23 2017 Maintenance Survey: Help wanted
PlantEngineering.com
Eyes on safety Making robots more human is one goal of collaboration 31
When you choose Motion Industries as your industrial parts supplier, you’ve selected a trusted partner that represents more of North America’s leading MRO brands than any other industrial supplier.
More Choices • Access to over 6.5 million SKUs • Over 550 locations • Convenient and simple ways to order via mobile, desktop, toll-free calling, or one of our locations
More Expertise • More than 1,500 experienced account representatives • Over 200 field product specialists available to solve your toughest challenges • Unmatched technical and application support
“Motion reduced our energy consumption by more than $140,000 a year.” – Director of Operations
MORE CHOICES. MORE E
More Solutions • Local parts and supplies inventory for fast turnaround • Repair and fabrication technicians • Account representatives and hundreds of branches located throughout North America for your convenience
Expect More With Motion.
©2017 M
EXPERTISE. MORE SOLUTIONS.
Call. 800-526-9328 800-526-9328 Click. www.MotionIndustries.com www.MotionIndustries.com Visit. Over 550 550 Locations Locations
Motion Industries, Inc.
MORE CHOICES. MORE EXPERTISE. MORE SOLUTIONS.
Call. 800-526-9328 800-526-9328 Click. www.MotionIndustries.com www.MotionIndustries.com Visit. Over 550 550 Locations Locations input #1 at www.plantengineering.com/information
©2017 Motion Industries, Inc.
A Clear Choice for Potable Water Components Flexible Tubing and Hose starting at $5.50 (100ft)
Hydro Mode
HydroMode™ polyethylene (PE) tubing is designed for use with potable water and beverages. This tubing is NSF-61 certified and works well with HydroMode push-to-connect fittings. HydroMode reinforced PVC hose is manufactured with polyester spiraled yarn which allows higher working pressures. It provides good chemical resistance, is lightweight, flexible and economically priced.
Tubing:
Hose:
• Five sizes - 5/32” to 1/2” • Seven colors: black, blue, natural, red, yellow, green or white • Shore A 98 hardness • NSF-61 certified • Flexible and lightweight
• 15˚F to 150˚F temperature range • Shore A 73 hardness • FDA compliant, NSF-61 certified • RoHS compliant • Reach Prop 65
Push-to-Connect Fittings starting at $3.50 (5 pack) • Designed for potable water and beverages • NSF-51 and NSF-61 certified • Easy tubing installation and removal • Optional retaining clips prevent accidental tube removal
Pressure Regulators starting at $24 HydroMode™ FR Series Food Grade Regulators are compact units with a highly sensitive diaphragm-operated design that provide economical, highperformance pressure regulation of drinkable water. • NSF electrodeposited chromium plated zinc body • FDA acetal bonnet, valve seat • Food grade nitrille/nylon diaphragm, O-ring • Lead-free brass and food grade nitrile valve plug • Mounting by pipe, bracket or through-panel
Lead-Free Brass Adapter Fittings starting at $5.50 (3 pack) HydroMode™ lead-free brass fittings are designed for use in potable water and beverage applications. These hose barb adapters work well with PVC hose and stainless steel hose clamps.
Research, price, buy at: http://go2adc.com/hydromode-ad
input #2 at www.plantengineering.com/information
Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2016 AutomationDirect, Cumming, GA USA. All rights reserved.
1-800-633-0405
the #1 value in automation
kaeser.com
success story
Clean Sweep! Air system study yields multiple benefits to bottom line Problem: An aerospace parts manufacturer was experiencing high maintenance costs as well as excessive downtime with their compressed air system. Their modulation control compressor caused unnecessary energy usage on the weekends and off peak times, resulting in exceptionally high energy costs. Additionally, problems with air quality led to product rejects and costly scrap rates.
Solution: A comprehensive Air Demand Analysis was conducted to understand the plant’s fluctuating demand. It revealed that the 200 hp modulating control compressor was grossly oversized. With proper controls and additional storage, two 50 hp compressors could efficiently handle the demand and save 871,500 kWh per year. A third 50 hp unit was added to ensure uptime and accommodate growth.
Result: These sweeping changes created immediate and sustainable energy savings. The combination of more storage, more efficient compressors and master controls drove system specific power consumption down 77%—and that doesn’t include the savings from leak reduction. As a direct result of the new air treatment equipment, the plant also saw improved product quality and reduced maintenance on the expensive production equipment that may surpass energy in terms of bottom line benefits. Specific Power of Previous System:
93.89 kW/100 cfm
Specific Power of New System:
21.14 kW/100 cfm
Annual Energy Costs of Previous System:
$107,431/year
Annual Energy Cost Savings:
$ 87,151/year
Savings Due to Fixing Leaks
$ 12,500/year
Utility Rebate:
$ 92,000
TOTAL FIRST YEAR SAVINGS:
$191,651
Let us help you measure and manage your compressed air costs!
COMPRESSORS
Kaeser Compressors, Inc. • 866-516-6888 • us.kaeser.com/PE Built for a lifetime is a trademark of Kaeser Compressors, Inc.
©2017 Kaeser Compressors, Inc.
input #3 at www.plantengineering.com/information
customer.us@kaeser.com
Can’t get it off? Having a hard time removing a corroded gear unit from your machine shaft? Well, stop fretting. Wise up and get TorqLOC® from SEW-EURODRIVE. With its stainless steel construction, keyless hollow shaft, and taper bushings, TorqLOC® disassembly is fast and easy. The same bolts used for assembly are used for disassembly.
Assembly
Not only does TorqLOC® reduce your maintenance headaches, it also reduces energy costs by eliminating belts, chains, and sprockets.
Disassembly
seweurodrive.com / 864-439-7537 input #4 at www.plantengineering.com/information
March 2017 Volume 71, No.2
Cover image courtesy: RIA/GE Global Research
COVER STORY 31 Robots, humans collaborate on safety A new age of collaborative robots put people closer to technology than ever before.
SPECIAL REPORT: 23 2017 Maintenance Survey Help wanted: More training, equipment upgrades Plant Engineering readers said equipment upgrades and more maintenance training would go a long way to decreasing downtime, but the failure of plant management to address that fundamental issue is seen as a barrier to realizing those improvements.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 2, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST, GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 3
2017
FLUKE ROADSHOW
Seattle May 2
Chicago May 4
input #5 at www.plantengineering.com/information
Presented by:
Atlanta May 9
Austin May 11
San Diego May 16
Philadelphia May 23
•
Learn how IIoT can transform your maintenance program
•
Get hands-on with the latest technology from Fluke Condition Monitoring
•
Explore the hottest trends in CMMS and eMaint’s latest innovations
•
Unlock the power of your asset and equipment monitoring data
•
See a sneak peek into the future of IIoT and connectivity
28
39
45
Maintenance Solutions 28 Digital training for tangible results A computer-based training program can help streamline coaching for operations personnel and front-line supervisors.
Electrical Solutions 39 Watts going on? Efficiency! In converting your lighting system to LEDs, don’t overlook seven common mistakes that could dim your success.
Mechanical Solutions 45
Air = money Compressed air leaks are not only a direct source of wasted energy, they also can contribute to system pressure drops, making pneumatic equipment function less efficiently and shortening its life cycle.
What’s Inside: 6
InSight
9
InFocus
52 Innovations 64 A Life in Manufacturing
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 5
INSIGHT
®
Know the score on the plant floor
We’re on the cusp of another baseball season, and I am once again preparing for my annual fantasy baseball draft. This will be the 33rd season that my team, the Bobbysox, has competed in this league, making it one of the longest continually-operating fantasy leagues anywhere. This means I’ve been a numbers geek for more than half my life. In the beginning, the weekly league statistics were prepared manually, with a rudimentary spreadsheet on a TS-80 computer and a printed copy of USA Today. Since our fantasy teams consist of a mix of players from all major league teams, it wasn’t as simple as just totaling up numbers. It was a painstaking process that took the better part of a day. When the printouts were finally mailed to each team member, we’d have to analyze our team’s stats relative to all the other teams and make decisions based on our best guesses as to what might happen next. Those decisions would impact player movement, potential trades and help determine where we might finish in the standings. The evolution of fantasy sports data and maintenance data is pretty similar, actually. Thanks to the emergence of better software analytics and data mining tools, the days of manual input of statistics—plant or baseball—should be far behind us. For my fantasy league, those numbers that were updated weekly and input by hand are now available on a phone app, updated in real time as the games are played. I can also get a historical record of what any of my players have done, both in the last seven days and throughout their career, and check on their injury status. Isn’t that what you’d like to do with your equipment? The goal of better maintenance data is to understand the health of the equipment now, understand its past operational data, see what past maintenance has been performed on the equipment and use all of that to better predict the future. It’s not too dissimilar to baseball, when you get down to the data. In manufacturing, we call it the repair shop. In baseball, we call it the disabled list. The goal in both cases is to keep your prime assets productive, and replace them as needed so you can remain profitable. That’s called predictive maintenance, one of the areas we studied in the 2017
6 • March 2017
PLANT ENGINEERING
PlantEngineering.com 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph. 630-571-4070, Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager 630-571-4070 x2212, BVavra@CFEMedia.com EMILY GUENTHER, Associate Content Manager 630-571-4070 x2220, EGuenther@CFEMedia.com AMANDA PELLICCIONE, Director of Research 860-432-4767, APelliccione@CFEMedia.com CHRIS VAVRA, Production Editor 630-571-4070 x2219, CVavra@CFEMedia.com
Editorial Advisory Board H. LANDIS “LANNY” FLOYD, IEEE Life Fellow H.Landis.Floyd@gmail.com SHON ISENHOUR, Partner, Eruditio LLC sisenhour@EruditioLLC.com DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC Industrial Internet Consortium (IIC) board member shiwanlin@thingswise.com
Bob Vavra Content Manager
Plant Engineering Maintenance Survey, co-sponsored by Advanced Technology Services (ATS). Only 47% of all plants utilize predictive maintenance as part of their overall maintenance strategy. It ranked behind preventive maintenance, which is employed in 78% of manufacturing plants, run to failure (the opposite of predictive maintenance) which is still utilized in 61% of plants, and computerized maintenance management systems (CMMS), which is part of the strategy just 59% of the time. While a multitude of maintenance strategies is employed in any given plant, perhaps one reason predictive maintenance is so far down the list is this other data point from our study: clipboards and other paper records are still used 39% of the time to manage maintenance data. While there is recognition of the value of automated data capture (53% of respondents use CMMS for at least part of the plant’s maintenance), there still is far too much manual data gathered in plants today. This is an unnecessary waste in an era where managing waste is one of the prime drivers of productivity. In manufacturing, the Industrial Internet of Things era allows us to get at that data quickly, analyze it more precisely and act on it immediately. Knowing the score about a piece of equipment allows you to make a smart decision before it goes down, and before it costs you the game. PE www.plantengineering.com
DAVE REIBER, Senior Reliability Leader at Reliabilityweb dave.reiber@reliabilityweb.com DAVID SKELTON, Vice president and general manager Phoenix Contact Development and Manufacturing dskelton@phoenixcontact.com BILLY RAY TAYLOR, Director of commercial and off-highway manufacturing The Goodyear Tire & Rubber Billytaylor@goodyear.com LARRY TURNER, President and CEO, Hannover Fairs USA lturner@hfusa.com MARK WATSON, Senior director, manufacturing technology, IHS Markit Mark.watson@ihsmarkit.com
CFE MEDIA CONTRIBUTOR GUIDELINES OVERVIEW
Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about—engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. * www.plantengineering.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.
Learn more at: www.plantengineering.com/contribute
Tired of the Same Routine? Buy a Vac that lasts! Stop throwing your money away on electric vacuum cleaners that are sure to fail. EXAIR vacuums have been engineered to withstand the dust, dirt, chips and liquids common to industrial environments. Ours have no electric motors or other moving parts to clog or wear out.
EXAIR’s 30 Day Unconditional Guarantee assures your complete satisfaction. Let our five year “Built To Last” warranty give you the peace of mind that your vacuum will always work and end your trips to the dumpster.
Two - Way Drum Pump
Maximum Lift 2-Way Drum Pump
The compressed air powered Reversible Drum Vac™ will quickly fill or empty a 55 gallon drum in 90 seconds. Coolant sumps can be easily refilled, floor spills vacuumed or contaminated liquids transferred to filtration tanks in minutes.
The High Lift Reversible Drum Vac™ will quickly fill or empty a 55 gallon drum from up to 15 feet in 85 seconds. This high powered Drum Vac has the strength to move liquids from below grade work areas, sumps or tanks! Uses no electricity nor moving parts.
• No moving parts - maintenance free • 5, 30, 55 and 110 gallon models • Maintenance free • Durable stainless steel construction • Built-in pressure / vacuum relief • Spill free - auto safety shutoff • Fits standard closed head drums • Installs quickly
Video demo on web site
www.exair.com/79/462.htm
NEW • Fits standard closed head drums • 30, 55 and 110 gallon models • For liquids up to 1400 centipoise
• Below grade coolant sumps • Deep well bulk storage tanks • Deep hole broaching
Pump 55 Gallons in 85 Seconds!
• Cisterns • Maintenance free • Safety shutoff
www.exair.com/79/4173.htm
High Capacity HEPA Cleaning
Heavy Duty Vacuum Resists Wear
EXAIR’s Heavy Duty HEPA Vac is engineered for dusty environments that require regular cleaning. The Heavy Duty HEPA Vac is powerfully designed to move more material with less wear – engineered to filter contaminants to HEPA standards.
Heavy Duty Dry Vac™ attaches to an ordinary 30, 55 or 110 gallon open-top drum to turn it into a powerful, industrial duty vacuum cleaner. It has been engineered to vacuum more dry materials in less time than ordinary vacs. Ideal for abrasives.
• 55 and 110 gallon models • Mold and allergen removal • No moving parts - maintenance free • Reduces exposure to airborne irritants • Removes industrial contaminants
Video demo on web site
• Eliminate exhaust debris
www.exair.com/79/4172.htm
• No motors to clog or wear out • 30, 55 and 110 gallon models • Heavy duty tools
• Safe - no electricity Eliminates painful shock hazard • Hardened alloy construction resists wear
www.exair.com/79/4170.htm
Quiet - only 77 dbA
Chip Vacuum Has No Moving Parts
Chip Trapper™ Extends Coolant Life
Chip Vac™ is powered by compressed air and vacuums chips directly into a 5, 30, 55, or 110 gallon drum. It is easy to move from drum to drum to keep materials separate for recycling. Clean chips from floors, fixtures, work surfaces and machines.
Chip Trapper™ and High Lift Chip Trapper™ offer a fast, easy way to clean chips, and shavings out of used coolants and liquids. Chip Trapper vacuums in the coolant that is filled with debris, traps the solids in a filter bag, and pumps out clean coolant.
• 55 and 110 gallon models • Mold and allergen removal • No moving parts - maintenance free • Reduces exposure to airborne irritants • Removes industrial contaminants • Eliminate exhaust debris
Video demo on web site
www.exair.com/79/465.htm
• CNC’s, lathes, saws, mills, drills • Parts washers, Pits, Tanks, etc. • 30, 55 and 110 gallon models
Video demo on web site
input #6 at www.plantengineering.com/information Manufacturing Intelligent Compressed Air® Products Since 1983 11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 (800) 903-9247 • fax: (513) 671-3363 • E-mail: techelp@exair.com • www.exair.com
@EXAIR
• New High Lift Chip Trapper available with 15 feet of lift for below grade sumps or elevated tanks • Removes unwanted solids from liquid
www.exair.com/79/4171.htm
is driving a smarter future World-class precision. Quality technology. Award-winning energy efficiency. Our experts are engineering variable frequency drives to be more communicative and intuitive, while still enabling reliable, energy-efficient results. With VLT® and VACON® offering powerful product lines, and a unique service portfolio with DrivePro®, Danfoss has the right drive to meet the application demands and unique conditions of every industry, even in harsh environments. Choosing the right drive and optimizing your entire system can yield potential energy savings of up to 60 percent. Danfoss is committed to innovating drives that can address climate change, rapid urbanization, and successful and sustained water and wastewater management, so you can tackle your industry’s challenges. To discover solutions for the future, visit www.danfossdrives.com
input #7 at www.plantengineering.com/information
5bn
worldwide will benefit daily from Danfoss Drives by 2025
IN FOCUS
HVLS fans can better distribute air flow in high-ceiling plants and warehouses, creating a more balanced temperature at all levels of the plant. All images courtesy: Rite-Hite
HVLS basics:
Balancing the air temperature
Destratification creates more comfort and lower costs. By Andy Olson Rite-Hite Fans
Large open workspaces are a hallmark of industrial and commercial facilities. Operations that include manufacturing, processing and warehousing need these wide-open areas for the specialized machinery and processes that allow them to be efficient. Unfortunately, the same floor plan that makes them efficiently operationally also makes them inefficient from a heating and cooling standpoint. Many plant managers attempt to address this problem by enhancing an existing system. For the most part, HVAC systems do an efficient job of providing heated or cooled air to www.plantengineering.com
specified areas of a building. However, while regular maintenance will keep an HVAC system running smoothly, it won’t optimize HVAC operation as much as the addition of a high-volume, low-speed (HVLS) fan network. As one would assume, HVLS fans can play a significant role in helping to cool a facility. But even greater benefits can be seen during cold weather. Before looking at those benefits, though, let’s first examine how HVLS fans keep working areas cool and operating at maximum efficiency.
Summer breeze feels nice
Worker comfort is no trivial matter. Studies have repeatedly shown that workers who are physically uncomfortable become distracted and are
“According to the U.S.
Department of Health and Human Services paper, “Workers in Hot Environments,” an air speed of two to three miles per hour creates an evaporative cooling sensation of seven to 11 degrees Fahrenheit.
”
PLANT ENGINEERING
March 2017 • 9
IN fOCUS more prone to making mistakes. This is particularly true in cases of extreme discomfort, as when heat fatigue, heat stroke and other types of heat stress strike. That’s why HVLS fans are becoming increasingly common in industrial facilities across the nation.
With or without air-conditioning, virtually any facility will benefit immensely from HVLS fans. In facilities that don’t possess air conditioning, the benefits of HVLS fans are most noticeable. Although smaller, traditional floormounted fans can be helpful in limited
The Most Advanced Steam Boiler Technology Saves Fuel Saves Space Saves Time Saves Money
spaces, their high wind speed and noise levels may cause problems and they use a relatively high amount of electricity. In comparison, HVLS fans use relatively little energy and provide a gentle, quiet breeze that is very comforting to workers. This calm wind has profound effects on the perceived temperature for workers. According to the U.S. Department of Health and Human Services paper, “Workers in Hot Environments,” an air speed of two to three miles per hour creates an evaporative cooling sensation of seven to 11 degrees Fahrenheit. To put this in perspective, the effective temperature of an 84-degree warehouse environment can be dropped to 73 degrees by adding a fan moving air at three miles per hour. This cooling effect can make workers up to 35% more productive. A large 24-foot diameter HVLS fan gently moves large volumes of air up to 22,000 square feet and replaces 10 to 20 floor fans. By mixing air, HVLS fans also help air-conditioning systems work more efficiently, allowing them to be operated at a set point up to five degrees higher.
Fans of winter
As counter-intuitive as it may seem, HVLS fans can be even more impactful during the cold weather months than in summer, especially in a large, cavernous facility. Even in facilities with strong HVAC systems, warm air is going to rise. Thus, in tall warehouses there may be a significant temperature difference between the floor-level workspace and the ceiling. By continually mixing air through a process called destratification, HVLS fans can diminish this problem, helping facility managers to provide more comfortable working environments and even cut energy usage by up to 30%.
Warming up with destratification
www.claytonindustries.com info@claytonindustries.com
800.423.4585
SEE US AT FOOD PRO EXPO BOOTH #E2449 Comp Code is 22K54
input #8 at www.plantengineering.com/information
During the heating season, there is often more than a 20-degree difference between the floor and ceiling at most manufacturing plants and warehouses as a result of warm air (light) rising and cold air (heavy) settling.
10 • March 2017
plant engineering
Typically, the air temperature will be one-half to one degree warmer for every foot in height. Heating systems must work hard for extended periods of time to maintain the temperature near the floor, or at the thermostat set point, wasting precious energy and dollars. The charts in Figure 1 illustrate this concept.
traditional ceiling fans, the full benefits of the HVAC system rarely are realized on the floor.
Saving energy and money
Because HVLS fans run so efficiently, their return on initial investment often ranges from as quickly as six months to
two years. However, this varies due to application variables. As shown in Table 1 (on page 12), winter energy savings are substantial. Users can reduce their heating bills by 20% to 30% when using an HVLS fan to gently mix warm air from the ceiling with cooler air below.
HVLS ceiling fans mitigate the rising heat effect by gently moving the warm air near the ceiling back down toward the floor where it is needed. The air reaches the floor below the fan where it then moves horizontally a few feet above the floor. The air eventually rises to the ceiling where it is cycled downward again. This mixing effect creates a much more uniform air temperature, with perhaps a single degree difference from floor to ceiling. Facilities equipped with HVLS fans lower the burden on the heating system, reduce energy consumption and save money. Conventional high-speed ceiling fans do not have this effect. Although they have been used to help circulate air for many years, they are ineffective in moving the warm air from ceiling to floor. By quickly spreading airflow away from the fan, little—if any—of that air reaches people working at the ground level. Thus, in facilities with plant engineering
March 2017 • 11
input #9 at www.plantengineering.com/information
IN fOCUS Important aspects to contemplate
Some of the variables in these ROI calculations include obstructions such as pallet racks, machinery and product staging, personnel work areas, and overall building layout, to name a few. Larger diameter fans will move air further down rack aisles and
over obstructions. Smaller diameter fans can be most effective in specific work areas, or where installation space is limited. Fan suppliers can help configure an array of fans, determining the number, size and locations that provide the maximum benefit for the investment.
If it’s electrical, we train it. ADVANCED TRANSFORMER MAINTENANCE & TESTING
CIRCUIT BREAKER MAINTENANCE, LOW-VOLTAGE
SUBSTATION MAINTENANCE II
suBstation maintenance i
COURSE 231, REV2 NOVEMBER 2016
certification course
COURSE 149, REV2, NOVEMBER 2016
COURSE 134, REV. 1 November 2016
Table 1: WInTer saVIngs Location
Winter energy savings
Edmonton, Canada
$3,620
Minneapolis, MN
$2,845
Toronto, Canada
$2,485
Cleveland, OH
$2,395
Boston, MA
$2,190
Kansas City, MO
$2,125
Indianapolis, IN
$2,080
Salt Lake City, UT
$2,050
Seattle, WA
$1,520
Typical annual winter energy savings possible based on 22,000 sq. ft. building with 30 ft. ceilings a 70 degree temperature set point and natural gas at $0.11 per cubic ft.
1
s
electrical safety for industrial facilities
1
s
s
s
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 877-594-3156 • avotraining.com
transformer maintenance & testing
Battery Maintenance & testing
s
s
s
s
s
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 s
s
s
1
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 s
Protective relay maintenance- basic
877-594-3156 • avotraining.com
1
CABLE TESTING & DIAGNOSTICS, MEDIUM-VOLTAGE
CirCuit Breaker maintenanCe SF6
s
1
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 s
s
s
s
www.avotraining.com 877-594-3156 4271 bronze way dallas, tx 75237 877-594-3156 • avotraining.com
1
s
s
s
s
CirCuit breaker maintenanCe, molded & insulated Case
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 s
1
s
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237
1
Infrared thermography level I
They’ll usually be able to provide installation when on-site resources are not available. While the basic concept is similar across all HVLS fan manufacturers, fan design and performance are important to consider, like the shape and number of blades, blade tilt, hub construction, blade-to-hub connection and safety features. The performance of different designs will vary in the uniformity of air movement directly below the fan, as well as the height and reach of air movement outward from the fan’s diameter.
Valuable investment for any season
24
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 877-594-3156 • avotraining.com s
1
s
s
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 877-594-3156 • avotraining.com s
1
s
s
s
www.avotraining.com 877-594-3156 4271 Bronze way dallas, tx 75237 877-594-3156 • avotraining.com s
s
s
s
1
s
877-594-3156 • avotraining.com
www.avotraining.com 877-594-3156 4271 bronze way dallas, tx 75237
1
Offering over 52 electrical safety & To be the best, train with the best. electrical maintenance training courses. By offering the broadest selection of electrical training, we have a training course for all things electrical. Be prepared for exams and take your knowledge to the next offering selection electrical level. A training By course is only asthe goodbroadest as the instructor teaching of it. That’s why our training, we have course for all things instructors are some of the most qualifiedaintraining the industry. Be the best, train with the electrical. Be prepared for exams and take your best. t
knowledge to the next level. A training course WWW.AVOTRAINING.COM 877-594-3156 is only as good as the instructor teaching AVO training courses are eligible for NETA ctd’s.* it.Many That’s why our instructors are some of the most qualified in the industry. Delivering hands-on skills with real world experience.
No matter the season or the temperature-controlled application, HVLS fans can provide numerous benefits. Not only will they enhance environmental control to help comfort workers and protect product, they do it by using less energy for less hassle than traditional high-speed floor fans. Capitalizing on the advantages of HVLS fans requires careful analysis of each application, as well as each HVLS fan design. PE Perry Knutson is director of engineering for Rite-Hite Doors. Brad Stone is director of engineering for Rite-Hite Products.
input #10 at www.plantengineering.com/information
To be the best, train with the best.
12 • March 2017
plant engineering
Striving to achieve a ‘reliable state’ Four ways to reorganize your people and processes By Stuart Grant DuPont Sustainable Solutions
In today’s rapidly evolving and increasingly competitive global economy, companies are under tremendous pressure to function at the peak of performance, and do so cost-effectively. But with so many initiatives and programs that comprise the daily operations of an organization competing for limited time and resources, it can be difficult for companies to know where to focus their attention. While those initiatives that companies consider a priority will vary depending upon the organization’s unique business situation and industry sector, one area that most companies in the manufacturing industry would be wise to focus on is the convergence of safety, reliability and productivity that enables the achievement of a “reliable state.” A reliable state is the point at which a company’s safety, reliability and productivity are optimal. As a result, organizations can realize increased performance, efficiency and profitability. As the term suggests, reliable operations are the keystone to achieving optimum safety and productivity. With respect to safety, the more reactive or corrective maintenance that a company must perform to repair equipment and components, the greater the risk of injury to workers as this type of maintenance can be more unpredictable and hazardous than preventive maintenance. Increasing the reliability of equipment by appropriate use of precision, predictive and planned maintenance keeps unscheduled repairs at a minimum and leads to a decrease in safety incidents and injuries. Similarly, when reactive or corrective maintenance needs to be performed to repair equipment or components, those assets are generally out of operation for a longer time than for preventive maintenance. Improving the reliability of equipment reduces the need for mechanical interventions (transient conditions), and keeps those assets operating at longer intervals, which in turn increases productivity. plant engineering
March 2017 • 13
A collective goal
What steps can companies take to keep their maintenance and reliability program functioning at its peak?
First and foremost, achieving a reliable state must be a collective goal of the entire organization, both company leadership and Continued on page 16
RESPOND QUICKER WITH REAL-TIME NETWORK MONITORING. THE NHL MP3 VOICE INDICATOR • Ethernet communications protocol • Supports a variety of monitoring functions
(SNMP, RSH, PHN, Ping) • Email real-time alerts • Features alarm and voice MP3 alerts up to 90dB
SEND E-MAIL TO MANAGER
Machine 1 and 2 error ETHERNET
DIGITAL INPUT / OUTPUT
To learn more, visit tinyurl.com/NHLVOICE
We also carry a wide-range of visual and audible indication for just about any application.
LME - Ethernet
LU7-USB
LKEH
BSV
1-888-214-2580 INFO3@PATLITE.COM
www.patlite.com input #11 at www.plantengineering.com/information
EHV
THE ROAD TO
2017 HANNOVER MESSE2016
Building on U.S. momentum, IIoT technology ‘Integrated Industry’ the theme for 2017 global trade event By Larry Turner Hannover Fairs USA
Every year Hannover Messe, the world’s largest industrial technology trade show held annually in Hannover, Germany, attracts industry leaders and decision makers to showcase intelligent automation solutions that increase factory floor productivity and efficiencies. This year’s event will be even bigger than Hannover Messe 2016, as it is the first time the show combines with CeMAT, the leading logistics industry trade show. Hannover Messe 2017 combined with CeMAT is expected to draw more than 200,000 visitors and 6,500 international exhibitors. Now more than ever, the global exhibitors on the floor of Hannover Messe will be clearly demonstrating machines and software intelligence that echo the show’s theme “Integrated Industry—Creating Value.”
American companies at Hannover Messe
Once again in 2017, the United States will showcase its industrial technology expertise from our country’s largest exhibitors to industrial technology-focused startups to associations and organizations that promote research and best practices for Industrie 4.0 and IIoT. American companies and associations will be demonstrating the latest solutions and projects that address trends across industrial automation, motion, drive & automation and various digital factory segments. Houston-based Tatsoft, a developer of industrial automation software, attended Hannover Messe for the first time in 2016 when the United States was the event’s partner-country. As with many other American companies that attended the show last year, Tatsoft collected very good results from the time and dollars it spent to exhibit. The company quickly realized that a consistent presence at the show will help them establish its brand globally and grow international sales.
14 • March 2017
plant engineering
only do we reach “Not global end-users but when companies and potential users from the United States visit Hannover Messe, they are able to see for themselves our technology and to compare our offering to any company in the world.
”
Marcos Taccolini, CEO of Tatsoft
During Hannover Messe 2017, Tatsoft will be exhibiting in the Digital Factory area. The company is launching its newest release of the Tatsoft FactoryStudio software platform, which was just announced in December. Tatsoft FactoryStudio is a development platform built completely in the Microsoft .NET Framework, delivering solutions to run on Windows PCs, Windows Compact Framework (Windows CE), Linux computers, Web browsers, tablets, virtual machines and smart devices with iOS or Android environments to deliver applications ranging from standalone HMIs to IT operations centers, data aggregation and real-time asset monitoring. The latest software platform provides extreme flexibility for multiple users. “Our main goal at Hannover Messe 2017 is to establish distributors, develop system integrators and solution providers’ channels that are capable of developing sales opportunities and implementing systems using the Tatsoft FactoryStudio platform,” said Marcos Taccolini, CEO of Tatsoft. “This year, we intend to develop international contacts to establish more regional distributors across Europe and the Middle East. We are utilizing Hannover Messe 2017 to grow our solutions network.” “Not only do we reach global end-users but when companies and potential users
from the United States visit Hannover Messe,” Taccolini added, “they are able to see for themselves our technology and to compare our offering to any company in the world.” Also during Hannover Messe 2017, Illinois-based Bimba Manufacturing, a repeat Hannover Messe exhibitor, will be demonstrating its factory automation products, new line of ISO pneumatic drives, linear robots, vacuums and IIoT technology platform, IntelliSense, which is a preventive maintenance tool for pneumatic cylinders. Bauer Gear Motors, Huco, Matrix, Warner Electric, Stieber, Twiflex and Wichita will be demonstrating Illinois-based Altra Industrial Motion’s industrial automation applications. Altra Industrial Motion believes it is important that its clients know it is a global corporation and will be communicating its participation at Hannover Messe 2017 to all of its U.S.-based customers. “Because Hannover Messe does a great job of attracting potential customers from all over the world, Altra can present its global capabilities and support network,” said David Brooksbank, director of marketing at Altra Industrial Motion. “We have two major objectives: first, we want to make sure our current customers fully understand the potential of working with one of our brands globally, and we want to attract new customers and outlets.” Also attending Hannover Messe 2017 is The Industrial Internet Consortium (IIC) headquarted in Needham, Massachusetts. IIC is an international organization with hundreds of member companies, academic institutions, government agencies and research organizations from dozens of countries, working together to build testbed projects proving best practices in the application of the Internet of Things (IoT) to verticals like healthcare, financial services, precision agriculture, smart cities, and manufacturing, to name a few. The IIC is focused on both international buyers and distributors that attend Hanwww.plantengineering.com
nover Messe. As the IIC did in Hannover Messe 2016, it will be showing off some of the best results of those testbed projects at this year’s event, displaying its strong partnership with Plattform Industrie 4.0 to work toward interoperability for the Industrial Internet. Richard Mark Soley, Ph.D., the executive director of IIC, said, “There is intense interest in North American companies, and those from Africa, Asia, Europe and elsewhere in our testbed projects. We believe that Hannover Messe 2017 is an important venue for them to learn more about the application of the Internet of Things to industrial systems.”
American exhibitors expand sales
Tatsoft recognized that year-over-year attendance at Hannover Messe will prop-
erly solidify the company’s presence in international markets and will allow the company to find the best local partner. Taking their global outreach one step further, Tatsoft recently opened a branch in the UK. Taccolini adds, “Tatsoft’s presence at Hannover Messe 2016 was key for the start of our global operations. Exhibiting at the show is ideal as it historically has had a very high number of international visitors that attend Hannover Messe exactly with the intention of getting updated on industrial technology and searching for potential new business partners.” “As a global company, it’s important for Altra to show our brands at a show as prestigious as Hannover Messe. We have exhibited for many years and find it very worthwhile to be present and use the trade show as a platform to promote our Europe-
an brands,” added Brooksbank. Commenting on IIC’s exhibition Dr. Soley adds, “As the largest event of its kind, this show is in a critically important market for one of the key verticals of the IIC. We wouldn’t dare miss out on attending Hann o v e r Me s s e 2017.” PE Larry Turner is president and CEO of Hannover Fairs USA, the U.S. division of Deutsche Messe and a member of Plant Engineering’s Editorial Advisory Board.
As Partner Country,
Poland poised to display innovation
As the 2017 Partner Country at Hannover Messe, Poland will showcase its desire to open foreign markets to build on its own domestic reindustrialization. The focus for Poland at Hannover Messe 2017, which will be April 23-28 in Hannover, Germany, will be its energy and IT sector. “Being next-door neighbors, Poland and Germany are already strong partners,” said Jochen Köckler, a member of the Managing Board of Deutsche Messe, the trade show’s organizer. “Poland’s industrial sector will demonstrate its innovative spirit and its dynamic uptake of digitalization—factors that make it a key player on the global stage.” Digitalization of Poland’s manufacturing processes is certainly proceeding rapidly, with digital manufacturing technology accounting for 4.1% of the nation’s GDP in 2015. Moreover, the Polish government is actively supporting the process of economic digitization with an
extensive program of financing options for the R&D sector. Another core focus of Poland’s overall economic strategy is energy. The renewable portion of the country’s total energy mix currently sits at just 7% but is prioritized for expansion. About 150 Polish companies will exhibit on about 43,000 sq. ft. of display space spread across all of Hannover Messe’s seven constituent trade shows. This compares with about 80 companies in 2016. The lineup will include a sizable contingent from Poland’s energy technology and industrial subcontracting sectors. Overall organization and coordination of this year’s Partner Countr y showcase rests with the Polish Agency for Enterprise Development. The showcase includes
theme-specific group pavilions in many of Hannover Messe’s exhibition halls. For instance, the National Center for Research and Development will run a pavilion at the Research & Technology show in Hall 2. The Polish government’s central pavilion will be in Hall 3. This is the heart of the showcase and will feature group presentations by 10 of the country’s provinces. Poland’s Ministry of Science and Higher Education also will be using the pavilion to profile innovations from the country’s industrial sector. PE
Hannover Messe 2017 will focus on the Industrial Internet of Things (IIoT) and the larger issues of connected manufacturing. Image courtesy: Hannover Messe www.plantengineering.com
plant engineering
March 2017 • 15
WORKSMART TIP™ #420
GET THE GOODWAY® GDS-C40 Chemical Descaler.
IN fOCUS AFTER
BEFORE
Goodway descaling solutions work quickly and effectively to dissolve mineral deposits on contact. Use in critical systems like chillers, boilers, heat exchangers and more to restore efficiency and performance. Make it look easy.
Four steps to organizational discipline
CALL US AT 888-364-7736 AND GET YOUR GDS-C40 TODAY! www.goodway.com input #12 at www.plantengineering.com/information
The MD III™ System includes all you need for complete Energized and De-Energized Testing of Motors, Generators & Transformers Combine the power of Motor Circuit Analysis (MCA™) and Electrical Signature Analysis (ESA) to evaluate and trend your entire motor system Auto diagnosis within instrument providing an immediate health status report Route-based testing and trending – ideal for Predictive Maintenance Excellent Post-Sale Service and Support Worldwide Training – Earn CEUs / IACET Accredited
Reports provide indication of early winding faults, rotor problems, incoming power issues, electrical and mechanical motor condition and driven load mechanical condition
Motor Testers
Continued from page 13 employees. Often this involves changing how the concept of reliability is perceived. Employees sometimes have the misperception that productivity gains achieved through reliability programs are primarily intended to downsize personnel within the company. That is why it is important for employees to realize that improving the reliability of equipment within their area of control is about creating a safer working environment for them and other employees.
www.alltestpro.com
Finally – Predictive Maintenance Made VERY Easy! The ideal instruments for troubleshooting, quality control and predictive maintenance of electric motors, transformers and generators.
input #13 at www.plantengineering.com/information
Companies need to adopt an integrated approach to their business processes if improved operations are to be effectively and efficiently implemented on a consistent basis. An integrated approach links critical elements, including: 1. Process management: Establishing the right strategy, governance and key performance indicators, developing an organizational structure to support processes and monitoring performance. 2. The technical model: The specific steps and procedures to conduct a maintenance and reliability program and address identified hazards. 3. A capabilities engine: The training and coaching necessary to provide employees the right skills and collaborative mindset to pursue operational discipline. 4. Mindsets and behaviors: Motivating employees, changing behaviors and encouraging individual ownership of results through the active participation of corporate leadership, from C-suite executives to the level of first-line management. Optimizing a company’s reliability, safety and productivity can seem a daunting task, particularly given the many competing priorities faced by organizations. But by thinking of them as interdependent priorities, and pursuing them through business processes that are fully integrated, the reliable state is attainable. PE Stuart Grant is global maintenance & reliability champion with DuPont Sustainable Solutions.
16 • March 2017
plant engineering
MROSolutions Pg 2
Pg 3
Pg 16 (Back Cover)
Pg 4
Pg 5
Pg 8
Pgs 6, 7
Pg 9
Pg 11
Pg 10
Pg 12
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
Pg 13
Pg 14
Keeping Industry in Motion
For more vendors, see our full line digital catalog Now Available via E-Reader!
Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 550 Locations
GRINDERS
MRO SOLUTIONS
Industrial Grinder
Industrial Grinder
• Cast iron tool rests and exhaust-type wheel guards • Base mounted on/off switch • Rubber feet minimize vibration • Wheel size: 10" x 1" x 7/8" • RPM: 1,800 • Supplied with 36 and 60 grit wheels • Factory connected (power cord not included) • Deluxe models include water pot, tool tray and lighted eyeshields
• Cast iron tool rests and exhaust-type wheel guards • Magnetic starter with overload protection • Lighted eyeshields (bulbs not included) • Suitable for 50/60 Hz operation • Wheel size: 14" x 3" x 1-1/4" • GA20 (Mi item# 00921995) cast iron pedestal sold separately • RPM: 1,800 • Factory connect for 230V, magnetic starter must be changed for other voltages • Wheels sold separately
10"
Mi Item #
14" Floor Stand
Mfr Part #
HP
Voltage
1022W 1021W 105W
1 1-1/2 1-1/2
115/230V 208-230/460V 575V
1022WD 1021WD
1 1-1/2
115/230V 208-230/460V
Standard Models 00920451 00920434 00920468
Deluxe Models 00920462 00920445
Mi Item # 00920516 00920550 00920533 00920523 00920556 00920540
Mfr Part # 1406W 1410W 1408W 1407W 1411W 1409W
HP 5 5 5 7-1/2 7-1/2 7-1/2
Voltage 230V 460V 575V 230V 460V 575V
Industrial Grinder 12"
• Cast iron tool rests and exhaust-type wheel guards • Manual starter with overload protection • Lighted eyeshield (bulbs not included) • 3-phase units suitable for 50/60 Hz, 1,500/1,800 rpm operation • Wheel size: 12" x 2" x 1-1/4" • RPM: 1,800 • Wheels sold separately
Mi Item # 00920498 00920479 00920485 00920505
Mfr Part # 1217W 1215W 1216W 129W
HP 2 2 3 3
A CUT ABOVE. Voltage 115/230V 1-Phase 208-230/460V 3-Phase 208-230/460V 3-Phase 575V 3-Phase
Visit us online at ZZZ 0L,QGXVWULDO6SHFLDOLVW FRP Whether it’s understanding the current regulations VXUURXQGLQJ FKHPLFDOV DQG OXEULFDQWV RU ȑQGLQJ VXEMHFW PDWWHU H[SHUWLVH DERXW VSHFLȑF FXWWLQJ WRROV 0L ,QGXVWULDO Supply is designed to keep you in the know.
Some products may ship direct from the manufacturer. 2
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
PISTON PUMPS
Mobile Variable Displacement Piston Pump PVM Series
• • • • • • • • •
Long pump life Quiet pump operation Inlet and outlet gauge ports and adjustable maximum displacement stops Astonishingly low 4% pressure ripple Low installed and operating costs Reduced maintenance Flexibility in machine design Design promotes leak-free system Other combinations of shaft, ports, port location, rotation, displacement and controls are available • All flanged ports are Code 61 unless noted otherwise • Maximum rpm: 1,800
Mi Item #
Mfr Part #
GPM @ 1,800 RPM
Rotation
Input Shaft
Flange Mount
2-Bolt Mount End Port—1.1 Cu. In./Rev Displacement 03064896
PVM018ER01AE01AAA07000000A0A
8.2
CW
SAE A, Straight Keyed
SAE A
02280173
PVM018ER01AE01AAA28000000A0A
8.2
CW
SAE A, Straight Keyed
SAE A
03228670
PVM018ER02AE01AAA28000000A0A
8.2
CW
SAE 19-1, Straight Keyed
SAE A
02845766
PVM018MR03AE01AAA28000000A0A
8.2
CW
SAE A, 9 Tooth Spline
SAE A
02845767
PVM020MR03AE01AAA23000000A0A
9
CW
SAE A, 9 Tooth Spline
SAE A
03458150
PVM020ML07CE01AAA07000000A0A
9
CCW
SAE B, 13 Tooth Spline
SAE B
02845768
PVM045MR07CE01AAA28000000A0A
20
CW
SAE B, 13 Tooth Spline
SAE B
03458297
PVM045ML07CE02AAA28000000A0A
20
CCW
SAE B, 13 Tooth Spline
SAE B
02845769
PVM050MR07CE01AAA23000000A0A
23
CW
SAE B, 13 Tooth Spline
SAE B
4-Bolt Mount—Side Port 03458449
PVM057ML11GE02AAA28000000A0A
27
CCW
SAE C, 14 Tooth Spline
SAE C
02452152
PVM063ML11GE02AAA23000000A0A
29
CCW
SAE C, 14 Tooth Spline
SAE C
02845772
PVM074MR11GS02AAA28000000A0A
33.5
CW
SAE C, 14 Tooth Spline
SAE C
02845773
PVM081MR11GS02AAA23000000A0A
37
CW
SAE C, 14 Tooth Spline
SAE C
02845774
PVM098MR11GS02AAA28000000A0A
45
CW
SAE C, 14 Tooth Spline
SAE C
03458749
PVM098ML11GS02AAB25200000A0A
45
CCW
SAE C, 14 Tooth Spline
SAE C
02845775
PVM106MR11GS02AAA23000000A0A
49
CW
SAE C, 14 Tooth Spline
SAE C
02845776
PVM131MR11GS02AAA28000000A0A
57
CW
SAE C, 14 Tooth Spline
SAE C
03458915
PVM131ML11GS02AAB28200000A0A
57
CCW
SAE C, 14 Tooth Spline
SAE C
02845777
PVM141MR11GS02AAA23000000A0A
63
CW
SAE C, 14 Tooth Spline
SAE C
03459023
PVM141ML11GS02AAB21110000A0A
63
CCW
SAE C, 14 Tooth Spline
SAE C
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
3
COUPLINGS & BUSHINGS
MRO SOLUTIONS
Keyless Rigid Coupling
Keyless Bushings
• Keyless, rigid, zero backlash coupling • Eliminates the need for costly mounting brackets and structural support • Transmits high torque and bending moments • Compact, double taper design with self-releasing tapers for easy removal • Exceptional concentricity • Installs right over existing keyways and splines • Not affected by shock or reversing loads
• Provide a high capacity, zero-backlash shaft-to-hub connection by means of a mechanical interference fit • Best suited for applications that require a recessed installation of the bushing with no axial movement of the mounted component relative to the shaft during tightening • Wide, double taper design for enhanced torque transmission and bending moment capacity • Exceptional concentricity with thru-bored hubs • No axial movement during installation • Self-centering • Eliminates need to hold shaft or lock machine while applying installation torque • Recessed installation without the need for a counter bore • RoHS compliant • Ability to transmit higher torques • Ability to mount over existing keyways • Complete axial and radial adjustability
B-LOC® WK Series
Mi Item # 02376400 02376404 02376411 03004678 02376419 02376421 02376423 02376424
Mfr Part # HWK0252100 HWK0302104 HWK0402108 HWK0502115 HWK0502200 HWK0602204 HWK0602207 HWK0602208
Shaft Size 1" 1-1/4" 1-1/2" 1-15/16" 2" 2-1/4" 2-7/16" 2-1/2"
B-LOC® B112 Series
Max Torque (ft-lbs) 492 703 1,430 2,639 2,724 3,678 3,984 4,087
Keyless Bushings B-LOC® B106 Series
• Recessed mounting is not important because the component mounts against the flange of the bushing • Provides a high capacity, zero-backlash shaft to hub connection by means of a mechanical interference fit • Best suited for applications where having no axial movement of the mounted component relative to the shaft during tightening is critical • Shallow, single taper design with integrated push-off threads • Exceptional concentricity • Optional integrated spacer sleeve to mount narrow hub components • No axial movement during installation • RoHS compliant • True zero-backlash means less equipment downtime • Ability to mount over existing keyways • Complete axial and radial adjustability • Simple installation, adjustment and removal Mi Item # 00235173 00235178 03046890 00235182 00235184 00235188 00235193 02929569
Mfr Part # B602108 B602115 B602200 B602203 B602207 B602208 B602215 B602307
Shaft Size 1-1/2" 1-15/16" 2" 2-3/16" 2-7/16" 2-1/2" 2-15/16" 3-7/16"
Max Torque (ft-lbs) 600 1,299 1,341 1,676 2,102 2,155 3,651 4,807
Mi Item # 00465005 02376769 02376770 01145753 01145822 02376776 02376782 02376787
Mfr Part # B122108 B122115 B122200 B122203 B122207 B122208 B122215 B122307
Shaft Size 1-1/2" 1-15/16" 2" 2-3/16" 2-7/16" 2-1/2" 2-15/16" 3-7/16"
Max Torque (ft-lbs) 2,011 2,969 3,065 3,771 4,669 4,789 10,039 12,815
STAY UP-TO-DATE WITH EVERYTHING SAFETY NEWS | VIDEOS | WHITEPAPERS | RESOURCES EXPERT TIPS
VALUABLE RESOURCES NEWS & LATEST TRENDS
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
Visit us online at www.MiSafetySpecialist.com
Some products may ship direct from the manufacturer. 4
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
SPEED REDUCERS
Right Angle Helical-Hypoid Speed Reducer Stainless Steel HERA®
Right Angle Helical-Hypoid Speed Reducer
• 90% efficiency • Up to 2 times more torque in a no-hassle replacement for worm speed reducers • Dimensionally interchangeable with up to four sizes of worm speed reducers for inventory consolidation • Easy, bolt-in interchanges—no cutting or welding • Helical and Hypoid gearing provides longer life expectancy than standard worm gearing • 316 stainless steel housings are polished for easy cleanability, no chipping or blistering paint • Factory filled with USDA H1 lubricant for application service life of the drive • HACCP compatible, BISSC Certified, and USDA accepted • Three-year warranty
HERA®
• 90% efficiency • Up to 2 times more torque in a no-hassle replacement for worm speed reducers • Dimensionally interchangeable with up to four sizes of worm speed reducers for inventory consolidation • Easy, bolt-in interchanges—no cutting or welding • Helical and Hypoid gearing provides longer life expectancy than standard worm gearing • Factory filled with PAG 460 lubricant for enhanced efficiency (USDA H1) • Three-year warranty Mi Item #
Mfr Part #
Exact Ratio
Input HP
Output RPM
Model HERA35ES—56C Frame Size—Output Torque 1,100 RPM 05100544 05100422 05100423 05100424 05100425 05100426 05100427 05100428
0250-56449 0250-56450 0250-56451 0250-56452 0250-56453 0250-56454 0250-56455 0250-56456
8.02 11.42 15.60 19.93 29.10 43.53 52.50 58.33
4.23 2.97 2.18 1.70 1.17 0.78 0.65 0.58
218 153 112 88 60 40 33 30
Model HERA35ES—143TC Frame Size—Output Torque 1,100 RPM 05100264 05100204 05100205 05100206 05100207 05100208 05100209 05100210
0250-56505 0250-56506 0250-56507 0250-56508 0250-56509 0250-56510 0250-56511 0250-56512
8.02 11.42 15.60 19.93 29.10 43.53 52.50 58.33
4.23 2.97 2.18 1.70 1.17 0.78 0.65 0.58
218 153 112 88 60 40 33 30
Model HERA45ES—56C Frame Size—Output Torque 2,149 RPM 04391284
0250-54033
7.80
8.50
224
Model HERA45ES—56C Frame Size—Output Torque 2,600 RPM 04391285 04391286 04391287 04359977 04391288 04391289 04391290
0250-54034 0250-54035 0250-54036 0250-54037 0250-54038 0250-54039 0250-54040
11.36 15.60 19.50 28.01 39.98 52.50 59.79
7.06 5.14 4.11 2.86 2.01 1.53 1.34
154 112 90 62 44 33 29
Model HERA45ES—143C Frame Size—Output Torque 2,149 RPM 04391303
0250-54081
7.80
8.50
224
Model HERA45ES—143TC Frame Size—Output Torque 2,600 RPM 04391112 04391113 04391114 04391115 04391116 04391117 04391118
0250-54082 0250-54083 0250-54084 0250-54085 0250-54086 0250-54087 0250-54088
11.36 15.60 19.50 28.01 39.98 52.50 59.79
7.06 5.14 4.11 2.86 2.01 1.53 1.34
154 112 90 62 44 33 29
Mi Item #
Mfr Part #
Exact Ratio
Input HP
Output RPM
Model SSHERA35ES—56C Frame Size—Output Torque 1,100 RPM 06088283 06088284 06088285 06088286 06088287 06088288 06088289 05843174
0250-56849 0250-56850 0250-56851 0250-56852 0250-56853 0250-56854 0250-56855 0250-56856
8.02 11.42 15.60 19.93 29.10 43.53 52.50 58.33
4.23 2.97 2.18 1.70 1.17 0.78 0.65 0.58
218 153 112 88 60 40 33 30
Model SSHERA35ES—143TC Frame Size—Output Torque 1,100 RPM 06088338 06088339 06088340 06088341 06088342 06088343 06088344 06088345
0250-56905 0250-56906 0250-56907 0250-56908 0250-56909 0250-56910 0250-56911 0250-56912
8.02 11.42 15.60 19.93 29.10 43.53 52.50 58.33
4.23 2.97 2.18 1.70 1.17 0.78 0.65 0.58
218 153 112 88 60 40 33 30
Model SSHERA45ES—56C Frame Size—Output Torque 2,149 RPM 06088660
0250-57233
7.80
8.50
224
Model SSHERA45ES—56C Frame Size—Output Torque 2,600 RPM 06088661 06088662 06088663 06088664 06088665 06088666 05899002
0250-57234 0250-57235 0250-57236 0250-57237 0250-57238 0250-57239 0250-57240
11.36 15.60 19.50 28.01 39.98 52.50 59.79
7.06 5.14 4.11 2.86 2.01 1.53 1.34
154 112 90 62 44 33 29
Model SSHERA45ES—143C Frame Size—Output Torque 2,149 RPM 06088707
0250-57281
7.80
8.50
224
Model SSHERA45ES—143TC Frame Size—Output Torque 2,600 RPM 06088708 06088709 06088710 06088711 06088712 06088713 06088714
0250-57282 0250-57283 0250-57284 0250-57285 0250-57286 0250-57287 0250-57288
11.36 15.60 19.50 28.01 39.98 52.50 59.79
7.06 5.14 4.11 2.86 2.01 1.53 1.34
154 112 90 62 44 33 29
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
5
ADHESIVES & SEALANTS
MRO SOLUTIONS
Threadlocker
Thread Sealant
222MS™
577™
Low Strength
Medium Strength
• For fastener diameters of 1/4" (6 mm) and smaller • Controlled lubricity allows for accurate clamp loads • Removable with standard hand tools Mi Item # 00987810 00770726 00772687 00774807
Mfr Part # 22205 22221 22231 22241
• General-purpose • Coarse threads Mi Item # 00982281 01510116
Container 0.5 mL Capsule 10 mL Bottle 50 mL Bottle 250 mL Bottle
High Strength 263™
• Prevents loosening and leakage from shock and vibration • Cures when confined in the absence of air between close fitting metal surfaces • Particularly suited for heavy-duty applications, bolts up to 3/4" • Primerless performance on both inactive and active metals • Upgraded temperature resistance up to 360ºF (182°C) • Oil-tolerant curing on as-received fasteners without cleaning
Medium Strength—Blue 243™
• Primerless performance on both inactive and active metals • Upgraded temperature resistance up to 360ºF (182°C) • Oil-tolerant curing on as-received fasteners without cleaning • For locking and sealing threaded fasteners between 1/4" and 3/4" • Prevents loosening and leakage from shock and vibration • Cures when confined in the absence of air between close fitting metal surfaces • Removable with standard hand tools Mfr Part # 1329837 1329467 1329505 1330333
Container 10 mL Bottle 50 mL Bottle 250 mL Bottle 1 L Bottle
Semi-Solid Stick Threadlocker Medium Strength—Blue
• Primerless performance on both inactive and active metals • Oil-tolerant curing on as-received fasteners without cleaning • For locking and sealing threaded fasteners between 1/4" and 3/4" • Prevents loosening and leakage from shock and vibration • Cures when confined in the absence of air between metal surfaces • Removable with standard hand tools Mi Item # 02565597 02565598
Container 50 mL Tube 250 mL Tube
Threadlocker
Threadlocker
Mi Item # 04335875 04335876 04335877 04429640
Mfr Part # 21456 21457
Mfr Part # 37684 37087
Container 9 g Stick 19 g Stick
Mi Item # 04335871 04335872 04335873 04359973
Mfr Part # 1330583 1330585 1330335 1330334
Container 10 mL Bottle 50 mL Bottle 250 mL Bottle 1 L Bottle
Thread Sealant
Controlled Strength 565™ PST®
• For metal tapered pipe thread fittings • Controlled lubricity prevents galling and protects from rust and corrosion • Replaces most tapes and pipe dopes, cures rapidly to withstand 10,000 psi • Perfect as a replacement for pre-coated parts • Can be used on fittings up to 2" (50 mm) in diameter • Controlled strength for ease of disassembly • CSA 3319-81 and 3319-01, UL MH007 (N), NSF/ANSI 61 certified, ULC-Canada approved, CFIA approved Mi Item # 01183609 01183715 01183758 02067537 02058917 01183888
Mfr Part # 56507 56531 56541 56543 56566 56571
Container 6 mL Tube 50 mL Tube 250 mL Tube 1 L Bottle 10 L Bottle 300 mL Cartridge
Some products may ship direct from the manufacturer. 6
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
ADHESIVES & SEALANTS
Thread Sealant
Instant Adhesive
567™ PST®
404™ Quick Set™
General-Purpose—High-Temperature • Instant sealer for tapered and straight or tapered fittings • Excellent solvent resistance—prevent galling and withstand temperatures up to 400°F (204°C) • Excellent for high-pressure applications—locks and seals tapered metal, pipe threads and fittings • Ideal for stainless steel, aluminum, galvanized metal and other inert metals • Disassembles with hand tools • Color: White Mi Item # 01184421 02391403 01184651
Mfr Part # 56707 33241 56790
• Excellent for bonding rubber, frequently used for rubber O-ring bonding • One part • Room temperature cure • Mil Spec: Mil-A-46050C Type II Class II • Commercial item description A-A-3097: Type II Class 2
Container 6 mL Tube 350 mL Brush Top Can 1L Bottle
• Eases disassembly and will not contaminate or clog lines • Semi-solid—will not spill or leak, making it great for overhead applications or carrying in a pocket or toolbox Container 19 g Stick
Thread Sealant 545™
• For locking and sealing metal pipes and fittings • Specially formulated to offer high lubricity for easy assembly and removal • Recommended for fine threaded fittings as used in hydraulic and pneumatic installations and small fittings in general • Contains no fillers or particles that could contaminate system fluids, foul valves, or clog fine filters and screens • Suitable for fittings up to 2" (50 mm) in diameter • Excellent solvent resistance • ABSSM and CFIA approved • Color: Purple Mi Item # 01175271 02286681 01175377 01175422
Mfr Part # 54505 32429 54531 54541
Mfr Part # 46551 46548 46561
Container 1/3 oz Bottle 4 oz Bottle 1 lb Bottle
Instant Adhesive Difficult-to-Bond Gel
• For the assembly of difficult-to-bond materials which require uniform stress distribution • Particularly suited for bonding porous or absorbent materials • No-run viscosity for large gaps and vertical surfaces • One part • Surface insensitive • Room temperature cure
Immediate Low Pressure
Mfr Part # 37127
Mi Item # 00776811 00776863 00776451
454™ Prism®
Thread Sealant Stick
Mi Item # 02565601
General-Purpose—Rubber
Mi Item # 01126063 00985770 01126288 01126470 01126492
Mfr Part # 45404 21925 45440 45474 45478
Container 3 g Tube 10 g Syringe 20 g Tube 200 g Tube 300 g Cartridge
Concrete Repair Fixmaster® Magna-Crete
Container 0.50 mL Capsule 10 mL Bottle 50 mL Bottle 250 mL Bottle
• Two-component, rapid setting concrete repair and grouting system • Chemically-resistant to most common liquids and chemicals • Bonds to concrete, wood, glass, steel and construction materials • Can be mixed and applied from -15°F to 115°F • Non shrinking with good chemical and corrosion resistance, high compression strength, and fast cure capability for making durable repairs on cracks, holes, spalled concrete and more Mi Item # 01510596
Mfr Part # 95555
Container 5 gal Kit
Coverage 21.6 sq-ft
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
7
AIR COMPRESSORS
MRO SOLUTIONS
Oil-Flooded Rotary Screw Air Compressor UP-Series
• Industry-leading performance delivers more air for less horsepower, saving thousands of dollars per year on energy • Smart, energy efficient controls means industry-leading performance delivers more air for less horsepower, saving thousands of dollars per year on energy • Five- and seven-year warranty programs available • Whisper-quiet operation allows for installation closer to point-of-use, reducing costs and ensuring a better and safer work environment • Closely maintained pressure for reducing discharge pressure and avoiding excessive pressure bands increases downstream tool and equipment life • Smart integration with 70% fewer connections, eliminating leaks and pressure drops, thus maximizing reliability • Small footprint frees up valuable floor space and reduces install costs • Optional Total Air System Package is a complete integrated air treatment package
Mi Item # 05416331 05416330 05416333 05416354 05416355 05416357 05416374 05416376 05416390 05416394 05416398 05416402 05416392 05416396 05416400 05416404
Mfr Part # 18002873 18002865 18002899 18003095 18003103 18003129 18003293 18003319 18003459 18003491 18003533 18003574 18003475 18003517 18003558 18003590
HP 5 5 5 7.5 7.5 7.5 10 10 15 15 15 15 15 15 15 15
Tank Size 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 120 gal 80 gal 120 gal 80 gal 120 gal 80 gal 120 gal
Voltage/ Phase 230-3-60 230-1-60 460-3-60 230-1-60 230-3-60 460-3-60 230-3-60 460-3-60 230-3-60 230-3-60 230-3-60 230-3-60 460-3-60 460-3-60 460-3-60 460-3-60
Flow (m3min/cfm) 0.52/18.5 0.52/18.5 0.52/18.5 0.79/28 0.79/28 0.79/28 1.08/38 1.08/38 1.55/55 1.55/55 1.42/50 1.42/50 1.55/55 1.55/55 1.42/50 1.42/50
Rated Pressure (PSIG) 125 125 125 125 125 125 125 125 125 125 150 150 125 125 150 150
18003996 18004002 18004028 18004226 18004234 18004259 18004424 18004440 18004580 18004622 18004663 18004705 18004689 18004606 18004648 18004721
5 5 5 7.5 7.5 7.5 10 10 15 15 15 15 15 15 15 15
80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 80 gal 120 gal 80 gal 120 gal 80 gal 80 gal 120 gal 120 gal
230-1-60 230-3-60 460-3-60 230-1-60 230-3-60 460-3-60 230-3-60 460-3-60 230-3-60 230-3-60 230-3-60 230-3-60 460-3-60 460-3-60 460-3-60 460-3-60
0.52/18.5 0.52/18.5 0.52/18.5 0.79/28 0.79/28 0.79/28 1.08/38 1.08/38 1.55/55 1.55/55 1.42/50 1.42/50 1.42/50 1.55/55 1.55/55 1.42/50
115 115 115 115 115 115 115 115 115 115 140 140 140 115 115 140
Total Air System Package 05416443 05416444 05416446 05416466 05416467 05416469 05416486 05416488 05416502 05416506 05416510 05416514 05416512 05416504 05416508 05416516
Some products may ship direct from the manufacturer. 8
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
ABRASIVE WHEELS & BRUSHES
ATB Master Wheel
Mi Item #
• Wide-face construction is highly effective on both metallic and non-metallic materials • Since the cutting action does not require the use of a compound, the need to clean finished parts is eliminated • May be used singly or mounted in multiple for a wider face • Certain styles are available with rectangular filaments • Applications: Deburring, edge breaking, finishing Mi Item #
Mfr Part #
Brush Dia
Grit Size
Fill Dia
Mfr Part #
Brush Dia
Grit Size
Fill Dia
Face Width
Trim Length
Max RPM
Silicon Carbide Grit Fill—Rectangular—2" Arbor Hole 03314614
22292
6"
80
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314615
22293
6"
120
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314609
22284
6"
180
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314616
22294
6"
320
0.045" x 0.090"
7/8"
1-1/16"
6,000
Aluminum Oxide Grit Fill—Rectangular—2" Arbor Hole
Face Trim Width Length
Max RPM
03314605
22280
6"
80
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314606
22281
6"
120
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314607
22282
6"
180
0.045" x 0.090"
7/8"
1-1/16"
6,000
03314608
22283
6"
320
0.045" x 0.090"
7/8"
1-1/16"
6,000
Silicon Carbide Grit Fill—Round Crimped—5/8" Arbor Hole 03314592 03314593 03314594 03314595 03314596 03314597 03314598 03314599 03314600 03314601 03314602 03314603 03314590 03314591
22248 22249 22250 22251 22252 22253 22254 22255 22256 22257 22258 22259 22240 22244
3" 3" 3" 3" 3" 3" 3" 3" 4" 4" 4" 4" 4" 4"
80 120 180 320 80 120 180 320 80 120 180 320 80 80
0.040" 0.040" 0.035" 0.022" 0.040" 0.040" 0.035" 0.022" 0.040" 0.040" 0.035" 0.022" 0.040" 0.040"
1/2" 1/2" 1/2" 1/2" 7/8" 7/8" 7/8" 7/8" 5/8" 5/8" 5/8" 5/8" 1/2" 5/8"
5/8" 5/8" 5/8" 5/8" 5/8" 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 3/4" 1-1/8" 1-1/8"
20,000 20,000 20,000 20,000 20,000 20,000 20,000 20,000 12,000 12,000 12,000 12,000 18,000 18,000
Silicon Carbide Grit Fill—Round Crimped—2" Arbor Hole 03314610 03314611 03314612 03314613 03314614 03314617 03314618 03314619 03314620 03314621 03314622 03314623 03314624 03314625 03314626 03314627 03314628 03239470 03314629 03314630 03239471
22285 22286 22287 22288 22289 22296 22297 22298 22299 22300 22312 22313 22314 22315 22326 22327 22328 22333 22334 22335 22336
6" 6" 6" 6" 6" 8" 8" 8" 8" 8" 10" 10" 10" 10" 12" 12" 12 14" 14" 14" 14"
80 120 180 320 500 80 120 180 320 500 80 120 180 320 120 180 320 80 120 180 320
0.040" 0.040" 0.035" 0.022" 0.018" 0.040" 0.040" 0.035" 0.022" 0.018" 0.040" 0.040" 0.035" 0.022" 0.040" 0.035" 0.022" 0.040" 0.040" 0.035" 0.022"
7/8" 7/8" 7/8" 7/8" 7/8" 7/8" 7/8" 7/8" 7/8" 7/8" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
1-1/16" 1-1/16" 1-1/16" 1-1/16" 1-1/16" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2-1/16" 2-1/16" 2-1/16" 2-1/16" 2-1/8" 2-1/8" 2-1/8" 2-1/8" 2-1/8" 2-1/8" 2-1/8"
6,000 6,000 6,000 6,000 6,000 4,500 4,500 4,500 4,500 4,500 3,600 3,600 3,600 3,600 3,000 3,000 3,000 2,400 2,400 2,400 2,400
End Brush
High-Speed—Knot • In many applications, higher speeds (up to 25,000 rpm) are required for effective brushing action, and these are perfect for the job • Made from the finest wire (offered in both high carbon and stainless steel), these rugged brushing tools are designed to offer efficient usage for a wide variety of tough cleaning and maintenance applications • Applications: Spot cleaning or facing, removal or slag, rust or scale, cleaning pipe ID, deburring or flash removal, cleaning of dies, molds and tooling, pipeline cleaning Mi Item # 06220958 07170526 07170532 07170544 07170548
Mfr Part # 30500 30502 30504 30503 30505
Fill Material AB Carbon Wire AB Carbon Wire AB Carbon Wire Stainless Steel Stainless Steel
Fill Dia 0.0200" 0.0140" 0.0104" 0.0140" 0.0104"
ATB Round Trim Cup Brush Reduced Flare
• Fill material: Silicone carbide grit • Applications: Engine blocks, cylinder heads, exhaust manifolds, transmission housings, water pumps and intake manifolds, bulk heads, wing spars, engine housings and components, hydraulic valve bodies, machine components, housings, gears and castings Mi Item # 03315068
Mfr Part # 32146
Brush Dia 2-1/2"
Grit Size 80
Fill Dia 0.040"
Max RPM 5,000
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
9
CAM FOLLOWERS & BALL BEARINGS
MRO SOLUTIONS
Roller® Cam Follower
Mi Item #
Hex Head, Stud Type
00105830 00105983 00106076 00106140 00106332 00106362 00106426 00106516
• Invented by RBC to solve some of the toughest machine and product control guidance challenges • Double row of cylindrical rollers delivers tremendous operating advantages in an economical package • Lubricated for life—no more need for periodic re-lubrication or expensive lubrication systems • Unique contacting lip seals provide positive protection against contamination while keeping grease inside Mi Item # 06023179 02416155 06929330 06926077 06928944 06927079 06928865 06927226 06927189 06927131
Mfr Part # RBC1 RBC11/8 RBC11/4 RBC11/2 RBC13/4 RBC17/8 RBC2 RBC21/2 RBC3 RBC4
OD 1.000" 1.125" 1.250" 1.500" 1.750" 1.875" 2.000" 2.500" 3.000" 4.000"
Width 0.625" 0.625" 0.750" 0.875" 1.000" 1.000" 1.250" 1.500" 1.750" 2.250"
Thread Type 7/16-20 7/16-20 1/2-20 5/8-18 3/4-16 3/4-16 7/8-14 1-14 1-1/4–12 1-1/2–12
Radial Ball Bearing 1600 Series™
• Precision ground on all surfaces with exceptional care given to the ball grooves • Careful heat treatment provides a uniform and exact degree of hardness for maximum life • Available open, with seals or with shields • Double-sealed and double-shielded bearings are supplied grease packed as standard Mi Item #
ID
OD
Width
1602DSTNTG18 1607DSTNTG18 1616DSTNTG18 1621DSTNTG18 1635DSTNTG18 1638DSTNTG18 1641DSTNTG18 1657DSTNTG18
0.2500" 0.4375" 0.5000" 0.5000" 0.7500" 0.7500" 1.0000" 1.2500"
0.6875" 0.9063" 1.1250" 1.3750" 1.7500" 2.0000" 2.0000" 2.5625"
0.2500" 0.3125" 0.3750" 0.4375" 0.5000" 0.5625" 0.5625" 0.6875"
Ball Bearing Insert Extended Inner Ring
• Permanently sealed and pre-lubricated for long life • Steel trash guard and inner ring labyrinth groove provide superior protection • Better protection in wet/moist environments • Two lubrication holes allow for re-greasing • Two knurled cup point set screws offer excellent resistance to loosening under vibratory conditions • Fully ground, SAE 52100 chrome alloy steel races • Black oxide finish provides added corrosion resistance • Optional low-torque seal (SFR suffix) is available Mi Item #
Mfr Part #
ID
OD
Width
ER10 ER12 ER16 ER19 ER20 ER23 ER24 ER31
0.6250" 0.7500" 1.0000" 1.1875" 1.2500" 1.4375" 1.5000" 1.9375"
47 mm 47 mm 52 mm 62 mm 72 mm 72 mm 80 mm 90 mm
1.4375" 1.2188" 1.3750" 1.5000" 1.6875" 1.6875" 1.9375" 2.0313"
0.6250" 0.7500" 1.0000" 1.1875" 1.5000"
47 mm 47 mm 52 mm 62 mm 80 mm
1.4375" 1.2188" 1.3750" 1.5000" 1.9375"
Double Seals
Mfr Part #
ID
OD
Width
1602DCTNTG18 1604DCTNTG18 1614DCTNTG18 1616DCTNTG18 1623DCTNTG18 1630DCTNTG18 1641DCTNTG18 1654DCTNTG18
0.2500" 0.3750" 0.3750" 0.5000" 0.6250" 0.7500" 1.0000" 1.2500"
0.6875" 0.8750" 1.1250" 1.1250" 1.3750" 1.6250" 2.0000" 2.5000"
0.2500" 0.3438" 0.3750" 0.3750" 0.4375" 0.5000" 0.5625" 0.6250"
Double Seals 00105821 00105885 00106005 00106067 00106201 00106264 00106418 00106485
Mfr Part #
Double Shields
00584894 00584916 00584956 00584992 00585006 00585044 00585057 02100009
Double Low-Torque Seals 02660446 06079187 02441068 04662301 03356528
ER10SFR ER12SFR ER16SFR ER19SFR ER24SFR
Some products may ship direct from the manufacturer. 10
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
LIFTING PRODUCTS
Hydraulic Air Pump Single-Acting
Electric Pump
PA6 Series
for Single- or Double-Acting Cylinders
• Power unit of choice for major manufacturers of auto body, frame straighteners and other equipment • Operate at 40 to 100 psi shop air pressure at the pump • dBA 85 at 10,000 psi • Serviceable pump motor is not a “throw away”, providing economical repair • Permanently vented cap • Internal relief valve protects circuit components, air inlet filter protects motor • Polyethylene reservoir
Hydraulic PE17 Series
• For use with single-acting or double-acting cylinders at operating pressures to 10,000 psi • For intermittent duty; starts under full load • Equipped with 1/2 hp, 3,450 rpm, single-phase, thermal protected induction motor • Low amperage draw—small generators and low amperage circuits can be used as power source • Thermoplastic reservoir • Extremely quiet noise level (67 to 81 dBA) • Capacity: 2 gallons • Model PE174 shown Mi Item # 00841479
Mfr Part # PE172
Style Standard
Mi Item # 00842052
Valve Type 2-Way
Length 11-3/8"
• Aluminum bronze bearing reduces wear caused by off-center loads • Maximum sized springs speed piston return and increase spring life • Solid steel cylinder body for durability • Chrome-plated piston rod resists wear and corrosion • 3/8" NPTF female half coupler is standard • Base mounting holes standard on 5- through 55-ton cylinders; optional on 75- and 100-ton cylinders • Wide range of accessories available to thread onto piston rod, collar or onto cylinder base • Model C556C shown Capacity 5 Tons 10 Tons
Stroke 5-1/4" 2-1/8"
Capacity 105 cu-in
Height 7-3/4"
Length 9-1/2"
Hand Pump
Hydraulic P Series
General-Purpose
Mfr Part # C55C C102C
Style Standard
Two-Speed—Single-Acting
Lifting Cylinder/Ram
Mi Item # 00841918 00841927
Mfr Part # PA6
Extended Height 13-3/4" 6-7/8"
Collar Thread Size 1-1/2"-16 2-1/4"-14
Lifting Cylinder/Ram
• Two-speed reduces handle strokes so you work faster and easier • Formed composite handle provides less flex and reduces operator fatigue • Convenient fill port allows pumps to be filled in a horizontal or vertical position • Relief valve inboard of check valve prevents loads from drifting down • Large valve knob gives added control for slowly metering loads down • More usable oil volume—use with larger or longer stroke cylinders • True unloading valve set for 850 psi (59 Bar) provides more efficiency and lower handle force • Link design reduces handle effort by 40% • Durable aluminum reservoir, manifold and end cap • Ergonomic non-slip handle grip provides more comfort • Spring loaded handle lock incorporated into handle • 3/8" NPTF oil port • Maximum psi: 10,000
Mi Item # 02786590 02786591
Mfr Part # P19L P59L
Volume per Stroke LP (cu-in) 0.250 0.720
Volume per Stroke HP (cu-in) 0.050 0.150
Shorty
Mini Jack
• Power Tech plated piston rods and gland nuts resist scoring and corrosion • Heavy-duty return spring (except for double-acting models) provides fast piston return and low collapsed height • Coupler is angled upward 5° for added clearance • Grooved piston top keeps load from sliding • Cylinders can be “dead-ended” at full capacity Mi Item # 00842222
Mfr Part # RSS202
Capacity 20 Tons
Sidewinder
• Operate either horizontally or vertically • Handles function in line with base for easier use in confined spaces
Extended Height 5-1/2"
Stroke 1-3/4"
Mi Item # 04046035
Mfr Part # 9105A
Capacity (Tons) 5
Stroke 3/4"
Retracted Height Minimum 2-1/2"
Max Height 3-3/8"
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
11
HYDRATION
MRO SOLUTIONS
Single Serve Powder
Powder Thirst Quencher Concentrate
QwikServ™
Sqwincher Zero Qwik Stik
16.9 oz Yield
Sugar-Free—20 oz Yield
• Helps replace fluids and electrolytes lost during perspiration • It is possible for water alone to replace lost fluid, but water cannot replace electrolytes to a level sufficient enough to prevent heat stress, and is even less effective when used by workers with less than perfect nutritional habits or health problems • Priced each, sold in packs of 96 per case Mi Item # 04639428 04639429 04639430 06217100
Mfr Part # 060900-OR 060901-FP 060902-LL 060904-GR
Flavor Orange Fruit Punch Lemon-Lime Grape
Electrolyte Freezer Pops Sqweeze
• Electrolyte fortified freezer pops replenish electrolytes and minerals lost due to heat • No caffeine, low sodium, non-carbonated and contains no fruit juice • Priced each, sold by case of 150 Mi Item # 03108788
Mfr Part # 159200201
Flavor Assorted
Size 3 oz each
• Helps replace fluids and electrolytes lost during perspiration • It is possible for water alone to replace lost fluid, but water cannot replace electrolytes to a level sufficient enough to prevent heat stress, and is even less effective when used by workers with less than perfect nutritional habits or health problems • Zero calories, zero sugar • Priced each, 50 per bag, 10 bags per case (500 per case) Mi Item #
Mfr Part #
Flavor
060099-SL 060100-OR 060101-MB 060102-FP 060103-LA 060104-PT 060105-RB 060106-LL 060107-GR 060109-CC
Strawberry Lemonade Orange Mixed Berry Fruit Punch Lemonade Peach Tea Raspberry Lemon-Lime Grape Cool Citrus
0.11 oz Package, 20 oz Yield 05494901 02933377 05164679 02933378 03250570 03250572 05163348 03733598 03694690 04639432
Powder Thirst Quencher Concentrate Sugar-Free
Powder Thirst Quencher Concentrate Sugar-Free—2-1/2 gal Yield Sqwincher Lite ZERO
• Helps replace fluids and electrolytes lost during perspiration • It is possible for water alone to replace lost fluid, but water cannot replace electrolytes to a level sufficient enough to prevent heat stress, and is even less effective when used by workers with less than perfect nutritional habits or health problems • Priced each, sold by case of 32 (4 bags of 8 packs each)
Sqwincher LITE Powder Stiks
• Perfect for those looking for less calories, no color and no artificial flavor or additives • Contains the perfect electrolyte blend, naturally flavored and naturally sweetened and contains no added color • Priced per each, sold by pack of 8, case qty 12 packs
Mi Item #
Mfr Part #
Flavor
060280-GR 060281-OR 060282-FP 060283-LL
Grape Orange Fruit Punch Lemon-Lime
1 oz Package, 20 oz Yield Mi Item #
Mfr Part #
Flavor
1.76 oz Package, 2-1/2 gal Yield 04156849 04156850 05494900 05264564 05264565 06041312
016800-LL 016801-OR 016803-FP 016804-GR 016805-SL 016802-AS
Lemon-Lime Orange Fruit Punch Grape Strawberry Lemonade Assorted
06462294 06462295 06462296 06462297
Some products may ship direct from the manufacturer. 12
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
MRO SOLUTIONS
MOTORS
General-Purpose AC Motor
Hostile-Duty® NEMA® Premium Efficient—IE3 • • • • • • • • • • • • • • •
WORLDMOTOR® features Class F insulation, Class B rise at full load on 60 Hz sine wave power Cast iron frame (140: rolled steel), cast iron end brackets Stainless steel nameplate (with “CE” mark) and zinc-plated hardware Shaft slinger on pulley end for IP54 protection Dual voltage 230/460V (1 to 100 hp) 40°C ambient, NEMA® design B performance on 60 Hz sine wave power Regreasable ball bearings 250 frame and up, lifting provisions 180 frame and up Double-shielded bearings 140 to 360, open on 400 to 440 1.15 service factor @ 60 Hz Steel fan cover and conduit box Field convertible to F2 mounting on 180 frame and larger Condensation drains with plastic plugs Conversion kits: All cast iron upgrade, C and D flanges, canopy kits (except 320 to 360) Applications: Pulp and paper plants, saw mills, mines, foundries, chemical plants, waste management facilities and other process-related industries requiring protection within harsh operating conditions
Mi Item #
Mfr Part #
HP
RPM
Voltage
Motor Frame Size
3-Phase TEFC—C-Face 04787165
H1P2DC
1
1,800
208-230/460
143TC
04787166
H1P3DC
1
1,200
208-230/460
145TC
04787177
H32P1DC
1-1/2
3,600
208-230/460
143TC
04787178
H32P2DC
1-1/2
1,800
208-230/460
145TC
04787179
H32P3DC
1-1/2
1,200
208-230/460
182TC
04787172
H2P1DC
2
3,600
208-230/460
145TC
04787173
H2P2DC
2
1,800
208-230/460
145TC
04787174
H2P3DC
2
1,200
208-230/460
184TC
04787180
H3P1DC
3
3,600
208-230/460
182TC
04787181
H3P2DC
3
1,800
208-230/460
182TC
04787182
H3P3DC
3
1,200
208-230/460
213TC
04787187
H5P1DC
5
3,600
208-230/460
184TC
04787188
H5P2DC
5
1,800
208-230/460
184TC
Mi Item #
Mfr Part #
HP
RPM
Voltage
Motor Frame Size
3-Phase TEFC—C-Face 04787189
H5P3DC
5
1,200
208-230/460
215TC
04787195
H7P1DC
7-1/2
3,600
208-230/460
213TC
04787196
H7P2DC
7-1/2
1,800
208-230/460
213TC
04787197
H7P3DC
7-1/2
1,200
208-230/460
254TC
04787159
H10P1DC
10
3,600
208-230/460
215TC
04787160
H10P2DC
10
1,800
208-230/460
215TC
04787161
H10P3DC
10
1,200
208-230/460
256TC
04787162
H15P1DC
15
3,600
208-230/460
254TC
04787163
H15P2DC
15
1,800
208-230/460
254TC
04787164
H15P3DC
15
1,200
208-230/460
284TC
04784952
H20P1DC
20
3,600
208-230/460
256TC
04787168
H20P2DC
20
1,800
208-230/460
256TC
04787169
H20P3DC
20
1,200
208-230/460
286TC
04787170
H25P1DSC
25
3,600
208-230/460
284TSC
04787171
H25P2DC
25
1,800
208-230/460
284TC
04787175
H30P1DSC
30
3,600
208-230/460
286TSC
04787176
H30P2DC
30
1,800
208-230/460
286TC
04787183
H40P2EC
40
1,800
230/460
324TC
04787185
H50P2EC
50
1,800
230/460
326TC
04787190
H60P2EC
60
1,800
230/460
364TC
04787193
H75P2EC
75
1,800
230/460
365TC
04787157
H100P2EC
100
1,800
230/460
405TC
Some products may ship direct from the manufacturer.
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
13
MOTORS
MRO SOLUTIONS
General-Purpose AC Motor 3-Phase—TEFC—Cast Iron W22
• All NEMA Premium ratings have a 1.25 service factor (up to 100 hp) resulting in cooler operation and extended life of the motor • All cast iron construction, including terminal box and fan cover (cast iron fan cover available as an option on 143 through 215T frames) • Solid feet for reduced vibration levels and impact absorption • Optimized ventilation system for cooler operation and extended life • High-grade FC200 cast iron provides superior mechanical strength and heat dissipation • Totally enclosed fan cooled with a true IP55 rating against dust and moisture • Exclusive W-Seal 364T and larger provides superior bearing protection • Taconite Labyrinth seal 586 frame and larger • Exclusive WEG painting system exceeds 200 hours ASTM 117 corrosion test (exceeds IEEE841 standard) • Balanced to 0.08" per second vibration limits (meets IEEE841 standard) • Four-bolt conduit cover with glued neoprene gasket • Impregnation resin and magnet wire are insulation class H • Stainless steel nameplate is laser etched with high contrast background • Corrosion-proof drains • Inverter-duty per NEMA MG1, Part 31 • Certified Class I Div 2, Groups A, B, C and D; Class II, Div 2, Groups F and G • Suitable for IEEE45 and USCG 259 marine-duty Mi Item #
Mfr Part #
HP
kW
RPM
NEMA Frame
208-230/460V 02323967
Mfr Part #
HP
kW
RPM
NEMA Frame
04656452
01018ET3E215T-W22
10
7.5
1,800
213/5T
04516807
01036ET3E215T-W22
10
7.5
3,600
213/5T
04516809
01512ET3E284T-W22
15
11
1,200
284/6T
04516812
01518ET3E254T-W22
15
11
1,800
254/6T
04516813
01536ET3E254T-W22
15
11
3,600
254/6T
04701982
02012ET3E286T-W22
20
15
1,200
254/6T
04516816
02018ET3E256T-W22
20
15
1,800
254/6T
04516818
02036ET3E256T-W22
20
15
3,600
254/6T
04516819
02512ET3E324T-W22
25
18.5
1,200
284/6T
04655227
02518ET3E284T-W22
25
18.5
1,800
284/6T
04516821
02536ET3E284TS-W22
25
18.5
3,600
284TS
04516822
03012ET3E326T-W22
30
22
1,200
324/6T
04702080
03018ET3E286TS-W22
30
22
1,800
284/6T
04702081
03018ET3E286T-W22
30
22
1,800
284/6T
04702099
03036ET3E286TS-W22
30
22
3,600
286TS
04671537
04012ET3E364T-W22
40
30
1,200
364/5T
04702131
04018ET3E324T-W22
40
30
1,800
324/6T
04702148
04036ET3E324TS-W22
40
30
3,600
324TS
Mi Item #
208-230/460V
5018ES3EB56
1/2
0.37
1,800
B56
04702164
05012ET3E365T-W22
50
37
1,200
364/5T
04701574
00118ET3E143T-W22
1
0.75
1,800
143/5T
04516823
05018ET3E326T-W22
50
37
1,800
324/6T
04494639
00136ET3E143T-W22
1
0.75
3,600
143/5T
04702196
05036ET3E326TS-W22
50
37
3,600
324/6T
04516788
00158ET3E145T-W22
1-1/2
1.1
1,800
143/5T
04702211
06012ET3E404T-W22
60
45
1,200
404/5T
04516786
00156ET3E143T-W22
1-1/2
1.1
3,600
143/5T
04702227
06018ET3E364T-W22
60
45
1,800
364/5T
04494643
00212ET3E184T-W22
2
1.5
1,200
182/4T
04494679
06036ET3E364TS-W22
60
45
3,600
364/5TS
04516790
00218ET3E145T-W22
2
1.5
1,800
143/5T
04702253
07512ET3E405T-W22
75
55
1,200
404/5T
04516791
00236ET3E145T-W22
2
1.5
3,600
143/5T
04702268
07518ET3E365T-W22
75
55
1,800
364/5T
04516792
00312ET3E213T-W22
3
2.2
1,200
213/5T
04702314
10018ET3E405T-W22
100
75
1,800
404/5T
04516794
00318ET3E182T-W22
3
2.2
1,800
182/4T
04516796
00336ET3E182T-W22
3
2.2
3,600
182/4T
04702361
12518ET3G444T-W22
125
90
1,800
444/5T
04516798
00512ET3E215T-W22
5
3.7
1,200
213/5T
04702395
15018ET3G445T-W22
150
110
1,800
444/5T
04516801
00518ET3E184T-W22
5
3.7
1,800
182/4T
04702443
20018ET3G447T-W22
200
150
1,800
444/5T
04516804
00536ET3E184T-W22
5
3.7
3,600
182/4T
04702479
25018ET3G447T-W22
250
185
1,800
445/7T
04701810
00712ET3E254T-W22
7-1/2
5.5
1,200
254/6T
04702514
30018ET3G449T-W22
300
220
1,800
447/9T
04516805
00718ET3E213T-W22
7-1/2
5.5
1,800
213/5T
04702536
35018ET3G449T-W22
350
260
1,800
447/9T
04577924
00736ET3E213T-W22
7-1/2
5.5
3,600
213/5T
04702554
40018ET3G449T-W22
400
300
1,800
L447/9T
04701867
01012ET3E256T-W22
10
7.5
1,200
254/6T
04702570
45018ET3G449T-W22
450
330
1,800
L447/9T
04702578
50018ET3G449T-W22
500
370
1,800
L447/9T
460V
Some products may ship direct from the manufacturer. 14
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations ALABAMA Birmingham, 205/251-3231 Brewton, 251/867-6363 Decatur, 256/355-0492 Demopolis, 334/287-0611 Dothan, 334/794-2747 Gadsden, 256/543-3441 Huntsville, 256/858-5020 Mobile, 251/661-7800 Monroeville, 251/743-4814 Montgomery, 334/262-5786 Muscle Shoals, 256/383-0862 Pennington, 205/654-2975 Tuscaloosa, 205/759-4261 ALASKA Anchorage, 907/563-5565 Fairbanks, 907/452-4488 Kenai, 907/283-4452 ARIZONA Flagstaff, 928/526-3296 Phoenix, 602/269-2331 Phoenix, 602/252-3700 Tucson, 520/882-6800 Yuma, 928/782-3919 General Tool & Supply Morenci, 928/865-6294 Tempe, 480/829-3835 Tucson, 520/624-6656 ARKANSAS Blytheville, 870/763-6880 Ft. Smith, 479/646-6868 Jonesboro, 870/974-7100 Little Rock, 501/568-3116 Pine Bluff, 870/534-1177 Russellville, 479/968-3422 Springdale, 479/756-6905 Stuttgart, 870/672-4785 Texarkana, 870/774-2547 Missouri Power Transmission Batesville, 870/793-3700 Blytheville, 870/762-1131 Conway, 501/450-9333 Fort Smith, 479/783-5300 Hot Springs, 501/262-1133 Springdale, 479/751-2844 CALIFORNIA Anaheim, 714/780-1791 Anaheim, 657/208-5650 Apple Valley, 760/810-4350 Bakersfield, 661/324-6741 Chico, 530/961-9950 Concord, 925/689-9880 Fontana, 909/357-9898 Fresno, 559/237-9131 Gardena, 310/327-5070 Gilroy, 408/848-3099 Hayward, 510/266-0200 Lodi, 209/334-2530 Los Angeles, 323/728-0281 Modesto, 209/529-0261 Oxnard, 805/487-4877 Palmdale, 661/948-8436 Sacramento, 916/455-1990 Salinas, 831/758-3345 San Diego, 858/565-0092 San Fernando, 818/365-0300 Santa Clara, 408/727-6408 Stockton, 209/943-2801 Turlock, 209/549-8155 Ukiah, 707/462-9766 Victorville, 760/561-7270 Visalia, 559/651-0111 Moss Rubber San Francisco, 650/871-6566 Benicia, 707/746-1600 COLORADO Denver, 303/399-1500 Ft. Morgan, 970/867-1045 Greeley, 970/336-6481 Pueblo, 719/546-0500 CONNECTICUT E. Windsor, 860/292-6091 Wallingford, 203/294-5427 DELAWARE Delmar, 302/462-3130 FLORIDA Bartow, 863/533-0574 Clewiston, 863/983-5500 Ft. Pierce, 772/464-5537 Jacksonville, 904/757-5080 Miami/Miramar, 954/704-8565 Orlando, 407/298-0380 Panama City, 850/769-2492 Pensacola, 850/433-0021 Tampa, 813/626-1191 Miller Industrial Solutions Cocoa, 321/632-4091 Daytona Beach, 386/255-4509 Deland, 386/736-3636 Ft. Lauderdale, 954/491-6222 Ft. Myers, 239/936-6264 Ft. Pierce, 772/464-0490
©201 Motion Industries, Inc.
Jacksonville, 904/737-9919 Lake City, 386/755-4330 Lakeland, 863/701-9500 Largo, 727/536-5521 Miami, 305/593-1724 Ocala, 352/732-4141 Orlando, 407/849-6000 Perry, 850/584-2161 Tampa, 813/247-7455 West Palm Beach, 561/863-5111 GEORGIA Albany, 229/888-0910 Athens, 706/353-7780 Atlanta, 770/948-5300 Augusta, 706/724-7401 Brunswick, 912/265-0178 Cartersville, 770/387-0131 Columbus, 706/324-0313 Dalton, 706/272-3900 Gainesville, 770/532-4268 LaGrange, 706/883-7995 Macon, 478/784-0500 Norcross, 770/441-9909 Savannah, 912/236-1591 Valdosta, 229/244-4548 IDAHO Caldwell, 208/377-4334 Pocatello, 208/233-3894 General Tool & Supply Boise, 503/226-3411 Lewiston, 208/798-3239 ILLINOIS Addison, 630/627-4605 Bloomington, 309/827-0436 Bourbonnais, 815/939-4466 Champaign, 217/352-8550 Chicago S., 312/850-3700 Chicago Hts., 708/754-6300 Countryside, 708/354-5900 Danville, 217/442-8800 Decatur, 217/877-3400 East Peoria, 309/694-6214 Elgin, 847/697-3100 Elk Grove Vill., 847/616-4001 Machesney Pk, 815/654-1154 Mattoon, 217/235-7151 Melrose Park, 708/344-4433 Montgomery, 630/897-8652 Mt. Vernon, 618/241-9500 Peru, 815/223-7800 Quincy, 217/222-6168 Rockdale, 815/725-6720 Rockford, 815/874-9461 Springfield, 217/523-8337 Waukegan, 847/623-8770 W. Chicago, 630/231-4453 Wheeling, 847/459-7727 INDIANA Columbus, 812/379-2329 Crawfordsville, 765/362-7227 Elkhart, 574/293-4343 Evansville, 812/423-7701 Ft. Wayne, 260/422-6451 Gary, 219/938-9200 Hammond N., 219/931-3010 Indianapolis, 317/248-2100 Kendallville, 260/347-4135 Kokomo, 765/453-2550 Lafayette, 765/448-6600 LaPorte, 219/362-8526 Muncie, 765/288-4474 Richmond, 765/966-3528 South Bend, 574/291-0770 Terre Haute, 812/232-8344 Warsaw, 574/268-0181 IOWA Ankeny, 515/965-1065 Cedar Rapids, 319/362-9940 Davenport, 563/391-8888 Dubuque, 563/556-3022 Ft. Dodge, 515/573-5753 Ft. Madison, 319/372-6611 Muscatine, 563/263-3452 Ottumwa, 641/682-5401 Sioux City, 712/258-0595 Waterloo, 319/235-7167 KANSAS Dodge City, 620/227-6080 Salina, 785/826-9970 Topeka, 785/233-6500 Wichita, 316/942-6700 Hub Supply Wichita, 316/265-9608 KENTUCKY Bowling Green, 270/842-6195 Carrollton, 502/732-8114 London, 606/878-6312 Louisville, 502/964-4804 Owensboro, 270/926-0330 Paducah, 270/443-6291 Versailles, 859/873-7212
LOUISIANA Bogalusa-IP, 985/590-6399 Broussard, 337/837-2230 Baton Rouge, 225/356-6131 DeRidder, 337/348-5100 Gonzales, 225/644-6568 New Orleans, 504/733-5400 Ruston, 318/255-6721 Shreveport, 318/687-2110 Westlake, 337/882-6004 West Monroe, 318/387-6875 Drago Supply Geismar, 225/673-6403 Lake Charles, 337/882-0392 Voorhies Supply Abbeville, 337/898-0315 Amelia, 985/631-3609 Harvey, 504/340-2271 Houma, 985/868-4554 Houma/Enterprise, 985/873-9881 Lafayette, 337/235-7545 New Iberia, 337/364-2431 New Iberia Equipment Services, 337/364-2431 MAINE Bangor, 207/942-5571 Livermore Falls, 207/897-4877 Portland, 207/828-4727 Portland-EFI, 207/828-4716 Presque Isle, 207/764-7270 Rumford, 207/364-7933 Union, 207/785-4666 MARYLAND Baltimore, 410/687-2700 MASSACHUSETTS Marlborough, 508/229-2688 Woburn, 781/376-5850 MICHIGAN Benton Harbor, 269/926-7216 Escanaba, 906/786-8110 Grand Rapids, 616/791-9770 Jackson, 517/788-6700 Kalamazoo, 269/381-1540 Kingsford, 906/774-1100 Lansing, 517/322-0540 Livonia, 734/261-4920 Ludington, 231/845-6256 Madison Hts, 248/583-8600 Saginaw, 989/771-2270 Taylor, 734/946-3788 Traverse City, 231/929-0074 LEAT Howell, 810/632-0002 MINNESOTA Duluth, 218/628-2825 Eden Prairie, 952/828-0800 Mankato, 507/345-7856 Marshall, 507/532-0198 Mountain Iron, 218/749-8663 St. Paul, 651/631-2430 Waite Park, 320/656-1111 MISSISSIPPI Columbus, 662/328-8041 Grenada, 662/226-6800 Jackson, 601/373-3383 Laurel, 601/649-1321 McComb, 601/684-3666 Meridian, 601/482-0433 Tupelo, 662/844-2119 Lewis Supply Corinth, 662/287-6107 MISSOURI Columbia, 573/814-0654 St. Louis, 314/770-2600 Joplin, 417/781-0010 Kansas City, 816/587-8844 Sedalia, 660/826-5661 Springfield, 417/862-5300 Missouri Power Transmission Cape Girardeau, 573/335-5546 Columbia, 573/474-1446 O’Fallon, 636/474-6522 Rolla, 573/364-8009 Springfield, 417/869-4014 St. Louis, 314/421-0919 Van Buren, 573/323-1260 MONTANA Billings, 406/252-6641 Missoula, 406/542-6692 Helena, 406/449-6318 NEBRASKA Columbus, 402/562-7406 Grand Island, 308/381-2279 Lincoln, 402/467-1153 Omaha, 402/344-7323
NEVADA Las Vegas, 702/651-9490 Reno, 775/355-0555 NEW HAMPSHIRE Manchester, 603/641-5649 NEW JERSEY Kenilworth, 908/241-1047 New Brunswick, 732/828-8711 Teterboro, 201/288-8111 Trenton, 609/588-0555 NEW MEXICO Albuquerque, 505/884-2606 Roswell, 575/762-4773 Farmington, 505/325-1809 NEW YORK Amherst, 716/743-0691 Albany, 518/438-1771 Elmira, 607/734-2158 New York City, 914/235-0029 Plattsburgh, 518/438-1771 Rochester, 585/247-1121 Schenectady-GE, 518/438-1771 Syracuse, 315/452-1775 NORTH CAROLINA Asheville, 828/684-3180 Charlotte, 704/588-4100 Greenville, 252/752-6400 Hickory, 828/324-5548 Kernersville, 336/993-2974 Lumberton, 910/738-4221 Raleigh, 919/779-7400 Rocky Mount, 252/972-3096 Wilmington, 910/343-1311 NORTH DAKOTA Bismarck, 701/223-5901 Dickinson, 701/225-9221 Fargo, 701/234-9015 Fargo, 701/492-0444 Grand Forks, 701/772-7177 OHIO Canton, 330/305-1991 Chillicothe, 740/775-1226 Cincinnati, 513/533-4900 Cleveland, 216/398-2200 Columbus, 614/444-3030 Dayton, 937/236-7711 Defiance, 419/784-4013 Findlay, 419/424-1003 Lancaster, 740/687-0405 Marion, 937/644-1613 Marysville, 937/644-1613 Piqua, 937/778-1905 Sandusky, 419/625-3432 Toledo, 419/726-7422 DST Cincinnati, 513/489-3588 Dayton, 937/461-4550 Mt. Vernon, 740/392-2100 Paragon Services & Supply Lima, 419/224-1988 LEAT Euclid, 216/692-2778 OKLAHOMA Broken Arrow, 918/459-6919 Lawton, 580/248-2211 Millerton, 580/746-2225 Muskogee, 918/682-3611 Oklahoma City, 405/943-3316 Missouri Power Transmission Oklahoma City, 405/236-0594 Stillwater, 405/372-6605 OREGON Albany, 541/926-5831 Eugene, 541/342-5946 Medford, 541/732-1552 Portland, 503/460-0403 Portland, 503/239-5021 Roseburg, 541/784-9003 Salem, 503/585-7411 General Tool & Supply Portland, 503/226-3411 PENNSYLVANIA Allentown, 610/366-9034 Altoona, 814/941-8330 Lancaster, 717/393-3901 Monroeville, 412/856-8034 New Castle, 724/654-6411 Pittsburgh, 412/787-1990 Reading, 610/376-7163 Sharon Hill, 610/616-8000 Williamsport, 570/322-2439 York, 717/848-1102 PUERTO RICO Toa Baja, 787/251-1550 RHODE ISLAND Warwick, 401/736-0515
SOUTH CAROLINA Columbia, 803/796-1071 Florence, 843/395-0095 Greenville, 864/288-7503 Hanahan, 843/554-9090 Spartanburg, 864/578-1470 LEAT Greer, 864/877-1313
Madison, 608/221-3328 Marinette, 715/732-1714 Milwaukee S., 414/649-2400 Portage, 608/742-5129 Racine, 262/554-0110 Sheboygan, 920/208-5600 Waukesha, 262/896-3880 Wausau, 715/848-2994
SOUTH DAKOTA Sioux Falls, 605/334-5333 Watertown, 605/886-4114
WYOMING Gillette, 307/682-8821 Mills, 307/266-2966 Rock Springs, 307/212-3300
TENNESSEE Chattanooga, 423/490-0852 Cookeville, 931/528-3797 Jackson, 731/423-4941 Kingsport, 423/349-5092 Knoxville, 865/546-1704 Memphis, 901/398-2000 Morristown, 423/587-6156 Murfreesboro, 615/895-0114 Nashville, 615/228-4020 Tullahoma, 931/454-0907 Lewis Supply Jackson, 731/424-5656 Memphis, 901/525-6871 TEXAS Abilene, 817/838-7878 Amarillo, 806/372-5300 Arlington, 817/277-5516 Austin, 512/989-5888 Brownwood, 325/643-9923 Bryan, 979/822-1656 Corpus Christi, 361/289-1773 Dallas, 214/351-2211 El Paso, 915/779-3335 Ft. Worth, 817/838-7878 Friona, 806/250-5450 Garland, 972/278-0220 Groves, 409/962-7575 Houston Petroleum Bearing, 713/956-0150 Laredo, 956/718-2229 Longview, 903/757-2383 Lufkin, 936/634-4428 Odessa, 432/362-7315 Freeport, 979/233-6476 Pasadena, 281/542-1660 San Antonio, 210/662-6772 Sherman, 903/892-4646 Temple, 254/773-4224 Tyler, 903/592-0873 Victoria, 361/576-0015 Waco, 254/772-1119 Weslaco, 956/546-5191 Wichita Falls, 940/766-3328 Drago Supply Houston, 281/471-7026 Port Arthur,409/983-4911 Hub Supply Amarillo, 806/341-3139 Ft. Worth, 817/602-2084 UTAH Logan, 435/753-7310 Ogden, 801/732-1881 Salt Lake City, 801/972-1036 VERMONT Barre, 802/622-3400 VIRGINIA Chesapeake, 757/487-0311 Covington, 540/962-7161 Harrisonburg, 540/434-1919 Lynchburg, 434/239-7111 Manassas, 703/393-2314 Richmond, 804/743-8000 Roanoke, 540/362-7695 Winchester, 540/662-4800 WASHINGTON Bellingham, 360/752-3303 Longview, 360/425-4650 Moses Lake, 509/765-4367 Pasco, 509/547-0721 Seattle, 206/762-3800 425/656-8307 Spokane, 509/924-4800 Tacoma, 253/572-7070 Vancouver, 360/750-1464 General Tool & Supply Mukilteo, 425/249-5660 Seattle, 206/762-1500 Spokane, 509/924-4800 WEST VIRGINIA Beckley, 304/254-0443 Charleston, 304/744-0201 Fairmont, 304/368-6300 Huntington, 304/525-6706 WISCONSIN Appleton, 920/731-4121 Eau Claire, 715/833-2440 Fond Du Lac, 920/923-7500 Green Bay, 920/983-6604 Janesville, 608/754-4199 La Crosse, 608/785-1200
MOTION CANADA ALBERTA Brooks, 403/501-3888 Calgary, 403/236-5581 Drayton Valley, 780/542-4814 Edmonton South, 780/465-0821 Edmonton North, 780/483-7775 Fort McMurray, 780/743-5504 Fort Saskatchewan, 780/992-6940 Grande Prairie, 780/539-5900 Lethbridge, 403/327-1571 Lloydminster, 780/875-2399 Nisku, 780/955-7494 Red Deer, 403/343-6733 BRITISH COLUMBIA Abbotsford, 604/556-0716 Burnaby, 604/637-2860 Coquitlam, 604/927-5800 Cranbrook, 250/426-8060 Fort St. John, 250/787-0656 Houston, 250/845-3308 Kamloops, 250/372-9518 Kitimat, 250/632-7107 Nanaimo, 250/753-6411 Prince George, 250/563-0452 Quesnel, 250/992-7935 MANITOBA Brandon, 204/725-1419 Winnipeg, 204/694-0050 NEW BRUNSWICK Hartland, 506/375-4441 Moncton, 506/859-4345 NOVA SCOTIA Dartmouth, 902/468-3231 New Glasgow, 902/755-3540 ONTARIO Belleville, 613/966-1923 Brockville, 613/342-8894 Guelph, 519/763-0710 London, 519/681-5800 Mississauga, 905/695-7878 North Bay, 705/476-3109 Ottawa, 613/723-6200 Sarnia, 519/332-4500 Scarborough, 905/695-7878 Waterloo, 519/884-1220 QUEBEC Pointe-Claire, 514/459-3301 Quebec City, 418/657-3000 Rimouski, 418/725-3750 Saguenay, 418/696-1221 Sept-Îles, 418/962-3232 Sherbrooke, 819/563-5732 St-Hubert, 450/445-0633 St-Hyacinthe, 450/774-3050 Trois-Rivières, 819/374-2788 SASKATCHEWAN Hudson Bay, 306/865-2245 Regina, 306/721-7233 Saskatoon, 306/931-7771 MOTION MEXICO For All Mexico Branches From Mexico, 81-8321-5100 From U.S., 011-52-81-8321-5100 CA Saltillo CH Chihuahua DF Mexico City GT Silao JA Guadalajara NL Monterrey QE Queretaro
PRSRT STD U.S. POSTAGE PAID MARIETTA, GA PERMIT No 774
1605 Alton Rd., Birmingham, AL 35210 Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations
SPEED REDUCERS
MRO SOLUTIONS
Right Angle Helical Bevel Speed Reducer
Inline Helical Speed Reducer
Ultramite®
Ultramite®
Base Mounted
Base Mounted
• 1/4 hp to 300 hp (0.19 kW to 37 kW) capacity, maximum torque 292,000 in-lbs • Ratios from 8:1 up to 10,000:1 • C-face and solid inputs, inch or metric • Solid or hollow outputs with TA taper bushings (exclusive lifetime removal guarantee) • Base, shaft, or flange mounted designs • Horizontal or vertical mounting • Triple reductions
• 1/4 hp to 100 hp (0.19 kW to 37 kW) capacity, maximum torque 44,000 in-lbs • Ratios from 1.4:1 up to 12,000:1 • C-face and solid inputs, inch or metric • Base or flange mounted designs • Horizontal or vertical mounting Mi Item #
Mfr Part #
Drive Size Reductions
Ratio
Input Type
4.361:1 4.392:1 4.559:1 177.0:1
140TC 210TC 250TC 180TC
Output Shaft: Straight Solid, Flange Mounted Mi Item #
Mfr Part #
Drive Size Reductions
Ratio
Input Type
Output Shaft: Straight Hollow Bore w/Shrink Disc 02484947 02484703 02484705 02484717 02484831 02484622
10UBBR3A20.A E 08UBBR3A28.N 08UBBR3A32.A D 08UBBR3A40.A D 09UBBR3A50.A D 07UBBR3A50.A C
10 08 08 08 09 07
Triple Triple Triple Triple Triple Triple
20.05:1 250TC 28.56:1 Input Shaft 33.24:1 210TC 40.36:1 210TC 49.87:1 210TC 54.28:1 180TC
08 08 08 08 08 08 08
Triple Triple Triple Triple Triple Triple Triple
25.35:1 40.36:1 40.36:1 62.47:1 62.47:1 98.08:1 98.08:1
210TC 180TC 210TC 180TC 210TC 180TC 140TC
08 09
Triple Triple
36.88:1 38.16:1
250TC 250TC
Output Shaft: Taper Hollow 02484275 08UBBJ3A25.0A D 02484286 08UBBJ3A40.A C 02484287 08UBBJ3A40.A D 02484292 08UBBJ3A63.A C 02484293 08UBBJ3A63.A D 02484298 08UBBJ3A100.A C 02484297 08UBBJ3A100.A B
04840556 04841156 04841586 00821786
03UCFN2B4.5A B 06UCFN2B4.5A D 08UCFN2B4.5A E 09UCFN3A180AC
03 06 08 09
Double Double Double Triple
Output Shaft: Straight Solid, Foot Mounted 04840553 03UCBN2B4.5A B 04781469 03UCBN2B4.5 A A 04841152 06UCBN2B4.5A C 04841153 06UCBN2B4.5A D 04841315 07UCBN2B4.5A D 04841316 07UCBN2B4.5N 04840753 04UCBN2B4.5N 04840750 04UCBN2B4.5A A 04840752 04UCBN2B4.5A C 04840751 04UCBN2B4.5A B 04841583 08UCBN2B4.5N 04841582 08UCBN2B4.5A E 04848245 204UCBN2A36 A A
03 03 06 06 07 07 04 04 04 04 08 08 204
Double Double Double Double Double Double Double Double Double Double Double Double Double
4.361:1 140TC 4.361:1 56C 4.392:1 180TC 4.392:1 210TC 4.484:1 210TC 4.484:1 Input Shaft 4.537:1 Input Shaft 4.537:1 56C 4.537:1 180TC 4.537:1 140TC 4.559:1 Input Shaft 4.559:1 250TC 35.25:1 56C
Output Shaft: Inch Hollow 02484250 08UBBQ3A36.AE 01648979 09UBBQ3A40.A E
https://tinyurl.com/jhtq85f
©2017 Motion Industries, Inc.
0M0317 00003W12457
Alarm management design: Meeting the standards Realize the advantages of planning before installation. By Melissa Topp Iconics
Alarm management is a necessity in automated process environments, such as in product manufacturing or facility maintenance. Although, each monitored process differs for each customer, there is some common ground. Every stakeholder in the alarm management process starts with an idea of how the alarm system should operate. The catch is that these ideas are often built on internal, companyspecific solutions. A more comprehensive alarm management solution, even one that meets industry standards such as ISA 18.2: Instrument Signals and Alarms, requires commitment on the part of the end user.
Implementing alarm management systems
Organizations initiating a review of alarm management systems, or redesigning an existing implementation, should take some time at the beginning of the planning phase to consider expectations of alarm priorities, frequency, and postalarm actions. Without early planning, operators might experience unexpected alarm overload due to a lack of clearly set prioritization or proper follow-up procedures for a wide array of alarm types. Or, at the other extreme, critical operational data could be missed if the right alarm messages are not sent. There are basic requirements in the design phase of an alarm management system. Designing an alarm system is an iterative and cyclical process, involving the addition or removal of information from three parts: generation, history, and presentation. During this initial design phase, www.plantengineering.com
customers need to balance the desire to cover all possible alarm contingencies with the need to limit the amount of information that needs to be processed. If there are too many alarm messages, the system will be unusable, and if there aren’t enough alarm messages, critical data could be missed. At the start, it is recommended that the alarm management system should err on the side of containing too much data, because it is easier to filter out excess data than to try and guess what data is missing. During the initial implementation stages, there may be some obstacles to overcome such as not having enough computer resources dedicated to alarm management or having customized displays. One solution could be to create a few generic displays that can be customized based on specific operations (such as aliasing, filtering, logging on users, etc.), rather than customizing all displays. This saves time in implementation and application maintenance.
Alarm management system features
Periodically, users should evaluate the alarms that are being sent through the Mobile HMIs can provide remote access access to alarm information. Image courtesy: Iconics
system to see if they are necessary for process management. Users should be able to figure out which alarms can be lowered in priority, filtered out of alarm overviews, temporarily disabled, or removed entirely. It is recommended that users select an alarm management system that follows ISA 18.2 guidelines. Such industry standards set customer expectations while still enabling vendors to create customized solutions for end users. Use of industry standards allows customers to feel confident that a chosen system can achieve optimal results. In addition to adhering to industry standards, there are other recommended features that users should explore. These include several processes that help reduce alarms in the system without permanently removing the alarms from configuration (such as suppression, out of service, disabling, or filtering). These features allow for a wide variety of choices in reducing the load on the system while preserving the original configuration to “undo” any changes, if needed. Customers should also be wary of some features, such as tying alarms to popular social media platforms. Many customers are dissuaded from this feature after realizing that proprietary information could be considered owned by the social media platform once it is published. With an early plan and attention to details, such as understanding common maintenance tasks, industry standards, and the latest time-saving features, alarm management can become a beneficial tool to help optimize operations. PE Melissa Topp is the director of global marketing at Iconics Inc. PLANT ENGINEERING
March 2017 • 17
IN fOCUS Standards: Process automation interoperability by 2021 Interoperability is needed for process automation, as explained at the ARC Forum in February, to gain a standards-based open, secure, interoperable process automation architecture by 2021. By Mark T. Hoske Content Manager, CFE Media
More end-user input is needed to help create an open, secure, interoperable process automation architecture, commercially available by 2021, said Don Bartusiak, ExxonMobil research and engineering chief engineer, process control, at the ARC Advisor y Group’s 2017 Forum, in Februar y. The Open Process Automation Forum started in 2016 to address these issues, and the industry initiative has moved beyond ExxonMobil, involving 57
attendees from 30 member companies at the Nov. 16-17 meeting, Bartusiak said. Companies include end users, distributed control system (DCS) vendors, hardware and software vendors, system integrators, and others. About 89% of automation companies are represented, and only about 1% of the end user companies are represented, Bartusiak said. “We need more end users.” Why? “Participants can win in their next generation of DCS implementations with participation,” Bartusiak suggested.
Olive oil is good for you. Compressor oil is not.
In 2010, ExxonMobil started a research and development initiative to explore replacement of the refining and chemical plant DCS fleet in use at the company within 15 years. State-of-the-art DCS won’t address business problems because of technical and commercial factors, Bartusiak said; the vision is to have standardsbased, open, secure interoperable process automation architecture, commercially available and ready for use by 2021. Through the initiative, ExxonMobil: • In 2014, developed functional characteristics to engage industry • In 2015, contracted with Lockheed Martin to define functional requirements and build a prototype • In 2016, formed the Open Process Automation Forum to develop a standards-based, open, secure, and interoperable process control architecture fit for end-user needs, with adaptive security, and easy integration. That means: • Best-in-class components; timely, leading-edge performance
Protect your product, your packaging and your reputation.
Premium Efficient OIL-FREE Compressors
• Conformant components integrated for systems that are fitfor-purpose for end user’s needs • Adaptive intrinsic security • Commercially available applications with multiple industry sectors
input #14 at www.plantengineering.com/information
800-394-6151
knw-series.com
Rogers Machinery Company, Inc.
Proudly Made in the U.S.A.
18 • March 2017
plant engineering
• The ability to protect suppliers intellectual property • Portable end-user software • Simplified replacements; reduced lifecycle cost • Markets for suppliers’ and systems integrators for components and services expansion • Innovation and value creation.
Prototype in early 2018
Requirements include a universal bus against which applications can draw data. The next steps are to build proofof-concept prototypes, establish standards, and build commercial systems. On the proof of concept with Lockheed Martin, Jan. 26, 2016, was a request for information; 53 responses were received in February. Work includes trade studies, system requirements for version 1, commercial agreements, request for proposals for prototype went to 82 suppliers and system integrators on Dec. 22, 2016, with responses due by Feb. 13, 2017. Between version 1 in the first quarter 2018 and version 2 in mid-2019 will be a conformance certification program to ensure interoperability. Five of the top 50 U.S. federal system integrators are members of the group. ExxonMobil experiences with system integrators on control system projects have been favorable, Bartusiak said. Suppliers also will benefit from standardization by reducing systemic costs, increasing margins by specializing on differentiating advantages, and increasing revenue by expanding markets. Forces of change include greater use of, and interest in, standards, technology, cybersecurity threats, regulations, new market entrants, customers, and substitutes for traditional technologies.
able applications, Bartusiak said, not now available in process controls. “The 20-year process control technology refresh starts now. If we only refresh every 20 years, how are we going to keep up with cybersecurity threats?” he asked. Thin k again of p ast st andards efforts; the best ones demonstrate
that they must be driven by many actively participating customers to create success, Bartusiak said. Please participate. PE Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
Performance Meets Peace of Mind. Guaranteed. Engineered for precision and power, the Model 850 picks up even the finest powders, anywhere in your plant. With clean, HEPA-filtered exhaust air, a streamlined filter cleaning system, a continuous bagging system, and a performance guarantee—it’s more than a cleaning system; it’s a business asset.
VAC-U-MAX MDL-850 Continuous-Duty Industrial Vacuum • Continuous-bagging system • Eliminates manual dumping of drums & collection containers • Available in 2.5HP, 5HP and 8.5HP • Features PTFE-coated primary filter & standard HEPA secondary filter • Faster discharge time of collected dust & debris. • Closed bags prevent fugitive dust clouds
Let us solve your industrial vacuum cleaning challenges. Visit vac-u-max.com/vacuum or call 800-VAC-U-MAX.
Non-standard railroad tracks
“We’re at the point now in plant efficiency like when railroads had different track sizes. Would you accept cell phones that couldn’t communicate to other vendors?” Smartphones add considerable value through interoperplant engineering
March 2017 • 19
WET/DRY • AIR OPERATED AND ELECTRIC DRUM-TOP • CONTINUOUS DUTY • COMBUSTIBLE DUST CENTRAL SYSTEMS • CONTINUOUS-BAGGING • LIQUID & SLUDGE • FLAMMABLE LIQUIDS SUBMERGED RECOVERY • METALWORKING • PHARMACEUTICAL • STEEL SHOT INTERCEPT HOPPERS & PRE-SEPARATORS • HSE / INDUSTRIAL HYGIENE SOLUTIONS
input #15 at www.plantengineering.com/information
MAPCON Mobile CMMS
IN fOCUS
CSIA Executive Conference hits Ft. Lauderdale May 2-5 More than 500 control system integrators and industry suppliers from around the world will gather in Fort Lauderdale, Fla. On May 2-5 for the annual Control System Integrators Association (CSIA) 2017 Executive Conference. With a theme of “From Best Practices to Transformative Business Models,” the conference will include over a dozen educational sessions, including several presented as part of two tracks.
Track 1: Small Company SIs and Best Practices
CSIA’s Best Practices have helped hundreds of system integrators grow from younger, smaller companies into the wellestablished ones they are today. Attendees will learn how they, too, can use CSIA Best Practices for growth.
Track 2: Transformative Business Models
(800) 922-4336 • mapcon.com input #16 at www.plantengineering.com/information
Technology is creating a very exciting future filled with opportunity for SIs — opportunities that will require a shift away from traditional SI business models. Through a series of presentations, panel discussions and an unconference, SIs will gain an understanding of how to take advantage of these emerging models. In addition to the educational sessions included during the conference, CSIA will offer a two-day intensive training workshop on Best Practices implementation prior to the start of the conference on May 1-2. Those attending the conference will have opportunities for networking, including the annual industry expo, awards banquet and a closing reception. The CSIA Fun Run/Walk will be held again this year, along with other special events and tours. See complete details and register at the CSIA 2017 Executive Conference Website. PE
February PMI leaps to 57.7% Rotating Union Expertise for the Most Complex Applications From DEUBLIN, the world leader in rotating union solutions. DEUBLIN offers both stock items, or unions engineered to your unique requirements. And you can count on the cost savings generated by precision engineering, and the highest quality components.
Visit WWW.DEUBLIN.COM to Select and Order Your Union Today!
847-689-8600
customerservice@deublin.com
www.deublin.com
input #17 at www.plantengineering.com/information
New orders and production levels continue to drive the manufacturing industry’s growth as they reached new highs in February. As a result, the Institute for Supply Management’s purchasing manufacturers’ index (PMI) jumped another 1.7 percentage points in February to 57.7%. The new orders index had a huge growth of 4.7 percentage points to 65.1%, the third straight month that index was above 60%. The production index jumped 1.5 percentage points to 62.9%. The only down note was the employment index dropping 1.9 percentage points to 54.2%. Overall, though, the manufacturing industry looks very busy and strong with 17 of the 18 industries reporting growth in February. “Comments from the panel largely indicate strong sales and demand, and reflect a positive view of business conditions with a watchful eye on commodities and the potential for inflation,” said Bradley Holcomb, chairman of the Institute for Supply Management’s manufacturing business survey committee. While the PMI has been above the growth level of 50% for 10 of the last 11 months, the February reading of 57.7% marked the sixth consecutive month of growth, and the fifth straight month growth rate exceeded 1.0 percentage points. PE
20 • March 2017
plant engineering
ONE SOURCE FOR
POWER
Your Northeastern Region Cat® Dealer is your single source for all of your power systems, compressed air and temperature control needs 24/7 – 365 days a year. Whether it is an emergency outage or a planned maintenance, we’re your one stop for commercial, industrial, institutional and manufacturing power systems solutions. In addition, we have all of the ancillary equipment including distribution cables, transfer switches, load banks, distribution panels and cable ramps. We’re the premier source for all your temporary power requirements… anytime, anywhere. To learn more, visit NECatDealers.com/power
SALES • RENTAL • SERVICE • PARTS SINCE 1927 Alban CAT www.albancat.com Baltimore, MD 800-492-6994
SINCE 1948 Cleveland Brothers
SINCE 1923 H.O. Penn Machinery
SINCE 1960 Milton CAT
SINCE 1916 Ransome CAT
www.clevelandbrothers.com Murrysville, PA 800-538-1020
www.hopenn.com Poughkeepsie, NY 844-CAT-1923
www.miltoncat.com Milford, MA 866-385-8538
www.ransome.com Bensalem, PA 877-RANSOME
input #18 at www.plantengineering.com/information © 2017 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com www.caterpillar.com
REDEFINING
HIGH-PERFORMANCE SYNTHETIC GEAR LUBRICANTS
Lubriplate
®
SYNTHETIC GEAR OILS
SYN LUBE SERIES High-Performance, 100% Synthetic, Polyalphaolefin (PAO)-Based Fluids. Compatible with Petroleum-Based Oils for Easy Conversion. Available in ISO Grades 150 through 1000.
Follow-Up Oil Analysis Monitoring Service Is Included At No Additional Cost On All Lubriplate Gear Oils.
3
SYN LUBE HD SERIES Heavy-Duty, Polyalphaolefin (PAO)-Based Synthetic Gear Lubricants. Meets AGMA EP (Extreme Pressure) Requirements. For Heavy-Duty Applications.
SYNTHETIC WORM GEAR LUBRICANT 100% Synthetic, Polyalphaolefin (PAO)-Based Fluid, ISO 460 Grade. Formulated Especially for Worm Gear Applications. Provides Excellent Oxidation Resistance.
PGO & PGO-FGL SERIES Ultra High-Performance, Polyalkylene Glycol (PAG)-Based, Gear Lubricants. ECO-Friendly - Extended Service Life, Energy Conserving. PGO-FGL Series is NSF H1 Registered, NSF/ISO 21469 Certified, Food Grade.
SFGO ULTRA SERIES NSF H1 Registered, NSF/ISO 21469 Certified, Food Machinery Grade. High-Performance, 100% Synthetic, H1 Fluids. Provides Excellent Oxidation Resistance.
PGO-FGL and SFGO ULTRA SERIES OILS Are Fortified With Lubriplate’s Proprietary Food Grade Anti-Wear Additive
Backed By:
Lubriplate ®
ESP
Complimentary Extra Services Package Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 www.lubriplate.com / LubeXpert@lubriplate.com
Plant Surveys / Tech Support / Training Color Coded Lube Charts & Machine Tags Lubrication Software / Follow-Up Oil Analysis
input #19 at www.plantengineering.com/information
.
2017MAINTENANCESURVEY
HELP WANTED:
More training, equipment upgrades Maintenance is crucial, but a lack of resources is an issue. By Bob Vavra Content Manager, CFE Media
T
here is a strong message from Plant Engineering readers in the 2017 Maintenance Survey: equipment upgrades and more maintenance training would go a long way to decreasing downtime. But the failure of plant management to address that fundamental issue is seen as a barrier to realizing those improvements. The 2017 Maintenance Survey polled Plant Engineering leaders on the challenges and opportunities available in an improved maintenance process. Of survey respondents, 42% said aging equipment was the leading culprit behind unscheduled downtime in their plant; another 19% cited operator error, and 13% said there was not enough time to perform proper maintenance. Respondents also were clear on how to address these issues: • 61% said upgrading equipment would decrease unscheduled downtime • 49% said improved and increased maintenance training would address the issue • 48% said using a preventive maintenance strategy would lower downtime
www.plantengineering.com
• 42% saw an opportunity to improve uptime by expanding monitoring capabilities. There was pessimism, however, as to whether this issue would be addressed in the near future. The biggest challenge, cited by 52% of respondents, was a lack of resources and staff. Outdated technology was mentioned by 37%, with a lack of training, the needs of new maintenance, available funding and a lack of support of management all were called out by about one-third of survey respondents. “It’s a tight job market, especially when to comes to the skills we’re looking for in high tech,” said Jeff Owens, CEO of Advanced Technology Services (ATS), which co-sponsored the survey. “We offer specialized training programs, and we’ve outfitted our technicians with tablets and technologies to help them solve complex machine problems.” In the area of maintenance training, safety is the predominant consideration, with 81% of respondents mentioning it. Basic mechanical and electrical skills are covered in about two-thirds of all training. Motors, lubrication and PLANT ENGINEERING
March 2017 • 23
2017MAINTENANCESURVEY predictive maintenance were cited by more than half of the plant personnel surveyed. Another area of discussion is the amount of maintenance being outsourced to third-party companies. While 13% of respondents said they do not outsource any maintenance functions, 65% said they outsource at least 30%, and 18% bring in outside help for more than that. Maintenance and plant managers cite a lack of time and personnel, and a lack of in-house specialized skills as the leading reasons their maintenance function is provided at least partially by third-party vendors. While budget costs are another factor in outsourced maintenance, 30% of managers said skilled maintenance professionals simply were not available for them to hire. “As factories becomes increasingly automated, maintenance is becoming critical to operations, and more companies are considering it a non-core function,” Owens said. “They’re feeling less ownership over it, and instead have begun to focus on things their customers touch and feel, such as product design and features.”
What gets maintained?
The Maintenance Survey also found a difference in which areas of the plant get the most attention from maintenance teams. Rotating equipment, such as motors and power transmission, got a lot of attention in 63% of plants, electrical distribution systems only received that level of attention 38% of the time. Automation systems and fluid power equipment also received a high level of attention from more than half of respondents. While most plant and maintenance managers are using technology to help in their maintenance processes, technology has not been fully embraced in all areas of the plant. A computerized maintenance management system (CMMS) is in use in 53% of plants, and another 52% used in-house spreadsheets and schedules to plan maintenance. But the age of the clipboard is far from over; 39% said they still use paper records as part of their maintenance process.
impact on decreased downtime (69%), reduced probability of failure (66%), overall equipment effectiveness (63%), improved safety (62%) and overall efficiency (59%). Predictive maintenance ranked highest for decreasing downtime (73%) and reducing failures (73%), while CMMS got the highest mark for overall efficiency (65%). Those maintenance processes still tend to be a hybrid across a plant, with several strategies in place at once. But in a day where prescriptive maintenance is on the horizon, more reactive maintenance strategies still prevails. Preventive maintenance is used in 78% of plants, while a fully reactive (run to failure) plan exists in 61%. The use of CMMS systems follow, but just 47% of plants use an analysis-based predictive maintenance system, and only 28% use reliability-centered maintenance.
IIoT and mobility
Two technologies that are being closely watched in maintenance management are the use of handheld devices and the Industrial Internet of Things (IIoT). Plant Engineering’s 2016 Salary Survey released last month found 64% of readers felt that IIoT would improve their maintenance management; the Maintenance Survey found similar sentiments. While 20% felt IIoT would have no impact on their maintenance operation and 24% were unsure what impact it might have, 32% believe it will help understand machine health, 30% said it would change the way plant maintenance is conducted and 27% said it would better help predict and prevent downtime. Mobility is another area where opinions vary widely. While 29% of respondents said they have no plans to use mobile devices in their maintenance function, 27% are studying such a deployment, 12% use mobility for scheduling, and 9% said mobile devices are fully implemented in the maintenance department. PE
The benefits of strategy
A run-to-failure strategy in the plant has one distinct advantage over other plant maintenance strategies—its low initial cost, as cited by 61% of respondents. But it gets very low grades for just about every other areas of maintenance benefits, including productivity, downtime and safety. On the other hand, plant and maintenance managers like preventive maintenance for its
24 • March 2017
PLANT ENGINEERING
www.plantengineering.com
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 25
2017MAINTENANCESURVEY
26 • March 2017
PLANT ENGINEERING
www.plantengineering.com
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 27
MAINTENANCESOLUTIONS
Digital training for tangible results Turning computer-based training into improved operations
W
By Jerry Wanichko T.A. Cook North America
Figure 1: The ingredients of a learning program that lasts. Image courtesy: T.A. Cook
28 • March 2017
hether it’s a new task or just a new way to do an old task, operations employees should frequently update and improve their skills. Regardless of industry, no one is ever finished learning—especially for those in charge of executing robust plant processes. Once a hazardous situation arises on the site-floor, it’s too late for training. Staff need to be able to think critically and solve problems quickly. If they are not aware of all aspects of plant operations, it will cost the company a lot in wasted time, opportunity and most importantly, safety. To communicate effectively the plethora of critical information to operations personnel, sites should consider digitizing their operating manuals and implementing a targeted computer-based training (CBT) program. A CBT program can help streamline coaching for operations personnel and front-line supervisors. If used as a complement to practical on-site training, the team will be more aware of the details and key information regarding equipment and specific processes. There are many advantages of CBT compared to a conventional classroom. It offers an ideal platform to create engaging, interactive courses with the help of images, audio elements, animations and videos. There is much more flexibility in regards to location and pace of learning. And, after what might be a high implementation cost, t he retur n on investment should
PLANT ENGINEERING
be high because there is no limit to the number of trainees that can take part. Also, updating the material is easy. A successful, efficient CBT program can influence a plant’s operational results.
Setting up a CBT program
Creating a comprehensive, CBT plan is a labor-intensive task. Ideally, a seasoned plant engineer will write the content and operations management and other engineering personnel will review it. To compile the necessary information, the developers must gather source material from all operation processes—everything from the piping and instrument diagrams to the control valve specifications. The program also should include site visits for formal demonstrations and equipment observations to give trainees an opportunity to get hands-on experience and help them retain what they’ve learned in the lessons. It is important that supplementary in-person course work is presented by credible instructors and plant operations engineers. Operation training programs should touch on topics such as safety procedures, process descriptions and control. Each program should begin by communicating the program learning objectives, with the final goal being positive behavioral change. Part of establishing a CBT program is identifying the exact behavioral goals a site hopes to achieve. Is there new equipment employees should learn how to use? Or a new in-house performance review system they need to be familiar with? A plant can create a CBT course on any subject that they might deem appropriate as long as the course’s content is aligned with specific work competencies.
Identifying site needs
The CBT developers must truly know their staff to determine what behavioral changes and critical information deficiencies their www.plantengineering.com
education courses should address. Historical data analysis, questionnaires and surveys, as well as talking directly to employees about their training needs and wants will help develop a program that fits a site’s specific requirements and yield tangible results. Any broad differences between an employee’s current skill level and his or her desired level should be addressed and the training courses tailored in a way to help fill these knowledge gaps. It will be easier to bridge any conceptual or practical knowledge if the training courses are grouped by function and area of responsibility. An assessment survey, based on an individual’s role, gives a comprehensive overview of employees’ skill set. By compiling the results into one document, the entire workforce’s strengths and weaknesses are put into perspective. Whether or not an individual worker is above or below average will most likely be based on bottom-line results, organizational efficiency and personal career development. With this information, it is easier for employees to only devote their time completing need-specific CBT. Digital learning gives the opportunity to “test out” of course sections so trainees will not waste time going through material they may already be familiar with. In fact, periodic testing and review throughout the program will help give an overall sense of whether the program is successful or not. For the program to be complete, each trainee must demonstrate their newly acquired skills. All these parts of the plant’s long-term training plan will play an important part in continuous improvement. Luckily, as the workforce and marketplace change, CBT developers can update the course information thanks to the convenience of digitized media.
Application
In addition to personalized content, CBT gives trainees the freedom to complete programs in their own way and at their own pace. As in any learning course, the more difficult or complex the content, the more important it is that individuals manage their cognitive load. Employees should be responsible for establishing their daily study routine to find what works for them. If trainees can take it upon themselves to learn all that a CBT program offers, they will be much better equipped to make judgements wisely and instantaneously when they are doing their jobs. www.plantengineering.com
In addition to a personalized routine and the plant’s A CBT program can supportive environment, the practical application (Figure help streamline 1) of what the CBT courses must offer will help trainees coaching for connect any theoretical techniques to everyday work tasks. operations personnel Once new material is digested, trainees should have the and front-line opportunity to do a simulation to demonstrate new skills supervisors. and use problem solving in a controlled environment. All the procedures associated with operations are important for plant permit requirements, so it is imperative that staff are fully prepared when they are on site. Once personnel move from training to the shop floor, they will not have a safety net. Spending some time in the field as part of the training routine helps put the team at ease and makes them more comfortable to solve problems as they arise. Once operators have completed training and have demonstrated that they have mastered all learning objectives, they should be much more capable of safely carrying out their on-site duties. Trial and error is not a costeffective learning technique and thus represents a massive opportunity expense for a site. CBT cannot replace all traditional maintenance training methods, but it can certainly act as a complement to guide staff improvement. Although workbooks and seminars have value, online learning is the wave of the future for staff education. Even though business is universal, determining the best way to develop a team is industry-dependent and must be site-specific. Between the ability to offer online material to many employees at once to the ability and quickly update material to reflect any new developments, CBT will reduce training costs in the long run and put a plant in a more competitive position. PE
“
”
Jer r y Wanichko is direc tor of con sult ing operations for T.A. Cook North America with more than 25 years of international consulting experience. plant engineering
March 2017 • 29
REIMAGINED WITH PROS IN MIND.
SEE PROBLEMS CLEARLY WITH THE RE-IMAGINED, SIMPLE-TO-USE
FLIR E75, E85, and E95 cameras offer the superior resolution and range performance needed to quickly identify hotspots and discover potential points of failure in electrical distribution and mechanical systems. Avoid costly shutdowns and lost production time through regular predictive maintenance routines with these rugged, intuitive cameras. Learn more at FLIR.com/exx-series.
input #20 at www.plantengineering.com/information
COVERSTORY
Robots, humans collaborate on safety A new age of collaborative robots put people closer to technology than ever before. By Tanya M. Anandan Robotic Industries Association (RIA)
While moving a collaborative robot’s arm to “teach” it a task is an important part of collaboration, it’s not the same as hand guiding a robot, one of the four methods of collaborative operation. Image courtesy: RIA/Yaskawa
In 2008, they were a mere curiosity. In 2012, they were largely viewed as a fad. But just a year later, the industry began to take note. A slew of rivals and suitors entered the fray in 2013. Now, collaborative robots are here to stay. Many would say they’re the future. Continued on page 32
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 31
CoverStory “Collaborative applications is that next new frontier and it’s really going to drive business and applications, and probably applications we don’t even know yet,” says Roberta Nelson Shea, global technical compliance officer for Universal Robots, headquartered in Odense, Denmark. An ABI Research study predicts the collaborative robotics market will surge to $1 billion by 2020, populating manufacturing with more than 40,000 collaborative robots. As that population grows, so does concern over robotics safety. One of the most anticipated technical specifications in the collaborative robotics realm was released in February 2016. ISO/ TS 15066:2016 Robots and Robotic Devices – Collaborative Robots provides data-driven guidelines for designers, integrators and users of human-robot collaborative systems on how to evaluate and mitigate risks. Nelson Shea is convener for the ISO Technical Committee 299 Working Group 3 (ISO/TC 299 WG3) that was responsible for developing the new technical specification. Nelson Shea has been involved with the robot safety standards since the first committee meeting in 1982, and as convener for ISO/TC 299 she continues to hold an impartial position in the standards community. She was chair of the ANSI/RIA 15.06 robot safety standards committee for 23 years, and is now chair emeritus. She said the initial idea of collaborative robotics was met by strong skepticism. “The premise about safety was to keep people away from robots. But then the conversation changed to say if the robot with its tool and part touches you and there’s no injury, why not allow contact?”
“Sawyer was grabbing parts and putting them in the assembly. But the human was making sure it was
fitting properly and inserting the last screws, using what humans are good at—dexterity, perception and logic. For us, elevating the role of the human on the assembly line to focus on quality—to focus on the
”
value-added—is very important.
Roland Menassa, leader of GE’s Global Research Automation Center
32 • March 2017
plant engineering
Factoring in people
“Traditionally, the design of automated systems has not factored in people. But with robots becoming mobile and developing a greater capacity to interact with humans, that design paradigm is not the way of the future,” said Roland Menassa, leader of GE’s Global Research Automation Center in Van Buren Township, Mich. “Now I can place a robot with fairly decent capability on the factory floor next to people and they can operate side by side,” he said. Menassa spent 24 years with General Motors. Now he is GE’s resident automation advocate. The Global Research Automation Center focuses on four main areas: robotics, controls, material handling, and work system integration, which tracks the flow of data on the factory floor. GE has embraced the Industrial Internet of Things (IIoT) and automation as a key ingredient. It’s taking the lead on factory optimization, or what it calls Brilliant Manufacturing, to optimize the flow of materials, people and processes within the organization and across its global supply chain. “When I came to GE, collaborative robots were starting to move on the market, so I visited different factories within GE to do an assessment,” said Menassa. “We are either a low-volume manufacturer of very large industrial goods such as gas turbines that weigh thousands of pounds, or human-scale, mid- to high-volume products like lighting fixtures and circuit breakers, where you have hundreds of SKUs on the line. “We’re still going to weld and have robots handling heavy equipment and performing very difficult processes,” Menassa added, “but when you look at where robotics has gone in the last 55 years, we still see a lot of people on the assembly line. And that’s primarily because of the challenges in compliant material. When we make our circuit breakers or lighting fixtures, there are wires and flexible materials that are very hard to handle. The challenge becomes, how do you interject automation in a manual process to handle compliant parts?” GE uses Sawyer, a single-arm collaborative robot by Rethink Robotics, on the assembly line at GE Lighting in Hendersonville, N.C. The collaborative robot inserts components into a LED street light fixture before human coworkers complete the assembly. “The factory never had a robot for many years,” said Menassa. “So to bring a robot www.plantengineering.com
inside the factory, we didn’t know what the workers would think. We had a workshop with the factory, looking at the different applications, looking at where it made sense to apply. We then held several campaigns within the plant itself where we actually had the robot on display. We introduced people to the notion of what that robot can do, how you really can touch it, and how you can work with it.” Power and force limited robots are specifically designed to have safe contact with humans by way of inherently safe features of the robot or the control system. These types of robots are typically made from lightweight materials, have force and torque sensing in their joints, and may have soft padded skins.
www.plantengineering.com
Four methods of collaborative operation
Under the ANSI/RIA 15.06 and ISO 10218 harmonized robot safety standards and the new TS 15066, there are four methods, or types, of collaborative operation: • Safety-rated monitored stop • Hand guiding • Speed and separation monitoring • Power and force limiting. These tend to be the most misunderstood aspects of human-robot collaboration. To avoid confusion, Nelson Shea suggests manufacturers think of each of the four methods of collaborative operation as scenarios rather than distinct modes.
Industry leaders say the addition to collaborative robots on the plant floor are designed to achieve more productivity and flexibility while creating a safer workplace for humans. Image courtesy: RIA/Universal Robots
plant engineering
March 2017 • 33
CoverStory
The bottom line for any collaborative robotic installation is to conduct a risk assessment. Image courtesy: RIA/GE
In every instance there is a shared space between a robot and a human operator. In a safety-rated monitored stop, the premise is that in a shared space with a human a robot does not move at all. With hand guiding, a common misconception is that this method is used for teaching. Nelson Shea says that’s not the case. “When you’re moving the robot’s arm around to teach it certain tasks, this is not hand guiding in the collaborative sense. It’s not running in automatic when you’re doing that,” she said. When used to describe collaborative operation, hand guiding indicates a condition where a robot and a person occupy a shared space and the robot is only moving when it is under direct control of the person. “In speed and separation monitoring, both the robot and the person can be moving in that space,” said Nelson Shea, “but if the
34 • March 2017
plant engineering
distance between the robot and the person becomes too close, the robot stops, effectively becoming just like the first scenario (safetyrated monitored stop). In power and force limiting, there can be contact between the person and the robot, but the robot is power and force limited and sufficiently padded or otherwise, such that if there’s any impact, there’s no pain and no injury.” She said it’s also possible to have any mix of the four methods of collaborative operation represented in one robot system, even all four of them. The new TS 15066 standard includes formulas for calculating the protective separation distance for speed and separation monitoring. But perhaps the most interesting part of the technical spec is the annex, which contains guidance on how to establish pain threshold limits for various parts of the body, particularly for power and force limiting applications. The data can then be extrapolated to determine speed limits for the collaborative application. “Although there is information about the four modes of collaborative operation, the www.plantengineering.com
more interesting stuff is for power and force limited robots,” said Jean-Philippe Jobin, CTO at Robotiq, a manufacturer of adaptive grippers for collaborative robots in Lévis, Quebec, Canada. “More types of these robots are on the market now, but there was no clear guidance except ISO 10218 to help people safely install those robots in their factories.” Jobin co-founded Robotiq in 2008 with president Samuel Bouchard and Vincent Duchaine as a University of Laval spin-off. Jobin is also a technical expert on the ISO committee with Nelson Shea.
Start with a risk assessment
Both Nelson Shea and Jobin stress that the bottom line for any collaborative robot integration is a risk assessment. “The risk assessment is the most important aspect,” said Jobin. “If your application requires a little bit higher force or power than what is stated in the document, it does not mean it is not safe. The data we have from this technical specification is relative to pain, while what is required from ISO 10218 is that no injury should occur. “There’s a difference between pain and injury,” he added. “A user could do tests to show that even if they are a bit above what it states in ISO/TS 15066, it’s still safe because they can prove that the robot cannot hurt or injure the people in those specific circumstances.” Jobin said it’s ver y important to note that the application is the main concern, not the robot, when assessing risk. “If you look at the document, it rarely states ‘robot,’ he said. “It states collaborative work cell or collaborative application. It involves the cables, jigs, clamps, the robot and the gripper, everything which is inside that cell.” He says it’s a common misconception that if the robot is “inherently safe” then the operation is safe. For instance, if your robot is manipulating sharp objects, then it www.plantengineering.com
is not safe to have a human beside it without protective safety measures. Another case is if the robot is handling a heavy object, which could cause injury if it’s dropped or become a projectile at a particular rate of speed. Safety was a major factor in the robot adoption process at GE Lighting and for instilling worker confidence in the new collaborative robotics paradigm. “At GE, safety is our overriding priority,” said Menassa. “With any application it’s not about if the robot is safe, it’s about ‘is the task safe?’ So we do the task assessment risk-based analysis. We observe all the rules and all the RIA standards. We brought people in from RIA to train us. We make sure we understand what the robot is doing, the shape of the end effector, is there anything sharp, and is there anything that could eventually hurt someone? “If we feel there is a need for protection beyond just the force or torque limiting capability of the robot, then we’ll place the appropriate safety device, such as a light screen or laser scanner, so we can mitigate the risk,” he added. The ANSI-registered technical report, RIA TR R15.306-2016 Task-based Risk Assessment Methodology, describes one method of risk assessment that complies with requirements of the 2012 R15.06 standard and was updated in 2016.
Collaborative robots safely work side by side with humans on a production line assembling street light fixtures. Image courtesy: RIA/GE Global Research
plant engineering
March 2017 • 35
CoverStory “Collaborative applications is that next new frontier
and it’s really going to drive business and applications, and probably applications
”
we don’t even know yet.
Roberta Nelson Shea, Universal Robots
“RIA publishes the method by which we do a task assessment. We go through the steps of the process and we use their methodology to assess if there’s any risk and how severe it is,” Menassa said. “We try to do any of the engineering designs around it to mitigate that risk.”
Eyes on the job
Besides its kinematically redundant sevenaxis arm, with allows the robot to work in tight spaces on GE’s plant floor, one of the more unique features to the Sawyer robot is its animated eyes on its LCD screen. The eyes don’t actually ‘see’ anything; there are embedded vision sensors in the head and arm for that. The eyes serve a much more human purpose. “People wonder ‘Why the eyes on the robot?’,” Menassa said. “To us, that’s very important. For people to feel safe around these robots, they need to have a sense of what the robot is going to do next. The eyes on that screen are very critical because they look to the left before the robot moves (reaches its arm) to the left.” After GE introduced its workers to the robot, the next step was to introduce Sawyer into the production area. “We took some of the applications that we thought were feasible and mocked them up inside of the plant, but off to the side, where people could start to get comfortable (with the robot),” said Menassa. “Having a robot do a task is very simple. The challenge in robotic applications is always the material presentation,” he added. “Where is the material coming from, how’s it coming, how are we going to grab it, and how are we going to hold it? How are the containers going
36 • March 2017
plant engineering
to recycle? What is the best orientation for Sawyer to pick up and drop off, so you’re not going through the gyrations in 3-D space? That’s a waste of cycle time. If we fix that, the robot can just execute its task.”
Value-added from the start
In December 2015, Sawyer joined his human coworkers on the main GE assembly line. “In any person’s task, whether it’s a 60-second cycle or a 2-minute cycle, you will see 50% to 70% is what we call nonvalue-added,” said Menassa. “It’s when you walk away from the job to grab a tool or a part, to look at a document, or when you’re walking around the cell. When you finally add the part to the assembly, that’s the only value-added time that you spend. The rest of it is non-value. In fact, some of it is waste. “Sawyer was grabbing parts and putting them in the assembly. But the human was making sure it was fitting properly and inserting the last screws, using what humans are good at—dexterity, perception and logic. For us, elevating the role of the human on the assembly line to focus on quality—to focus on the value-added—is very important. “It was a tremendous win,” he adds. “Here’s a business that needs to expand its volume because of demand. The question is how do you achieve that higher output without adding people? Sometimes it’s very hard to add people because of the space constraints. By adding robots, we were able to achieve higher output with the same number of people, at the lowest cost possible with technology that is low cost and flexible. The notion of low-cost, flexible automation is really collaborative robotics.” Menassa says GE also is developing mobile collaborative robots with partner suppliers. “Coupling collaborative with mobility will give us the ultimate vision of having a mobile robot that can navigate the factory and perform multiple tasks, leveraging every minute of that robot, especially in low-volume production. Now we have mobile robots that can tend CNC and additive machines,” he said. “Bringing robots to machines will allow GE to stay flexible and agile while synchronizing the scale up of our product volumes with mobile collaborative automation.” PE Tanya M. Anandan is a contributing editor for the Robotic Industries Association (RIA), a CFE Media Partner. www.plantengineering.com
JOHN
AKA CASANOVA L I F T T R U C K O P E R AT O R
LOVES A TRUCK THAT WON ’ T LET HIS
backside
TAKE A BACKSEAT At the heart of every good operation is a group of hardworking people. Hyster engineers design solutions to empower these people. From adjustable ergonomics to total fleet solutions, we’ve got your back. Explore our solutions and full line of tough trucks. Visit www.hyster.com
input #21 at www.plantengineering.com/information
Get Your Business Set For Growth. To grow your business, you need to not only streamline operations and expand into new markets, but act on opportunities to enhance the customer experience. Epicor provides industry-specific, tailored ERP solutions to get your business set for growth and scale with business demand, fast. Together, we are the Grow Getters.
Get your business set for growth at: epicor.com/getsetforgrowth
input #22 at www.plantengineering.com/information
ELECTRICALSOLUTIONS Effective LED lighting can both improve visibility and manage costs within a plant, but proper selection and installation of lighting is important to a successful deployment of LED technology. All images courtesy: MyLEDLighting Guide
Watts going on?
Efficiency!
Seven mistakes to avoid when upgrading your plant to LEDs. By Dwayne Kula MyLEDLightingGuide
www.plantengineering.com
L
ighting may not be the biggest expense in your operating budget, but its performance effects every area of your plant—from productivity to safety. Industrial environments pose lighting challenges that aren’t seen in traditional office or corporate environments: hard-toreach ceilings; large, open spaces; extreme temperatures; and nontraditional operating hours, to name just a few. As LEDs have become more prolific, and less expensive, they’re being used more and more in plant operations. It can be tempting to cut corners or rush an LED lighting upgrade when you have several other irons in the fire. But hurrying through the process without fully under-
standing all the decisions that need to be made can leave you with a system that’s less than satisfactory. Avoid these seven common mistakes when upgrading to LEDs.
1.
Choosing the wrong light level
Wattage is what most of us are used to dealing with when it comes to making lighting decisions—the higher the wattage, the brighter the lamp. Wattage, however, doesn’t actually represent lamp brightness; it measures power consumption. For this reason, LED wattage isn’t comparable to wattage used to describe other types of lamps; LEDs naturally have a lower PLANT ENGINEERING
March 2017 • 39
ELECTRICALSOLUTIONS
Before
After
The before and after images of a U.S. Steel facility show the effectiveness of proper LED lighting in enclosed spaces.
w att a ge b e caus e t he y’re designed to be more energy efficient. Many people see the LED wattage level listed and assume it means that LEDs are dimmer than their counterparts. LEDs use the lumens rating to represent total light output (lamp brightness). The higher the lumen rating is, the brighter the light. Today, it can be difficult to recognize which type of lighting system you need if you don’t understand what lu m e n s a re , t h e d i f f e rence between wattage and lumens, or the number of lumens you need. Several LED manufacturers still sell based on wattage instead of lumens. This makes it challenging for you to tr uly u nd e rst and w h at you’re getting in an LED lamp, and can lead to a purchase of the wrong lighting system for your plant.
2.
Not paying attention to codes and standards
Are you over- or underlighting? It’s important to stay up to date on the latest requirements so you don’t spend money unnecessarily. For e x amp l e , l i g ht i n g p ower densit y (LPD)—a l i g ht i ng p owe r re qu i re ment t hat is p ar t of t he ANSI/ASHR AE/IES 90.1 energ y standard—recently was reduced by 23% in manufacturing facilities (to 0.9 watts per square foot) and 27% in warehouses (to 0.48 watts per square foot)
40 • March 2017 PLANT ENGINEERING
www.plantengineering.com
as part of ANSI/ASHRAE/IES 90.1-2016. This update helps plants save energy without compromising lighting quality.
3.
Purchasing without investigating your options
No matter what you’re purchasing, you don’t ever want to make a buying decision based in incor re c t infor mat ion. Misinfor mat ion f rom manufacturers is not uncommon, making it harder to select a lighting system that gives you what you need without added costs or performance issues. Manufac turers can b e a go o d star ting p oint for information gathering, but talking to outside experts or consultants w ho aren’t connected to a sp ecif ic product can provide an unbiased perspective and comparisons b etween lighting systems and lamps that seem similar.
4.
Not using available technology
In the past, lighting controls were often an afterthought—and they were very expensive. Today, lighting controls can be added to nearly all types of lighting systems, including LED systems. When it comes to saving money, there’s nothing better than shutting your lights off (or at least dimming them)—and LEDs do that well. They respond immediately, with no warmup time or concerns about hot restrike. Lighting controls can set lamps to illuminate specific areas during times of high traffic, turn off or dim based on activity and occupancy levels, and supplement available daylight entering through windows and skylights. If you don’t have lighting controls in place, it’s time to seriously consider investing in a system that can help you manage lighting usage. With the savings you’ll see, it’s possible that the reduction in your energy bills could pay for the system in a few years. If you do have lighting controls in place, but aren’t using them—which we’ve seen happen—now is the time to start.
5.
FINDING THE RIGHT
REPLACEMENT FILTER IS A
PIECE OF CAKE Make Donaldson your first call for replacement filters and parts—no matter the collector. We stock over 90,000 filters and replacement parts including: n n n
n
Cartridge filters Bag filters Pleated bag filters PowerCore® filter packs
n n
Panel filters Parts (hardware, motors,
cages, rotary valves, ductwork, controls, fans, and more)
Live, expert service specialists can help you determine the size and style you need within minutes. Plus, our Ready 2 Ship program means your order is out the door within 24 hours. Call now to order your replacement filters and parts.
Not taking advantage of incentives
Because a lighting upgrade or retrofit is a utility-based initiative, LEDs certified by the DesignLights Consortium (DLC) are eligible for utility rebates. This voluntary DLC certification requires participating LED lighting products to comply with distribution, color and longevity/stress performance standards. A quick look at your local utility’s website will tell you what LEDs rebates are available. Consultants and experts who regularly work with utility companies are often available to help you fill out rebate forms to make sure you supply the correct information, get your rebate as quickly as possible, and understand the true costs associated with the lighting system once the rebates are in place.
plant engineering
March 2017 • 41
800.365.1331 Donaldson.com © 2017 Donaldson Company, Inc.
input #23 at www.plantengineering.com/information
eLeCTRICALSOLUTIONS
6.
Not investigating in a retrofit
If the existing fixtures in your plant are in good condition, and the design and layout of the lighting system meets the needs of your plant, then a new LED lighting system may not be necessar y. Instead, you can save time, money
and plant disruption by using an LED retrofit kit that allows your fixtures to accept LED lamps. In fact, the LED engines in retrofit kits are as efficient, or sometimes more efficient, than LED engines in new fixtures. Because of their efficiency, they can replace existing lumi-
“If you do have lighting controls in place, but aren’t using them— which we’ve seen happen—now is the
”
time to start.
naries in other wise perfectly fine lighting fixtures in a plant.
7.
Forgetting about areas beyond the plant floor
The lighting used in your plant’s parking lots, conference rooms and front-office areas is just as important as the lighting used in your plant environment itself. These areas are often overlooked in plant operations, but the lighting in these spaces can impact overall safety, comfort and productivity as well. Even though they’re not working in the plant, office workers in manufacturing facilities can benefit from lighting improvements that decrease fatigue and glare, provide appropriate lighting levels for the tasks at hand, and function automatically through lighting controls based on occupancy and schedules. Whe n you r l i g ht i ng up g r a d e s aren’t r ushe d, you have t ime to establish procedures and processes to make sure you end up with the right LED lighting system for your plant. Avoid these common mistakes, and you’ll end up with a system that offers the savings and performance you expect. PE Dwayne Kula is founder of MyLEDLightingGuide, a consultant that helps commercial and industrial building owners save energy and money by finding efficient LED lighting solutions that will work in their specific environments and to their specifications. input #24 at www.plantengineering.com/information
42 • March 2017
plant engineering
ADVERTISEMENT
F
or over 50 years, professionals have trusted FLIR to save them time and money on the job. From thermal imaging to measurement and diagnostic systems, FLIR leads the way in innovation with advanced, easy-to-use sensing solutions. As technology continues to advance, so does FLIR – by building smarter tools that makes detecting potential problems faster and easier.
Exx-Series features a brighter, larger display with more vibrant thermal details
FLIR’s Advanced Sensing Solutions Lead the Way in Innovation Take the new generation of advanced thermal imaging cameras for electrical-mechanical, plant and building professionals: the FLIR E75, E85, and E95. The advanced, redesigned, Wi-Fi-enabled Exx-Series features intelligent interchangeable lenses, laser-assisted autofocus modes and area measurement functionality, improvements to FLIR’s patented MSX® imaging technology, and a larger, more vibrant 4-inch touchscreen.
This gives professionals a clearer, more accurate temperature measurement while eliminating the need for manual lens calibration.
The FLIR E95 advanced thermal imaging camera for electrical-mechanical, plant and building professionals
While many other thermal imagers simply show the thermal image, FLIR’s exclusive MSX Technology embosses structural features, numbers, and other key details (captured by the onboard digital camera) onto the thermal image without compromising integrity. These detail-rich IR images add perspective and , making it easier to identify where temperature anomalies are for much faster troubleshooting.
Compact, capable and easy-to-use are only some of the ways to describe FLIR’s growing list of innovative thermal tools. The new E75, E85, and E95 cameras also feature a rugged, water-resistant, drop-tested design, and scratchresistant Dragontrail™ cover glass over an optically-bonded, projected capacitive (PCAP) touchscreen. FLIR takes functionality even further with a simplified user interface that delivers faster, more intuitive operation. Enhanced Wi-Fi connectivity allows users to link the cameras to mobile devices for transferring and sharing images and sending reports from the field to help expedite repair decisions. Bluetooth to Meterlink enabled test meters allows embedding of additional measurement data into image files for simpler archiving and report generation.
With the improved image clarity of a 5 MP digital camera on the new Exx-Series, there’s little need to use another device to take a high quality visible-light snapshot. “Redesigned from the handle up, the new series of Exx cameras is a significant achievement in terms of advanced functionality, performance, and ease of use in thermal cameras for electrical-mechanical, plant, and building inspections,” says Andy Teich, President and CEO at FLIR. “With an ever-broadening base of users who demand thermal cameras that are compact, capable and easy to use, the advanced Exx cameras check every box.”
With every new product, FLIR continues to make it easier to see and detect invisible problems before they become serious issues – saving time and money. The constant innovation puts them ahead of the game, making FLIR tools an invaluable addition to the maintenance engineer’s toolbox.
+1 503 498 3335 • Richard.Wexler@flir.com • flir.com/exx-series
Webcasts
Plant Engineering Webcasts help you obtain educational information on specific topics and learn about the latest industry trends. Check out some of our Webcasts on topics like:
• Maintenance • lloT series: OT/IT convergence, collaboration • Energy Management • lloT series: Edge, cloud, fog computing • lloT series: Maintenance optimization • System Integration case studies • lloT series: Network integration, cyber security • Safety www.plantengineering.com.com/webcasts
MECHANICALSOLUTIONS Compressed air leaks not only waste energy, they can cause system pressure drops which can make a system run less effectively. All images courtesy: Atlas Copco
Air = money
Compressed air leaks are expensive, and too often overlooked. By Bob Baker Atlas Copco Industrial Air Division
www.plantengineering.com
C
ompressed air is not free. In fact, when comparing the percentage of power input to value delivered, a poorlyoperated compressed air system can cost more than water, electricity, steam or even natural gas. Air leaks also can slow a plant’s operation by using more power than necessary to supply compressed air. If this goes unchecked for too long, these air leaks can lead to unnecessary production shutdowns. Compressed air leaks are not only a direct source of wasted energy, they also can contribute to system pressure drops, making pneumatic equipment function less efficiently and shortening its life cycle. Air leaks cause equipment to cycle more frequently, thereby increasing the running time of the air compressors, which leads to additional maintenance requirements and possible increased unscheduled downtime. Simply put, air leaks contribute to unnecessary compressor capacity. Leaks, coupled with the usual problem of higher than required system operating pressures, lead to what is called “artificial demand.” All of this adversely affects production efficiency and shortens the life of almost all system equipment and pneumatic tools as well. The combination of
excess energy use and reduced equipment longevity are a double blow to plant owners’ bottom lines. For example, a small manufacturing company was considering buying a second air compressor larger than what they presently had. Before making the purchase, they contracted a compressed air audit, and it was a good thing they did. The findings showed more than $75,000 of the $100,000 the company had been spending annually on compressed air was being wasted due to compressed air leaks, uncontrolled demand, and poor applications. Installing a larger air compressor would only have compounded the problem by increasing energy consumption. What the company really needed was a program to educate its maintenance staff about testing procedures and technologies that would eliminate energy waste and allow the plant to run more efficiently.
Searching for leaks
There’s a perception that air leaks are most often found in the overhead distribution (the air system network piping), and of course, some are. However the real problems are usually found at ground level in air hoses, PLANT ENGINEERING
March 2017 • 45
mechanicalSOLUTIONS The facts on air leaks Compressed air leaks are hard to find, but their presence, large or small, is a matter of money leaking away. For example (based on 8,760 operating hours per year at $0.10 per kWh energy cost): • A $200/year leak cannot be felt or heard. • An $800/year leak can be felt but not heard. • A $1,400/year leak can be felt and heard. Using that same calculation, the annual cost of air leaks are: • 1/16-inch diameter leak = 7 cfm = $1,045 • 1/8-inch diameter leak = 25 cfm = $4,190 • 1/4-inch diameter leak = 100 cfm = $16,764* • 3/8-inch diameter leak = 230 cfm = $36,322 *At 100 psig. At 125 psig, the leak factor increases by more than 20%, or $20,117 annually.
hose connections and fittings, quick couplers, filters, regulators and line lubricators. There are a few other often-overlooked causes of leaks to keep in mind: • Air cylinders often leak around the rod seals or piston packing. • Piston-packing leaks are apparent at the cylinder control valve exhaust port. • Pipe fittings may be loose because equipment has been installed improperly or because sealant was applied incorrectly during installation. • Poor quality materials may save money initially, but don’t forget that cheap can cost you. • The location of the piping can cause future leaks. • If lift trucks, pallet jacks or other material-handling equipment bump a pipe connection occasionally, the fittings may crack.
input #25 at www.plantengineering.com/information
An open ¼-in. air valve used in an assembly line conveyor can waste an estimated $16,000 a year in energy costs.
HD ENV - A NEW ERA IN VIBRATION MONITORING ®
Providing earlier pre-warning than any other vibration monitoring technology • maximized planning horizon • extended component lifetime • reduced repair costs • minimized unplanned downtime
Get started right away - use your existing transducer installation.
spminstrument.us 1-800-505-5636 input #26 at www.plantengineering.com/information
MECHANICALSOLUTIONS
Reliability is everything
Gerald “Gerry” Bauer
President, EccoFab - Rockford, IL
Sullair.com/GerrysStory
• Sometimes leaks are the result of human error; workers may leave leaking tools on or neglect to close valves and stop the supply of air when there is no need for a particular application or when production has stopped for the day. The above small leaks in less considered places are really the biggest contributors, because there are usually so many of them within the facilities production areas.
Leaks, pressure and artificial demand It doesn’t quit. It doesn’t even think about quitting. In fact, it doesn’t think of anything but the job at hand.
Sound familiar? Our compressors are a lot like the people who use them. Discover the complete line of Sullair stationary air compressors, featuring the legendary Sullair air end. To learn more about our complete line, including air treatment products, contact your local distributor or visit our website.
input #27 at www.plantengineering.com/information
Sullair.com © 2017 Sullair, LLC. All rights reserved.
In the above, we mentioned that air leak loss and higher than normally required system air pressure lead to artificial demand. Now let’s look at some formulas that will help us understand this concept a little better. Values for pressures above 15 psig can be calculated by the following approximate formula by S.A. Moss. M=0.5303 x A x C x P1 √T1 M = leak rate in lbs per second A = area of leak in square inches C = coefficient of flow P1 = upstream total pressure in psia T1 = upstream temperature in degrees Rankin (70 + 460 = 530) Mass flows (M) are converted to volume flows (cu ft/min) by using a density factor of 14.7 psia, 70 F, 0%RH, which is 0.07494 lb/cu ft.
48 • March 2017
PLANT ENGINEERING
Here is an example using a 1/8-inch air leak: A = πd2/4 = 3.14 x (0.125)2 / 4 = .0123 in2 C = coefficient of flow = 1 P1 = 100 psig = 114.7 psia T1 = (70 + 460 = 530) square root of 530 = 23.0217 M=0.5303 x A x C x P1 √T1 M=0.5303 x .0123 x 1 x 114.7 23.0217 M = .0326 lb/sec Air at 70°F and 14.7 psia weighs .07494 lb/cu ft (.0326 lb/sec x 60 sec/ min)/.07494 lb/cu ft = 26.1 cu ft/min To put some of these formulas in simpler terms, here’s a table (above) that shows the cfm compressed air loss based on a specific orifice diameter as well as the increase in air leak loss as the system pressure rises. We use an energy rule-of-thumb in the industr y when referencing compressor drive motor horsepower (kW) values and how increasing (or decreasing) the system pressure can increase the kW use by the following: for every 2 psig increase in pressure, you need 1% more energy to achieve that increased system pressure (or the reverse, of course, when decreasing the pressure). So a 2:1 ratio is our initial point. www.plantengineering.com
ONE SOURCE With air leaks and increased pressure, it is almost a 1:1 ratio. The chart shows that a pressure increase from 100 psig to 125 psig leads to an additional 22 cfm in compressed air loss. This illustrates that if you can lower the system pressure, you can lower the compressed air leaks and drive motor energy use at the same time.
Sizing the system
After you fix lots of leaks and lower the system pressure, you may end up with air compressors too large for your system. If that is the case, the compressors could be cycling more frequently or partially loaded more often and running very inefficiently when looking at specific power (kw/100 cfm). For example, some compressor equipment running at 70% of capacity can still be using approximately 90% of power. In a multiple compressor installation, you may want to consider turning off one of the units, while This open 1/8-in. copper tubing at right used for cooling wastes an estimated $4,000 a year.
FOR STOCK AND CUSTOM
“
Compressed air
SPRING SOLUTIONS
leaks are not only a direct source of wasted energy, they also can contribute to system pressure drops, making pneumatic equipment function less efficiently and shortening its life
”
cycle.
in a single compressor system you may want to consider purchasing a smaller compressor. In many installations a variable speed drive (VSD) compressor will fit the application
35,000 Stock Designs Prototype to Full Production Stock Products Ship Within 8 Hours ISO9001:2008
MADE IN THE USA input #28 at www.plantengineering.com/information
www.plantengineering.com
plant engineering
March 2017 • 49
www.centuryspring.com 800-237-5225 Los Angeles, CA
mechanicalSOLUTIONS
This damaged air hose is just 3/8-in. in diameter, but because the air blows non-stop, it wastes an estimated $36,000 a year in energy costs.
perfectly, as it can adjust to meet demand without wasting energy through partial load inefficiency. Let’s review: fewer leaks, less pressure, and pneumatic equipment runs better and lasts longer. On top of that, installing a VSD can save up to 35% in additional drive motor energy. Any company committed to reducing energy costs should conduct an in-plant air-leak sur vey. Including the benefits of reduced operating expenses, energ y
demand and energy consumption mentioned above, many facilities could realize additional profits to their bottom line from utility companies who offer significant cash rebates to manufacturers who implement energy conservation programs. Next time you notice an air leak, don’t ignore it. It may be only air, but that air equals money. Instead, take action. Have your air system checked by conducting a compressed air audit, determine if you’re suf fer ing f rom ar t if icial demand and implement an energy savings plan. Keeping compressed air in your system will ultimately keep money in your wallet. PE Bob Baker is training manager for the Atlas Copco Industrial Air Division in the U.S.
“Leaks, coupled with the usual problem of higher than required system operating pressures, lead to what is
”
called ‘artificial demand.’ 50 • March 2017
plant engineering
www.plantengineering.com
CFE Media’s
New Products for Engineers Database Looking for new products? Look no further! The New Products for Engineers Database is a platform that provides an opportunity for engineering and technical professionals to access the latest NEW product information for the manufacturing, commercial construction, and manufacturing control industries.
Start searching now! www.plantengineering.com/NP4E
IN NOVATIONS
Submit new product releases to our New Products for Engineers Database
gspplatform.cfemedia.com/pe
High-temperature casters A new line of casters and wheels are engineered to withstand the rigors of high temperatures. These new products are designed for use in food manufacturing, autoclaves, product finish systems and other extreme temperature environments. Temperature capabilities begin at 250°F and top out at 750°F; wheel diameters span 3-in to 12-in; load capacities per caster range from 260 lb. to 9,000 lb. Wheel offerings include the new Ultratherm with a high performance elastic rubber tread. The Ultratherm wheel is available in a high temp swivel or rigid caster. Other non-metal high temp wheels include the new Thermolast, a 30% glass-fiber-reinforced nylon 6/6, and Duratherm, a durable composite material designed for oven racks that outlasts high heat phenolic. For casters, the Inferno series offers light, medium, and heavy duty plus a new high heat stainless steel line. The MagmaMax Extra Heavy Duty Series is rated up to 750°F with a maximum load capacity of 9,000 lb per caster. The Inferno Heavy Duty and the MagmaMax series boast extra thick forgings and proven kingpinless swivel technology for superior durability over the life of the casters.
Energy loggers
Hamilton Caster & Mfg. Co. www.HamiltonCaster.com Input #201 at www.plantengineering.com/information
The 1732 and 1734 three-phase energy loggers are powerful designed to more easily identify sources of electrical energy waste. These new loggers are easy to set up and use, and capture key measurements—voltage, current, power, power factor and other variables like temperature—to enable managers to understand their energy usage and correlate it to their activities. Facility managers and electricians can easily discover wasted energy to reduce energy bills, perform energy studies over a range of electrical power and energy parameters and perform simple current-only load studies. The loggers are rated 600 V CAT IV/1000 V CAT III— the highest safety rating in the industry—for safe use at the service entrance and downstream.
The Norgren two-way solenoid valves use a proprietary internal design that lets them close smoothly and gently, preventing large pressure spikes while still maintaining closing speed. Tests conclude these valves reduce water hammer by up to 80% compared with similar solenoid valves, eliminating the need for costly remedial measures. The Norgren 82410 is available in brass and the Norgren 82740 is available in 316 stainless steel for more aggressive operating environments. Both are installed easily in new equipment or can serve as replacements to upgrade existing systems.
Fluke Corporation www.fluke.com
IMI Precision Engineering store.norgren.com
Input #200 at www.plantengineering.com/information
Input #202 at www.plantengineering.com/information
52 • March 2017
PLANT ENGINEERING
Solenoid valves
www.plantengineering.com
Catapult your career forward Engineers: You are the designers of the world. You take complicated problems and break them down into manageable pieces to build safe and sustainable products, buildings, and infrastructure. The reasons you have decided to be an engineer may be is as varied as the many things that engineers have created, but one thing is certain—you play a major role in shaping the world of tomorrow.
CFE Media is excited to launch CFE EDU, a brand new platform that will give you the tools to continue to shape the future while advancing your career forward. CFE EDU is an interactive online platform that offers multi-media educational courses on engineering topics that are critical to your work.
Courses are AIA CES accredited.
Courses launch on February 28, 2017.
CFE EDU Course List: Critical Power
Hospital Electrical Systems One (1) AIA CES accredited LU and 1 HSW credit available for attendees
Data Centers
Section 1 One (1) AIA CES accredited LU credit available for attendees
Safety First
Arc Flash 101 One (1) AIA CES accredited LU and 1 HSW credit available for attendees
Learn more and register at CFEedu.cfemedia.com
IN NOVATIONS
Submit new product releases to our New Products for Engineers Database
gspplatform.cfemedia.com/pe
Machining center The VTC-805E vertical traveling column machining center brings high versatility and productivity to those shops that need to tackle long and/or heavy parts. The machine combines an increased Y-axis stroke, long bed/table size, high spindle speed and torque and the new SmoothG CNC control for efficient, powerful machining. For manufacturers that need as much Y-axis travel as possible, the VTC805E provides an extended Y-axis travel of 32 in. as a cost-effective alternative to a bridge-style machine. The machine’s fixed table measures 82.7 by 32.3 in. (2,100 mm x 820 mm), while its moving column design provides a 69.3-in. X axis and 28.3-in. Z axis. Its optional center partition transforms the VTC-805E’s table into two separate work areas, allowing operators to process parts on one side and load/ unload parts on the other side, resulting in an overall reduction in cycle times. Mazak Corporation www.mazakusa.com Input #203 at www.plantengineering.com/information
4-20mA Transmitter
Digital accelerometer A next-generation USB digital accelerometer features a compact design and industry-leading price. It was designed to ensure longevity and continued accuracy by placing the delicate onboard electronics in a protective insulated connector rather than the vibrating accelerometer. The USB digital accelerometer supports Windows, Mac, Android and iOS with a wide variety of different apps and software solutions, including the VibeRMS app for iPhone and iPad. GTI’s sensor features a resonant frequency up to 25 kHz, and uses a Piezoelectric sensor for optimal data capture accuracy and range.
The Parker 4-20mA Transmitter enhances any existing wired sensor by providing wireless capabilities to convey data from an existing sensor up to 1,000 ft range to the SCOUT Mobile 3.0 mobile app. With Parker’s easy-to-use transmitter, there is no need to reprogram or recode the existing control system. Parker Hannifin www.parker.com Input #205 at www.plantengineering.com/ information
GTI Predictive Technology info@gtipredictive.com Input #204 at www.plantengineering.com/information
54 • March 2017
PLANT ENGINEERING
www.plantengineering.com
eNewsletters Plant Engineering’s electronic newsletters deliver news and information on the latest trends in manufacturing in every corner of the plant floor. Applied Automation Education and Training Energy Management IIoT: Machines, Equipment and Asset Management IIoT: Operations and IT IIoT: Process Control and Automation Maintenance Connection New Products for Engineers Showcase Oil & Gas Engineering PLANTMAIL! Plant Safety Predictive and Preventive Maintenance Product Focus Whitepaper Connection
Get your plant ahead of the curve. Subscribe today: www.plantengineering.com/newsletters
IN NOVATIONS
Submit new product releases to our New Products for Engineers Database
gspplatform.cfemedia.com/pe
Weigh hopper
Thermal imaging cameras The E75, E85, and E95 thermal imaging cameras have been redesigned to meet both changing customer needs and to take advantage of improved imaging capabilities. The E75, E85, and E95 are Wi-Fi-enabled and offer interchangeable lenses, laser-assisted autofocus modes and area measurement functionality, and a 4-in. touchscreen. Other features include increases sensitivity and native resolution to help professionals identify hot spots or building deficiencies before they become an issue. The three models also feature an embedded, superresolution process called UltraMax, which is designed to improve effective resolution by four times—up to 645,888 pixels—and thermal sensitivity by up to 50%. The cameras also feature a rugged, waterresistant housing and scratch-resistant glass over the touchscreen. It also includes enhanced Bluetooth.
A new weigh hopper with a fill/pass valve for dilute-phase pneumatic conveying delivers higher accuracy than loss-of-weight systems requiring higher-capacity load cells. Single or multiple hoppers can be positioned along a common vacuum or positive pressure pneumatic conveying line for discharging of dry bulk solids into single or multiple process equipment, storage vessels or downstream use points by weight. Downstream of the last fill/pass valve, the conveying line can be routed to the original material source point or into a dust collection device. The system’s controller weighs a batch by changing the position of the valve that diverts conveyed material into the hopper. As the hopper fills, load cells transmit weight gain information to a PLC. Once the batch weight has been reached, the valve redirects material away from the hopper. Flexicon Corp. www.flexicon.com Input #207 at www.plantengineering.com/information
Flir Systems www.flir.com Input #206 at www.plantengineering.com/information
Water fittings and tubing A line of push-to-connect fittings and tubing is designed for potable water and beverage systems, including applications such as brewing, coffee/drink dispensing, soup and liquid food production and municipal/residential water treatment. The HydroMode push-to-connect fittings are perfect for use with polyethylene and other flexible tubing; all fittings are made of NSF-approved materials with NSF-51 and NSF-61 certifications. Rated for up to 145 psi at 70°C (158°F), the body and collet of the fittings are made from acetal, while the O-rings are made of synthetic rubber; optional retaining clips prevent accidental tube removal. HydroMode polyethylene tubing, available in 100 to 1,000-foot packages, is designed for use with potable water and beverages. This tubing is NSF-61 certified, has a Shore A 98 hardness rating, and works well with HydroMode push-to-connect fittings. AutomationDirect www.automationdirect.com Input #208 at www.plantengineering.com/information
56 • March 2017
PLANT ENGINEERING
www.plantengineering.com
WEBCAST SERIES
The Industrial Internet of Things (IIoT) is a transformational strategy that is revolutionizing manufacturing operations across the world. CFE Media publications take an in-depth look at IIoT-related issues, strategies, and opportunities in the 2017 IIoT Webcast series.
The 2017 Industrial Internet of Things (IIoT) Webcast Series: Webcast One: Get your head into the cloud Thursday, April 13, 2017 Automation technologies are converging with information technologies. To handle growing volumes of data generated by IIoT-enabled devices, companies will need powerful data processing capability. Cloud-based environments transform how process-automation projects are engineered and instantiated, replacing client/server. This Webcast focuses on how emergent IIoT technologies change the way process and automation engineers execute projects and sustain productivity in today’s, and tomorrow’s, cyber-physical world.
Sponsored by: B+B SmartWorx, Rittal
Webcast Two: Take sensing and control to the edge Thursday, June 8, 2017 Put computing power at the process edge, where measurements happen, and aggregate the results in the cloud. With ubiquitous, lowcost sensing, you can condition-monitor not just high-priced machines and equipment, but also plant substructures like steam traps and vents. Connected assets and rich data do more than give a hint of impending failure. It’s a way to better understand how a process works, and thereby optimize its results. This Webcast will focus on how better sensing leads to big data, and how in future, process control will be found—at the process.
Webcast Three: IIoT transforms predictive maintenance Thursday, August 24, 2017 Manufacturers exploiting the latest IIoT industrial-connectivity and analytics advances are melding operations and maintenance data to spot trends that lead managers to contextualized, actionable insights. At the same time, they are building the plant-floor technology infrastructure of the future. Connecting complex machinery and equipment to operations and enterprise systems enables machine learning, predictive maintenance and secure monitor and alarm. IIoT addresses significant integration challenges posed by the unique data types generated by the many kinds of machinery and equipment found in plant environments, from CNC machines to robotics.
Sponsored by: Deublin, GTI, Rittal
Webcast Four: How IIoT helps cybersecurity efforts Thursday, October 19, 2017 Cybersecurity is a threat to enterprises large and small, at risk of being attacked from unexpected sources both inside and outside the enterprise. IIoT can reduce the cybersecurity risks inherent in legacy automation, instrumentation, equipment, and devices. The Industrial Internet Consortium has released a technical report for an industrial Internet security framework. The intent is to give all interested parties, including device makers, application developers, systems integrators and executives the guidance needed to deploy IIoT systems with best practices built in. The report will be the starting point for this Webcast presentation and discussion.
Register for the IIoT series today at www.plantengineering.com/lloT
IN NOVATIONS
Submit new product releases to our New Products for Engineers Database
gspplatform.cfemedia.com/pe
Medium-voltage drive The Sinamics Perfect Harmony GH180 medium-voltage drive features an innovative PCBbased power cell with reduced part count by more than 70% on previous design, increasing reliability and making it the most compact medium-voltage drive in the market. The design allows for less maintenance and greater availability. And when combined with up to 90% savings on cable costs as well as substantial savings on conduit, the result is a significantly lower cost of ownership over the drive’s lifecycle. This next-generation drive offers a simplified system, with enhanced serviceability and reduced commissioning. The drive also supports 480 V or 600 V input voltages up to 400A—making this drive ideal for new or retrofit applications of existing motors. Siemens www.siemens.com Input #209 at www.plantengineering.com/information
Circuit breaker The PowerPact B-frame circuit breaker offers robust power protection in a compact size. With its easy installation, the new B-frame circuit breaker brings “efficiency that clicks” to the work day. The 125A B-frame circuit breaker uses economical, thermal magnetic sensing elements in each of the various 1-, 2-, 3- and 4-pole construction types. Designed to be flexible, it offers unique integrated DIN rail and traditional backpan mounting capabilities without extra adapter brackets. A wide variety of external mechanical operators for control panel applications complement fieldinstallable electrical accessories that let customers easily configure the product to their specific needs. PowerPact B circuit breakers are UL-listed, ANCE, NOM, CSA, IEC, CCC, and EAC certified and CE marked for global markets. Schneider Electric www.schneider-electric.us Input #210 at www.plantengineering.com/information
Wireless gateway A cost-effective wireless process sensing and condition-based monitoring solution with significant benefits and value for the industrial, factory and commercial markets is available in a package. The wireless product include a gateway, universal transmitter and a selection of measurement sensors. The communication transmission is industry-standard 900 MHz, license-free and has a range of 5,280 feet. The self-configuring communication network is plug-and-play and will be working in minutes rather than hours and requires no prior wireless experience. Common applications include: motor temperature and current draw, pump vibration, bearing vibration or temperature monitoring, conveyor vibration monitoring, exhaust and cooling tower fan monitoring, filter monitoring and many more. Wireless Industrial Networks (WIN) www.wirelessindustrialnetworks.com Input #211 at www.plantengineering.com/information
58 • March 2017
PLANT ENGINEERING
www.plantengineering.com
CFE Media’s
Global System Integrator Database CFE Media’s Global System Integrator Database is an interactive community of global end-users and system integrators hosted by Control Engineering, Plant Engineering, and our global partners in Asia and Europe. The newest version of the online database is even easier to use. Features and updates:
• Relevancy score indicates how closely
• New feature allows an end-user to
• Users can now preview the most
• The most relevant data about an
an integrator’s qualifications match a user’s search criteria
pertinent data of a System Integrator before clicking to view the full corporate profile
“
request a quote for a project directly from the database site
integrator’s engineering services appear on one page on their corporate profile – other details are organized by tabs.
As a Systems Integrator there are quite a few options available for online advertising. They vary in functionality and design, but the Global System Integrator Database has been our go to. It is easy to use, professionally designed, and has given us a great deal of exposure to clients we wouldn’t normally be able to reach. We have had more clients contact us with this solution than any other System Integrator database combined. We not only going to renew our profile this year, we plan on upgrading.
”
William Aja, Panacea Technologies
Find and connect with the most suitable service provider for your unique application.
www.plantengineering.com/global-si-database
MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers.
DIGITAL REPORTS
Pultruded Grating Performance at a Molded Grating Price • Made from fiberglass won’t rust, rot or corrode • Fire Retardant • Easily Field Fabricated • Low Electrical & Thermal Conductivity • Non-skid Surface • Stronger than fiberglass molded grating • Lighter than steel or aluminum grating
Quality • Performance • Value
2016 DIGITAL REPORT
PLANT SAFETY STRATEGIES
AVAILABLE FOR QUICK SHIPMENT
AccuTrak® VPE-2000 EXCLUSIVELY
The World Leader in Pultrusion and Pultruded Fiberglass Structures & Shapes
Find Leaks: Compressed Air, Any Gas, Vacuum, Any Refrigerant Diagnose Faults: Valves, Motors, Pumps, Bearings, Steam Traps, Electric Arc & Corona
276-645-8000 • www.strongwell.com
SuperiorSignal.com/PE
Input #100 at plantengineering.hotims.com
Input #101 at plantengineering.hotims.com
WELDER
EASY TO LOCKOUT/TAGOUT
meltric.com 800.433.7642
A company of MARECHAL ELECTRIC GROUP
Input #103 at plantengineering.hotims.com
60 • March Month 2017 2014
PLANT ENGINEERING
Input #102 at plantengineering.hotims.com
10/17/2016 11:23:06 AM
2017 DIGITAL REPORT
Attend Pressure & Profit:
Find Out How to Design, Optimize, & Monetize Compressed Air Systems for Manufacturing What is Pressure & Profit? We will show you ways to improve your system so you can reduce downtime, scrap rates, and maintenance and lower production costs. We’ll talk to you about new DOE efficiency standards, variable frequency drive, leaks, controls, and a lot more. It’s not a sales pitch. We won’t try and sell you anything.
Rated up to 200A 600V
Gates Industrial Safety
DIGITAL REPORTS
PROTECT FROM ARC FL ASH Safely breaks load UL Switch-Rated
To download this digital report visit: www.plantengineering.com/DigitalReport/ PlantSafetyStrategies Sponsored by:
PE_DigitalReport_SixthPage_PlantSafetyStrategies.indd 1
RECEPTACLES OFF BUTTON
There is no more fundamental right in the American workplace than the right to work safely. Creating that safe work environment is both a mechanical and a human process. We’ve come a long way in areas such as arc flash, machine guarding and light curtains, and we’ve added robotics to do the difficult or hazardous jobs that humans can’t or shouldn’t do. We are working hard to work safer.
Who Should Attend? Energy managers, plant and production managers, consulting and plant engineers or anyone responsible for compressed air system design or maintenance. How Can I Register? Visit www.kaeser.com/conferences to register. Tickets are $99. Early bird and discounts for bringing a colleague are available. Contact conference organizer Bob Glenn (bob.glenn@kaeser.com) for more information. Input #104 at plantengineering.hotims.com
MOTION CONTROL
Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety. Intelligent motion control helps manufacturing end users, machine builders, and system integrators who work on these project.
To download this digital report visit: www.plantengineering.com/DigitalReport/ MotionControl Sponsored by:
Mitsubishi, Yaskawa Input #105 at plantengineering.hotims.com
www.plantengineering.com
PE_DigitalReport_SixthPage_MotionControl.indd 1
2/1/2017 12:45:38 PM
Sensor Brackets and so much more...
Please request your... 2D / 3D CAD Files Catalogs Stock & Customs
softnoze com
PRODUCTMART
Dust, Mist and Fume Collectors Camfil APC is looking for more reps and dealers. Do you have what it takes?
Mount | Apply | Position | Protect
WORLD LEADER IN SENSOR INTEGRATION COMPONENTS
AIR POLLUTION CONTROL
TM
TM
Input #106 at plantengineering.hotims.com
Need Work Benches
?
In Stock-Factory Direct
Camfil APC’s sales volume nearly tripled from 2009 to 2015. We are a growing company with a strong financial backing. Camfil APC is a division and proud member of the Camfil group, a $800 million international conglomerate. As a rep, your commission is self-determined! The harder you work, the more money you make. Camfil APC does not determine your commission level in a contract like most competitors do. You decide how much money you make! Learn more at www.camfilapc.com/reseller
workbenchmarket.com Input #107 at plantengineering.hotims.com
e-mail: filterman@camfil.com • 800-479-6801
Go online to view the weekly Top 5 Reader Favorites!
Input #108 at plantengineering.hotims.com
OIL MIST & SMOKE IN YOUR SHOP? www.mistcollectors.com Tel: 1-800-645-4174
www.plantengineering.com Input #109 at plantengineering.hotims.com
Stay current with technology and trends in electrical, mechanical, maintenenace and automation.
Input #110 at plantengineering.hotims.com
stay informed
To subscribe, visit
www.plantengineering.com/subscribe Input #111 at plantengineering.hotims.com
www.plantengineering.com
Input #112 at plantengineering.hotims.com
PLANT ENGINEERING
March 2017 • 61
For more information on how to advertise in Plant Engineering’s Internet Connection, call Jim Langhenry at 630-571-4070 x2203 abb.us
dynatect.com
solonmfg.com
ABB is a leader in power and automation technologies that enable customers to improve performance while lowering environmental impact. ABB Inc.
Dynatect designs and manufactures a complete line of components to protect equipment and people. Dynatect
Solon Manufacturing Co. engineers and manufactures Solon Belleville Springs and pressure switches. Solon Manufacturing Co.
aitkenproducts.com
emaint.com
uecorp.com
eMaint improves the way over 50,000 users worldwide manage, monitor, and control assets for a connected world. eMaint Enterprises
UEC provides innovative, customizable power distribution and monitoring solutions. Universal Electric Corp.
flexicon.com
VAC-U-MAX specializes in design and manufacture of pneumatic systems and support equipment for conveying, weighing and batching of dry materials. VAC-U-MAX
Aitken Products manufacturers and distributes high-quality industrial heaters. Aitken’s products are for a variety of industrial applications and are available when needed. Aitken Products Inc.
a3automate.org The Association for Advancing Automation is the global advocate for the benefits of automating. Association for Advancing Automation
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.
atlascopco.us
us.kaeser.com
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco
Manufacturer of air system products, including rotary screw compressors, portable compressors, rotary lobe blowers, vacuum packages, refrigerated and desiccant dryers, filters, and condensate management systems. Kaeser Compressors Inc.
automationdirect.com AutomationDirect offers over 16,000+ industrial automation products through their free catalog and online superstore including PLCs, operator interfaces, drives, enclosures, sensors and more. AutomationDirect
lubriplate.com
avotraining.com
mhia.org MHIA is the leading non-profit trade association representing the U.S. material handling and logistics industry. Material Handling Industry of America
baldor.com
noria.com
Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.
Noria is a worldwide leader in providing lubrication consulting services and training. Noria Corp.
camfilapc.com
Orival is a leading manufacturer of self-cleaning water filters, automatic water filters and strainers, for use as industrial water filters, irrigation filters, cooling tower filters, and more. Orival Inc.
centuryspring.com Century Spring has been supplying quality stock and custom springs, metal stampings, and wire forms for MRO and OEM applications since 1927. Century Spring Corp.
donaldson.com Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.
62 • March 2017
plant engineering
yaskawa.com Yaskawa is the world’s largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.
For almost 50 years, AVO has been helping organizations create safe and reliable electrical systems. AVO Training Institute
Camfil Air Pollution Control (APC) is a leading global manufacturer of industrial dust, fume and mist collection equipment and is part of Camfil, the world’s largest air filtration company. Camfil APC
vac-u-max.com
orival.com
rogers-machinery.com Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems. Rogers Machinery
seweurodrive.com One of the largest global suppliers of drive technology, SEW-EURODRIVE specializes in gear reducers, motors and electronic motor controls. SEW-EURODRIVE USA
www.plantengineering.com
Place next to your computer as a reference or go online to www.plantengineering.com for hot links to these companies.
Remove at Line
7 h 201 Marc
CONTACTS ®
Advertiser Contacts for plant engineers
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph. 630-571-4070, Fax 630-214-4504
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Plant Engineering.
CONTENT SPECIALISTS/EDITORIAL
Advertiser
PlantEngineering.com
BOB VAVRA, Content Manager 630-571-4070 x2212, BVavra@CFEMedia.com
Page
Reader Service #
Phone #
Web site
Aitken Products, Inc
46
25
800-569-9341
www.aitkenproducts.com
EMILY GUENTHER, Associate Content Manager 630-571-4070 x2220, EGuenther@CFEMedia.com
ALL-TEST Pro, LLC
16
13
860-399-4222
www.alltestpro.com
AMANDA PELLICCIONE, Director of Research 860-432-4767, APelliccione@CFEMedia.com
AutomationDirect
Gate C-2
2
800-633-0405
www.automationdirect.com
CHRIS VAVRA, Production Editor 630-571-4070 x2219, CVavra@CFEMedia.com
AVO Training Institute
12
10
877-594-3156
WWW.AVOTRAINING.COM
Baldor Electric Company
C-4
30
800-828-4920
www.baldor.com
PUBLICATION SERVICES
Caterpillar - Northeast
21
18
JIM LANGHENRY, Co-Founder & Publisher 630-571-4070 x2203, JLanghenry@CFEMedia.com
CENTURY SPRING CORP
49
28
STEVE ROURKE, Co-Founder 630-571-4070 x2204, SRourke@CFEMedia.com
CFE Edu
TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com KRISTEN NIMMO, Marketing Manager 630-571-4070 x2215, KNimmo@CFEMedia.com
www.NECatDealers.com/power 800-237-5225
www.centuryspring.com
53
630-571-4070
http://CFEedu.cfemedia.com
CFE Media’s Global System Integrator Database
59
630-571-4070
www.plantengineering.com/global-si-database
CFE Media’s New Products for Engineers Database
51
630-571-4070
www.plantengineering.com/NP4E
Clayton Industries
10
800-423-4585
www.claytonindustries.com
8
MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com
Danfoss
8
7
KATIE SPAIN, Art Director 630-571-4070 x2218, KSpain@CFEMedia.com
DEUBLIN
20
17
847-689-8600
WWW.DEUBLIN.COM
PAUL BROUCH, Director of Operations 630-571-4070 x2208, PBrouch@CFEMedia.com
Donaldson Co., Inc
41
23
800-365-1331
www.DonaldsonTorit.com
MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com
EPICOR
38
22
800-999-1809
www.epicor.com
Exair Corp
7
6
800-903-9247
www.exair.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com
FLIR
30, 43
20
800-GO-INFRA
www.flir.com
RICK ELLIS, Audience Management Director 303-246-1250, REllis@CFEMedia.com LETTERS TO THE EDITOR Please e-mail your opinions to BVavra@CFEMedia.com INFORMATION For a Media Kit or Editorial Calendar, e-mail Trudy Kelly at TKelly@CFEMedia.com REPRINTS For custom reprints or electronic usage, contact: Brett Petillo, Wright’s Media 281-419-5725, bpetillo@wrightsmedia.com
PUBLICATION SALES Tom Corcoran, West, TX, OK 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Karen Cira, Southeast 879 Autumn Rain Ln. Charlotte, NC 28209 Maggie Hatcher, AL, FL 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523
TCorcoran@CFEMedia.com Tel. 215-275-6420 Fax 484-631-0598 KCira@CFEMedia.com Tel. 704-523-5466 Fax 630-214-4504 MHatcher@CFEMedia.com Tel. 630-571-4070 x2221 Fax 630-214-4504
Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com 246 South Franklin St. Tel. 216-409-8314 Chagrin Falls, OH 44022 Fax 440-348-1980 Richard A. Groth Jr., NJ/ E. PA 12 Pine St. Franklin, MA 02038
RGroth@CFEMedia.com Tel. 774-277-7266 Fax 508-590-0432
Jerry Preston, West Coast 6746 E. Tyndall Circle Mesa, AZ 85215
JPreston@CFEMedia.com Tel. 602-369-3037
Stuart Smith, International SSM Global Media Ltd.
stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588
www.danfossdrives.com
FLUKE ROADSHOW 2017
4
5
888-443-5853
www.fluke.com/roadshow2017
GOODWAY
16
12
888-364-7736
www.goodway.com
GTI Spindle Technology
11
9
603-669-5993
www.gtipredictive.com
21
252-931-5100
www.hyster.com
630-571-4070
www.plantengineering.com/lloT
866-516-6888
www.us.kaeser.com/PE
Hyster
37
IIoT Webcasts
57
Kaeser Compressors, Inc
1
3
Lubriplate Lubricants Co
22
19
800-733-4755
www.lubriplate.com
MAPCON
20
16
800-922-4336
www.mapcon.com
MIL-COMM
42
24
201-935-8561
www.mil-comm.com
Gate C-1, 16A-16P
1
800-523-9328
www.MotionIndustries.com
13
11
Motion Industries, Inc PATLITE
888-214-2580
www.patlite.com
Plant Engineering Electronic Newsletters 55
630-571-4070
www.plantengineering.com/newsletters
Plant Engineering Webcasts
44
630-571-4070
www.plantengineering.com/webcasts
Rogers Machinery
18
14
800-394-6151
www.knw-series.com
SEW-EURODRIVE, Inc.
2
4
864-439-7537
www.seweurodrive.com
SPM Instrument
47
26
800-505-5636
www.spminstrument.us
Sullair Industrial Products
48
27
219-879-5451
www.sullair.com
Vac-U-Max
19
15
973-759-4600
www.vac-u-max.com
Yaskawa America, Inc
C-3
29
800-927-5292
www.yaskawa.com
www.plantengineering.com
PLANT ENGINEERING
March 2017 • 63
A LIFE IN MANUFACTURING As part of Plant Engineering’s 70th anniversary celebration, we’re asking industry leaders and manufacturing professionals to tell us about their careers in manufacturing and the impact on them, their companies and their communities. If you’d like to contribute your thoughts, please send them to content manager Bob Vavra at bvavra@cfemedia.com.
Maintenance meant continuous growth, change By Dave Reiber, CRL/CMRP Senior Reliability Leader at Reliabilityweb
I
started with GM in 1985 at the truck plant in Flint, Mich. I was working as an electrician in the Saginaw area, and GM was hiring electricians. I didn’t think that I wanted to lock myself into one place for one employer; things were very slow in the construction business. At the same time, GM was selling every truck that they made before they were assembled. They hired more than 100 electricians in the surrounding plants within three years after I started my career there. I decided to aspire to greater things and explore the best way to expand learning and how I could make a bigger impact on the masses. I went from being an electrician, troubleshooting breakdowns to a global manager of GM’s maintenance business processes and condition monitoring tools, such as vibration, infrared, and ultrasound. A big part of the strength of any asset condition management team is leadership support. In 1996, after some negotiations, and leadership is blessing, I was lucky enough to take over the Maximo deployment team and the predictive maintenance teams. There was a lot of ownership to be developed, and so much opportunity to get some quick wins and increase throughput as well as quality gains. I got a couple
of promotions and was now the North America lead for the Maximo system, and we started down the road of sharing processes, and data integrity across the corporation. It would have been easy to keep those gains in the United States, but we needed to share the wins with the rest of the corporation globally. That’s when the big challenges started. We started in the U.S. by sharing with the other assembly sites, then we branched out to the powertrain sites, foundries, and the engineering centers. After some time, we decided that these gains and common business processes had to get standard and go global. I remember the real challenge was when I had to decide that we would never be completely common, but rather as common as possible. At the time, we were running at least 17 separate maintenance software systems, including some one-offs that were created in Microsoft Access and Excel. Some of them worked quite well. That success became a problem when we told the global team that we were about to bring everyone to a common database, and that we were about to establish a common business process. The culture change that needed to happen took about 2 ½ years. We appointed regional leads from all points of the globe and set up voting and weighting metrics to establish which problem to take on first.
The road was long with many heavy discussions, but in that time we established a global common process to support all maintenance activities from project and engineering work to emergency maintenance. Complete with flow charts, swim lanes, and RASICs (Responsible, Approving, Supporting, Informed, Consulted) to demonstrate responsibilities, accountability and leadership support. There were several years of tough times. GM went through a severe downturn in sales, and a bankruptcy. Despite the challenges, we fought on to complete the common process project. When I left General Motors in 2015, the Global Manufacturing System, including the maintenance process, was well-established. There is a global team assigned to make it work, by sharing lessons learned and common reporting of data. I am now working in the reliability field for Reliabilityweb, conducting training classes, reviewing books and articles, and sharing my experience through many conferences and symposiums. I am thankful for a fruitful career in manufacturing. PE A member of Plant Engineering’s Editorial Advisory Board, Dave Reiber’s career at GM included global maintenance and reliability opportunities, and certification as a leader and instructor on the topic of reliability best practices.
“The road was long with many heavy discussions, but in that
time we established a global common process to support all maintenance activities from project and engineering work to emergency maintenance.
”
64 • March 2017
PLANT ENGINEERING
www.plantengineering.com
PROVEN WORLDWIDE
30+ Million Pieces of Evidence... and Counting 20 million inverters, 10 million servo axes and 300,000 robots in the field are proof positive that Yaskawa has the engineering expertise, innovative technology and unsurpassed quality to create solutions which inspire complete customer confidence. Yaskawa’s A1000 is a full-featured drive, providing outstanding quality, performance, flexibility, and environmental friendliness through 1000HP. Enjoy network communications, feedback, and expandable I/O to control anything from simple fans and pumps to complex machines. No matter how you add it up, nobody equals Yaskawa. Call us today.
For more info: http://budurl.me/YAI1012
YASKAWA AMERICA
input #29 at www.plantengineering.com/information DRIVES & MOTION DIVISION
YASKAWA.COM
1-800-YASKAWA
Direct Drive
The Ultimate Cooling Solution Direct drive cooling tower systems from Baldor Electric Company eliminate the need for mechanical components such as gearboxes, jack shafts and couplings – greatly reducing cooling tower maintenance and power consumption while increasing system reliability. The field-proven, high torque Baldor•Reliance AC laminated motor is controlled by a purpose built ABB matched performance adjustable speed drive to provide optimal speed, quieter operation and lower energy use. For new projects or retrofit applications, you can count on Baldor•Reliance for the ultimate cooling solution.
baldor.com
479-646-4711
©2017 Baldor Electric Company
See us at ABB Customer World | March 13-16, 2017 | Houston, TX
input #30 at www.plantengineering.com/information