can even train operators on different coal and biomass feed stocks. The developments we’ve accomplished and the technology we’ve installed at the AVESTAR Center show the growing viability of IGCC power plants and indicate the growing demand for a well-trained workforce. We look forward to working with Invensys as we train and enable the clean-coal operators of the future.” The U.S. Energy Information Administration estimates that the United States has enough coal to last more than 200 years, but plants that continue to use conventional fossil-fuel technologies will emit unacceptable levels of CO2 and other pollutants. IGCC with carbon capture offers an environmentally friendly alternative by capturing 90% of the CO2 produced in traditional fossil-fuel-burning processes while at the same time reducing sulfur, mercury and other NOx emissions. The IGCC process is more environmentally friendly than other coal-burning processes, but is also extremely complex and requires skillfully trained personnel to operate what is effectively both a chemical processing plant and a power plant. 44 |
MAINTENANCE TECHNOLOGY
Benefits here, now and later Combining high-fidelity, real-time IGCC dynamic simulation with a fully interactive 3D virtual plant environment allows both control room and field operators to coordinate their actions and collaborate as a team. Additional benefits include training for safety-critical tasks, rare occurrences and emergency shutdowns. Aside from training, education and research applications, the DOE and its partners will use these realistic, hands-on, dynamic simulator-based systems to showcase clean-coal technologies that support a clean energy future. “Our EYESIM immersive training system makes the theoretical and conceptual side of training more realistic and tangible by allowing operators and trainees to become familiar with the layout of the physical plant and how it will operate under almost any condition,” notes Tobias Scheele, Ph.D., Vice President, Advanced Applications, Invensys Operations Management. “The solution combines stereoscopic 360-degree views with collision effects, sounds, lighting and weather conditions to give the plant operator a realistic walkthrough environment and simulated hands-on experience with the plant’s physical operation, helping plant personnel improve operations excellence.” A separate EYESIM virtual-reality training system will be installed and commissioned at West Virginia University in Morgantown for student education and simulator training as part of assigned course work. In addition to training and plant design functions, the NETL and its research and development partners, including Invensys, will use the simulator to showcase the feasibility of clean-coal technology as a means to support future electrical generation demand without emitting environmental pollutants or greenhouse gases. By offering a comprehensive IGCC training program, the DOE aims to develop a workforce well prepared to operate, control and manage commercial-scale gasification-based power plants with CO2 capture. MT To learn more about AVESTAR and the NETL, visit www. netl.doe.gov/avestar. For details on other Invensys SimSciEsscor simulation solutions, visit iom.invensys.com/EN/Pages/ SimSci-Esscor.aspx. NOVEMBER 2012
SUPPLY CHAIN LINKS
More Real-World Simulator Training Eni Refining and Marketing, Italy’s largest international refiner, is using a novel training solution built on Invensys Operations Management simulation technology. Combining immersive 3D virtual-reality software with its own refining expertise, Eni has installed EYESIM training kiosks at several of its facilities around the globe, providing a unique approach to refinery process training. Using proven Invensys simulation software, which has been integrated with a gaming console controller, trainees, operators and other personnel can walk through a virtual refinery, learning process operations and procedures. They can also score and improve their performance with unrestricted access to the kiosks, which offer a fully lifelike plant experience. The focus is on reducing risks, improving safety and increasing the productivity and efficiency of the refinery. The EYESIM solution enables engineers and operators to see and safely interact with the refinery and the processes they control. Applying gaming and other skills familiar to a new generation of employees, the solution combines virtual-reality technologies with high-fidelity process and control simulation, computer-based maintenance and documentation management and other applications to provide a highly realistic and safe training environment for improving operating efficiency and skills. For more info, enter 14 at www.MT-freeinfo.com For more info, enter 78 at www.MT-freeinfo.com NOVEMBER 2012
MT-ONLINE.COM | 45
HOLD THESE DATES April 30 – May 3, 2013
Come Help Us Celebrate Our 10th Anniversary
As Always, You’ll Find Just What You Need: Training Networking Solutions Program Details & Registration Information Will Be Announced Soon
Plan Now To Attend MARTS 2013 The Hyatt Regency O’Hare Hotel, Rosemont, IL.
www.martsconference.com For more info, enter 79 at www.MT-freeinfo.com
SOLUTION SPOTLIGHT
Satisfying An Appetite For Real-Time Data
U
Special To MT
pon acquiring a new manufacturing plant, a multinational food manufacturing company discovered that the operation’s custom-made batch software and human-machine interface (HMI) system were on the way to becoming obsolete. Translation: increased maintenance costs, wasted batches and limited production flexibility. Not only were the plant’s legacy systems aging and out of compliance with the new owner’s corporate standards, they were no longer supported by the OEM or by company resources. The custom-batch system had no scheduling or historical batch record-keeping capabilities, making it difficult to manage production. Often, managers only became aware of wasted batches when shortages of raw materials for given recipes occurred—because needed ingredients had already been used. Moreover, the system’s inflexibility prevented the plant from making softwareprogramming changes for routine enhancements. Bringing in the new The new owner wanted a new solution—in the form of offthe-shelf batch software and an HMI system to deliver increased control and visibility. This solution needed to generate detailed records of batch and process data, as well as integrated enterprise resource planning (ERP) system data. It also needed to be flexible enough for repeat uses in other corporate operations. The company contracted the services of control and information-systems integrator Cybertrol Engineering (Minneapolis, MN), a member of the Rockwell Automation PartnerNetwork™ program. Cybertrol implemented a manufacturing-intelligence solution utilizing the Rockwell Automation FactoryTalk® software suite. The FactoryTalk suite includes FactoryTalk Batch software, which provides operators with electronic reports and access to real-time data through tighter integration with the plant’s ERP system. The enhanced integration allows the company to drive the batch schedule from—and store all recipes in—the ERP system. All procedures remain in the FactoryTalk Batch software, allowing for enhanced reliability for recipe execution and flexible product changeover, and less operator actions and probability for operator error. Cybertrol also implemented: n FactoryTalk VantagePoint EMI software to provide data
analysis to business network users, as well as to plant operators who can use it to gain access to historical production data throughout the facility: This software taps into information from systems across operations that have been automatically identified, gathered and stored by FactoryTalk Historian software. FactoryTalk VantagePoint EMI provides management reports to track and compare batch NOVEMBER 2012
cycle times, so users can identify and correct maintenance and procedural problems that impact productivity. For example, if a transfer pump begins to wear, operators will see transfer times increase and have the ability to schedule a rebuild with minimal interruptions to production. n FactoryTalk View Site Edition software to provide
production personnel the ability to set up unique parameters, like agitator and transfer pump speeds: Utilizing FactoryTalk Security not only helps protect critical machine settings, it also requires supervisor overrides for certain functions, reducing losses previously caused by incorrect operator actions. Counting on results* As Ben Durbin, Cybertrol President, notes, “With plant floor and ERP system integration, plus access to real-time data, our client was able to immediately identify and correct production issues that had been causing lost batches all along.” Thanks to Cybertrol and Rockwell Automation, the plant estimates it now saves at least one batch per month. Based on this type of proven success, the corporate business has already rolled out similar manufacturing-intelligence solutions in its other facilities. MT *Specific results may vary for other customers. Rockwell Automation Milwaukee, WI For more info, enter 30 at www.MT-freeinfo.com
Allen-Bradley, FactoryTalk and PartnerNetwork are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are the properties of their respective companies. MT-ONLINE.COM | 47
CAPACITY ASSURANCE MARKETPLACE
Multiprocess Welding Power Source
M
Pipe Inspection Software For Tablets
iller Electric’s Multimatic 200 is an all-in-one, portable multiprocess welding power source capable of performing MIG, stick and TIG welding processes in one compact design. The Auto-Set Elite feature allows operators to quickly and easily set weld parameters based on material type and thickness, as well as fine-tune those parameters to match each specific application. The system weighs 29 pounds, and connects to common 120- and 230-volt power receptacles with the Miller-exclusive MVP multi-voltage plug.
esigned for touchscreen data entry on a tablet PC, WinCan ProTouch from Pipeline Analytics allows operators to easily document pipe inspections made with a video crawler, push camera or zoom survey camera. ProTouch generates basic reports that include schematics and captured images, and can also export inspections to freely distributable viewer software. Data is fully compatible with the company’s WinCan v8, which means an operator can transfer the data to exploit v8’s enhanced reporting, querying, GIS features and standards support.
Miller Electric Mfg. Co. Appleton, WI
Pipeline Analytics Pittsburgh, PA
D
For more info, enter 31 at www.MT-freeinfo.com
VSD-Equipped Single-Stage Compressor Lineup
For more info, enter 32 at www.MT-freeinfo.com
Water-Soluble Cutting Fluid
P
ullair has expanded its line of V250S Single-Stage Rotary Screw Air Compressors with models that include Variable Speed Drive (VSD) technology. Based on the same footprint and operating characteristics of the company’s comparable constant-speed designs, the new units incorporate Sullair’s WS Microprocessor Controller. Featuring an easy-to-read graphics display that highlights frequently used compressor information, this control system is programmed to monitor all necessary functions and provides a WSPC interface for service diagnostics and trending capabilities. Sullair’s VSDequipped models range from 250 to 350 hp, with capacities of 1085 to 1580 cfm, and pressures of 100 to 125 psig.
rolong® Super Lubricants notes that its Ultra Cut 1 Water Soluble Cutting Fluid can help eliminate uneven cuts, reduce power consumption and increase tool life. Designed to maximize results in sawing, grinding, boring, turning or milling processes that require coolants, it protects metals from corrosion and extends the life of cutting solutions and tools. It also can be used as a flood coolant and for making emulsions in machine shops. Ultra Cut 1 comes in gallon-size bottles, 5-gallon buckets and 55-gallon drums.
Sullair Corp. Michigan City, IN
Prolong Super Lubricants Pomona, CA
S
For more info, enter 33 at www.MT-freeinfo.com
48 | MAINTENANCE TECHNOLOGY
For more info, enter 34 at www.MT-freeinfo.com NOVEMBER 2012
CAPACITY ASSURANCE MARKETPLACE
Expanded Electronic Parts Catalog
A
Industrial Diesel Engine With Notable Power Density
C
llied Electronics has released its 2013 Allied Catalog, which showcases 10,000 new products in addition to the 115,000 that were already featured in the book. New to this year’s catalog is an extensive product offering from Siemens. Other new suppliers include FLIR Commercial Systems, Interfan, Keithley Instruments/ Tektronix, Spacecraft, wakefield-vette, WIKA Instrument Corporation and Yokogawa. This year’s catalog selection is complemented by over two million parts accessible online.
aterpillar’s latest generation of its Cat® C9.3 ACERT™ industrial engine is designed to meet U.S. EPA Tier 4 Final/EU Stage IV emission standards. The engine is a six-cylinder, 9.3-liter platform that produces excellent power density, with ratings from 300-400 hp (224-298kW). It is equipped with a robust, fully-integrated Clean Emission Module (CEM), which includes a diesel oxidation catalyst (DOC), diesel particulate filter (DPF), and selective catalytic reduction (SCR) technology that reduces NOx.
Allied Electronics, Inc. Fort Worth, TX
Caterpillar, Inc. Peoria, IL
For more info, enter 35 at www.MT-freeinfo.com
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NOVEMBER 2012
MT-ONLINE.COM | 49
CAPACITY ASSURANCE MARKETPLACE
Fluid Storage With Spill Containment
I
High-Speed Gearbox Series
D
FH Group’s Fluid Storage & Dispensing Systems incorporate spill containment systems that can prevent costly clean-ups, make fluid dispensing easier and provide compliance with EPA regulations such as 40 CFR 264.175. All 21 IFH standard centralized systems are equipped with a drip pan, making dispensing of fluids into containers from self-closing faucets quick and spill-free. For all two-, three- and four-container systems with outboard console mounting, a spill containment pan is provided at the base of the system to collect any accidental spills.
avid Brown’s HX highspeed gearboxes are designed specifically for critical applications such as pumps, compressors and generators in the oil and gas and power industries. The line’s core platform is easily adaptable to suit all packaging requirements through a flexible case design and multiple oil inlet/outlet positions, combined with optimized oil flow. The gearboxes are fully compliant with major international standards such as API and AGMA. Bearing choices are available to suit all application demands.
The IFH Group, Inc. Rock Falls, IL
David Brown Gear Systems Ltd. Huddersfield, UK
For more info, enter 37 at www.MT-freeinfo.com For more info, enter 38 at www.MT-freeinfo.com
Repaired or Replaced for years, for reason.*
Leonova Diamond is the latest proof of our commitment to developing first class condition monitoring products for more profitable maintenance. Use SPM HD for accurate rolling element bearing analysis. Reduce data collection time with tri-axial vibration measurements. Add balancing, laser alignment, orbit analysis and much more, all in a rugged and lightweight instrument.
Investigate at www.wahlheatspy.com and see what you’ve been missing. 800-421-2853 sales@palmerwahl.com
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50 | MAINTENANCE TECHNOLOGY
REVOLUTIONARY VIBRATION AND BEARING ANALYSIS
*Call for details.
For a total Condition Monitoring package, contact us today! Tel. 1-800-505-5636 leonovabyspm.com spminstrument.com
NOVEMBER 2012
For more info, enter 83 at www.MT-freeinfo.com
Announcing
CAPACITY ASSURANCE MARKETPLACE
Steam-System Component Literature
S
pirax Sarco has released the 14th edition of its Mechanical Product Manual. Subtitled “First for Steam Solutions,” it provides a complete range of information needed to evaluate and apply steamsystem components. It includes technical information about Spirax Sarco’s regulators, steam traps, condensate recovery, strainers, high-purity, liquid drain traps, pipeline auxiliaries, humidification and engineered products. For a free copy, visit www.spiraxsarco.com/us or contact your local Spirax Sarco representative. Spirax Sarco, Inc. Blythewood, SC For more info, enter 39 at www.MT-freeinfo.com
DPM-Reading Technology Goes Wireless
C
ognex Corp.’s DataMan® DPM-reading technology has gone mobile. The industrial-grade DataMan 9500 mobile computer can even the most challenging DPM (direct part mark) codes in applications where operators need to view the data on an integrated handheld device. Designed for the factory floor, the product features the 2DMax™ algorithm for decoding difficult-to-read codes, including dot peen and laser-etched, on any metal surface. Small and lightweight, the computer connects to factory networks via 802.11 a/b/g protocols on the 2.4GHz and 5GHz bands for real-time wireless communication. Cognex Corp. Natick, MA For more info, enter 40 at www.MT-freeinfo.com
ENGINEERED TO SERVE INDUSTRY MAINTENANCE At Revere, we engineer controls for an incredible range of industrial applications. From mining conveyor controls to 15 kV switchgear and plant wide PLC systems for municipal, industrial and energy applications. System upgrades, expansions, and maintenance. Control your systems. Control your business.
CONTROL SYSTEMS T 1.205.824.0004
For more info, enter 84 at www.MT-freeinfo.com NOVEMBER 2012
// REVERECONTROL.COM
For more info, enter 85 at www.MT-freeinfo.com MT-ONLINE.COM | 51
CAPACITY ASSURANCE MARKETPLACE
MCC Combats Arc Flash Incidents
A
ccording to ABB, its new MNS-MCC Low Voltage Motor Control Center is the first product of its kind to address the causes of arc flash incidents while providing superior equipment and personnel protection. For flexibility and minimization of downtime, the product offers a plug-in type, withdrawable and full-height-unit technology, with up to 4000A horizontal bus and 1600A vertical bus. The design is available in a variety of unit types, including starters, softstarters, variable frequency drives and mains and feeder breakers. The company notes that no other MCC allows operators to remove a unit with the door closed, with no tools and without disconnecting wires.
N
uSoLŽ Alumax 89 from Chemtool is specifically formulated for all operations on non-ferrous alloys, exotic ferrous alloys (including titanium), Inconel and Monel, plastics and composites. According to the manufacturer, while NuSoL Alumax 89 provides the type of wetting, detergency and boundary lubrication that’s associated with other NuSoL metalworking fluids, this product incorporates a new performance-enhancing additive package that demonstrates lower foaming characteristics for typical use concentrations (5-15%).
ABB Low Voltage Products New Berlin, WI
Chemtool, Inc. Rockton, IL
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Your Best Solution
High-Performance Metalworking Fluid
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ATP List Services TM
s 0RECISION #LEANERS s s $EGREASERS s s ,UBRICANTS 0ENETRANTS s s 3EALANTS !DHESIVES 4HREADLOCKERS s
Customized, Targeted Lists For Your Marketing Needs www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110 info@atplists.com esandkam@atplists.com
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52 | MAINTENANCE TECHNOLOGY
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NOVEMBER 2012
CAPACITY ASSURANCE MARKETPLACE
Compressor Solutions For Large-Scale Oil & Gas Applications
Y
ork by Johnson Controls provides a single-source solution for large-scale process applications in the oil & gas industry. These compressors and controllers ensure facilities stay up and operational while lowering maintenance costs and increasing efficiency. The company’s Quantum™ HD controller offers secure networking features that enable remote control and systems monitoring from any Web-enabled device. The controller has been developed to operate as a single platform with custom programmed features, including compressor sequencing, condenser control, digital output control and real-time historical trending. The enhanced design features a high-definition display, as well as open access to all points for easy service and components that can be individually replaced.
Johnson Controls Milwaukee, WI For more info, enter 43 at www.MT-freeinfo.com
Heavy-Duty Slurry Pumps
T
he ITT Goulds Pumps XHD Extra Heavy-Duty Lined Slurry Pump is designed for extreme slurry applications and can replace existing slurry pumps with minimal baseplate and piping changes. The pump can be maintained even while running with more accessible and adjustable parts than other slurry pumps. The XHD is intended for applications such as primary metals, mineral processing, non-metallic mining, power utilities and sand and aggregates. Goulds Pumps A subsidiary of ITT Corp., Inc. Seneca Falls, NY For more info, enter 44 at www.MT-freeinfo.com
“Industrial Lubrication Fundamentals” 3-Day, On Site, Certification Preparation Training Program
With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certified lubrication personnel working on your reliability efforts!
Unlock the Secrets that let you Tap your True Maintenance Potential and Maximize Asset Reliability! World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprint all commence with a best practice lubrication program! Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certification exams. Exams can be arranged to take place at your site immediately following the training. For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certification Domain of Knowledge Content. Contact ENGTECH Industries Inc at 519.469.9173 or email info@engtechindustries.com
For more info, enter 82 at www.MT-freeinfo.com
NOVEMBER 2012
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MT-ONLINE.COM | 53
INFORMATION HIGHWAY For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: jpreston@atpnetwork.com Web Spotlight: Grace
Engineered Products
U.S. Tsubaki Power Transmission, LLC is excited to announce the integration of KabelSchlepp America into its operations as part of the Tsubakimoto Chain Company’s global acquisition of the German-based Cable & Hose Carrier manufacturer. KabelSchlepp America will now operate as a division of U.S. Tsubaki and will expand Tsubaki’s presence in the U.S. market by adding cable & hose carrier systems to its already extensive product lineup.
For more info, enter 90 at www.MT-freeinfo.com www.kabelschlepp.com
Increase Productivity and Safety with Mechanical LOTO
Workers performing mechanical LOTO procedures must isolate electrical energy. Externally-mounted voltage detectors provide a means of checking voltage inside an electrical panel. Without these devices, a mechanic performing mechanical LOTO would be required to work in tandem with an electrician using a voltmeter to physically verify voltage inside an electrical panel. In this case, the electrician is exposed to voltage. With The Combo Unit, the mechanic can single-handedly check for zero electrical energy without any exposure to voltage.
For more info, enter 89 at www.MT-freeinfo.com http://graceport.com
PIP is a consortium of process plant owners and engineering construction contractors harmonizing member’s internal standards for design, procurement, construction and maintenance into industry-wide Practices. PIP has published over 450 Practices. A current listing of published Practices is available on the PIP website at: http://pip.org/practices/index.asp. For more info, enter 91 at www.MT-freeinfo.com www.pip.org
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For rate information on advertising in the Classified Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 e-mail: jpreston@atpnetwork.com
NOVEMBER 2012
Index ADVERTISER
20 YEARS
November 2012 M A I N T E N A N C E
Volume 25, No. 11 TECHNOLOGY
NOVEMBER 2012 Volume 25, No. 11
®
•
WEB ADDRESS
Your Source For CAPACITY ASSURANCE SOLUTIONS
RS #
PAGE #
A.T.S. Electro-Lube Int’l Inc......................................www.atselectrolube.com ....................................... 71 .............................23 ALL-TEST Pro, LLC...................................................www.alltestpro.com/c/244 .................................... 69 .............................21 ATP Lists.......................................................................www.atplists.com ................................................... 87 .............................52 Baldor Electric Company..........................................www.baldor.com .................................................... 92 ..........................IBC CRC Industries............................................................www.crcindustries.com/ei .................................... 86 .............................52 CyberMetrics Corp.....................................................www.faciliworks.com ............................................ 62 ...............................1 Dreisilker Electric Motors Inc...................................www.dreisilker.com................................................ 74 .............................33 Engtech Industries Inc. ..............................................www.engtechindustries.com ................................ 88 .............................53 Fluke..............................................................................www.fluke.com/vibrationmeter .......................... 67 ...............................7 Grace Engineered Products. Inc...............................info.graceport.com/pesd_mt5 ............................ 78 .............................45 Grace Engineered Products. Inc...............................info.graceport.com................................................. 89 .............................54 Grainger .......................................................................www.grainger.com/green...................................... 63 ...............................2 IAVA ..............................................................................IAVA.org................................................................... 75 .............................37 Innovator Of The Year Award ..................................www.reliabilityinnovator.com ............................. 72 .............................24 Inpro/Seal, LLC C/O Waukesha Bearing, Inc........www.inpro-seal.com.............................................. 93 ............................BC MARTS-Applied Technology...................................www.martsconference.com.................................. 79 .............................46 Meggitt Sensing Systems ...........................................www.wilcoxon.com ............................................... 64 ...............................4 Meltric Corporation ..................................................www.meltric.com................................................... 76 .............................41 Neil Bloom Workshop...............................................www.mt-online/rcm.............................................. 70 .............................22 Palmer Wahl Instrumentation Group ....................www.wahlheatspy.com.......................................... 82 .............................50 PdMA Corporation ...................................................www.pdma.com ..................................................... 68 .............................12 Process Industry Practices.........................................www.pip.org ............................................................ 84,91...................51,54 Revere Control Systems.............................................www.reverecontrol.com........................................ 85 .............................51 Scalewatcher ................................................................www.scalewatcher.com ......................................... 73 .............................32 SKF CMC-Fort Collins .............................................www.bakerinst.com ............................................... 81 .............................49 SPM Instrument, Inc. ................................................www.spminstrument.com.................................... 83 .............................50 SPM Instrument, Inc. ................................................www.leonovabyspm.com ..................................... 61 .......................... IFC Strategic Work Systems, Inc......................................www.swspitcrew.com ............................................ 65 ...............................4 TEAM Industrial Services.........................................www.teamindustrialservices................................. 66 ...............................5 U.S. Tsubaki Power Transmission, LLC ..................www.kabelschlepp.com.com................................ 90 .............................54
Access MT-freeinfo.com and enter the reader service number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Maintenance Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Reproduction of Materials: Materials produced by Maintenance Technology may not be reproduced in any form for any purpose without permission. For Reprints: Contact the publisher, Bill Kiesel (847) 382-8100 ext. 116.
MAINTENANCE TECHNOLOGY/JANUARY 2007
NOVEMBER 2012
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viewpoint John Swann, President, SPX Hydraulic Technologies and Former VP, New Venture Development, SPX
Looking Beyond Best Practice
T
oday’s operational leaders must navigate unprecedented levels of ambiguity and complexity. Rising customer expectations, relentless cost competition, capital constraints and rapid technological change are redefining performance requirements and forcing managers to quickly adapt and identify new ways to innovate within the production environment. Foresight is the foundation of competitive advantage. Winners and losers are often differentiated by the ability to anticipate trends and address emergent operational needs in advance of disruptive change, such as shifting workforce demographics, the introduction of new production or engineering standards or the launch of a breakthrough technology. Widely regarded as best practice for continuous operational improvement, proven methodologies such as Lean or Six Sigma are well-suited for optimization of existing business processes through iterative analysis and change implementation. Likewise, promising “Big Data” technologies such as predictive analytics and prognostics are potential game-changers for improving manufacturing production and maintenance efficiency. However, following best-practice processes or deploying the latest enabling technology alone rarely results in something truly unique. Real innovation requires a clear understanding of how the future can unfold, as well as the organizational discipline and fortitude to act in ways that positively influence that future. No longer reserved for senior executives, business strategists or technical visionaries wearing black turtlenecks or hoodies, innovation is for everyone. Many leading companies have formal innovation programs designed to capture, analyze and implement new ideas for generating customer and shareholder value. These ideas come in the form of new products or services, new business models, new processes or new technologies and can range in potential business impact from the incremental to the breakthrough. If your company doesn’t have an organized innovation program, you can apply a simple yet effective
process across all levels and functions within an organization. It only takes a few steps to get started: Turn on the “Forward Radar” . . . Effectively capture a diverse set of market-based inputs from a range of stakeholders inside (functional, technical) and outside (customers, analysts, suppliers) of the organization. Identify Articulated or Unarticulated Needs . . . Use these inputs to anticipate future trends and identify emergent or unmet customer needs. Develop a Value Hypothesis . . . Recognize how you could potentially serve these needs in ways that create value for customers and shareholders. Execute . . . Harness the passion, conviction and courage necessary to implement the plan and turn an idea into a business reality. One way to jump-start the innovation process is to assemble cross-functional “scout teams” to work directly with customers, suppliers and/or channel partners to discuss emerging trends and identify unmet or unarticulated needs. Focused, fast-paced and fun, the scout team sessions allow participants to shift the conversation from the day-to-day transactional to a more strategic discussion about the future. Starting with a specific trend or problem statement can help scope the exercise and keep the team focused. Regardless of how you choose to initiate an innovation process within your organization, the underlying objective is to encourage individuals to reject the status quo, understand future possibilities and empower positive action to shape that future. By applying this mind-set and a few basic steps to improve the innovation process within the production environment, others may soon be following your “best practice.” MT For more info, enter 15 at www.MT-freeinfo.com
The opinions expressed in this Viewpoint section are those of the author, and don’t necessarily reflect those of the staff and management of Maintenance Technology magazine.
56 | MAINTENANCE TECHNOLOGY
NOVEMBER 2012
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