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36 Lubrication Guide 14 CMMS success in 10 steps

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A drive to succeed Turn detective to troubleshoot ac drives 28

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the #1 value in automation

COMPRESSORS

CSuccess USTOMER Story Sweet Savings!

A compressed air audit opens a world of savings opportunities PROBLEM:

One of the world’s leading candy and gum manufacturers had no idea how much their compressed air system was costing them. Four compressors (totaling 290 hp) supplied the air needed for pneumatic controls, packaging, and wax line extrusion applications. Excessive water in the compressed air lines, steep maintenance costs,

and high noise levels had them looking for a new solution.

SOLUTION:

A comprehensive Air Demand Analysis (ADA) established a demand profile for the plant and showed how they were using compressed air throughout the week. It also identified areas of waste and inefficiency. By installing a 100 hp variable frequency drive compressor and two 75 hp fixed speed compressors, they would have all the air needed—with one of the fixed speeds acting as a back-up. This split system solution would bring energy—and noise levels—well under control. A Sigma Air Manager 4.0 master controller could provide on demand energy reports so they would always know how their system was performing and what it was costing.

RESULT:

In just over 9.5 months, the project has paid for itself. Annual energy costs

have been cut by more than 800,000 kWh. Part of these savings came from reducing the plant pressure from 125 psi to 100 psi. Additionally, the new energy efficient dryers installed have taken care of the moisture concerns. Needless to say, these savings couldn’t get any sweeter.

Specific Power of Previous System: . . . . . . . . . . . . . . . . . . . . .47.16 kW/100 cfm Specific Power of New System: . . . . . . . . . . . . . . . . . . . . . . . . .17.77 kW/100 cfm Annual Energy Cost of Previous System: . . . . . . . . . . . . . . . . . . . . . . . . . $128,756 TOTAL ANNUAL ENERGY SAVINGS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,235 Utility Incentive:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,200

Let us help you measure and manage your compressed air costs! input #2 at www.plantengineering.com/information

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Makes no cents! Adding an inefficient worm gearbox to a premium efficient motor doesn’t make sense if you are trying to save money. Why gain 2-3% energy savings with a more efficient motor and then lose 50% or more through the worm gear? Solution: Use a helical-bevel gearmotor from SEW-EURODRIVE and obtain 96% efficiency. Now that makes a lot of cents!

seweurodrive.com | 864-439-7537 input #3 at www.plantengineering.com/information

JUNE 2017

SOLUTIONS

COVER STORY: Many suppliers are providing software tools that can allow manufacturers to extract the parameter set and fault log from the drive. Cover image courtesy: Danfoss

INSIGHT 8 | The cloudâ&#x20AC;&#x2122;s role in data management 10 | Motor insulation systems: Six testing tips 14 | CMMS implementation: 10 steps to success 18 | To use robots effectively, get started, get coaching

Notable 20 | A collection of news and other fun items

Research 22 | 2016 Safety Study Discrete industry safety practices

INNOVATIONS 80 | New Products 88 | Soft starters an option when VFDs donâ&#x20AC;&#x2122;t work 90 | The ABCs of VFDs

Lubrication Guide 33 | Cutting through the fog on pneumatic lubrication Choosing the right strategy to prolong the life of key equipment

36 | Lubrication Guide A look at the top product offerings in machine and compressor lubrications

Automation 41 | An antidote to downtime Remote monitoring protects against skill shortages, complexity.

SPECIAL REPORT Energy Management 47 | Microgrids drive a new energy strategy Energy Master Planning provides a bridge to the future.

51 | Empowered to cut wasted energy DOE program is designed to find and eliminate energy waste.

55 | Overcome the high cost of staying cool Calculate seasonal energy efficiency for your HVAC system.

58 | Control room temperatures: Strategies to beat the heat Air-to-water exchangers can reduce VFD heat exposure.

PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 5, 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.

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PLANT ENGINEERING

June 2017

WHY WE DO IT

CLEAN AIR MATTERS

Farr Gold SeriesÂ® Dust Collector

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Handte EM Profi Coolant Mist Collector for machining

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Dust, Mist and Fume Collectors AIR POLLUTION CONTROL

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REIMAGINING PLANT ENGINEERING By Bob Vavra, Content Manager, CFE Media

A bright, dynamic presentation of manufacturing knowledge

n the 70 years since Plant Engineering’s debut, one goal that has guided the efforts of editors and writers for this publication—plant personnel needed a credible source for great information on how to run their facilities better, safer and more efficiently. All that really has changed in the last seven decades is that the means of delivering that great information itself has gotten better and more efficient. The place Plant Engineering enjoys in the manufacturing sector, and the loyalty we’ve engendered over those years continue to drive our efforts every day. I am grateful to our audience for their continued use of Plant Engineering’s content, regardless of its media source. For example, our Web traffic at PlantEngineering.com is at an all-time high, and up 7% so far this year. Our online content is viewed in 191 countries each month. The need for great information about manufacturing knows no borders. What also is true is that, for our readers, the printed version of Plant Engineering remains a valuable tool. In an era of 24/7 news cycles and a constant barrage of information from a variety of sources and in a variety of formats, the simple printed page still carries weight and power for the plant manager. We know this to be true because we asked our readers about how they interact with print, both on its own, and in comparison to other media. We asked our readers to tell us how they use the print magazine in 2017 and what types of articles they need to run their plants better. One piece of information we gained from that study: readers are 20% more engaged with our print magazine than with the digital product. The June issue of Plant Engineering marks the start of a fresh chapter in our 70-year relationship with manufacturing professionals. Our June issue turns those reader comments into a new, clean, and better-organized Plant Engineering. Each month, there will be three sections to our magazine, each created as a direct result of reader feedback and input:

INSIGHTS: A monthly look at the new trends, technologies and strategies that will change and improve manufacturing. Articles will www.plantengineering.com

focus on everything from the latest on the Industrial Internet of Things (IIoT), to ways to improve safety and maintenance, and provide better training. A hallmark of this section will be conversations with industry professionals and thought leaders on the next big trends. We want our readers to be prepared for tomorrow by understanding what’s being discussed today.

SOLUTIONS: The industry’s top manufacturing experts will provide their knowledge on how to make every part of your plant run more effectively. Every plant system, from automation to electrical, from maintenance to mechanical, will be highlighted each month. Plant Engineering assembles industry best practices each month to focus on how to operate a world-class manufacturing plant today, and build a better plant for the future. We are the leader in delivering actionable solutions for plant-floor issues, and in informing plant managers on the best new strategies. We’re adding more data, and access to more content online as part of this effort.

INNOVATIONS: Introducing new products to our readers has been a part of Plant Engineering since 1947. As we begin the 30th year of the industry-leading Product of the Year program, our Innovations section will feature not only new products from the industry’s top suppliers, but also a focus on how to effectively use those product categories to improve plant operations. New product introductions give plant managers a look at the tools they need to advance their operations, and no one has been more proactive about bringing those products and solutions to light than Plant Engineering. We believe the future of publishing, and of manufacturing, is bright and dynamic. We hope to reflect that future in this month’s issue of Plant Engineering, and in the issues to come. As always, we welcome your comments and critiques, and your suggestions on ways we can continue to improve. PE PLANT ENGINEERING

June 2017

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INSIG Motor insulation systems: Six testing tips

INSIGHT The cloud’s role in data management

Watch for factors that may impact accuracy.

CMMS implementation: 10 steps to success

Wireless solutions offer flexibility, lower costs for most users.

Standard procedures, new technologies, and performance metrics can ease the path.

To use robots effectively, get started, get coaching

S 10

The human touch: 3 questions with Robotiq’s David Gariépy

NOTABLE PMA names Hardy as new president

RESEARCH

Try to take this for a spin

2016 Safety Study

Discrete industry safety practices

May PMI ticks up slightly

Frequency of safety meetings at discrete manufacturing facilities 38%

Monthly 34%

As needed 23%

Weekly 19%

Daily 15%

Every shift 9%

Every other week Quarterly

EDITOR INSIGHT Hollywood, they call them “In‘pitch meetings’—a group tossing around ideas for the next big thing.

”

25 www.plantengineering.com

PLANT ENGINEERING

June 2017

INSIGHT

By Rebecca Bolt, GE Automation & Controls

The cloud’s role in data management Wireless solutions offer flexibility, lower costs for most users.

illions of sensors all around the world are making consumer devices smarter, safer and more efficient. Wearable products have revolutionized our understanding of wellness by providing more information about our daily health. Appliances and systems in our homes now are connected and make intelligent decisions to enhance our lives. Entire cities now are employing big data and sensors to prevent crime, manage crowds, reduce energy use, and much more. The connectivity of and communication between these devices, as we know, is referred to as the Industrial Internet of Things (IIoT). But before these devices can start communicating with end users and each other, they must collect and analyze data—lots and lots of data. Data for many of these devices is collected, stored, and analyzed in cloudbased environments, such as Amazon and Google.Even our Fitbit trackers have Number of Internet of Things a cloud where our health analytics are connected devices expected stored. While there’s a lot of data gathered by 2020. This includes industrial from consumer products, there’s a much and consumer-based devices. larger amount of data Source: IHM Markit found in industrial machines and an even greater need for the same type of connectivity and analytics. IIoT will increase efficiencies, reduce costs, and improve employee health and safety while generating new revenue streams for businesses. Controls have been managing machines all around us for centuries. Just as our machines

By The

NUMBERS

30.7 billion

June 2017

PLANT ENGINEERING

have evolved, so, too, have the analytics our machines provide. However, the data those machines collect and analyze, up to this point, has been limited to the memory of internal computers running at or inside the machine; the intelligence of those machines essentially has been limited to that memory. New industrial control systems now are providing the same type of connectivity, communication, and analytics for our industrial assets as consumers have seen for several years. These connected controllers and systems not only run our machines like they used to run, but they also now have the capability to create an outer loop and custom applications that gather data in real time and advise the controller to make more intelligent decisions. Just as connected sensors and wireless devices transport data to consumer clouds, the vehicles to transport big data to the industrial cloud are edge devices and sensors in or near machines. Many machines and plant systems don’t offer the type of connectivity and deep analytics today’s industry demands. These machines require third-party solutions to gather data and provide critical analytics. The more data gathered, and the closer to the machine you run data, the more accurate and intelligent the decisions the machine makes. Some machines can’t be reached with traditional Ethernet cables because of the distance between the internet source and the machine. Not only would it be cost prohibitive to drop and run that wired connection, but the proximity would make data gathered less favorable. Connecting to these machines wirelessly makes sense. Cloud-based wireless solutions provide greater flexibility than wired solutions. The cloud empowers the elasticity of data storage and performance and is not subject to the constraints typical of a local computer. Connecting to the www.plantengineering.com

cloud also enables a fleet of machines to be managed and to communicate with each other, providing thorough analytics for the entire fleet. For example, there’s an app that leverages the power of the industrial internet, connects to a fleet of wind turbines and enables them to coordinate the speed and direction of their blades to maximize the wind farm’s overall energy output. However, the cloud is not always a viable option due to latency, costs, regulations, and other factors. Think also about the criticality of the data being analyzed. If a self-driving car was required to go to the cloud to make important decisions, the car’s response time would be too slow. Industrial assets are the same way. Some things can be done in the cloud, but other problems need to be analyzed as close to the machine as possible. Digital industrial companies are developing products that are designed to work on the industrial edge and make collecting, storing, and analyzing data

“IIoT will increase

efficiencies, reduce costs, d improve employee health and safety while generating new revenue streams for businesses.

”

eas e a d o e accuate. Th e y g couldn’t have imagined IIoT as it is today. Similarly, we can’t speculate on where it will be three years from now. The rate at which things are changing makes it difficult to recommend specific assets or systems that should be hard-wired or should be wireless or which apps should run in the cloud versus at the industrial edge, so it’s important to think the process through strategically and go the route that As the technology around cloud-based data manmakes the most sense for your plant. PE agement evolves, it’s important to take a strategic approach to deploying analytics on the plant floor. Image courtesy: GE Automation & Controls

www.plantengineering.com

Rebecca Boll is a general manager of sales for GE Automation & Controls.

PLANT ENGINEERING

June 2017

INS GHT k

ll, Electrical Apparatus Service Association (EASA)

Motor insulation systems: Six testing tips Watch for environmental factors that may impact data accuracy.

lt houg h t here are many ways to assess motor insulation systems, the insulation resistance (IR) test remains a useful tool for determining if a motor should be removed from or placed into service. When conducting the test and e valuating the results, consider these six tips.

Insulation resistance (IR) tests are useful for determining whether a motor should be removed. During the test, the user should discharge for safety and accuracy and record important test conditions. Users should also be aware of factors that might affect the IR test.

1 . Discharge for safety and accuracy. Discharge the winding to ground b efore and after IR testing. A good rule of thumb is to ground the winding for 15 minutes or four times the test time, whichever is greater.

3. Record important test conditions. Document the ambient temperature, relative humidity, dew point, winding temperature, time since service, test voltage and connection arrangement. 4. Simple test procedure. Energize the winding for one minute at an appropriate voltage (see Table 1) and correct the measured IR value to 40°C by multiplying by a KT from Table 2. Most modern insulation falls under the “Thermosetting” category. Use the “Thermoplastic” values if you know it is a much older winding with an asphaltic or shellac mica system. 5. Watch for factors that can affect the IR test. During the test, watch out for these four factors that can have an impact on the test and its results:

2. Winding configuration for testing. If possible, isolate and test each phase separately and ground the two phases not under test. This allows for testing of the phase-tophase insulation as well as the ground insulation.

t 4VSGBDF DPOUBNJOBUJPO TVDI BT PJM EVTU BOE salts may be conductive, causing lower IR. Cleaning and drying the winding will usually improve the IR.

t *G UIF XJOEJOH UFNQFSBUVSF JT BU PS CFMPX UIF dew point, moisture may accumulate on the surface, causing low IR values. When the winding is otherwise Table 1: Guidelines for dc voltages to be applied during in good condition, insulation resistance tests dr ying will resolve this issue. Winding rated voltage (V)a Insulation resistance test direct voltage (V) <100

500

1,000 - 2,500

500 - 1,000

2,501 - 5,000

1,000 - 2,500

5,001 - 12,000

2,500 - 5,000

>12,000

5,000 - 10,000

Rated line-to-line voltage for three-phase AC machines, line-to-line ground (earth) for single-phase machines, and rated direct voltage for DC machines or field windings

June 2017

PLANT ENGINEERING

t 8 J O E J O H * 3 decreases when winding temperature increases, which is why correction to a baseline temperature is recommended.

www.plantengineering.com

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input #6 at www.plantengineering.com/information

IN GHT Table 3: Recommended minimum insulation resistance values at 40oC (All values in MÎŠ)

Table 2: KT versus temperature for thermoplastic and thermosetting insulation stator winding systems T(oC)

KT Thermoplastic

KT Thermosetting

0.125

0.7

0.25

0.8

0.5

0.9

1.0

1.5

2.3

3.3

4.6

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Minimum insulation resistance

Test specimen

IR1min = kV + 1

For most windings made before about 1970, all field windings, and others not described below.

IR1min = 100

For most DC armature and ac windings built after about 1970 (form-wound coils)

IR1min = 5

For most machines with random-wound stator coils and form-wound coils rated below 1kV

Notes: 1. IR1min is the recommended insulation resistance, in megohms, at 40oC of the entire machine winding. 2. kV is the rated machine terminal-to-terminal voltage, in rms kV.

6. Evaluate the test results. 5BCMF TIPXT UIF SFDPNNFOEFE WBMVFT GPS UIF DPSSFDUFE *3 -PXFS WBMVFT XBSSBOU GVSUIFS JOWFTUJHBUJPO CFGPSF UIF VOJU JT QMBDFE JOUP TFSWJDF 4PNF NBDIJOFT

EP PQFSBUF CFMPX UIFTF WBMVFT )BWJOH IJTUPSJDBM EBUB PO IBOE JT WBMVBCMF PE Mike Howell is a technical support specialist at the Electrical Apparatus Service Association (EASA), a CFE Media content partner.

LETTER TO THE EDITOR Level the manufacturing playing field Editorâ&#x20AC;&#x2122;s Note: Last monthâ&#x20AC;&#x2122;s Insight column by Bob Vavra (â&#x20AC;&#x153;Confronting the elephant in the roomâ&#x20AC;?) produced many reader comments, evenly divided on both sides of the topic. We share one such opposing viewpoint: * GJOE ZPVS UBLF PO UIF OFX BENJOJTUSBUJPO T TUBODF PO 6 4 NBOVGBDUVSJOH B CJU EJTUVSCJOH -PXFSJOH DPSQPSBUF UBYFT MFTT SFHVMBUJPO BOE NPSF GBWPSBCMF USBEF BHSFFNFOUT UP FODPVSBHF KPC HSPXUI UP NF JT OPU EFUSJNFOUBM UP B HMPCBM NBOVGBDUVSJOH FOWJSPONFOU *U IFMQT LFFQ VT JO UIF HBNF * EPO U TFF UIF NFTTBHF BT CFJOH IPTUJMF UP GPSFJHO USBEF CVU BO BUUFNQU UP MFWFM UIF QMBZJOH GJFME 5IF BSHVNFOU IBTO U CFFO XJUI (FSNBOZ CVU XJUI $IJOB BOE PUIFST XIP IBWF CFFO HVJMUZ GPS ZFBST PG EVNQJOH MPX DPTU QSPEVDUT JOUP PVS NBSLFU OPU POMZ BU UIF DPOTVNFS MFWFM

June 2017

PLANT ENGINEERING

-PPL XIBU UIF $IJOFTF BT XFMM BT &VSPQFBO QBQFS DPN QBOJFT IBWF CFFO EPJOH GPS ZFBST EVNQJOH MPX DPTU DPBUFE BOE VODPBUFE QBQFS POUP PVS TIPSFT BU UIF FYQFOTF PG 6 4 QBQFS NJMMT BOE UIF KPCT BOE DPNNVOJUJFT UIBU EFQFOEFE PO UIFN 5IF 6 4 HPWFSONFOU IBT GPS ZFBST UVSOFE B CMJOE FZF UPXBSET UIJT JTTVF 8IJMF * BHSFF XF OFFE HMPCBM DPPQFSBUJPO XJUI SFHBSE UP NBOVGBDUVSJOH XF BMTP OFFE DPPQFSBUJPO XJUI SFHBSE UP GBJS USBEF 5IBOL ZPV GPS ZPVS PWFSTJHIU PG UIF Plant Engineering DPOUFOU * GJOE UIF NBHB[JOF UP CF UIF CFTU PG UIF QFSJPEJDBMT * SFBE Bob Tees vice president and general manager Mac Paper Converters Inc. www.plantengineering.com

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input #7 at www.plantengineering.com/information

INS GHT k

k , CFE Media

CMMS implementation: 10 steps to success Standard procedures, new technologies, and metrics can ease the path.

mplementing a computerized maintenance management system (CMMS) can be easier and more effective by paying attention to 10 key considerations. When shifting toward condition-based maintenance, hardware and software also can help, as can defining and using standard operating procedures and the right set of performance metrics. This was among advice from experts at the Fluke Roadshow 2017, in Chicago, May 4. Covering the 10 keys to CMMS implementation success, Bill Green, leader of implementation and success, eMaint (a Fluke company),

said that even after a CMMS installation, evaluation and improvements should be a continuous process with input from all involved (See Fig. 1). Green’s 10 steps for smarter CMMS implementation are.

1. Choose a cross-functional implementation team

Include executives to approve or provide funding, maintenance (a champion and the future system administrator), project leaders (a manager to keep things on track and analyst to gather requirements), subject matter experts (define how the system is used), IT staff (provide system environFigure 1: A wirelessly enabled vibration monitor can take measurements ment), and implementation consultants from a fan, send it to a smart phone application, as shown by Dave Rob(provide specific expertise). ley, a field engineer for Fluke Industrial at the Fluke Roadshow 2017 in Chicago in May. Information can also feed that information into a cloudbased computerized maintenance management system, if desired. Image courtesy: Mark T. Hoske, CFE Media

2. Familiarize the core team A professional services team can provide upfront training to the core team, especially with training, a framework, experts, and involving future trainers. Those doing the training should know the software details, even if the

“Maintenance and operations personnel might use different words to refer to the same things. Standard terms must be agreed upon.

”

June 2017

PLANT ENGINEERING

www.plantengineering.com

SEPTEMBER 12-13, 2017 George R. Brown Convention Center | Houston, TX

Insulation Expo (IEX) USA and Plant Engineering are pleased to invite you to Houston, Texas in September for the industry’s only dedicated commercial and industrial insulation show. At this 2–day event you will have the opportunity to connect with industry professionals including engineers, manufacturers, and distributors. Insulation Expo (IEX) USA will provide you with actionable takeaways through compelling education, product innovations, personalized exhibitor recommendations and more. For more information, visit iexusa.com

INTERESTED IN EXHIBITING? FOR MORE INFORMATION OR TO BOOK YOUR SPACE, PLEASE CONTACT MARK SWAGERTY, SALES MANAGER AT 203 840 5847 OR MSWAGERTY@REEDEXPO.COM input #8 at www.plantengineering.com/information

INS GHT software is known to be intuitive. Online and inperson training may be available.

3. Develop and standardize workflow processes Look at the current business and standard operating procedures, which can be how things are done, even if theyâ&#x20AC;&#x2122;re not documented, apply process improvements, create a CMMS workflow using the new business processes. Define maintenance coding (such as work order classes, types, priorities, problems, actions, and failure codes), workflow procedures and who is responsible for what, and define hierarchies (assets, criticalities, and locations).

4. Establish or update standard operating procedures. 5. Prioritize the CMMS implementation steps Tackle low-hanging fruit first with a focus on critical data. Leverage experiences of a seasoned CMMS implementer, learn from colleagues, and define the implementation timeline.

6. Work on the configuration Look at forms, fields, dropdowns, and tabled data derived from standards, defined in the implementation phase and documented in standard operating procedures. Itâ&#x20AC;&#x2122;s important to differentiate the users of the system versus the users of data from the system and ensure data entry consistency with established data standards. For instance, maintenance and operations personnel might use different words to refer to the same things. Standard terms must be agreed upon.

By The

7. Populate and validate data

NUMBERS

59% Percentage of readers using CMMS as part of their overall maintenance strategy; it ranks behind preventive maintenance (78%) and run-to-failure (61%). Source: 2017 Plant Engineering Maintenance Study

June 2017

PLANT ENGINEERING

Having the right amount of good quality data is critical for success of a CMMS implementation. All data that goes in needs to be maintained, and all m ai nt ai n e d d at a needs to go into the system. Thoroughly test established processes and procedures developed to support the mainte-

The hierarchy of maintenance Predictive maintenance activities are improving, said Alex Desselle, a Fluke product application specialist whose career includes work with Monsanto and GE. Desselle noted that most companies have a long way to go because too much maintenance remains reactive; that is, a run-to-failure strategy. In the hierarchy of maintenance, the most efficient strategies are: t 3FMJBCJMJUZ DFOUFSFE NBJOUFOBODF t 1SFEJDUJWF .BJOUFOBODF 1E. t $POEJUJPO CBTFE NPOJUPSJOH t 1SFWFOUJWF .BJOUFOBODF 1.

t 3FBDUJWF 3VO UP GBJMVSF

nance function. Data collection can be seen as a service. Use available import tools rather than manually transfer data.

8. Train the main users This critical step to ensure investments follows the trainers training. The person doing the training needs to be proficient in the software and in soft skills such as communication and organization.

9. Develop a go-live strategy Support and coaching are important steps. This may include soft go-live dates for certain areas of the CMMS. Depending on the organization and implementation, bite-sized chunks or a series of continuous improvement projects may be the best way. Highlight implementation milestones. If there is a hard go-live date, create a plan B, if those involved are ready to lower risk of data loss or production delays.

10. Establish a process auditing system for continuous improvement Use intelligence from the CMMS to drive decisions and make continuous adjustments. Define success metrics from the start. Establish a team responsible for continuous improvements, incorporating the cycle of plan, do, check, act and repeat. PE Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.plantengineering.com

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INS GHT

To use robots effectively, get started, get coaching The human touch: 3 questions with Robotiq’s David Gariépy

s robots become a larger part of the manufacturing landscape, programming the robots may be an early barrier to their use on the plant floor. Quebec City, Canada-based Robotiq has introduced a series of downloadable programming templates to help get the process started. Robotiq integration coach David Garié py talks with Plant Engineering about how manufacturers are dipping their toes into the robotics market, some of the challenges of working with collaborative robots, known as cobots, and some of the challenges they face. Plant Engineering (PE): When manufacturers are first exploring using robots on their assembly line, do they know what they need, or, as your job title implies, is there some coaching to be done? Garié py: Most of the time, they want to validate the possibility to automate a given task and be guided on how to do it. The coaching is really useful, as we can do a proof of concept, give them the program code we used and explain the programming logic so they have something to start with. The coaching service is useful at the beginning of the process but also during the implementation. We help them remove the blockers they might encounter and speed up their integration process. It allows them to grow their

“Keep it small and simple. Highly predictable and repeatable tasks are the best ones to start with.

”

David Gariépy, Robotiq

June 2017

PLANT ENGINEERING

know-how skills faster and go forward with a new project sooner. PE: What’s the one challenge manufacturers face when integrating robots into their manufacturing process? How can they meet those challenges? Garié py: The main challenge is definitely the knowhow skills; 82% of manufacturers believe the skills gap will impact their ability to meet the customer’s demand. It is 10 times more difficult to find robotics skills than machinist skills in the U.S. workforce. How can they meet those challenges? By getting started with cobots as soon as possible. At first, they should keep it small and simple. Highly predictable and repeatable tasks are the best ones to start with. They can then build their know-how skills and start scaling up to more robots with more complex applications. So start small and build on your success. Another interesting fact is that once you’ve started, the subsequent cobots implementation usually takes 30% to 50% less time than the first one. The free coaching service and programs templates that Robotiq is offering allow manufacturers to simplify and speed up the implementation of cobots in their production line. PE: As the concept of cobots continues to evolve, how do we keep humans engaged and i p the manufacturing process? G p p g o j p m T

py: The biggest misconception ve about cobots, and robots in that it has to be done at the cost reality, the opposite usually haplows manufacturers to become ductive, so they get more orders. mployees then can be moved to m re rewarding jobs and eventually, new jobs are created. Our goal at Robotiq is to free human hands from repetitive tasks in order to give them the freedom to think, to create, and to innovate. PE www.plantengineering.com

Engineered with TIA Portal

One controller, one engineering, one communication for standard and fail-safe automation 5 ways integrated safety makes plants safer

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usa.siemens.com/safety-CD

ÂŠ2016 Siemens Industry, Inc.

SIMATIC Safety Integrated â&#x20AC;&#x201C; all built in

NOTABLE By Bob Vavra, CFE Media

A collection of news and other fun items

PMA names Hardy as new president

May PMI ticks up slightly

Roy Hardy is forging a new career for himself as president of the Precision Metalforming Association (PMA). Hardy was named the associationâ&#x20AC;&#x2122;s president after serving for the last eight years as president of the Forging Industry Association (FIA). â&#x20AC;&#x153;He has a proven track record of leadership and a wealth of industry knowledge that will be a tremendous asset to PMA members, our staff and our board,â&#x20AC;? said PMA board chairman Dave Arndt. â&#x20AC;&#x153;Roy will build on recent years of solid growth and will lead PMAâ&#x20AC;&#x2122;s continued growth at this critical time for U.S. manufacturing.â&#x20AC;? Hardy succeeds Bill Gaskin, who retired after a 40-year career with the PMA, including spending the last 17 years as president. â&#x20AC;&#x153;Bill Gaskin leaves an unparalleled legacy of 40 years of service to PMA and the metalforming industry,â&#x20AC;? said Arndt. â&#x20AC;&#x153;The board, members and staff thank Bill for his leadership, and we know that Roy will continue to build on the tremendous work done by Bill.â&#x20AC;? PE

U.S. manufacturing continued its resurgence in 2017 as the PMI Index rose slightly in May to 54.9%. The increase of 0.1 percentage points ended a two-month decline and signaled that the manufacturing sector remains on solid ground. The PMI has been above the 50% growth threshold for 11 of the last 12 months, and has not dipped below 54% since November 2016. â&#x20AC;&#x153;Comments from the panel generally reflect stable to growing business conditions, with new orders, employment and inventories of raw materials all growing in May compared to April,â&#x20AC;? said Bradley Holcomb, chairman of the Manufacturing Business Survey Committee for the Institute for Supply Management (ISM), which publishes the monthly PMI index. Among the committee comments: t i4BMFT IBWF QJDLFE VQ DPNQBSFE UP UIF MBTU UXP months. Customer demand has increased.â&#x20AC;? (plastics and rubber products) t i&DPOPNZ JT TUJMM TUSPOH CVU UIF QPMJUJDBM DMJNBUF can change things very quickly.â&#x20AC;? (transportation equipment) t i(MPCBM QSJDF JODSFBTFT GPS DPNNPEJUJFT w FMFDUSJDBM equipment, appliances and components) t i#VTJOFTT JT CPPNJOH BOE HFUUJOH EJSFDU FNQMPZFFT is increasingly difficult.â&#x20AC;? (fabricated metal products) t i%JGGJDVMU UP GJOE RVBMJGJFE MBCPS GPS GBDUPSZ QPTJ tions.â&#x20AC;? (food, beverage and tobacco products)

Try to take this for a spin The hottest new toy of 2017 is the fidget spinner, a three-pronged magnetic device that is held between the thumb and a finger and simply spins, with the magnets creating an almost perpetual force to keep the spinner in motion. Itâ&#x20AC;&#x2122;s advertised as a way to relieve stress. A fidget spinner built by the creative guys at Ohio-based Hamilton Caster isnâ&#x20AC;&#x2122;t going to be mass-produced, but it provides a look into the bigger science surrounding the toy. â&#x20AC;&#x153;Fidget spinners work through torque and friction reduction,â&#x20AC;? said Jevon Lambright, a mechanical design engineer at Hamilton who helped design what they called the Hamilton Spinfidgeter. â&#x20AC;&#x153;When you hit the outer leg, the force applied spins the central bearing, and the three weighted legs keep some torque going due to the initial force input. â&#x20AC;? The Spinfidgeter was scaled to match the size of the companyâ&#x20AC;&#x2122;s standard 6205 ball bearings, This is Hamilton Casterâ&#x20AC;&#x2122;s superso the finished product is sized fidget spinner. Image cour7.5 in. long, about three tesy: Hamilton Caster times larger than the typical fidget spinner. Mark Lippert, a member of the ownership group at familyowned Hamilton Caster, told Plant Engineering that the company has made five of the supersized toys to give away to respondents who offer the five best ideas in the companyâ&#x20AC;&#x2122;s online new product survey. One small issue is these spinners really canâ&#x20AC;&#x2122;t easily be held between your thumb and finger, and that might be frustrating. PE

June 2017

PLANT ENGINEERING

May marked another milestone for the index. It has now been eight years since the index registered a reading below 43.3%, which is the indexâ&#x20AC;&#x2122;s threshold to indicate growth in the overall economy. The May PMI figure translates to an annual growth rate of 3.7% in domestic gross products, according to ISM officials. PE

By The

NUMBERS

54.9% May reading for the Institute for Supply Managementâ&#x20AC;&#x2122;s monthly PMI Index. It rose 0.1 percentage points, as manufacturing growth remains solid. www.plantengineering.com

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M More RESEARCH research

Plant Engineering covers several research topics each year. All reports are available at www.plantengineering.com/research

2016 SAFETY STUDY

Discrete industry safety practices

he Plant Engineering 2016 Safety Study indicated that 35% of plant personnel work for a company serving a discrete industryâ&#x20AC;&#x201D;such as automotive, aerospace, or electronic product manufacturing. Below are five key findings from this study regarding safety practices within discrete manufacturing facilities:

1. Commitment to safety: Sixty-eight percent of operations and senior management are very committed to safety within their facilities, while 57% of line supervisors and 49% of line workers are equally dedicated.

2. Work groups: When it comes to feeling safe on the job, 72% of plant management/corporate executives and

64% of safety executives/managers do not feel threatened at work, while 66% of engineering staff and 53% of operations personnel feel very safe.

3. Safety training: The average discrete manufacturing facility send their employees to 18 hours of job-related safety training, 12 hours of first-aid/personal safety training, and 10 hours of ergonomics training.

4. Enforcement: In an effort to implement safety protocols, 68% of facilities will penalize personnel (suspension, termination, etc.) when procedures are not followed properly. Conversely, only 28% of facilities have incentive-based programs in place to encourage a safe environment.

Frequency of safety meetings at discrete manufacturing facilities

5. Strategies: Looking at proactive 38%

Monthly 34%

As needed 23%

Weekly 19%

Daily 15%

Every shift 9%

Every other week 4%

Quarterly

View more information at www.plantengineering.com/2016Safety

Mandatory safety meetings are typically held monthly or weekly at discrete manufacturing facilities, but 34% will call a meeting to review safety procedures as needed/at undefined intervals. Source: Plant Engineering

19:

tactics, 79% of facilities hold regular safety meetings with all employees and 66% have organized a safety committee. Another 68% follow a job safety analysis (JSA) procedure in which safety is integrated into current tasks and potential hazards are easily identified.

Amanda Pelliccione is research director at CFE Media.

Average number of hours that plants spend on schedule maintenance each week.

Average annual salary $150,000 or more

Source: Plant Engineering 2017 Maintenance Study

Less than $70,000

12% 18%

facilities conduct regular energy audits, the 54% ofmajority of which occur yearly or every other year.

$100,000 to $149,999

37%

21%

$70,000 to $89,999

Source: Plant Engineering 2016 Energy Management Study 12%

78%

of facilities have observed a decrease in the cost of insurance claims over time as a result of their safety program. Source: Plant Engineering 2016 Safety Study

June 2017

PLANT ENGINEERING

$90,000 to $99,999

The average plant/facility engineering professional earned $104,000 in 2016. Source: Plant Engineering 2016 Salary Survey www.plantengineering.com

Ed Countess Senior Staff Engineer NovaTech Process Solutions

“Phoenix Contact provides peace of mind.” NovaTech Process Solutions relies on ORING redundancy modules from Phoenix Contact. “I never worry about 2 a.m. calls from the instrument tech regarding failed power equipment. I have the utmost confidence that when I ship a system with Phoenix Contact power supplies, they’ll provide problem-free service for years to come.” ORING redundancy modules from Phoenix Contact deliver long-lasting confidence in your process. Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_oring

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Being knowledgeable of the proper safety measures, codes, and regulations in both new and existing facilities is an absolute necessity. It just might even save your life one day. Safety First: Arc Flash 101 is a new online and on-demand course CFE Edu is offering for you to stay up to date on the latest electrical safety information. CFE Edu is an interactive online platform taught by industry experts that offers exclusive, multi-media content on engineering topics that are critical to your work.

Safety First: Arc Flash 101 will: ✓ Explain the importance of electrical safety ✓ Define codes and standards as they relate to electrical safety ✓ Explore arc flash and safety measures ✓ Summarize codes and standards for electrical safety (i.e. NFPA 70E) Led by industry experts Lanny Floyd and Hugh Hoagland, this on-demand online course offers instructor-led discussions, videos, and high-quality presentations on an interactive and intuitive platform. The course is self-paced, accessible 24/7, and approved for one (1) AIA CES learning unit and one (1) HSW credit.

What’s included in all CFE Edu courses: ✓ Exclusive content--not found anywhere else--that includes research and expert knowledge from instructors working within the industry ✓ Interaction with course authors ✓ Videos, quizzes, and interactive content designed for a proven learning experience with associated CEU credits ✓ Full access to your course 24/7 with a computer, tablet or smartphone ✓ Course cost is $39.99

Learn more and register at CFEedu.cfemedia.com *Contact CFE Edu Manager, Emily Guenther, at eguenther@cfemedia.com for more information or with any questions about CFE Edu.

INSIGHT

PlantEngineering.com 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph. 630-571-4070, Fax 630-214-4504

By Bob Vavra, Content Manager

Welcome to the summer of innovation

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 DAVE REIBER, Senior Reliability Leader, Reliabilityweb.com 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

Summer has arrived, and with it the new staple of the warm weather months— the summer blockbuster movie. Many are sequels or remakes, so you’re already familiar with the plot and the characters— you’ve pretty much seem this show before. The season got started early with the latest in the “Fast and Furious” franchise and the brilliantly named “Guardians of the Galaxy Vol. 2”—as if you might somehow not connect it to the money machine from a couple of years ago. While there are a few original stories floating around out there, the biggest budget films are retreads of the same old story: sequels to “Pirates of the Caribbean,” “Cars,” and “Despicable Me,” a movie versions of the old TV series “Baywatch,” and reworkings of the scary movie classics “The Amityville Horror” and “The Mummy.” One definition of insanity is doing the same thing over and over and expecting a different result, but that old saw wasn’t coined by a Hollywood producer. There are just a just a few dozen movies that made more money than the original, and that’s hard to qualify because ticket prices—and therefore revenues—can change from year to year. Only eight movie sequels received Academy Award nominations for Best Picture; both “Godfather” sequels and both “Lord of the Rings” sequels were among them. But as this summer’s movie list demonstrates, sometimes it’s just easier to do what you’ve done before as long as it’s profitable. And on the surface, that’s a logical philosophy. The challenge is that your customers want an improved product, not just the same product. You can’t have the same plot in all of your sequels, although you take the best aspects of those products—Johnny Depp’s outlandish performance or the ability to find creative ways to turn fast cars into smoldering heaps of metal. We all crave familiarity. We like our weekend jeans and shirt, root for our favorite teams and enjoy comfort food—especially mom’s home cooking. We are creatures of habit, and breaking out of those habits can be hard and uncomfortable. Yet what has advanced our society, and our manufacturing industry, is the idea of www.plantengineering.com

improvement. We have not settled for the same; we have innovated and invented and dreamed and created new ways of doing what we do and have improved on what we’ve already done. As summer arrives and plants around the country prepare for some downtime and maintenance, this is a good time to stop and evaluate what you do and why you do it. We did that this month with Plant Engineering, and you can see the results in this issue. We didn’t depend on history nor instinct; we evaluated the data and asked our audience. While we prepare to retool this summer, we should take the time to think not just about the physical plant, but our people and especially our processes. As we begin to embrace data as a driver of change in our plants, summer is a good time to take the data as a place to start the discussions with manufacturing and organizational teams throughout our enterprise. In Hollywood, they call them “pitch meetings”—a group tossing around ideas for the next big thing. The easy thing to do is say, “Let’s make another Spider Man movie!” (They are, incidentally.) Take away all the glamor, and every movie is at its core the same thing—plots and people, sets and stages, sound and film. What makes one movie a blockbuster and another a flop is what one does with those tools. Manufacturing a car is no different, and the summer is a good time to step back, take stock, and see how you can take those fundamentals and create something better. Welcome to your summer of innovation. Enjoy the show. PE PLANT ENGINEERING

June 2017

CFE Mediaâ&#x20AC;&#x2122;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 hnical professionals to access the latest NEW product information for the manufacturing, commercial construction, and manufacturing control industries.

Start searching now! www.plantengineering.com/NP4E

SOLUTIO S COVER STORY

AUTOMATION

A drive to succeed

An antidote to downtime

Remote monitoring protects against skill shortages, complexity.

Turn into a detective to troubleshoot drives

SPECIAL REPORT Microgrids drive a new energy strategy Energy Master Planning provides a bridge to the future.

“

To control future energy costs, improve resiliency, and become more sustainable, plant managers need a plan.

”

LUBRICATION GUIDE Cutting through the fog on pneumatic lubrication Choosing the right strategy to prolong the life of key equipment

“

Oil aerosol delivered in compressed air reduces the effects of these factors and extends the life of pneumatic components.

”

www.plantengineering.com

Empowered to cut wasted energy

DOE program is designed to find and eliminate energy waste.

Overcome the high cost of staying cool Calculate seasonal energy efficiency for your HVAC system.

Control room temperature: Strategies to beat the heat

Air-to-water exchangers can reduce VFD heat exposure.

PLANT ENGINEERING

June 2017

COVER STORY By Tim Park, Danfoss Drives

Proper handling of spare units can help limit the risk of sensitive shelf life in repair efforts. All images courtesy: Danfoss

A drive to succeed Turn into a detective to troubleshoot ac drives.

c drives are an integral part of any manufacturing plant, as they often are responsible for controlling critical processes. The proper operation of ac drives can mean reliable and efficient plant performance, less downtime, and reduced energy costs, all of which equate to saving substantial money. However, when a possible problem arises with a drive, it is imperative that quick action be taken toward problem resolution. When approaching a problem with an ac drive, itâ&#x20AC;&#x2122;s realistic to make some assumptions. Consider these things initial points of investigation:

1. Was the operator or the process owner happy with the way the drive worked for some time

June 2017

PLANT ENGINEERING

after commissioning? Did the unit function acceptably for some period, e.g., a month? Is there any data on the commissioning process available for reference (i.e. setup sheets, schematics, or configuration files)?

2. Has the process changed? Has any other equipment been added in the same vicinity, perhaps sharing the same source? The performance and calibration of the drive may need to change with these changes.

3. What is the performance complaint? Is the problem really drive-related, or is other equipment involved? The point here is to troubleshoot an application, not just a drive. Keeping an open mind is critical. www.plantengineering.com

By The

NUMBERS

75% Percentage of ac drives used on pumps, fans, and compressors. Source: Danfoss

Fault codes Each manufactured product will have a specific set of fault codes; the list of these codes is an integral part of your troubleshooting “kit”. Many manufacturers have several series of drive product; there is a great deal of consistency in the meaning of these codes from compact to premium products. You typically can look for fault codes to fall within the four general categories in the table: Description

Application related?

Many such software tools allow you to trend data on a screen to allow you to use your PC as a virtual oscilloscope for more detailed analysis of conditions. E ach of thes e datafiles are very important if you want to solicit input from a technical support contact at the factory. Having these files available to email a support engineer can allow him to become familiar enough with your application to provide effective and prompt support from a remote location.

Solution

No, memory-related faults are specific to the drive’s hardware and firmware. Internal calibration and Repair/replace drive option board problems are not related to the way the controller is being employed.

Repairs and logistics

Many suppliers are providing software tools that can allow manufacturers to extract the parameter set and fault log from the drive.

Once the facts have been gathered, the next step is to assess what makes sense to handle the repairs of the Possibly power supply overload, Verify or remove field wiring Drive problems – drives. Many times, keepexternal interlocks and safeties and see if the fault can be external require attention or resetting. cleared ing a spare drive on the Source power No, voltage imbalance indications Work with an electrician or shelf makes sense. Many problem are no fault of the drive. power company to correct power ratings typically are Yes, ground fault and overcurrent Motor or load Validate/replace motor or delivered in the same physiare faults with the origin in the related problem motor wiring motor circuit. cal frame. That means you might want to have a 2hp Fault logs also are available to allow the techni- on the shelf to support the lower end of the power cian to extract information about how the drive ratings, and 5hp, 20hp, 40hp, etc. applying the same was running at the time of each of the faults logged logic. However, this is not an insignificant investment and is not always practical. by the drive. Furthermore, most drives do have a shelf life, so stocking units for replacement spares—while an Data extraction with PC While interpretation is still required, many manufacturers are providing software tools that can allow AC drives you to extract the parameter set and fault log from An ac drive is a device used to control the drive. When dealing with 20-50 faults logged by the speed of an electrical motor to enhance process control, reduce the drive, along with related operational parameters, energy usage and generate energy this data can be difficult to gather. efficiently, decrease mechanical stress These tools also offer you the chance to compare on motor control applications, and the current parameter set with where it was on comoptimize the operation of various missioning day and how varied it may be from facapplications relying on electric motors. tory default values. Drive problems – internal

www.plantengineering.com

PLANT ENGINEERING

June 2017

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 Available On-Demand This Webcast focuses on how emergent IIoT technologies change the way process and automation engineers execute projects and sustain productivity in todayâ&#x20AC;&#x2122;s, and tomorrowâ&#x20AC;&#x2122;s, cyber-physical world.

Sponsored by:

Webcast Two: Sensing and control at the edge: Microcontroller kits Thursday, June 8, 2017 Microcontroller kits emerge as a go-to tool in IIoT-based industrial automation.

Sponsored by:

Webcast Three: IIoT transforms predictive maintenance Thursday, August 24, 2017 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: Bosch Rexroth, Deublin, GTI Spindle Technology, IBM, 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.

COVER STORY

Properly troubleshooting and maintaining VFDs equipment can improve the management process.

attractive idea—can present problems. Either some inventory controls on the part of your supplier or your own may make this less of a problem. Proper handling of spare units can help limit the risk of sensitive shelf life on repair efforts. For more information on these risks, research “capacitor reforming”. There are commonly three classes of standard ac drives: compact, standard, and premium. Smaller units of all these product classes frequently are considered non-repairable. As you move up in prodSuppliers are developing service contracts, planned replacements, and upgrade plans along with extended warranties.

M More SOLUTIONS

uct size and complexity, it’s easier to provide component parts that make sense rather than opting for full replacements. Your drive manuKEYWORD: facturer can supply you with a parts Drives at PlantEngineering.com breakdown of what makes sense to ARTICLE: Still relevant: dc drives stock in support of your equipment. important in an ac age The more important replacement ARTICLE: VFD trends and solutions parts are the ones that have things for drive systems connected to them, like control boards, or touch, like keypads and WEBSITE: Under the ‘Mechanical’ adjustments. Also, having replacetab on our Website is a complete ment cooling fans as a field replacerundown of current products and ment is a good idea. articles around the subject of Like most industries, the mainmotors and drives. tenance of drives is developing into a bit of a specialty. Suppliers, working with local contractors, are developing service (depot repair and on-site) contracts, planned replacements, and upgrade plans along with extended warranties. These can run up to five or six years, if that makes sense for your operation. Onsite repair is a necessity when the size of the unit grows to greater than about 50HP to 100HP. It’s important to remember that ac drives are complex electronic equipment and that they operate as part of an application. Properly troubleshooting and maintaining this equipment can help you to be more effective in managing the process in your facility and keeping your plant running effectively. PE Tim Park is senior applications engineer for Danfoss Drives.

www.plantengineering.com

PLANT ENGINEERING

June 2017

THE PEOPLE THE PRODUCTS AND

THE SERVICES

TO KEEP YOUR PLANT RUNNING SMOOTHLY

Lubriplate

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Complimentary Plant Surveys ? +9+72/3+8 >4:7 +=')9 1:(7/)'39 7+6:/7+2+398 ? *+39/@+8 455479:3/9/+8 ,47 1:(7/)'39 )43841/*'9/43

Color Coded Tags and Charts ? 4147 )4*+* 38:7+8 9.+ )477+)9 1:(7/)'39 /8 :8+* ? "'-8 574;/*+* ,47 2')./3+7> '3* 1:(+ 8947'-+ )439'/3+78

Lubrication Maintenance Software ? "7')08 1:(7/)'9/43 '3* 2'/39+3'3)+ 8).+*:1+8 ? '8+* 43 ' )4251+9+ 8:7;+> 4, 9.+ 51'39 '3* 2')./3+7>

Follow-Up Lubricant Analysis ? "+898 ,47 ;/8)48/9> ')/*/9> )439'2/3'9+8 '3* <+'7 2+9'18 ? 3)1:*+8 ,:11 /39+757+9'9/43 '3* 7+)422+3*+* ')9/438

Training Programs / Tech Support ? ;'/1'(1+ 43 8/9+ 47 '9 ' .49+1 )43,+7+3)+ 7442 ? "411 7++ "+).3/)'1 !:55479 491/3+ '3* 2'/1

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Plant Surveys / Tech Support / Training Color Coded Lube Charts & Machine Tags Lubrication Software / Follow-Up Oil Analysis

input #13 at www.plantengineering.com/information

LUBRICATION GUIDE

By Charles Werdehoff, IMI Precision Engineering

Cutting through the fog on pneumatic lubrication Choosing the right strategy to prolong the life of key equipment

neumatic devices that push, pull, lift, position, or convey last longer and perform better when supplied with compressed air that is clean, dr y, pressure-regulated, and lubricated. The ser vice life of many air tools, cylinders, valves, air motors, and other air-driven equipment can be extended by consistent aerosol lubrication. Why lubricate? Environmental factors like extreme temperatures and excessive moisture, along with operational factors such as startup and operational friction, reduce the life of most working pneumatic devices. Oil aerosol delivered in compressed air reduces the effects of these factors and extends the life of pneumatic components.

How aerosol lubricators work Aerosol lubricators automatically deliver a metered amount of oil into the air path of operating pneumatic equipment. Lubricators function KEYWORD: by creating a presPneumatics at PlantEngineering.com sure drop that causes ARTICLE: Pneumatic systems: 10 oil to be siphoned ways to save energy into an adjustable dome. Us i n g t h e ARTICLE: Storing pneumatic energy d om e a dj u s t m e nt for emergency situations and obser ving the ARTICLE: Six steps to energy drip rate allows an efficiency in pneumatic systems operator to set the

M More SOLUTIONS

www.plantengineering.com

amount oil to be delivered to downstream equipment. Operating manuals for pneumatic equipment typically specif y the amount of oil required to keep the device op erating optimally. Lubricators should be adjusted to deliver the amount of oil specified at defined operating conditions and then validated after the equipment is in operation.

Oil-fog, direct to the tool The mostly widely used type of lubricator is oil-fog, sometimes called direct feed. These lubricators deliver 100% of the oil drops seen in the dome direc tly into t he air

A standard oil-fog or direct feed lubricator delivers oil drops 2 microns or larger directly into the air stream. They are best located near the tool they are lubricating. All images courtesy: IMI Precision Engineering PLANT ENGINEERING

June 2017

BRICATION

GU DE

stream. Oil particles traveling downstream are normally 2 microns or larger. Because of gravity, these particles only will remain airborne for a distance up to about 15 feet, and they normally will not travel up or follow intricate flow paths. As a result, oil-fog lubricators should be located in-line and near the tool they are lubricating. They are very efficient at delivering the right amount of oil directly to the cylinder, valve, or tool. It is not always possible to meet optimal conditions for oil-fog lubricators. When these conditions are not met, the oil will collect in the air line instead of travelling to the equipment. The result is reduced air flow and either inadequate or excessive tool lubrication. Standard oil-fog lubricators are not efficient for applications where the air line has vertical air paths, multiple tool lines, or bends in the air stream that prevent larger oil particles from reaching a tool. In these situations, a microfog lubricator provides better lubrication results.

The micro-fog path Wit h a micro-fog lubr icator, the oil drip is atomized into particles smaller than 2 microns. Approximately 10% of the oil drip seen in the dome is transported into the airflow and the rest of the oil is returned to the bowl for future use. Because the particles are small, they can travel long distances, vertically, and through intricate flow paths. Because only 10% of the oil is being delivered downstream, they are good for applications that A micro-fog lubricator atomizes oil into droplets smaller than 2 microns. These can travel vertically, over long distances, or through intricate flow paths and can be used to lubricate multiple tools.

June 2017

PLANT ENGINEERING

By The

NUMBERS

$5 billion Amount estimated each year spent by U.S. manufacturers on energy for compressed air systems. The same report found that manufacturers waste between 30% and 35% of that energy. Source: 2012 U.S. Department of Energy study/Plant Engineering article.

require better adjustability of small amounts of direct lubrication.

Filter-regulator-lubricator A lubricator is almost always used together with a filter and regulator pre-conditioning the air. These can be stand-alone components or an integrated filter-regulator-lubricator. Air leaving a compressor contains water and contaminants that can cause damage and shorten the life of downstream equipment. Even pre-lubricated components can fail when contaminated air degrades the lubrication or washes it out. Allowing contaminated air into a lubricator can result in reduced oil feed. Filtering ensures that clean dry air is sent through the lubricator and on to the operating equipment. Regulating air flow to meet conditions specified by the equipment operating manual ensures the equipment performs optimally. Aerosol lubrication is the final step after filtration and regulation. Proper lubrication protects equipment, prolongs tool life, helps control costs, and keeps processes running efficiently and productively. PE Charles Werdehoff is a precision engineering and product marketing manager for IMI Norgren Filter/Regulator and Lubricant (FRL) Products. www.plantengineering.com

input #14 at www.plantengineering.com/information

LUBRICATIONGUIDE Lubriplate Lubricants Co. Newark, N.J. www.lubriplate.com

Ingersoll Rand Compression Technologies & Services Davidson, N.C. www.ingersollrandproducts.com

Lubrication Engineers Inc.

MIL-COMM Products Co.

Wichita, Kan. www.lelubricants.com

East Rutherford, N.J. www.mil-comm.com

General Purpose Lubricant ISO Viscosity Grade

Viscosity, SUS at 100 F

135-165

HO-0

Multilec Industrial Oil

MC2500 Synthetic Oil

194-236

HO-1

Multilec Industrial Oil

284-346

HO-2

Multilec Industrial Oil

150

630-770

HO-3

Multilec Industrial Oil

220

900-1100

HO-4

Multilec Industrial Oil

460

1935-2365

HO-6

135-165

HO-0

Monolec Hydraulic Oil

194-236

HO-1

Monolec Hydraulic Oil

284-346

HO-2

Monolec Hydraulic Oil

Antiwear Hydraulic Oil

Spindle Oil 2

29-35

GG Oil

54-66

No. 0

95-115

No. 1

135-165

10-R

284-346

Way Lube 68

220

900-1100

SPO-255

Monolec Way Lubricant

Way Oil

Extreme Pressure Gear Oil 68

284-346

APG-80

Duolec Vari-Purpose Gear Lubricant

150

630-770

APG-90

Duolec Vari-Purpose Gear Lubricant

MC3000 Synthetic Oil

320

135-1650

APG 80W-140

Duolec Vari-Purpose Gear Lubricant

460

1935-2365

SPO-277

Almasol Worm Gear Lubricant

Cling Type Gear Shield

Gear Shield Extra Heavy

Pyroshield Syn Hvy & XHvy Open Gear Lubricants

General Purpose Extreme Pressure Lithium Base Grease

NLGI 2

No. 1242

Almagard Vari-Purpose Lubricant

Molybdenum Disulfide Extreme Pressure Grease

NLGI 2

No. 3000

HI Grease

FGL-2

H1 Quinplex Food Machinery Lubricant

H1 Fluid

FMO-2400AW

H1 Quinplex White Gear Lubricant

General Purpose Synthetic Fluid

Syn Lube 460

Monolec Syn Industrial Oil

Worm Gear Oil

June 2017

PLANT ENGINEERING

www.plantengineering.com

MACHINE LUBRICANTS Shaeffer Manufacturing Co.

Sullair LLC

Summit, KlÃ¼ber Lubrication NA LP

Ultrachem Inc., Fuchs Corp.

St. Louis, Mo. www.schaefferoil.com

Michigan City, Ind. www.sullair.com

Tyler, Texas http://klsummit.com

New Castle, Del. http://ultracheminc.com

112 HTC ISO 32; 254 HTC Supreme ISO 32

P-ACO 32

112 HTC ISO 46; 254 HTC Supreme ISO 46

P-ACO 46

112 HTC ISO 68; 254 HTC ISO 68

P-ACO 68

112 HTC ISO 150; 254 HTC Supreme ISO 150

P-ACO 150

112 HTC ISO 220; 254 HTC Supreme ISO 220

P-ACO 220

P-ACO 460

112 HTC ISO 32; 254 HTC Supreme ISO 32

HySyn - 163

Chemlube AW 32

112 HTC ISO 46; 254 HTC Supreme ISO 46

HySyn - 223

Chemlube AW 46

112 HTC ISO 68; 254 HTC Supreme ISO 68

HySyn - 329

Chemlube AW 68

324 Spindle Oil ISO 10

324 Spindle Oil ISO 22; 112 HTC ISO 22

160 Moly Slide & Way Lube ISO 32

160 Moly Slide & Way Lube ISO 68

160 Moly Slide & Way Lube ISO 220

203B ISO 68, 203C ISO 68

SH-10068 - 9.9 @100C, cSt

Omnigear 68 EP

167 ISO 150; 203B ISO 150, 203C ISO 150, 267 ISO 150, 293 ISO 150; 293A ISO 150

SH-1015 - 17.8 @100C, cSt

Omnigear 150 EP

167 ISO 320;268 ISO 320; 294 ISO 320; 294A ISO 320

SH-1032 - 32.8 @100C, cSt

Omnigear 320 EP

147 Steam Cylinder Oil

Syngear WT - 52.6 @100C, cSt

Chemlube 634

200S Silver Streak Special

221 #2, 274 #2, 274M #2, 238 #2, 260 #2

195 , 271, 272

Omnilube FGM2

280 ISO Grade 22-220, 269 ISO grade 32-100, 276 ISO Grades 100-1000

Omnilube FGG 1220

264 Pure Synthetic Hydraulic Fluid ISO Grades 32-150

Chemlube 630

www.plantengineering.com

PLANT ENGINEERING

June 2017

LUBRICATIONGUIDE Lubriplate Lubricants Co. Newark, N.J. www.lubriplate.com

Ingersoll Rand Compression Technologies & Services Davidson, N.C. www.ingersollrandproducts.com

Lubrication Engineers Inc.

MIL-COMM Products Co.

Wichita, Kan. www.lelubricants.com

East Rutherford, N.J. www.mil-comm.com

Polyalphaolefin (PAO) Compressor Oil 32

140

Syn Lube 32

Monolec Syn Industrial Oil

134

Syn Lube 46

Monolec Syn Industrial Oil

139

Syn Lube 68

Monolec Syn Industrial Oil

100

150

Syn Lube 100

Monolec Syn Industrial Oil

150

131

Syn Lube 150

Monolec Syn Industrial Oil

Partial Synthetic Compressor Oil 32

146

145

100

XL-700

150

105

All Season Select, XL-740HT

220

105

Centrifugal Compressor Oil 32

127

Techtrol Gold III

Monolec Centrifugal Compressor Oil

136

120

160

Engineering is personal. So is the way you use information. CFE Media delivers a world of knowledge to you.

Personally. CFE Media is home to some of the most trusted names in the business. To do your job better each day, you need a trusted source of information:

CFE Media â&#x20AC;&#x201D; Content for Engineers

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COMPRESSOR LUBRICANTS Shaeffer Manufacturing Co.

Sullair LLC

Summit, Klüber Lubrication NA LP

Ultrachem Inc., Fuchs Corp.

St. Louis, Mo. www.schaefferoil.com

Michigan City, Ind. www.sullair.com

Tyler, Texas http://klsummit.com

New Castle, Del. http://ultracheminc.com

158 Pure Synthetic Compressor Oil ISO 32

Sullube

SH-32 - 163

Chemlube 221

158 Pure Synthetic Compressor Oil ISO 46

Sullube

SH-46 - 220

Chemlube 228

158 Pure Synthetic Compressor Oil ISO 68

SH-68 - 339

Chemlube 268

158 Pure Synthetic Compressor Oil ISO 100

SH-100 - 482

Chemlube 299

158 Pure Synthetic Compressor Oil ISO 150

SH-150 - 737

Chemlube 300

254 HTC Supreme ISO 32

SRFII/8000

PS 32

254 HTC Supreme ISO 46

SRFII/8000

PS 46

254 HTC Supreme ISO 68

PS 68

254 HTC Supreme ISO 100

PS 100

254 HTC Supreme ISO 150

PS 150

254 HTC Supreme ISO 220

PS 220

Supra-32 - 185

Chemlube CF 32

CCL

Chemlube CF 46

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:

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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 an integrator’s qualifications match a user’s search criteria

Users can now preview the most pertinent data of a System Integrator before clicking to view the full corporate profile

“

New feature allows an end-user to request a quote for a project directly from the database site

The most relevant data about an 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

AUTOMATION SOLUTIONS

By Ante Tomicic and Phil Bush, Rockwell Automation

An antidote to downtime Remote monitoring protects against skill shortages, complexity.

voiding downtime is a fundamental goal in any industrial operation. Improving uptime drives maintenance strategies, influences equipment purchases and sales goals, and it is entrenched in the minds of workers. Even with a concerted effort to fight downtime, some companies are finding it more difficult than ever to control. There are a few reasons for this. First, the jobs that are most vital to preventing downtime—industrial maintenance technicians—are becoming harder to fill. Experienced maintenance technicians are retiring and too few skilled young technicians are entering the workforce to replace them. This is part of a larger industrial skills gap that is expected to result in 2 million manufacturing jobs going unfilled between 2015 and 2025, according to report from Deloitte Consulting and the Manufacturing Institute. S e c on d, c on n e c te d op e r at i on s a re a d d ing greater complexity to industrial environments. Production syste ms are c onve rg i ng Remote monitoring with information sys“Understanding asset performance tems, and production is key to optimize your operations d ow nt i m e n ow g o e s and prevent costly downtime hand in hand with netevents. Remote monitoring and work downtime. There’s analytics provides a simple and a significant opportunisecure approach to help monitor ty to use data available equipment and collect valuable from connected operaperformance analytics. It can give tions to help reduce or you valuable insights into how prevent downtime, but well your assets are working and that opportunity only alert you when performance falls can b e realized with outside of acceptable performance the right resources and standards.” expertise in place. Finally, t he simulSource: Rockwell Automation taneous move to more www.plantengineering.com

flexible manufacturing processes has introduced its own complexity. Today, many companies need to produce multiple products in one facility while minimizing changeover disruptions. To keep operations up and running amid these challenges, more companies are turning to remote monitoring and support services.

Support is always there Remote monitoring begins with collecting data from a company’s industrial assets. This data—which includes voltage, vibration parameters, temperature readings, and warning and fault information—then is contextualized into actionable information and delivered to workers. Remote monitoring can be internally managed, with automated systems that deliver information directly to on-site workers. It also can be externally managed by a remote-monitoring service provider’s team of off-site specialists. These specialists monitor critical equipment and systems, and they can quickly notify on-site personnel of any detected issues and potential responses to those issues, or even predict some failures before they happen. These remote-monitoring services can be scaled to address a company’s exact needs, whether it is monitoring a single machine in a plant, several pieces of equipment, a full production line, or applications, systems, and networks across multiple plants. Some companies also choose to build additional services on top of remote monitoring. These services can include various forms of administrative support, such as system backups, recovery support, and patch and update recommendations. They also can include parts and on-site engineering support being delivered within specific response-time windows. It’s not only manufacturing and industrial producers that can reap the rewards of remote monitoring. Machine builders can use it to gain PLANT ENGINEERING

June 2017

CALLING ALL SYSTEM INTEGRATORS...

2018 System Integrator of the Year

call for entries

Entries are due August 18, 2017 2018

Control Engineering and Plant Engineering’s annual

System Integrator of the Year Awards Questions?

Who should enter? If you’re a system integrator with demonstrable industry success, Control Engineering and Plant Engineering urge you to enter the 2018 System Integrator of the Year competition. Past System Integrator of the Year winners—Class of 2017, Class of 2016, and Class of 2015—are not eligible to enter the 2018 System Integrator of the Year program.

Contact Bailey Rice Director of Business and Market Development CFE Media brice@cfemedia.com (630) 571-4070 x 2206 2017 System Integrators of the Year

15 | 2016 SI Giants 29

What’s in it for the winners? The chosen System Integrator of the Year winners will receive worldwide recognition from Control Engineering and Plant Engineering. The winners also will be featured as the cover story of the Global System Integrator Report, distributed in December 2017.

How will the competition be judged? Control Engineering and Plant Engineering’s panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of the System Integrator of the Year: r #VTJOFTT TLJMMT r 5FDIOJDBM DPNQFUFODF r $VTUPNFS TBUJTGBDUJPO

Finding the right recipe People, processes are crucial to SI success story 23

A supplement to CONTROL ENGINEERING and PLANT ENGINEERING magazines

Tell us how you measure up in these three areas. Get the application: www.plantengineering.com/SIYApplication

AUTOMATION SOLUTIONS

new insights into the performance of their distributed assets. They can also use it to expand their service offerings, with the option to either manage the monitoring in-house or outsource it to a third party. Industrial companies struggling to fill maintenance positions face a higher risk of downtime or even full plant shutdowns. In these cases, remote monitoring services can be used for key maintenance tasks when local talent isnâ&#x20AC;&#x2122;t available.

Case study: Distance learning A coating company recently modernized the production lines at one of its facilities with new automation technology to increase capacity and address obsolescence issues. The project included installing new HMI systems on each line, and transitioning a paint line from decades-old motor generators and dc motors to new integrated controllers and drives. But because the facility is in a rural area, the company

www.plantengineering.com

had limited access to engineers with knowledge about the new technology. The company decided to use a remote service provider for around-t he-clo ck system monitoring. The remote team monitors about 2,500 data points from controllers, drives, HMIs, and regulatory compliance parameters, and can notify on-site staff of any issues. In addition to augmenting on-site staff, the remote monitoring support has provided

M More SOLUTIONS KEYWORD: Remote Monitoring at PlantEngineering.com

ARTICLE: Remote monitoring technologies lower costs, improve operations ARTICLE: Advances in wireless remote monitoring WEBCAST: Information Management for IIoT

Remote monitoring can take place either in a control room environment, as seen below, or by using internet and cloud capabilities. Either way, the goal is to centralize data capture and management. Image courtesy: Rockwell Automation

PLANT ENGINEERING

June 2017

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:

r Maintenance r lloT series: OT/IT convergence, collaboration r Energy Management r lloT series: Edge, cloud, fog computing r lloT series: Maintenance optimization r System Integration case studies r lloT series: Network integration, cyber security r Safety www.plantengineering.com.com/webcasts

AUTOMATION SOLUTIONS

predictive maintenance benefits to the facility. The remote support team can track the progress of maintenance issues, monitor trends and tolerances of devices, and track lifecycles. The team can then alert on-site staff of issues as they arise, and help them head off problems before a line stoppage occurs. After implementing remote monitoring, the coating company saw a 50% reduction in maintenance downtime at the facility.

Case studies: Improved response Other companies have used remote support to help manage the added complexity of modern operations where traditional IT support may not be a good fit. This was the case for a large food manufacturer that deployed Ethernet and managed switches on the plant floor. The manufacturer initially decided to use its traditional IT provider to support the equipment, but they couldn’t provide the response time needed to keep things running on the plant floor. As a result, the manufacturer switched to an industrial remote support provider. The support included monitoring of more than 400 switches, alarm profiles to monitor eight key parameters in those switches, and a 10-minute guaranteed response time to any critical alarm. After the change, the company saw a significant improvement in uptime. In another case, a paper mill was experiencing challenges with instability and sheet breaks when switching between products. The company had recently installed a new drives

By The

NUMBERS

$24.7 billion The estimate of the global remote monitoring market in 2015, which includes commercial and industrial applications. Source: IHS Markit

www.plantengineering.com

“To keep operations up and running amid these challenges, more companies are turning to remote monitoring and support services.

”

system, but lacked the technical expertise to manage and support the system. The company made the move to a ser vice provider for remote technical support and troubleshooting. The support significantly reduced downtime, resulting in an annual revenue increase of $630,000. The mill also realized hundreds of thousands of dollars in additional savings in training and support costs.

A secure approach Remote support is so widely used now that service providers have largely developed standardized services that can meet the needs of most industrial companies. Before selecting a service provider, however, companies should be sure the provider meets certain security requirements. Companies should make it a point to work with a trusted service provider, one that follows core security principles when designing products. They also should confirm the provider’s platform delivers secure remote access, such as by limiting entry points, using outboundonly connections, and limiting access by user, site, and device. By addressing security upfront, industrial companies can worry less about the risks of remote access and focus more on how it can help them keep their operations running in today’s fast-changing world. PE Ante Tomicic is remote support services supervisor and Phil Bush is remote monitoring and analytics product manager for Rockwell Automation.

PLANT ENGINEERING

June 2017

2017 Global Automation & Manufacturing Summit November 7, 2017 Presented in partnership with:

Registration opening soon!

Under the theme â&#x20AC;&#x153;Empowering Manufacturing Future,â&#x20AC;? CFE Media will produce its 2017 Global Automation and Manufacturing Summit (GAMS) on Tuesday, November 7, 2017. The now-annual GAMS event will be colocated with Hannover Fairs USAâ&#x20AC;&#x2122;s Industrial Automation/MDA Pavilion at the 2017 FABTECH Show at McCormick Place, Chicago. The event will begin at noon with a networking luncheon on the show floor. Three sessions will follow, focusing on three key aspects of the adoption of the Industrial Internet of Things (IIoT) in manufacturing. The event will conclude with a cocktail reception and networking event.

The three GAMS sessions include: 1:00 pm to 2:00 pm: CYBERSECURITY: HOW FAR DO WE NEED TO GO? t 5IF QSPCMFN PG TFDVSJUZ GPS **P5 JT POF PG UIF NPTU EJTDVTTFE JTTVFT BT NBOVGBDUVSFST MPPL UP EFQMPZ UIJT UFDI nology solution. Weâ&#x20AC;&#x2122;ll look at the real issues, perhaps debunk a few myths, and talk about the common-sense ways manufacturers can secure their data and their operational integrity. t 5IF QSFTFOUBUJPO XJMM CF MFE CZ %S 3JDIBSE 4PMFZ DIBJSNBO PG UIF *OEVTUSJBM *OUFSOFU $POTPSUJVN $IBJSNBO BOE Chief Executive Officer of OMG (Object Management Group) executive director of the Cloud Standards Customer Council.

2:15 pm to 3:15 pm: IIoT IN DISCRETE MANUFACTURING: MANAGING THE PROCESS t 8IFO JU DPNFT UP **P5 NBOVGBDUVSFST JO EJTDSFUF JOEVTUSJFT QBSUJDVMBSMZ JO UIF NFUBMGPSNJOH BOE $/$ JOEVTUSJFT have a different set of expectations from those in the process industriesâ&#x20AC;&#x201D;and a different set of challenges. Weâ&#x20AC;&#x2122;ll talk with industry experts to look at how to get the most out of IIoT, and how to use data to improve operations, supply chain and safety. t 4QFBLFST XJMM JODMVEF ,FWJO -FXJT WJDF QSFTJEFOU EJHJUBM GBDUPSZ GBDUPSZ BVUPNBUJPO BU 4JFNFOT "VSFMJP #BOEB CEO and president, Beckhoff Automation North America and Derek Harper, vice president of information technology at Faurecia North America.

3:30 pm to 4:30 pm: MAINTENANCE AND IIoT: FOLLOW THE NUMBERS t 5IF EBUB HFOFSBUFE CZ **P5 DBO QPJOU B NBJOUFOBODF QSPGFTTJPOBM UP B QSPCMFN PO UIF QMBOU Ăž PPSÂ&#x2030;JG IF T MPPLJOH BU the right numbers at the right time. More sophisticated analytics are helping maintenance teams focus on the right data at the right time, and weâ&#x20AC;&#x2122;ll talk with them on how this strategy can lead to more uptime and better safety. t 5IF QSFTFOUBUJPO XJMM CF MFE CZ 4BM 4QFEB SFTFBSDI EJSFDUPS GPS EJTDSFUF NBOVGBDUVSJOH GPS "3$ "EWJTPSZ (SPVQ BOE XJMM JODMVEF .PIBNFE "CVBMJ EJTSVQUJWF UFDIOPMPHZ FYFDVUJWF BU '03$". *OD BOE 4DPUU $ )JCCBSE WJDF QSFTJEFOU PG UFDIOPMPHZ JOEVTUSJBM BQQMJDBUJPOT GPS #PTDI 3FYSPUI $PSQPSBUJPO

SPECIAL REPORT ENERGY MANAGEMENT By Philip Barton, Schneider Electric

Microgrid systems can be implemented to minimize downtime, lower costs, and increase sustainability all in one project. All images courtesy: Schneider Electric

Microgrids drive a new energy strategy Energy Master Planning provides a bridge to the future.

he steady increase in energy usage across North America is forcing users to contend with high and variable energy costs. Total energy production in the United States increased for the sixth consecutive year in 2016, according to the U.S. Energy Information Administration (EIA). During the same period, electricity generation from wind, solar, and other distributed energy resources also grew, ushering in a new energy landscape. To control future energy costs, improve resiliency, and become more sustainable, plant managers need a plan. This detailed process is often referred to as an Energy Master Plan, comprised of enterpriselevel strategies designed to manage energy costs while also mitigating the risk of downtime from power outages. Microgrids enable manufacturers to adapt to the new energy landscape, driven by greater decentralization, decarbonization, and digiti-

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zation of energy. Microgrids are an attractive tool to help manufacturers integrate renewable energy resources as part of an energy master plan. Microgrids are synonymous with allowing customer-sited generation to work grid-tied and

By The

NUMBERS

62% Number of manufacturers working with their utilities to develop energy strategies. Source: 2016 Plant Engineering Energy Management Study

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June 2017

SPECIAL REPORT ENERGY MANAGEMENT

infrastructure. With microgrids, systems can be implemented to minimize downtime, lower costs, and increase sustainability all in a single project. Energy storage increasingly complements the new distributed resources and doubles as a power system backup for added resiliency. Energy management While battery energy storage systems alone work Total U.S. energy production as an excellent anchor resource, battery systems are increased for the sixth consecutive still relatively expensive unless they can serve mulyear in 2016, according to the U.S. tiple use cases. Where electric power and natural gas Energy Information Administration. are expensive, batteries and solar work well finanThe U.S. energy production reached cially. Centralized power is 30% to 40% efficient at 91% of total U.S. energy use, with the point of use, and cogeneration plants often have increases in crude oil and natural a 55% to 80% combined efficiency at the point of use. No need to “rip gas production offsetting a 10% Through microgrids, manufacturers can leverage and replace” decrease in coal production. O n e of t h e m o s t cleaner and more efficient resources all while using exciting trends in less grid infrastructure and helping these disparate “The United States saw little microgrids is mixing cogeneration resources work in harmony. change in production from nuclear Renewables also can be used as a less expensive the old with the new. electric power and renewable form of generation as they help establish applications Microgrids allow for energy (across all sectors) in 2015. of virtual power plants. These applications innovate seamless modernizaHowever, the United States saw by combining variable wind and solar with dynamic tion of aging electrishifts in the sources of electricity load management and storage to present a flatter load c a l i n f r a s t r u c tu re, generation from renewable fuels, as curve from the utilities point of view. And storage upgrading a facildeclines in hydroelectric generation were mostly offset by increases in ity’s legacy electrical must be thought of as not just batteries, but thermal electricity generation from wind system to optimize inertia and flexibility in loads and processes. and solar” EIA officials said in its Flexibility in microgrid design is of increasing energy use, without Monthly Energy review in April 2017. needing to “rip and importance because many plants are in off-grid replace” the existing areas of the world—most notably in fields such as energy production, distilleries, or mining—and it’s just as pivotal for Installations of solar panels and other advanced microgrid programs at those facilities to remain functional Schneider Electric’s Boston One Campus in Andover, Mass., is an example and cost effective as on-grid enterof how to incorporate distributed energy into an existing facility. prises. For many plant managers in remote locations, using renewable energy via a solarassisted microgrids is more cost-effective than transporting other fuel and establishing new distribution and transmission infrastructure. N e w, a d v a n c e d microgrids couple solar photovoltaic (PV) with other distributed energy resources as an anchor resource to island—or separate—from the grid independently of the grid. Microgrids also enhance the resiliency of operations while helping manufacturers generate new value, drive benefits in modernization, avoid costs, and meet new shareholder requirements for sustainability and reporting.

June 2017

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“To control future energy costs, improve resiliency, and become sustainable, plant managers need a

and enhance resiliency, helping to power campuses and small communities independent of the grid plan. This detailed process is often during an outage. In addition to the economic benefits, microgrids referred to as an Energy Master Plan, also contribute to the sustainability of a corporation. comprised of enterprise-level strategies Many Fortune 500 manufacturers have instituted sustainability goals. In fact, shareholder interest designed to manage energy costs while in sustainability is another key factor driving microgrid adoption within the new energy landalso mitigating the risk of downtime from scape. With an increased commitment to sustainability, shareholders require more renewable energy power outages. use than ever, and microgrids help incorporate renewables within their budget. As sustainability becomes a higher priority, shareholders also are requiring accurate measurement of ment of renewables and other distributed energy renewable energy usage. Microgrids can integrate resources. advanced monitoring, software and reporting tools to help provide more detailed, accurate reporting, Implementing microgrids and greater understanding of energy spend and usage Though microgrid implementation can seem across the operation. daunting for facilities that have been operating Additionally, an increased focus on sustainability the same infrastructure for decades, the industry enables access to “green funds,” which provide lower continues to remove the barriers to entry, makcost to capital for modernization efforts but are ing it easier to incorporate renewables and enter only available for manufacturers and other large the microgrid market. New funding mechanisms corporations that can demonstrate social respon- such as Microgrid as a Service models enable sibility, primarily through sustainability. upgrades without upfront capital expenditure. Shifting to renewable-powered facilities seems Through advanced microgrid tools, end-users simple, however manufacturers often face per- can incorporate more inverter-based resources ceived barriers when implementing renewables that enable renewable energy usage and leverage with legacy infrastructure that contends with con- software solutions to better monitor, analyze and temporary energy requirements. Greenfield man- report on energy use while also easing scale. ufacturing projects are rare; As plant managers look to manufacturers often need to modernize their plants in all incorporate solar and renewaspects, the way they source, able energy sources within an manage, and control energy existing electrical infrastruccannot and should not be KEYWORD: ture to meet peak loads, build ignored. Microgrids are an Energy Management at employee engagement and sateffective solution to upgrade PlantEngineering.com isfy shareholders. electrical infrastructure RESEARCH: 2016 Energy Finally, modern microgrid while helping manufacturers Management Study: Six findings on tools offer additional autonto achieve more sustainable energy management programs omy and scalability as plant business practices—generatoperators modernize operaing tangible value that can be WEBCAST: Energy Management tions. Contemporary advanced reinvested in other areas of Strategies for Manufacturing microgrid tools bring together the operation. PE ARTICLE: Implementing energy hardware, software, advanced management for machinery and controls, and electrical disPhilip Barton is director of processing plants tribution into a single-source the North American Microgrid 2016 PRODUCT OF THE YEAR solution that simplifies the Competency Center for SchneiFINALISTS: Energy Management i nt e g r at i on an d m an a ge der Electric.

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M More SOLUTIONS

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June 2017

Reimagining Plant Engineering The use of the pictures, descriptions and accounts of this magazine... Is fully encouraged.

COVER STORY COVER

INSIGHT

M More ADVICE

STORY

Regardless of what a sensored, connected, integrated factory is called, IIoT continues its march forward as the expected architecture for process manufacturing facilities. The competitive advantages enabled by increased and consistent visibility, accuracy and datadriven insights on production results are simply too important for most firms to ignore, hence the growth in IIoT deployments.

By Michael Risse, Seeq Corp.

Donâ&#x20AC;&#x2122;t get caught behind

INSIGHT

By Rebecca Bolt, GE Automation & Controls

typical of a local computer. Connecting to the cloud also enables a fleet of machines to be managed and to communicate with each other, providing thorough analytics for the entire fleet. For example, thereâ&#x20AC;&#x2122;s an app that leverages the power of the industrial internet, connects to a fleet of wind turbines and enables them to coordinate the speed and direction of their blades to maximize the wind farmâ&#x20AC;&#x2122;s overall energy output. However, the cloud is not always a viable option due to latency, costs, regulations, and other factors. Think also about the criticality of the data being analyzed. If a self-driving car was required to go to the cloud to make important decisions, the carâ&#x20AC;&#x2122;s response time would be too slow. Industrial assets are the same way. Some things can be done in the cloud, but other problems need to be analyzed as close to the machine as possible. Digital industrial companies are developing products that are designed to work on the industrial edge and make collecting, storing, and analyzing data

The cloudâ&#x20AC;&#x2122;s role in data management Deck is needed...

illions of sensors all around the world are making consumer devices smarter, safer and more efficient. Wearable products have revolutionized our understanding of wellness by providing more information about our daily health. Appliances and systems in our homes now are connected and make intelligent decisions to enhance our lives. Entire cities now are employing big data and sensors to prevent crime, manage crowds, reduce energy use, and much more. The connectivity of and communication between these devices, as we know, is referred to as the Industrial Internet of Things (IIoT). But before these devices can start communicating with end users and each other, they must collect and analyze dataâ&#x20AC;&#x201D;lots and lots of data. Data for many of these devices is collected, stored, and analyzed in cloudbased environments such as the Amazons and Googles of Number of Internet of Things the world. Even connected devices expected by our Fitbit trackers have a cloud 2020. This includes both industrial where our health analytics are and consumer-based devices. stored. While Source: IHM Markit thereâ&#x20AC;&#x2122;s a lot of d at a g at h e r e d from consumer products, thereâ&#x20AC;&#x2122;s a much larger amount of data found in industrial machines and an even greater need for the same type of connectivity and analytics. IIoT will increase efficiencies, reduce costs, and improve employee health and safety while generating new revenue streams for businesses.

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30.7 billion

June 2017

Controls have been managing machines all around us for centuries. Just as our machines have evolved, so, too, have the analytics our machines provide. However, the data those machines collect and analyze, up to this point, has been limited to the memory of internal computers running at or inside the machine; the intelligence of those machines essentially has been limited to that memory. New industrial control systems now are providing the same type of connectivity, communication, and analytics for our industrial assets as consumers have seen for several years. These connected controllers and systems not only run our machines like they used to run, but they also now have the capability to create an outer loop and custom applications that gather data in real time and advise the controller to make more intelligent decisions. Just as connected sensors and wireless devices transport data to consumer clouds, the vehicles to transport big data to the industrial cloud are edge devices and sensors in or near machines. Many machines and plant systems donâ&#x20AC;&#x2122;t offer the type of connectivity and deep analytics todayâ&#x20AC;&#x2122;s industry demands. These machines require thirdparty solutions to gather data and provide critical analytics. The more data gathered, and the closer to the machine you run data, the more accurate and intelligent the decisions the machine makes. Some machines canâ&#x20AC;&#x2122;t be reached with traditional Ethernet cables because of the distance between the internet source and the machine. Not only would it be cost prohibitive to drop and run that wired connection, but the proximity would make data gathered less favorable. Connecting to these machines wirelessly makes sense. Cloud-based, wireless solutions provide greater flexibility than wired solutions. The cloud empowers the elasticity of data storage and performance and is not subject to the constraints

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As we look ahead in 2017, there are many ways to discuss whatâ&#x20AC;&#x2122;s ahead for IIoT. For example there are new IIoT technologies to consider, such as drones, robots, voice-powered artificial intelligence (AI) and virtual reality solutions. And while those will likely have a future in IIoT, there is also an important issue we need to address first: most firms need to catch up to the technology opportunities available today.

â&#x20AC;&#x153;

IIoT efficiencies, improve emplo while gener streams fo eas e a d o e accuate. Th e y g couldnâ&#x20AC;&#x2122;t have imagined IIoT as it is today. Similarly, we canâ&#x20AC;&#x2122;t specul will be three years from now. The things are changing makes it diffi mend specific assets or systems t hard-wired or should be wireless should run in the cloud versus a al edge, so itâ&#x20AC;&#x2122;s important to thin through strategically and go the ro the most sense for your plant. PE

IIoT arrives:

T 2

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INNOVATIONS Compressed air pipe

Input #204 at www.plantengineering.com/information

www.flir.com

Toshiba www.toshiba.com

Input #201 at www.plantengineering.com/information

Input #205 at www.plantengineering.com/information

Handheld production control system The Commander XT1000 is a handheld production control system designed as an assembly aide while collecting critical hydraulic bolting data. The wireless control device will lead the operator through each bolt to the correct torque and in sequence and store the data real-time to the cloud. It can also control and operate the pump and tool independently. The Commander XT1000 has its own software, but it can also interface with others. The Commander XT1000 includes a high-resolution camera for recording images of the bolting operation. Torq-Comm www.torq-comm.com Input #202 at www.plantengineering.com/information

Mobile portable compressor The M58 is designed to deliver 210 cfm at 100 psig for rental houses, construction, demolition, sandblasting, repair trucks and other demanding applications. The portable compressor has a powder coated, fully weatherproofed steel cabinet built to withstand harsh conditions. It also has a single-point lifting ball for easy mounting or dismounting. The eye-level curbside instrument panel is equipped with a smart electronic controller with a protective metal cover. The 28-gallon fuel tank is designed to provide extended operation up to 10 hours.

Belt-type oil skimmer The Mini-Skimmer is a belt-type oil skimmer designed to collect over a quart of oil per hour despite its tiny housing, measuring just 3 in. x 3 in. x 2.75 in. It also is designed to skim unwanted tramp oils from coolants and clean wastewater. The oil skimmer has an on/off switch to allow users to easily monitor its activity for machine shops, ultrasonic cleaners and parts washers. The skimmer for small machining operations is portable, with a stretch-resistant, fiberglassreinforced cogged belt. It has a liquid tight housing made of anodized aluminum and a motor with the highest torque for a skimmer of its size. Wayne Products

Kaeser

www.wayneproducts.com

www.us.kaeser.com

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t /FX BTTFU NPOJUPSJOH TFSWJDFT GSPN WFOEPST XIP are leveraging IIoT to provide remote predictive analytics capabilities for their assets installed at customer sites.

t ( SFFOGJFME EFQMPZNFOUT XIJDI BSF QSJNBSJMZ found in â&#x20AC;&#x153;smartâ&#x20AC;? solutions related to advanced monitoring and visibility

The enthusiasm and growth in IIoT momentum over the last year is obvious in the pages of this magazine, as there continue to be IIoT-related articles in FWFSZ JTTVF #VU UIJT EPFT OPU NFBO UIF JOEVTUSZ IBT agreed on its naming conventions.

t #SPXOGJFME VQHSBEFT XIJDI BSF UIF JOUSPEVDUJPO of IIoT technologies and approaches to existing facilities to expand asset and process visibility and analytics

So we continue to refer to â&#x20AC;&#x153;digital transformation,â&#x20AC;? â&#x20AC;&#x153;smart manufacturing,â&#x20AC;? the â&#x20AC;&#x153;fourth industrial revolution,â&#x20AC;? and â&#x20AC;&#x153;Industrie 4.0,â&#x20AC;? in addition to IIoT.

January/February 2017

June 2017

he Industrial Internet of Things (IIoT) has progressed from dream to hype to reality. Today, the basic deployment scenarios of the IIoT solutions we implement for our end user manufacturing customers include:

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January/February 2017

SOLUTIONS

MAINTENANCE Mobile safety strategy: Six things to consider

Kaeser

Outdoor IP camera dome The IKS-WR7413 IP is designed to monitor everything that is happening outdoors even in complete darkness. With its 3-megapixel video resolution and LED IR illuminators, the camera dome provides high video quality with four simultaneous video streams. The IKS-WR7413 can be adjusted to cover a wide field-of-view or narrow its focus to a smaller area for additional detail, and it is outfitted with four adaptive infrared LEDs to capture images up to 25 feet away in the complete absence of light. Additional capabilities include: recording in two different codecs, integration with ONVIF-compliant recorders, and memory storage up to 64 GB.

Flir

Delivering IIoT: Pioneer Energy Mobile Alkane Gas Separators produce both methane and natural gas liquid streams at well sites.

By Jason Dea and Gary Edwards, Intelex Technologies

www.us.kaeser.com

Input #200 at www.plantengineering.com/information

Handheld camera

In the world of software startups there is an expression: â&#x20AC;&#x153;fail fast.â&#x20AC;? This means itâ&#x20AC;&#x2122;s better to try something and learn it doesnâ&#x20AC;&#x2122;t work than to wonder if it might have

SOLUTIONS

The SmartPipe is a modular, aluminum compressed air distribution system designed with lightweight materials and simple connectors that can be installed without threading, welding or sweating. Available in multiple sizes from 1/2 to 6 inches, SmartPipe is ideal for headers and branch lines all the way down to the point of use. SmartPipe is made from smooth, calibrated aluminum and will not rust. It has a low coefficient of friction and provides laminar flow. Full bore fittings minimize pressure drop and leak-free connectors prevent costly compressed air loss. SmartPipe can be easily integrated into existing steel or copper systems and modified to accommodate changing needs.

HyLite www.hyliteledlighting.com

The X6570sc handheld camera is a part of the X6000sc series and is designed to provide researchers, engineers and scientists with measurement accuracy, advanced processing algorithms and connectivity. The longwave performance camera records 640 x 512 full frame video at 234 Hz (up to 14,550 Hz with windowing) with the rapid integration times needed to analyze highspeed processes or monitor fast temperature spikes. The camera is sensitive enough to distinguish temperature differences down to 20 mK and offers connection options. The X6570sc also has saved user configurations for efficient transfer between test teams.

End users should be complimented for any IIoT investments or trial deployments they have completed, because at the end of the day they have done something and at least tried.

MAINTENANCE

Submit new product releases to our New Products for Engineers Database gspplatform.cfemedia.com/pe

Adjustable LED lamp The Lotus Lamp is designed for versatility with a 180 F adjustable mounting arm that allows the lamp to be installed in multiple positions and at different lengths for use in a wide variety of applications. The lamp is designed for use with recessed cans, canopy lights, parking garage fixtures, parking lot lights, flood/spot lights, high ceilings and high/low bays. The LED Lotus replaces anything up to 400 W metal halide and high-pressure sodium lamps with up to 80% energy savings. The Lotus has 60,000 hours of rated life and comes with a 20 kA in-line surge protection device to protect the lamp against disruptive and damaging power surges and transients. The Lotus is completely protected from contact, dust and water splashes.

Part of this gap may be due to the oftARTICLE: Improving arc flash cited advice that companies should start safety through design small and have IIoT deployments prove ARTICLE: New solutions their value and impact before moving on address arc flash energy to more widespread implementations. reduction This is great advice and hard to argue KEYWORD: arc flash with, and aligns with the limited number of large IIoT deployments within companies. Certainly an early success will bode well for organizational enthusiasm for continued IIoT investments.

Implementation is not only practical, but now itâ&#x20AC;&#x2122;s a competetive necessity.

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INNOVATIONS

WEBCAST: Arc Flash University: Safe Use of Electrical Testing Devices. Now on demand at plantengineering. com

Itâ&#x20AC;&#x2122;s time to get started

Rebecca Boll is a general mana GE Automation & Controls.

Caption is also needed...

Analyst research shows a large gap between the expectations and advantages of IIoT, and the state of current deployment efforts. Further, IIoT deployments are generally piecemeal rather than broadly applied across a plant. What this means is that IIoT enthusiasm and potential benefits are not being realized by many end users, with the opportunity still ahead of them,

instead of being already recognized in bottom line results.

Combine smart devices with flexible technology to provide real-time alerts.

Biodegradable coatings system The biobased and biodegradable system replaces hazardous synthetic chemicals with safe, green alternatives for corrosion protection in metalworking industries. BioCorr is water-based and designed for preservation of metals by combining film-forming additives with Vapor phase Corrosion Inhibitors (VpCIs). Ecoline 3220 is a canola oilbased, temporary coating that clings to metal surfaces for vapor corrosion inhibition and lubrication. Ecoline 3690 is an open-air solution for marine and high humidity conditions and has no effect on rubber, plastics, or paint. Ecoline Cleaner/ Degreaser is a soyabased solution designed for tough cleaning jobs and can be used on all metals and alloys. The cleaner is non-flammable, and all the products in the system are VOC, chromate and nitrite free.

rganizations go through significant evolutions in many areas of their businesses. The technical challenges in managing risks around workplace safety are similar in many respects to other parts of the enterprise: there is software to minimize the hurdles that impede getting information from a source into a system which in turn enables the right people to make informed, proactive and actionable decisions. Archaic environmental health and safety (EHS) programs rely on employees to collect data manually, transpose the information into spreadsheets or disparate, disconnected software productsâ&#x20AC;&#x201D;or worse yet, paper bindersâ&#x20AC;&#x201D;and perpetually repeat this process. Such programs may suffice in meeting minimum regulatory standards, but they typically fall short due to human error and the sheer quantity of information involved. Absent adequate software, actionable intelligence is not available to inform proactive decision-making and preventive actions.

Similarly, all smart mobile devices feature some form of a camera capable of capturing high-quality photos and videos. Both c ap a b i l i t i e s a l r e a d y are frequently used to safety managerâ&#x20AC;&#x2122;s interest, but the real enrich incident and audit reporting, but when tied to EHS systems they question to ask is: Does this tool work instantly provide essential visual support. in the hands of my workers who are at No mobile device is complete without a series the frontlines and highest risk? of apps designed to fulfill Gary Edwards, Intelex Technologies its main purpose: communication. B etween

â&#x20AC;&#x153;Beautiful scorecards might light up a

www.cortecvci.com Input #207 at www.plantengineering.com/information

January/February 2017

In the case of incident management, for example, no reports are complete without some form of location-based data. GPS and mapping services are embedded into almost all current smart mobile devices (phones and tablets) as native apps. Critical location data can be pushed to managers and employees instantly when on-device apps connect with EHS tools.

Mobile devices integrated with EHS

Cortec Corporation

PLANT ENGINEERING

tools to leverage real-time connectivity, native apps, and easy in-the-field data entry, are game changing. They place employees, not the safety manager, in the center of influence. With mobile devices, data can be collected on the fly from all personnel. Conversely, these same field staff and their managers can receive data-driven insights and alerts as they go. Mobile devices unleash potential by exposing and reducing hazards and unsafe behaviors, facilitating broader employee (and contractor) adoption and by transforming real-time source data lifted from the field into instantly actionable intelligence.

â&#x20AC;?

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January/February 2017

SPECIAL REPORT ENERGY MANAGEMENT

By Kitt Butler, Advanced Energy and Jay Wrobel and Pete Langlois, U.S. Department of Energy

Empowered to cut wasted energy DOE program is designed to find and eliminate energy waste.

ndustrial and commercial facilities are big energy consumers, but they are also big energy wasters. According to the Lawrence Livermore National Laboratory, the industrial and commercial sectors used approximately 33.5 quads of energy in 2016. (One quad is equal to 1 quadrillion British thermal units.) Of those 33.5 quads, nearly halfâ&#x20AC;&#x201D;15.7 quadsâ&#x20AC;&#x201D;were wasted due to inefficient energy systems or end use. The loss is more than $340 billion dollars, including $247 billion in the industrial sector. One way to seek continual and sustained energy performance improvement is through implementing a formal energy management system (EnMS). An EnMS incorporates energy management into an organizationâ&#x20AC;&#x2122;s day-to-day culture and routine, using a framework of procedures and practices that enables better monitoring, managing, and improvement of energy use. Critically, an EnMS can help ensure these improvements are maintained. The U.S. Department of Energy (DOE) and U.S. Environmental Protection Agency (EPA), including expanding support from the DOEâ&#x20AC;&#x2122;s Advanced Manufacturing Office, offer many resources to help more organizations do just that. Establishing a practice of managing energy comprehensively allows plants and facilities to be more competitive and functional, saves money, and supports organizations in meeting sustainability or energy-related goals. An established energy culture helps produce big dividends by enabling companies to use their energy more efficiently and reduce losses and waste. Through its 50001 Ready program formed around the ISO 50001 energy management standard, the DOE is enhancing its ongoing support for EnMS adoption and allowing more facilities to realize and be recognized for their long-term energy improvements.

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ISO 50001 ISO 50001 was first developed in 2011 by the International Organization for Standardization, based on the successful ISO 9001 and ISO 14001 standards, to help organizations establish and maintain an EnMS. Implementing an ISO 50001 EnMS prepares organizations to continually improve their energy performance through holistic and systematic energy management that promotes best practices and behaviors. â&#x20AC;&#x153;ISO 50001 adoption is proven to produce longterm, persistent energy savings through the establishment of a â&#x20AC;&#x2DC;cultureâ&#x20AC;&#x2122; of managing energy,â&#x20AC;? said Pete Langlois, energy efficiency and sustainability manager for the DOEâ&#x20AC;&#x2122;s Advanced Manufacturing Office. Starting with determining the scope and boundaries of the EnMS, the ISO 50001 standard outlines requirements that the management system covers. Broadly, these requirements include establishing an energy policy and objectives, supporting a responsible energy team with executive commitment and developing plans to achieve identified energy opportunities. The primary steps identified in ISO 50001 include: t 4FU BO FOFSHZ QPMJDZ t )BWF NBOBHFNFOU DPNNJUNFOU t &NQPXFS BO FOFSHZ UFBN t *EFOUJGZ XIFSF FOFSHZ JT VTFE t $SFBUF QMBOT UP JNQSPWF FOFSHZ VTF t )BWF NBOBHFNFOU BQQSPWF QMBOT t 5SBDL QSPHSFTT BOE SFBTTFTT FOFSHZ BDUJPO QMBOT Although pursuing ISO 50001 requires staffing and organizational change, any organization regardless of size or geographical location can implement the standard and capture savings. The DOE estimates more than 12,000 facilities are currently ISO 50001-certified, and ISO estimates that the standard has the potential to affect 60% of the energy used throughout the world. PLANT ENGINEERING

June 2017

SPECIAL REPORT ENERGY MANAGEMENT Plan-Do-Check-Act (PDCA) ISO 50001 relies on the Plan-Do-Check-Act (PDCA) cycle of continual improvement. t 1MBO IFMQT FOTVSF UIBU UIF BQQSPQSJBUF TUFQT BSF JO place to meet a facilityâ&#x20AC;&#x2122;s energy policy. t %P GPDVTFT PO JNQMFNFOUJOH UIF FOFSHZ NBOBHF ment action plans through training, documentation, operational control, and more. t $IFDL JOWPMWFT BOBMZ[JOH NFBTVSJOH BOE NPOJ toring performance and processes in light of the energy objectives and policy. t "DU FOTVSFT UIBU FOFSHZ QSPKFDUT BSF DPOUJOVBMMZ considered as a course of business and that energy performance remains an executive level priority. As the demand for ISO 50001 in the U.S. industrial and commercial sectors increased, the DOE with support of the U.S. Council for Energy-Efficient Manufacturing (U.S. CEEM), created the Superior Energy Performance (SEP) recognition program. The SEP program adds a third-party process to verify the actual energy performance improvements from ISO 50001 certification. Through SEP, the DOE provides recognition of ISO 50001-derived energy improvement. While the EPA has developed energy management guidelines that contain most of the elements of ISO 50001, there has been no DOE recognition available for those facilities not interested in pursuing ISO 50001

certification. To fill this gap, the DOE has developed 50001 Ready to provide recognition, along with supporting tools and resources, freely available to a wider QPPM PG PSHBOJ[BUJPOT JOUFSFTUFE JO JNQMFNFOUJOH BO EnMS based on the ISO 50001 structure, whether they want to ultimately become certified or not.

Getting 50001 Ready After receiving feedback from facilities certified in the SEP program, the DOE began developing resources for facilities to have a â&#x20AC;&#x2DC;do it yourself â&#x20AC;&#x2122; method for instituting an EnMS, called the 50001 Ready program. The program emphasis is on broader ISO 50001 process adoption and energy improvement to encourage more GBDJMJUJFT UP QVSTVF UIF *40 TUBOEBSE BOE SFBMJ[F FOFSHZ savings. Facilities can be part of the 50001 Ready program by using the recently released 50001 Ready Navigator online tool (more information can be found at energy. gov/50001ready). This implementation management resource is free and can be adopted by facilities and PSHBOJ[BUJPOT BT UIFZ BJN UP JODSFBTF FOFSHZ TBWJOHT *U helps align the best practice guidelines outlined by ISO 50001 and allows facilities to self-direct and self-attest to their implementation progress by providing worksheets, templates, and team management resources. The 50001 Ready Navigator tool also is structured as an open system so that utilities, trade associations, and others

Getting started with 50001 Ready Establishing an EnMS requires effort and resources. Accessing DOEâ&#x20AC;&#x2122;s new 50001 Ready Navigator tool (energy.gov/50001Ready) and becoming 50001 Ready is a great way to get started for a company of any size. Many helpful resources are available, and experienced consultants with DOE-developed materials and certifications make great partners for achieving savings. Just as pursuing ISO 50001/SEP requires a commitment of time, effort and resources, so too does being qualified to assist with certification. A number of specialized credentials are needed to walk facilities through the steps. The Institute for Energy Management Professionals (ienmp.org) maintains databases of current professionals with these credentials.

Credentials

Certified Practitioner in Energy Management SystemsIndustrial t *40 TZTUFN EFWFMPQNFOU GPS JOEVTUSJBM BOE DPNNFSDJBM TJUFT t $PBDIJOH BOE DPOTVMUJOH PO *40 JNQMFNFOUBUJPO

Superior Energy Performance-Performance VerifierIndustrial t $BQBCMF PG TFSWJOH PO BO *40 4&1 UIJSE QBSUZ BVEJU UFBN t $FSUJGJFT UIF FOFSHZ TBWJOHT MJOFBS SFHSFTTJPO NPEFM UIBU JT EFWFM oped to SEP standards

June 2017

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t 3FDPNNFOET DFSUJGJDBUJPO UP UIF 4&1 MFBE BVEJUPS

ISO 50001 Lead Auditor t $FSUJGJFE UP MFBE *40 DFSUJGJDBUJPO BVEJU BOE QPUFOUJBM UP also support SEP.

SEP Trainer t 3FGFSFODFE BOE FOEPSTFE CZ UIF %0& 0GGJDF PG &OFSHZ &GGJDJFODZ & Renewable Energy t "CMF UP MFBE *40 4&1 USBJOJOH FWFOUT GPS JOEVTUSJBM BOE DPNNFS cial sites t $BQBCMF PG GPSNJOH BOE MFBEJOH DPIPSUT XJUI BDDFTT UP BMM %0& ISO/SEP presentations and instructional materials Overall, systematic energy management allows an organization to develop a sustainable culture of energy performance improvement and energy efficiency. It is an excellent way for commercial and industrial facilities to elevate their energy management practices, reduce their environmental impact, and increase competitiveness. With the announcement of the 50001 Ready program, the DOE is expanding its support to help more facilities realize the savings and benefits from an energy management system.

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can rebrand and use it as they see fit. It is an extremely flexible resource that is ready for wide adoption. The 50001 Ready Navigator tool lines up directly with the EnMS requirements of ISO 50001. It includes 25 tasks that facilities must complete, divided into four sections: t 1MBOOJOH t &OFSHZ 3FWJFX t $POUJOVBM *NQSPWFNFOU t 4ZTUFN .BOBHFNFOU The tasks range from setting the scope and boundaries of an EnMS to determining significant energy uses and progressing through management review. When all tasks are complete, the organization can send a request, if desired, to the DOE for recognition of its 50001 Ready EnMS. The DOE will add the organization to a list of all 50001 Ready facilities, with the option to have this status publicly available on the programâ&#x20AC;&#x2122;s website. Although 50001 Ready is built around the ISO 50001 standard, having a 50001 Ready-EnMS does not signify ISO 50001 PS 4&1 DFSUJGJDBUJPO 5IFTF SFRVJSF BEEJUJPOBM TUFQT including audits and third-party verification.

The value of ISO 50001 %0& NFBTVSFE SFTVMUT PG GBDJMJUJFT BDIJFWJOH 4&1 DFSUJGJDB tionâ&#x20AC;&#x201D;for which ISO 50001 is requiredâ&#x20AC;&#x201D;demonstrate that facilities can attain up to 30% improvement in energy performance over three years with paybacks under 2.5 years (with many facilities reporting less than a 1-year payback). The long-term energy and cost savings produced through such a holistic framework are greater and more consistent than those associated with a project-by-project energy improvement system. Many of the savings are generated through no- and low-cost operational and procedural changes. The broader result is a comprehensive, standardized, systematic, and rigorous way to achieve verified energy savings and sustain growth for the future. â&#x20AC;&#x153;ISO 50001 allows business leaders to establish a practice around the use of energy that reduces business risk and improves productivity and operations,â&#x20AC;? said Jay Wrobel, technical assistance manager, for the DOEâ&#x20AC;&#x2122;s Advanced Manufacturing Office. The benefits go beyond solely energy and cost savings, though. Investing in this type of EnMS promotes energy efficiency throughout an organization. It leads to increased employee awareness and stewardship and a stronger understanding of energy use and consumption. Organizations are better able to identify and integrate future projects into their new framework, fostering continual improvement. www.plantengineering.com

1VSTVJOH *40 BOE 4&1 DFSUJGJDBUJPO DBO CF B SPCVTU QSPDFTT 5IF 4&1 DFSUJGJDBUJPO QSPDFTT JT EFUBJMFE and thorough, so a commitment must be made topEPXO "U B HFOFSBM MFWFM 4&1 DFSUJGJDBUJPO SFRVJSFT three main steps: 1. Implementing an ISO 50001 EnMS, 2. ( FUUJOH *40 DFSUJGJFE CZ BO 4&1 RVBMJGJFE lead auditor 3. 3FDFJWJOH B DFSUJGJFE BVEJU GSPN BO 4&1 WFSJGJDB tion body showing continued improvement in energy performance. 5IF 4&1 BOE *40 DFSUJGJDBUJPO JT B UISFF ZFBS certification with recertification audits to evaluate whether 4&1 SFRVJSFNFOUT BSF TUJMM CFJOH NFU Many organizations have realized the extensive benefits BTTPDJBUFE XJUI *40 BOE 4&1 $VSSFOUMZ JOEVT trial and commercial facilities of all sizes in 19 U.S. states BOE 8BTIJOHUPO % $ BSF 4&1 DFSUJGJFE BOE UIPVTBOET worldwide have an EnMS that more generally meets ISO 50001 requirements. . $PNQBOZ GPS FYBNQMF TBWFT NJMMJPO CZ IBWJOH six locations certified to ISO 50001. â&#x20AC;&#x153;The proven performance of our ISO 50001-certified facilities has led 3M UP JODMVEF *40 BOE 4VQFSJPS &OFSHZ 1FSGPSNBODF among our strategies to meet our next set of corporate energy efficiency goals,â&#x20AC;? said Jean Bennington Sweeney, 3M chief sustainability officer. Schneider Electric has at least 21 certified sites. â&#x20AC;&#x153;The ISO 50001 framework not only builds upon our energy management systems, but also help us drive consistency and performance improvements across our locations,â&#x20AC;? said Steve Sacco, Schneider Electric, vice president, Safety, Environment & Real Estate. Another example is North $BSPMJOB CBTFE $VNNJOT XIJDI BDIJFWFE HSFBUFS UIBO 12% reduction in energy consumption and savings of QFS ZFBS XJUI B TJNQMF QBZCBDL PG NPOUIT Many utilities also support strategic energy management as an energy efficiency program and offer incentives for performance. However, increasing program participation continues to be a primary goal. Utilities are beginning to use the DOE cohort model to add customers, with utility efficiency and customer engagement resources to support coaching. PE Kitt Butler is senior program manager at Advanced Energy. Jay Wrobel is the manager of technical assistance and Pete Langlois is a program manager, both with the U.S. Department of Energyâ&#x20AC;&#x2122;s Advanced Manufacturing Office in Washington D.C. PLANT ENGINEERING

June 2017

DIGITAL REPORTS Plant Engineering is excited to introduce our new Digital Reports Sponsored by: Mitsubishi, Yaskawa 2017 DIGITAL REPORT

Sponsored by: Cisco, Iconics 2017 D IGITAL R EPORT IIoT

MOTION CONTROL

www.plantengineering.com/ DigitalReport/MotionControl Sponsored by: FS Elliott, Kaeser 2017 DIGITAL REPORT

www.plantengineering.com/ DigitalReport/lloT Sponsored by: Kepware, Rittal 2017 DIGITAL REPORT IIoT: OPERATIONS & IT

COMPRESSED AIR STRATEGIES

www.plantengineering.com/ DigitalReport/AirCompressedStrategies Sponsored by: Maple Systems, Pepperl+Fuchs

www.plantengineering.com/ DigitalReport/lloTOpsandIT Sponsored by: Beckhoff, Bosch Rexroth, ePlan, Hilscher

2017 D IGITAL R EPORT

2017

D IGITAL R EPORT

HMI IIoT: Machines, Equipment & Asset Management

www.plantengineering.com/ DigitalReport/HMI

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SPECIAL REPORT ENERGY MANAGEMENT By Eric Corzine, Rittal Corp.

Overcome the high cost of staying cool Calculate seasonal energy efficiency for your HVAC system.

onfusion about the application and accuracy of the Energy Efficiency Ratio (EER) and the Seasonal Energy Efficiency Ratio (SEER) leaves many plant engineers struggling to ensure their energy calculations will deliver the most value to plant operations. Understanding the definitions, calculations, regulations, and key considerations can provide clarity on saving energy and money on cooling industrial enclosures.

The SEER 13 standard is estimated to limit air pollution and reduce fossil fuel consumption by up to 33 million metric tons of carbon, according to the Washington, D.C.-based Environmental and Energy Study Institute. The U.S. Department of Energy estimated 4.2 quadrillion Btu would be saved between 2006 and 2030 with a SEER 13 standard. While legislation on the standard has not been approved, the concepts of SEER are being applied in the industry.

Why does SEER matter? The difference between EER and SEER Introduced by the Air Conditioning & Refrigeration Institute in 1975, EER measures and compares the efficiencies of HVAC unit to another. SEER was signed into law by President George H.W. Bush in 1992. SEER is considered an improvement because it takes seasonal temperatures into account to better approximate what happens in the actual end use application for the cooling unit. SEER is calculated by dividing the BTU of cooling output during its normal annual usage by the total electric energy input in watt hours (WÂˇh) during the same period.

Itâ&#x20AC;&#x2122;s true that SEER does not apply to industrial enclosure air conditioners, as theyâ&#x20AC;&#x2122;re deployed to run year-round to cool installed equipment. However, that doesnâ&#x20AC;&#x2122;t mean SEER shouldnâ&#x20AC;&#x2122;t be a consideration when calculating potential savings from energy energy-efficient enclosure cooling systems. For example, when comparing costs and benefits of a cooling system retrofit, SEER can be useful as a variable to calculate energy savings, a critical consideration in overall plant efficiency. Consider the following scenario to demonstrate how understanding SEER can be useful in an industrial enclosure air conditioning purchasing decision. In this example: t :PVS QMBOU JT MPDBUFE JO UIF (SFBU -BLFT SFHJPO

SEER=(BTU / h) Ăˇ W Every air conditioning unit is assigned a SEER rating. The higher the SEER (for the climate), the more energy energy-efficient the cooling unit. For example, upgrading from a SEER 9 to a SEER 13 unit can reduce power consumption by 30%. A SEER 13 standard was to take effect starting in 2006 as the standard for optimal energy efficiency. www.plantengineering.com

t :PV SF SVOOJOH FODMPTVSF DPPMJOH VOJUT GPS three shifts a day, five days a week. t :PV TXJUDI PVU ZPVS FODMPTVSF DPPMJOH VOJUT with energy-efficient 2600W, wall-mounted cooling units with a SEER rating of 6.2 (adjusted for your temperate climate)

PLANT ENGINEERING

June 2017

SPECIAL REPORT ENERGY MANAGEMENT

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GJDJFOU B SBUJP DBMDVMBUFE CZ EJWJEJOH UIF BNPVOU PG DPPMJOH DBQBDJUZ CZ UIF BNPVOU PG QPXFS DPO TVNQUJPO 5IJT DBMDVMBUJPO JT NBEF BU BO JOUFSOBM BOE BNCJFOU UFNQFSBUVSF UZQJDBMMZ ยก' JOUFSOBMMZ BOE FYUFSOBMMZ Cooling Coefficient = Net Capacity (Watts) Power Input (Watts) "OPUIFS JOEVTUSJBM FOFSHZ FGGJDJFODZ NFUSJD UIBU JT NBOEBUFE JO "4)3"& JT 4FOTJCMF $PFGGJDJFOU PG 1FSGPSNBODF 4$01 SCOP = Net Sensible Cooling Capacity (Watts) Total Power Input (Watts) 5IF 4$01 PGUFO JT PGUFO VTFE UP DPNQBSF UIF FGGJ DJFODJFT PG EJGGFSFOU NBLFT BOE NPEFMT PG DPPMJOH VOJUT :PV DBO PGUFO GJOE JU JO CVZFS T HVJEFT BOE CSPDIVSFT " IJHIFS 4$01 JT CFUUFS $PPMJOH VOJUT GPS DPNQVUFS SPPNT VTF 4$01 CFDBVTF JU CFUUFS DBQUVSFT UIF DPOEJUJPOT GPVOE JO UIFN 4$01 XBT DIPTFO TQFDJGJDBMMZ UP NFBTVSF DMJ NBUF DPOUSPM JO JOEVTUSJBM TFUUJOHT GPS UXP SFBTPOT t & &3 XBT EFFNFE JOBEFRVBUF CFDBVTF JU JODMVEFT MBUFOU DPPMJOH t 4&&3 BMTP HJWFT DSFEJU GPS MBUFOU DPPMJOH CVU EPFT OPU BDDPVOU GPS UIF GBDU UIBU UIF DPPM JOH MPBE JO B UZQJDBM JOEVTUSJBM TFUUJOH JT OPU TFBTPOBCMF CVU SBUIFS DPOTJTUFOU ZFBS SPVOE

Taking steps to upgrade $POTJEFSJOH IPX DSJUJDBM FOFSHZ DPTUT BSF UP NPTU JOEVTUSJBM PQFSBUJPOT NBLJOH UIF EFDJ TJPO UP VQHSBEF FODMPTVSF DPPMJOH TZTUFNT JT B TJHOJGJDBOU GJSTU TUFQ " HPPE QMBDF UP TUBSU JT CZ FWBMVBUJOH ZPVS GBDJMJUZ T FOFSHZ FGGJDJFODZ 5IF &OWJSPONFOUBM 1SPUFDUJPO "HFODZ T FOFSHZ QFSGPSNBODF SBU JOH TZTUFN IFMQT GBDJMJUZ NBOBHFST BTTFTT IPX FGGJDJFOUMZ UIFJS CVJMEJOHT VTF FOFSHZ SFMBUJWF UP TJNJMBS CVJMEJOHT :PV DBO GJOE PVU ZPVS

SEER ratings is calculated by dividing the BTU of cooling output during its normal annual usage by the total electric energy input in watt hours (W-h) during the same period. Image courtesy: Rittal

June 2017

PLANT ENGINEERING

www.plantengineering.com

“Understanding the definitions, calculations, regulations, and key energy performance ratings through EPA’s Energy Star Portfolio Manager, an interactive online tool that tracks energy and water consumption. The energy performance of a building is expressed on a scale of 1 to 100. For example, a rating of 50 indicates that the building performs better than 50% of all similar buildings over the course of a year. When it comes to evaluating the cooling efficiency of enclosures, it’s important to know how much heat energy the air-conditioning system must remove. One way to figure this out is to add up the heat loads of all electronic components as specified by their respective manufacturers. Another is to add up the power, P, that the electronics consumes and then multiply it by one minus the efficiency, E, of the system: P(1-E) The number you reach will define the need for cooling capacity. Also, several sizing software tools are available to help you figure out how enclosure air conditioners will perform. Some even walk users through the application factors and determine the need for cooling, and can calculate the internal enclosure temperature and suggest an appropriate air conditioner with the best cooling capacity relative to power consumption. For example, consider an enclosure air conditioner with a cooling capacity and power consumption at 95/95, 60 Hz of 2,700 W and 1,500 W, respectively. Then є = 2,700/1,500 = 1.8. This energy cooling factor was arrived upon by taking the ratio between useful cooling capacity and power consumption: є = Ѳ k/Pel (Ѳk = useful cooling capacity, W and Pel = power consumption, W) We also know that with enclosure air conditioners, internal and external humidity affect performance. As you consider systems with the most reliable ways of discharging condensate from the enclosure, you may want to investigate advanced fan and filter units with condensate evaporators to eliminate moisture.

Making the right decisions Now that we have established that cooling induswww.plantengineering.com

considerations can provide clarity on saving energy and money on cooling industrial enclosures.

”

trial enclosure with energy-efficient air conditioning units can significantly prolong the life of your equipment, save energy, and reduce downtime, it’s time to address the purchasing process. Besides EER, SEER, AND SCOP measurements, here are some other factors to consider before making your purchase. t C ooling Output – Measured in watts, this is the ability of the cooling device to remove heat from a system. Also sometimes measured in tons, as 1 ton of refrigeration is freezing 2,000 pounds of water at 32°F for 24 hours. t Internal Heat Load – the This is the amount of heat energy that the electronics inside the enclosure produce. It’s important to know how much heat energy (in Btu/hour or in watts/ hour) is generated in the enclosure before shopping for an air conditioner that has enough capacity for your needs. t Mains Operating Frequency – In North America, 60 Hz is the norm (compared to 50 Hz in the rest of the world), so when an air conditioner operates at 60 Hz, its fans and compressor rotate faster and cools somewhat more efficiently. If shopping outside of North America, it’s helpful to know that some units are dual-rated so they can operate at both 50 Hz and 60 Hz. Industrial plant operators and managers are paying more attention to enclosure climate control, and the most efficient means of keeping equipment housed within them cool. This is a good thing—even if we don’t yet have formal standards for testing and establishing cooling capacities in North America. What’s important is to get ahead of existing and future air conditioning unit ratings and regulations, and educate yourself on making the best decision that fits your plant’s operating needs and budget. PE Eric Corzine is climate control product manager at Rittal Corp. PLANT ENGINEERING

June 2017

SPECIAL REPORT ENERGY MANAGEMENT By Mark Harshman, Siemens

Control room temperatures: Strategies to beat the heat Air-to-water exchangers can reduce VFD heat exposure. he installation of large, medium-voltage VFDs in mechanical equipment rooms creates the problem of harmful ambient room temperatures. This means facility managers and plant engineers must mitigate the heat generated by VFDs. The room temperature must remain low enough not to harm equipment and to meet OSHA standards for technicians who must operate or maintain equipment in the room. Most electrical equipment of this type is specified to operate at a 104°F ambient air temperature, which may be too warm for operators working over an extended time. Automation and computer equipment, which share the equipment room, may not be rated to operate at these temperatures. Several methods have been used to address the heat load caused by electronic power systems in enclosed rooms. These include: 7UDGLWLRQDO DLU FRQGLWLRQLQJ

M More SOLUTIONS KEYWORD:

5HPRYLQJ ODUJHU KHDW JHQ erators (e.g., transformers)

Heat Exchangers at PlantEngineering.com

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ARTICLE: Applying heat exchanger control strategies ARTICLE: Cabinet electronics: Thermal considerations ALSO: OSHA recognizes heat stress as an area covered under its General Duty Clause Section 5(a) (1), requiring employers to mitigate “recognizable hazards.” The full text of the General Duty Clause is at osha.gov.

June 2017

PLANT ENGINEERING

These approaches all have a place and are dependent on several variables including plant location, environmental conditions, VFD topology, equipment type, desired reliability, and available space. The use of conventional air conditioning units has been implemented the most frequently.

Unfortunately, high-horsepower medium-voltage VFDs generate large heat loads into the equipment room, requiring large air conditioning units. For example, a 6000Hp VFD might require an HVAC unit at an initial cost of more than $200,000, as well as additional operating costs associated with utility use, and relatively low reliability. Some VFD topologies allow remote location of primary heat generators such as transformers. However, this removes only 50% of the heat load and requires additional site work to locate the transformer remotely, and it increases the cost of running power cables from the transformer to the power electronics section of the VFD. Although the use of air-to-air heat exchangers has been a relatively new approach, it has been used successfully to eliminate the need for air conditioning entirely by creating a closed-loop air system for the VFD and a secondary loop which is exhausted externally to the environment. These systems have been around for several years and can quickly provide a two- or three-year payback when compared to an equivalent air-conditioning system’s initial cost and yearly operating utility costs.

Air-to-water exchangers A recent improvement to the problem of equipment room heating is the modification of air-to-air heat exchangers to air-to-water exchangers. The exchanger is integral to the VFD and provides a much smaller footprint, lower capital, and operating costs. It also can provide additional cooling benefits when a VFD is running at lower than rated loads and speeds. This approach can be applied in plants where process water is available. The water can be used www.plantengineering.com

VFDs Variable-frequency drives control the speed of an ac motor, which provides flexibility to the process since speed can be changed easily for process optimization. It takes the fixed power supplied to it and converts it into a variable frequency and variable voltage source which then feeds a motor. This allows the drive to control the speed and torque the motor produces. A VFD may enhance the user’s profitability by improving the process, which in turn produces a faster return on investment. Source: Plant Engineering Website

to circulate in a heat exchanger and remove heat generated by a VFD. The use of air-to-water heat exchangers allows the room air to cool a VFD and hot exhaust air, which normally exhausts into an equipment room and is cooled by an air-conditioning system, to flow through a radiator where the heat is carried away by the water while the cool air is returned into the room. This is a completely closed loop air system which maintains the temperature in an equipment room. The approach also isolates a VFD and other equipment from potentially hazardous or caustic environmental contaminants, eliminates air conditioning requirements for the VFD, and can cool the room and other equipment if the VFD is running lightly loaded or at a reduced speed. This approach is applicable only where plant water is readily available. In those cases, chilled water, when sufficiently cooled, can improve the operation further and eliminate all HVAC requirements. The exchanger is sized to handle the heat generated by the VFD when it is running at its full rating. The design allows for up to 95°F inlet water at 15-30 gallons per minute (gpm), but the air exhaust temperature will be approximately 41°F warmer than the inlet water temperature. Chilled water below 77°F will yield a lower exhaust temperature and can lower the ambient temperature of an equipment room. New designs aimed at reducing HVAC costs are available now and can be tailored to a specific plant location and site environment. These new ideas can eliminate costly HVAC and improve plant economics in terms of energy costs, reliability, and efficiency. PE

The use of air-to-water heat exchangers allows the room air to cool a VFD and hot exhaust air. Image courtesy: CFE Media archives/McGuire Engineering

Mark Harshman is a power electronics engineering leader for Siemens. www.plantengineering.com

PLANT ENGINEERING

June 2017

We proudly salute manufacturing innovation and invite you to explore and celebrate the success stories of these participating manufacturing innovators: AutomationDirect

Mapcon

AVO Training Institute

Mil-Comm Products Co.

Baldor

MovinCool

CamďŹ l Air Pollution Control

Phoenix Contact

Carlo Gavazzi Inc.

PRUFTECHNIK Inc.

Century Spring Corporation

Rittal Corporation

Eruditio

Rogers Machinery

Flexicon Corp.

SEW Eurodrive Inc.

GTI Spindle Technology

SPM Instrument Inc.

Kaeser Compressors

Vac-U-Max

Lubriplate

Look for the special Innovations videos at:

www.plantengineering.com/innovations

A DV E R T I S E M E N T

AutomationDirect We ship super-fast (and FREE on orders over $49). The majority of our products are stocked for same-day shipping, when you place your order by 6p.m. E.T. (with approved company credit or credit card). Plus, you get free two day (transit) shipping on orders over $49 within the U.S., Canada and Puerto Rico; shipped via ground service or LTL (certain heavy items are excluded). We guarantee it.

Company headquarters located just north of Atlanta, Georgia

A well-recognized name in the industrial automation market, AutomationDirect is a distributor of thousands of products including Programmable Logic Controllers (PLCs), AC/DC drives and motors, operator interface panel/HMIs, power supplies, sensors, pushbuttons, NEMA enclosures, pneumatic supplies, wire, and much more. In business since 1994, the company headquarters is located just north of Atlanta, Georgia. For over 20 years we’ve been saving our customers time and money on industrial automation products. We have a huge inventory that is constantly growing in order to provide you with the quality components needed to keep your projects on schedule. We’ve heavily invested in new infrastructure that will allow us to continue offering the service and support you deserve. We make ordering easy and our service is exceptional. Shop online with our exhaustive product listings or browse our online catalog; fax or phone us – you’ll get friendly, efﬁcient service from the most helpful sales team in the business. Independent surveys completed by readers of industrial trade magazines for their Readers’ Choice Awards have placed us at the top of the list for service 15+ years in a row.

We want you to be pleased with every order. That’s why we offer a 30-day money-back guarantee on almost every stock product we sell, including our software (see Terms and Conditions for certain exclusions).

Orders ship quickly from our state-of-the-art warehouse

For more information, contact us at 800-633-0405 or visit us online at www.automationdirect.com.

1-800-633-0405 | AutomationDirect.com input #34 at www.plantengineering.com/information

A DV E R T I S E M E N T

Designed for Food Safety: Dodge Mechanical Products and Baldor-Reliance Motors Food and Beverage processing equipment should be designed, used, and maintained with food safety principals as a priority. Failure to adhere to these practices can cost companies thousands, if not millions, to resolve. It is critical that food and beverage companies not only consider the initial purchase price, but also the Total Cost of Ownership (TCO) that includes the cleanability, maintenance, and reliability of the equipment provided by suppliers who understand the principles of sanitary design.

Industry leading DodgeÂŽ mechanical and Baldor-RelianceÂŽ electrical products help ensure the highest level of food safety, reliability, and performance in the food industry. Long before we invested in the people, equipment and material required to produce Dodge washdown reducers and ! $' / ! # ( $,# *)- "$)$'( , #+ () $*' ) and attention in listening to equipment designers, operators a %! #) " #) # # # # '( ! '# $*) ) ' )$* ( %'$ (( # %%! ) $#( # ) $$ # + ' # *()'- $ notes when they shared their wish lists of product capabilitie That was over 30 years ago, and weâ&#x20AC;&#x2122;re still listening to customer input. That is why Baldor-Reliance Stainless Steel motors and Dodge Ultra Kleen gear reducers are engineered to meet the toughest demands of food production and processing. These products have been designed, tested and certiďŹ ed to meet IP69K requirements for water protection, and provide the necessary protection from severe washdown conditions without allowing caustic chemicals or water to enter the product.

Baldor-mediarelations@abb.com | 479-646-4711 | www.baldor.com input #35 at www.plantengineering.com/information

A DV E R T I S E M E N T

Camfil APC Helps Keep Plants Safe, Clean and Compliant Camﬁl APC designs quality, technologically advanced equipment to help plants clean up the dust, mist and fume created from manufacturing processes. They improve employee health and help plants go green by stopping thousands of different pollutants from entering the workplace and outside air.

operating expenses. They can perform a battery of tests on dust samples and simulate speciﬁc challenges to make more informed decisions on equipment, ﬁlter cartridges and engineered controls to mitigate dust hazards. Tests include particle size analysis, moisture analysis, abrasion and terminal velocity testing.

Dust, Mist and Fume Collectors for all Plant Applications

The company also has a rig dedicated for ANSI/ ASHRAE Standard 199 testing. The test rig provides manufacturers with real world, applesto-apples comparison data on emissions, pressure drop, compressed air usage, energy consumption, and emission readings for Camﬁl APC dust collectors. They can see what it really costs to operate the collector over time and make accurate system comparisons.

Camfil APC offers a complete line of dust, mist and fume collectors for use in many industries. All equipment and filters are manufactured at the ISO 9001 certified facility in Jonesboro, AR. The flagship dry dust collector is the Farr Gold Series ®, used in hundreds of manufacturing plants. The Quad Pulse Package is a compact dry dust collector. The Handte EM Profi and Oil Expert systems collect coolant and oil mist, and the Handte Vortex wet scrubber is a low maintenance dust-collecting option that uses water as the filter.

Dust testing and ASHRAE Standard 199 Testing Camﬁl APC offers testing services that help manufacturers select the best dust collector for their application, with the lowest energy and

Comprehensive Training Camfil regularly conducts two-day training sessions on the operation and maintenance of its Farr Gold Series ® dust collector system, proper techniques for industrial ventilation, and compliance with National Fire Protection Association (NFPA) standards for explosive dust. Trainees learn about dust collection technology through hands-on, interactive sessions. Topics include: Types of industrial dust collectors, filter options, flammable and combustible dust, NFPA regulations on dust, variable frequency drive programming, and start-up procedures. Attendees will also visit the test labs, showroom and manufacturing facilities.

800-479-6801 or 870-933-8048 | filterman@camfil.com | www.camfilapc.com input #36 at www.plantengineering.com/information

A DV E R T I S E M E N T

Eruditio: Education, Application, Innovation Inspired Blended Learning® for Reliability Leaders The ﬁrst of its kind, the iBL platform has received exemplary reviews from all those who have journeyed through the program. iBL is a self-paced, project based, blended learning curriculum that mixes classroom learning, online learning, professional coaching, and on-the-job execution for maximum results. It can be used to train Reliability and Maintenance Engineers, Planners and Schedulers and Maintenance Managers just to name a few. Graduates enroll expecting to see at least a 10X return on their training investment, however the last graduating class averaged a 30X ROI! It is the only Blended Learning curriculum indorsed by the University of Tennessee RMC and graduates can receive the RMIC credentials from UT upon completion of their improvement project. To see the students talk about their experience visit ibltraining.com.

Augmented Reliability® Eruditio’s augmented reality platform, Augmented Reliability ®, is a shining example of how this team innovates and develops new and exciting ways to bring education into the modern age. Using a mobile device, users can scan a target image and experience a lesson using 3D animations, audio, videos, and more, right there in their environment. The application goes beyond typical educational lessons. Imagine scanning a motor, pump, or electrical panel, and seeing a bill of materials, or an inspection procedure that shows you where to perform each action. No more guess work, and fewer mistakes. AR is the future. “I believe it is going to be as big a part of our lives as cell phones today. The demand is growing and the technology is evolving and improving constantly”, said Creative Director, Jon Bailey.

Cutting Edge eLearning Development One of the staples of Eruditio has been eLearning. As working adults, it’s hard to take weeks to travel the country for training. eLearning allows the users to take the courses anywhere, and at their pace. They also offer a level of standardization and repeatability of content that does not exist in the traditional instructor led world. Eruditio is constantly building content for their students, let them build custom content for you too.

info@eruditioLLC.com | 843.375.8222 | www.erudtioLLC.com input #37 at www.plantengineering.com/information

A DV E R T I S E M E N T

Flexicon stand-alone bulk handling equipment to engineered, plant-wide systems Choose from a broad range of reliable, high performance equipment:

Continuous growth required the company to recently double the size of its US headquarters.

Flexicon provides an unparalleled level of service through its administrative, engineering and manufacturing capabilities on four continents, and extensive worldwide network of applications engineers, authorized representatives and ﬁeld support technicians—a unique consolidation of bulk handling specialists with hundreds of years of combined experience. An extensive research and development program continually sets new standards for bulk handling equipment performance with entirely new designs, product improvements and equipment that complies with chemical, food, dairy and pharmaceutical requirements nationally and internationally. Flexicon’s design engineering staff devises efﬁcient solutions to the most unusual problems with highly custom equipment, endowing the company with a depth and breadth of bulk handling experience unequalled by any other manufacturer.

2 Flexible Screw Conveyors 2 Volumetric Feeding Conveyors 2 Tubular Cable Conveyors 2 Pneumatic Conveying Systems 2 Bulk Bag Fillers

Products range from individual equipment to automated systems that source bulk material from interior and exterior plant locations, transport it between process equipment and storage vessels, weigh it, blend it, feed it to packaging lines, extruders, molding machines and storage vessels, and load it into railcars and trailers.

Bulk Bag Dischargers Bulk Bag Conditioners Weigh Batching Systems Manual Dumping Stations 2 Drum/Box/ Container Dumpers

A separate Flexicon Project Engineering Division manages large-scale bulk handling projects across the chemical, mineral, food, dairy and pharmaceutical industries worldwide. Supervised by dedicated Project Managers, these custom-engineered, automated systems integrate Flexicon equipment with bulk handling and process equipment of other manufacturers including: 2 Gravimetric/Volumetric Feeders 2 Silos and other storage vessels 2 Dryers/Coolers 2 Mixers/Blenders

Equipment overview Flexicon is a world leader in the design and manufacture of bulk handling equipment and custom-engineered and integrated plant-wide systems that transport, discharge, ﬁll, weigh, blend, deliver and/or feed a broad range of powder and bulk solid materials.

2 2 2 2

Basic, stand-alone machines to automated plant-wide systems, all Flexicon equipment is backed by Flexicon’s Lifetime Performance Guarantee.

+1 610 814 2400 | sales@ﬂexicon.com www.ﬂexicon.com input #38 at www.plantengineering.com/information

2 2 2 2

Screeners Crushers/Grinders Packaging Machines Other bulk processing equipment

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Custom Solutions from a Tradition of Innovation With a heritage that extends back to 1919, Kaeser Compressors is a leader in manufacturing compressed air equipment and helping customers around the world assemble those components into the most reliable and energy efﬁcient systems possible. With a cutting edge research and development team committed to building industryleading products, innovation is our lifeblood. Kaeser’s custom engineered compressed air systems are yet one more way we deliver lasting value to our customers.

the built-for-a-lifetime™ reliability you expect from the Kaeser name. Energy efﬁciency and remote operations are supported by our Sigma Air Manager 4.0, which precisely controls air production to meet your pressure needs as well as offering energy consumption and operational information via your choice of industrial communications interfaces.

Solutions for rental systems or whenever portability is critical are also available.

Kaeser isn’t intimidated by demanding applications. Our commitment to designing the best engineered solutions results in compressed air systems that remain reliable even in the toughest of applications in the harshest of environments.

Our custom enclosures are ideal for installations where floor space is limited.

There is nothing cookie-cutter about our engineered air solution envelopes. Our team of designers works with you to determine your system needs, select the optimal mix of equipment and then design a skid, container or custom enclosure to suit the operating environment. We can also produce 2D and 3D CAD drawings of the proposed system to facilitate installation planning. Our turnkey enclosures and skids integrate our superior quality air compressors, blowers, dryers, filters, and other system components into rugged systems built to specification for any climate or location. Each and every component is selected for optimal efficiency and is backed by

kd k piped and wired, ready for operation.

We invite you to watch the Custom Containerized Systems by Kaeser Compressors time-lapse video: www.youtube.com/watch?v=leHRqSGnib8 Contact us today for a custom solution for your compressed air needs.

866-516-6888 | customer.us@kaeser.com | www.us.kaeser.com/engineeredsolutions input #39 at www.plantengineering.com/information

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Lubriplate’s Complimentary ESP Extra Services Package helps maximize your lubrication maintenance program

Complimentary Value Added Services Offered Include... A Toll Free Technical Support Hotline and E-mail You can call Lubriplate’s technical service center toll free at 800-347-5343 for quick answers to tough lubrication questions by phone, or you can e-mail questions to LubeXpert@lubriplate.com seven days a week.

Complete Plant Surveys and Lubricant Inventory Consolidation Complete plant surveys by Lubriplate’s professional staff of lubrication engineers are also available to determine your exact lubricant requirements and identify opportunities for lubricant inventory consolidation.

Color Coded, Lubricant Specification, Machinery Tags Lubriplate offers customized, color coded machinery tags to help prevent lubricant misapplication and ensure that the proper lubricant is used when servicing a particular piece of equipment. Based on a complete plant survey, tags can be provided for each piece of equipment in your plant.

Lubrication Maintenance Software Lubriplate offers a PC based computer software program that puts your entire lubrication and maintenance schedules at your ﬁngertips. This service is based on a complete survey of your entire plant. Contact Dan Moroses (Newark ofﬁce) for details at 973-589-9150.

No-Charge Follow-up Oil/Fluid and Grease Analysis Lubriplate’s Oil|Fluid and Grease Analysis Program is offered at no-charge on all Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO Cleanliness (optional). An interpretation of the results is included along with suggested actions to take.

In Plant User Lubrication Training Programs We offer training programs tailored to your needs. These educational training sessions focus on all facets of machinery lubrication and are not a sales presentation. Seminars are graphically presented with overheads and other support material. Available on-site at your facility or in a local conference room. Contact us at 800-733-4755 for more information.

/XEULSODWH /XEULFDQWV &RPSDQ\ 1-800-733-4755 | www.lubriplate.com | LubeXpert@lubriplate.com input #40 at www.plantengineering.com/information

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MAPCON Mobile Lets You Bring Your CMMS Anywhere! Mapcon Technologies, Inc. has been creating CMMS software since 1982. Many innovations have come along in the past 35+ years, but perhaps none more important than mobile technology. In order to adapt to the growing demand, Mapcon created their own mobile CMMS - called MAPCON Mobile. Despite common complaints that people spend too much time on their phones, making use of a mobile app can help companies save time and money.

Portability MAPCON Mobile allows users to carry their CMMS system with them wherever they go! Maintenance professionals can create work requests from the ﬂoor, and even attach images for added clarity and accuracy. Sending requests instantly from the ﬂoor instead of wasting time trekking back to a PC can help decrease machine downtime, and save companies money. Take your reports on-the-go! With MAPCON Mobile, reports can be generated straight from a user’s mobile device. Reports display as PDF documents right on an employee’s smartphone or tablet. MAPCON Mobile makes creating work requests with pictures a breeze!

Mobile Alerts

For added convenience, MAPCON Mobile also includes notiﬁcations. Even when a user doesn’t have the app open, they will receive notices when something requires their attention. Knowing immediately when a purchase order needs approval or when a work order has been sent can really help get repairs made and parts reordered in a timely manner.

Attachments MAPCON Mobile allows images to be added to work requests, which can help with repairs. A picture of needed repairs can be attached, which will help clarify the exact issue for the maintenance technician. Additionally, a document such as an instruction manual or warranty can be brought up on a users’ mobile device if it has been attached to equipment or work requests. Staff equipped with a mobile device and MAPCON Mobile can carry all the power of an unlimited maintenance library right in their pocket.

Phone: 800-922-4336 | sales@mapcon.com | www.mapcon.com input #41 at www.plantengineering.com/information

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Protecting people, processes and equipment MovinCool brings cool, refrigerated air to production lines without the need to spend hundreds of thousands on 100 or more tons of cooling. MovinCool portable AC units help reduce the risk of heat exhaustion and increase employee morale, leading to improved manufacturing quality and productivity.

MovinCool, the world’s largest manufacturer of commercial spot air conditioners, offers a wide range of models, with capacities from 10,000 to 60,000 Btu/h. MovinCool protects people, processes and equipment from their hottest environments as well as provides moisture removal. MovinCool’s portable models can be quickly wheeled into place whenever needed, with virtually no installation required. The company’s latest portable heat pump models combines both cooling and heating capabilities in a single, self-contained unit. Applications include: < IT data centers, computer rooms, server and telecom closets < Hospitals, laboratories < Ofﬁces, schools, temporary buildings < Warehouses, factories, food-processing facilities < Outdoor sporting and other events, movie sets < Moisture removal (disasters, construction sites) For more than thirty years, MovinCool’s Classic & Classic Plus series of industrial air conditioning units has provided effective cooling solutions for factories, warehouses and workplaces.

MovinCool spot cooling units prevent product defects by eliminating warping and condensation due to excess heat and humidity. Our portable AC units reduce processing time for most heat-related production processes by up to 94%. Within the air conditioning industry, MovinCool has a reputation for highest quality. Dealers who specialize in spot air conditioners, and who stand to lose signiﬁcant proﬁt if they have to replace a unit once it is installed, consistently say they prefer MovinCool air conditioners because of their superior reliability. MovinCool is a brand of DENSO, one of the world’s largest manufacturers of automotive parts. DENSO supplies advanced automotive technology, systems and components, including air conditioners, to all of the world’s major car manufacturers. In the 1980s, DENSO pioneered the concept of workspace spot cooling to meet its own factory needs. Since then, MovinCool has developed spot cooling systems to accommodate many different applications. For more information, please visit www.movincool.com/industrial-cooling

(800) 264-9573 | info@movincool.com | www.movincool.com input #42 at www.plantengineering.com/information

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Smart Redundancy Modules Save Critical Applications The high degree of availability of machines and systems installed across the world is a key prerequisite for business success in any industrial sector. Increased proﬁtability can only come from continuously powered control-cabinet components. For this reason, users are increasingly implementing redundant power supplies. These are frequently combined with redundancy modules, such as ORING modules from Phoenix Contact.

Monitoring the load current If one of the two power supplies in a system fails, the second unit must be able to support the entire load. If the load current exceeds the output capability of that single power supply, the system will fail. For that reason, the load must be monitored to indicate the loss of redundancy when the load current surpasses the output of any single power supply. Phoenix Contact ORING modules inform users of this overload remotely.

Increase service life As a result of irregularities when output voltages are configured unevenly, often only one power supply unit feeds the load while the other device idles. This places thermal stress on the power supply, which reduces the life of the device. If both power supplies are operated at half the rated power, their temperature would decrease, which increases service life. Phoenix Contact’s proprietary Auto Current Balancing (ACB) technology integrated in the ORING modules effectively doubles the service life of the redundant power supplies, ensuring that both power supply units load evenly. ORING modules monitor the complete redundant system – extending from the output voltages of the power supplies through the wiring and the decoupling section up to the load current . The floating ‘Redundancy OK’ and ‘ACB OK’ signal contacts, as well as the LED displays, are used to monitor the units’ proper operation. The load utilization of the power supplies is transparently displayed as a bar chart. Users are quickly informed about various states, allowing them to immediately spot and resolve problems. In sensitive applications, a redundant configuration of the power solution ensures high availability. In this context, corresponding power supply concepts are recommended. Depending on the application, ORING modules provide the highest form of redundancy and monitoring

(800) 888-7388 | info@phoenixcon.com | www.phoenixcontact.com/oring input #43 at www.plantengineering.com/information

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High-Quality, Affordable Enclosure Solutions for Any Industrial or IT Application only is energy consumption far less than with conventional technology, but the improved cooling leads to longer service life of the components inside the enclosure and the cooling unit itself.

TS 8: The World’s Most Adaptable Enclosure

Rittal designs and manufactures the world’s leading industrial and IT enclosures, racks and accessories, including high efﬁciency, high density power management and climate control systems for industrial, data center, outdoor and hybrid applications. Rittal’s off-the-shelf standard, modiﬁed standard and custom-engineered products are known throughout the world as high-quality, affordable solutions for practically any industrial or IT infrastructure application – from single enclosures to comprehensive systems.

Up to 75% Savings in Energy Costs Rittal’s Blue e+ is a completely new generation of cooling units that represents a quantum leap in terms of cost-effectiveness and energy conservation due to its speed-regulated components and patented heat pipe technology. As well as providing far higher energy efﬁciency than existing cooling solutions, the units also offer a range of powerful new features that provide longer component life, ﬂexibility and ease of use. Unique inverter technology provides cooling output that is always exactly the amount needed at the time. Not

The TS 8 has sold more than 10 million units around the world and is one of Rittal’s most popular enclosure products. Available in carbon, 304 and 316 stainless steel varieties for various environments, this enclosure cabinet has the ability to bay with other cabinets on all sides, can be assembled by one individual, and has a remarkable number of conﬁgurations possible for internal electronics placement. Combined with Rittal’s climate control and power distribution systems, the TS 8 enclosure safely and efﬁciently protects electronic equipment, control and processing systems in the harshest environments.

Versatile, Durable Wallmount Enclosures Rittal’s wallmount portfolio is available in over 100 standard sizes in both carbon and stainless steel models. NEMA-rated for strong protection with knife-edge perimeters, they also feature secure locking systems and foamed-in-place gaskets for dust and moisture prevention. Easy to install, these wallmounts offer vast ﬂexibility due to maximum use of interior space. customerservice@rittal.us (800) 477-4000 www.rittalenclosures.com

input #44 at www.plantengineering.com/information

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SEW-EURODRIVE … Power Transmission Innovation MOVIGEAR® The MOVIGEAR® Mechatronic Drive System for horizontalmaterials handling from SEW-EURODRIVE sets new standards in terms of efﬁciency and functionality. MOVIGEAR® not only combines the gear unit, motor and drive electronics within one highly reliable, efﬁcient, and hygienically designed unit, it also reduces total start-up cost and annual operating costs in your material handling system…by as much as 50%!

IE3 Compliant DRN.. Motor Our new DRN.. induction motors meet the stringent IE3 super-p energy efficiency standard. They also fit existing gear units – g for easy upgrades and retrofits of existing DRE (IE2) gearmoto The weight and dimensions of the new DRN motors have only marginal changes as compared to the DRE series. Due to its outstanding system stability, tight control, and high-cycling capacity, the DRN.. electric motor can replace a servo motor in many cases. Plus, its multiple brake sizes allow a higher torq for a stopping brake or a lower torque for a VFD holding brake finally, its wide HP range and various connector options enab DRN motor to be used in a wide variety of new and retro-fit applications.

DRC Electronic Motor The DRC electronic motor provides an ultra-efficient motor a electronics package for those gear units already installed in y system. Like MOVIGEAR, the DRC electronic motor consists permanent-field synchronous motor with integrated drive electronics in a completely enclosed housing. The DRC electronic motor offers greater flexibility allowing it to moun to any gear unit plus, offers an optional mechanical brake.

About SEW-EURODRIVE Engineering excellence and customer responsiveness disting a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability in the toughest operating conditions. With its global headquarters in Germany, the privately held company currently employs over 16,000 employees with a presence in 48 countries worldwide. U.S. operations include a state-of-the-art manufacturing center, ﬁve regional assembly plants, more than 63 technical sales ofﬁces and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-tocoast and around the world.

SEW-EURODRIVE, Inc. | Tel: 864-439-7537 | www.seweurodrive.com input #45 at www.plantengineering.com/information

Electrical Safety Compliance Assessment Electrical accidents are described by OSHA as one of their “Fatal Four.” That’s why it is essential to have an Electrical Safety Program that meets the comprehensive compliance standards and regulations established by OSHA, NEC, NFPA, IEEE, NESC, ANSI and other governing bodies. Because these assessments can be time-consuming, complex and confusing, AVO’s team of Electrical Safety Specialists are ready to walk you through it. We will come to your facility and conduct an audit that covers all ﬁve key components of the Electrical Safety Program (illustrated below) or assess the individual components you choose.

The components of an assessment 1. Assess installation for NEC and OSHA compliance 2. Electrical Hazards Audit for NFPA 70E, NESC and OSHA 1910.269 Standards 3. Review facility’s Electrical Safe Work Practice for compliance with current standards and regulations 4. Assess Personal Protective Equipment for safety compliance 5. Recommend Electrical Safety Training for employee: the next step to compliance

Be prepared for an OSHA “Drop-Out” random visits. Staying safe and compliant isn’t a choice, but whom you choose as your electrical safety partner is. Choose AVO Training Institute. Please visit www.avotraining.com for more information.

input #46 at www.plantengineering.com/information

A Global Force With Electronic Automation Components Founded in 1931, CARLO GAVAZZI is a multinational electronics group active in the design, manufacture and marketing of electronic and electrical components for industrial automation and building automation. With several ISO9001 and ISO14001 certiﬁed manufacturing and R&D facilities throughout Europe and Asia, and dozens of sales ofﬁces spanning the globe, you are assured that product support, service, and inventory are only a phone call, email or mouse click away. CARLO GAVAZZI products are developed and manufactured in full compliance with the most important standard regulations, such as UL and CSA. Typical customers are original equipment manufacturers (OEMs) of packaging machines, injection molding (plastics) machines, agriculture machines, food and beverage production, conveying and materials handling equipment, door and entrance control systems, parking guidance systems, elevators and escalators as well as heating, ventilation and air conditioning devices. System integrators and distributors are typically the channels we utilize to reach the market. sales@CarloGavazzi.com | 847.465.6100 www.GavazziOnline.com input #47 at www.plantengineering.com/information

Century Spring Advances Custom Capabilities Including Ultra-Durable Exotic Alloys Springs manufactured with exotic alloys can lead to longer lasting parts that resist severe environmental strains better than traditional materials For decades, Century Spring has been the premier supplier of American made in-stock spring solutions, with over 35,000 spring designs ready for same day shipment. Century has also served the unique needs of OEM and MRO markets through ever expanding, on demand, manufacturing capabilities. Century Spring produces a broad variety of custom parts to serve virtually any need and in recent months has added an array of state-of-the art CNC coiling and bending machines capable of producing incredibly accurate parts at very high speeds. These machines are equipped with advanced measurement tools that ensure every part produced meets quality and consistency expectations. Century has also worked extensively to advance expertise in the production of parts using exotic alloys such as Elgiloy, Inconel and 316 Stainless Steel — materials useful for high/low temperature and corrosive environments. They can also be used to produce more durable parts for simple applications. Exotic alloys have a higher initial price tag, however, when used for the right application, can result in signiﬁcant savings over time and ensure better operating efﬁciency and dependability. Century’s team of skilled engineers are available on-demand to help identify and design the best part for any need. Century welcomes any questions about these new advancements. Contact them today at custom@centuryspring.com, 800-237-5225, or visit www.centuryspring.com. input #48 at www.plantengineering.com/information

iPad and the IIoT When you think about leading innovators of the 21st century, Apple is always at the top. Through the creation of the iPhone, iPad and apps, Apple has changed the way we interact and monitor our world. GTI Predictive leverages technological advances like the iPad to bring the industrial reliability maintenance community a powerful, affordable, and industry changing solution. Combining different technologies as apps for the iPad, the GTI Predictive Platform is changing predictive technology. The iPad platform provides apps for vibration data collection and analysis, ﬁeld and shop balancing, infrared thermography, laser shaft alignment and more. Data is stored in our Cloud-based web app for ubiquitous analyzation and dissemination. Using many tools already found in the iPad, GTI Predictive Technology can provide unique solutions within our powerful apps – integrated reporting, GPS location, photos in route mode and reports, communication through email and data sharing between apps. VibePro7: route data collection, onsite analysis and remote web based vibration data analysis. BalancePro: single and two channel balancing for both inboard and overhung machines. ThermoPro: capture thermal images and in-app reporting with the FLIR One camera attachment for iPad. GTI@lign: after diagnosing misalignment through vibration and phase correct with wireless laser shaft alignment.

info@gtipredictive.com | 603.669.5993 www.gtipredictive.com

input #49 at www.plantengineering.com/information

Machine-Tough Synthetic Lubricants Advanced Technology for Problem Machines and Equipment Use MIL-COMM Extreme Performance lubricantsâ&#x20AC;Śengineered for U.S. Military heavy weaponry systems requiring the ultimate in heavy load, extreme pressure, anti-corrosion and extreme temperature performance. Now available for your ďŹ ght against friction and equipment failure. Proven to signiďŹ cantly outlast and outperform traditional commercial lubricants â&#x20AC;&#x201C; delivering quality improvements and cost savings to your business. Make machinery and friction parts work to maximum efďŹ ciency. Improve parts durabilityâ&#x20AC;Ś extend the life of machinery.

Drastically reduce downtime. Save electricity and fuel costs. Boost return on investment.

MIL-COMM lubricants â&#x20AC;&#x201C; for the most demanding machine and equipment applications.

MIL-COMMâ&#x20AC;&#x2122;s propriety micro-particle technology and uniquely engineered synthetic oils and performance additives go to work on problem machinery and plant equipment, solving issues other lubricants simply cannot. Corrosion-resistant and cold-weather tough at â&#x20AC;&#x201C; 70 F to + 450 F. Used globally in Arctic, desert and tropical environmental conditions. Available in a range of viscosities and formulations for ideal use, including TW25B ÂŽ synthetic grease; MC2500 ÂŽ synthetic oil; MC3000 ÂŽ synthetic semi-ďŹ&#x201A;uid lubricant, ideal for lubricators, and MC1210 ÂŽ Heavy Grease. Custom-engineered lubricant solutions for speciďŹ c machine tasks are also available. FREE SAMPLES TO INDUSTRY-QUALIFIED PROFESSIONALS

201-935-8561 info@mil-comm.com www.mil-comm.com

input #50 at www.plantengineering.com/information

ROTALIGN touch: Precision meets Connectivity Cloud-based shaft alignment system that combines precision measurement with mobile connectivity ROTALIGN touch achieves optimal machine performance and product quality. Its features include Softfoot diagnosis, thermal growth trending, and vibration spot check to measure overall values, vertical machine alignment, and cardan shaft alignment. Its tablet-like touchscreen with 3D display enables a fully intuitive and visual work sequence. Additionally, the device includes a 5 Megapixel camera, RFID system, and a Cloud-based alignment structure. The RFID reader allows unique identiďŹ cation of each machine and facilitates retrieval of its last alignment ďŹ le stored on the ROTALIGN touch computer. The built-in camera lets users customize reports with photos. The onboard WiFi and Bluetooth feature enables devices to send measurement results back from any location directly via the Cloud. PRUFTECHNIK offers trainings and free ďŹ rmware upgrades for the ROTALIGN touch.

www.pruftechnik.com/us input #51 at www.plantengineering.com/information

World Leader in Oil-Free Air Compressors The Kobelco KNW Series – Kobelco KNW Series oil free compressors are designed, assembled, manufactured and tested in the USA by Rogers Machinery Company and Kobelco Compressors Manufacturing Indiana. Together, we are the premier manufacturer, packager, and supplier of oil-free, rotary screw air compressors in North America. Proudly, we provide industry with the highest quality, oil-free, risk-free air compressors on the market today — The Kobelco KNW Series. The Kobelco KNW Series can be custom built to your speciﬁcations and is also available as a standard design package. We provide nationwide parts and service support through our authorized distributor network. We also provide air system energy audits, air dryers, ﬁlters, receivers, and sequencers.

Oil Free – Risk Free – Industries such as Food and Beverage, Pharmaceutical, Electronics, Medical Products and Packaging have discovered that the higher the quality of compressed air that they use, the better their product and lower cost to produce it. Kobelco KNW Series oil free compressors provide ISO 8573.1 Class 0 compressed air quality. All Kobelco KNW Series oil free compressors are delivered ready to run and are designed for 24/7 operation. They are available in an air or water-cooled conﬁguration to best suit your requirements. KNW-Series.com | 800-394-6151 | Portland, Oregon USA input #52 at www.plantengineering.com/information

New Vibration Technique allows for accurate Bearing & Gear Analysis down to 15 RPM A new achievement in vibration monitoring technology HD ENV® is an ideal complement to traditional vibration analysis. Capable of detecting at a very early stage such machine problems which are generally difficult to find in good time with conventional non-enveloping techniques – for example gear and bearing damages – the method utilizes cleverly engineered and patented algorithms for digital signal processing, preserving the true highest peak of the vibration signal. Signals buried in machine noise are revealed through high definition digital enveloping, extracting and enhancing the signals of interest from the overall machinery vibration signal. HD ENV® enables the detection of gear and bearing faults very early on in the damage process, making it possible to closely monitor the development throughout the stages. Significantly extending the planning horizon for predictive maintenance, the method is a boost to maintenance efficiency. The HD ENV® technique can be used with existing vibration transducer installations and thus quickly and easily integrates into existing industrial infrastructures. HD ENV can be used to monitor applications in the 15-20,000 RPM range. Contact info@spminstrument.us | Phone: 1-800-505-5636 www.spminstrument.com input #53 at www.plantengineering.com/information

Designing Vacuum Conveying Systems for “Receipt-to-Process” Vacuum Transfer of Powders & Other Bulk Materials How Does Vacuum Conveying Work? VAC-U-MAX is a worldwide leader in the design and manufacture of vacuum conveying systems for bulk material transfer. As all processes vary, so does the vacuum conveying technology used to move powders, pellets, flakes, granules, and other bulk materials from source to destination. When properly defining pneumatic conveying technologies, it is important to define all parts of the bulk material handling system, including the heart of the system, the vacuum receivers. Consider the advantages and disadvantages of dilute vs. dense phase conveying, and respective dilute phase positive pressure conveying vs. dense phase positive pressure conveying. To learn more about the top ten design considerations for the dust-free transport of powders and bulk ingredients to your processing or packaging line, visit www.vac-u-max.com and download whitepaper. info@vac-u-max.com | www.vac-u-max.com (973) 759-4600 or (800) VAC-U-MAX input #54 at www.plantengineering.com/information

DIGITAL REPORTS 2017

D I G I TA L R EPORT IIoT: Machines, Equipment & Asset Management

Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies. These include easier real-time sensor data access via tablets, PC-based control, data analytics, smarter machines, cybersecurity, how to get data more easily from maintenance software, human machine interfaces and controllers, along with easier industrial connectivity. To view and download this digital report visit: www.plantengineering.com/DigitalReport/lloTMEAM

Sponsored by:

DIGITAL REPORTS It’s often called the “fifth utility.” Compressed air plays a vital role in most manufacturing plants, and availability of compressed air is crucial to a wide variety of operations. To view and download this digital report visit: www.plantengineering.com/DigitalReport/ AirCompressedStrategies

Sponsored by:

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 #15 at www.plantengineering.com/information

INNOVATIO S NEW PRODUCTS Soft starters an option when VFDs don’t work

Motor damage takes place as a result of mechanical wear and tear and huge inrush currents.

“

A soft starter is a viable option if it is impossible to use a VFD with a motor. A soft starter minimizes the initial impact that a motor receives upon starting.

”

The ABCs of VFDs Find the right application to match the motor need.

“ See more products in the New Products for Engineers Database.

gspplatform.cfemedia.com/pe

www.plantengineering.com

Many plants are shifting to ac motors from hydraulic motors and in some cases dc motors when powering heavy loads, which were more popular in the past.

”

PLANT ENGINEERING

June 2017

INNOVATIONS Gas chromatograph

Reliability is everything Gerald “Gerry” Bauer President, EccoFab - Rockford, IL

f Sullair.com/GerrysStory

The PGC5009 fast process gas chromatograph offers simulated distillation analysis using fast temperature programmed process chromatography. With a patented resistively-heated column design and rapid cooling system, the PGC5009 provides superior chromatography. This creates accurate and reproducible retention times and weight percentage measurements required for boiling point curve calculation, enabling optimized refinery process control. ABB www.abb.com Input #200 at www.plantengineering.com/information

Waste ejector pump

It doesn’t quit. It doesn’t even think about quitting. In fact, it doesn’t think of anything but the job at hand.

The Model 700 industrial vertical non-clog waste ejector pump is designed for use in industrial, sanitary process, and rendering wastes. The Model 700 features heads to 100 feet total dynamic head (TDH) and flows to 1,500 gallons per minute. The impeller is an enclosed two vane non-clog design with wiping vanes which reduce axial loading and prolong bearing life. Wiping vanes aid in keeping particles from behind the impeller and pump bearing assembly. There is a flanged discharge on all sizes. Designed specifically for solids handling, the 700 Series incorporates a long radius elbow, reducing friction loss and allowing smooth flow through the discharge pipe. Vertiflo Pump Co. www.vertiflopump.com

Sound familiar?

Input #201 at www.plantengineering.com/information

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 #16 at www.plantengineering.com/information

Motion control stepper products A new line of motion control stepper products includes controllers, stepper motors, an integrated controller/drive, an integrated drive/stepper motor, and an integrated controller/drive/stepper motor. The integrated controller/drive and drive/stepper motor units save space and money, and simplify installation by combining multiple components into one unit. IDEC www.idec.com Input #202 at www.plantengineering.com/information

June 2017

PLANT ENGINEERING

www.plantengineering.com

Submit new product releases to our New Products for Engineers Database gspplatform.cfemedia.com/pe

Motor control The motor control devices of the Simocode pro product series were developed specifically for the management of motors in the low-voltage range. The system operates independently of the controller and offers comprehensive protection, monitoring, safety, and control functions between the motor feeder and the automation system. The motor control devices can be integrated simply into virtually any control system, given the flexible connectivity options. The motor control centers with the EtherNet/IP option in Simocode can be supplied with star or redundant-ring network topologies. Because the EtherNet/IP communication protocol is provided on the individual communicating device, no additional communication devices, such as protocol converters or adapters, are required. Siemens www.usa.siemens.com/simocode Input #203 at www.plantengineering.com/information

Flowmeter The Optimass 2000 S400 16-inch Coriolis mass flowmeter features the highest flow capacity of any Coriolis meter on the market. The large diameter mass flowmeter is ideal for bulk measurement of petroleum and oil, as well as syrup, molasses, and raw chemicals. The meter has been approved for custody transfer of liquids and gases. With its unique four straight tube design, the Optimass 2000 S400 features the smallest installation footprint in its class and offers significant energy savings with a lower pressure drop. The meterâ&#x20AC;&#x2122;s small installation footprint makes it ideal for applications where space is limited, like offshore platforms, or where alterations of existing pipework otherwise would be necessary. Krohne http://cdn.krohne.com/dlc/ Input #204 at www.plantengineering.com/information

www.plantengineering.com

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June 2017

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C S UST. D S VALUE. Is your dust collector locking up your profits? Free your cashflow with the game-changing performance of the new Downflo® Evolution (DFE) that offers the lowest cost of total ownership. It delivers up to:

INNOVATIONS Gear motors A full line of gear motors and gearheads has been designed to pair with every servo motor in the full Sigma-7 range, creating complete gear motor solutions rated from a low of 50 watts to as high as 15 kilowatts. Five gear ratios are available, ranging from 3/1 to 50/1. The gear motors have been designed with precision helical gearing with a 40% greater tooth surface area for smoother, quieter, and more accurate operation, an enhanced system of bearings, including 45% larger planet bearings for guaranteed alignment, and balanced, concentric shaft couplings to minimize vibration during high speed operation and reduce the inertia of the gear motor system. Yaskawa www.yaskawa.com Input #205 at www.plantengineering.com/information

Serial console The Avocent ACS800 serial console models have two, four, or eight serial ports with multi-protocol serial support, four USB ports, an environmental sensor port and a digital output port. Networking connectivity is available through dual Gigabit Ethernet ports, an optional internal analog modem, as well as through an optional external 4G/LTE cellular router. Mounting of the Avocent ACS800 can be either desktop-based, or with one of three available mounting kits.

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Input #206 at www.plantengineering.com/information

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Visit DonaldsonTorit.com for information on the DFE and other great Torit products. m 800 365 33 G E

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Coating thickness tester The CG206 coating thickness tester is designed to accelerate condition monitoring inspections of industrial storage equipment, tanks, and vessels in manufacturing and petrochemical sites. It can be used to inspect plant equipment that is prone to damage, corrosion, or deterioration, including chemical or oil storage tanks, boilers, and pressure vessels. In addition to examining newly-installed equipment for quality control, plant maintenance technicians can use the CG206 for periodic condition monitoring to identify changes that indicate a potential structural weakness or failure. It features a measurement range of 0 to 1350Îźm (0 to 53mils) and automatically powers down after three minutes of inactivity. When constant-on functioning is required, users easily can disable the automatic power-off mode

N OR A E L C NEVER ZE HARD SANITI GAIN. HATS A BLE A S O P DIS Y HARD R SANITALINERS. HAT Save time and money cleaning and sanitizing the inside of hard hats and suspensions. HARDLINER is a soft disposable cloth liner that fits inside the hard hat suspension. Helps prevent the transfer of hair and scalp dLsease. Hardliner is an aid to help comply with OSHA 29 CFR 1910.132(a). TM

HARDLINER For a Free Sample mention PE12

For information or a free sample contact: GKR Industries, Inc. 13653 S. Kenton Ave., Crestwood,IL 60445 or call 800-526â&#x20AC;&#x201C;7879 www.gkrindustries.com input #19 at www.plantengineering.com/information

Extech www.extech.com/cg206 Input #207 at www.plantengineering.com/information

Automated guided vehicle The Agile1500 is the first automated guided vehicle (AGV) that is modular, scalable, and reconfigurable. It can carry more than 1.5 tons, with a maximum speed of 5 feet per second. It also can increase overall plant safety thanks to advanced security features and an integrated laser scanner that stops the AGV upon detection of an obstacle along its route. It works with multiple navigation systems that use both natural landmarks (walls, objects, etc.) as well as predefined points (magnetic spot and magnetic tape). Comau www.comau.com Input #208 at www.plantengineering.com/information

PLANT ENGINEERING

June 2017

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REPAIR. RESTORE. RETURN. Concerned about the condition of your telescopic way covers and ball screws? Dynatect can bring them back to new condition at a fraction of the cost. 3 For all brands of way covers and ball screws

INNOVATIONS Potable water solenoid valves The NS-Series National Sanitation Foundation (NSF) certified potable water solenoid valves can be used in food and beverage grade potable water applications. Stainless steel or thermoplastic bodies and synthetic seating and sealing materials makes NS series valves suitable for use with a variety of liquids, oils, and gases. Valve operation is normally closed and open when electrically energized. The valves can be mounted in any position and a spring-loaded plunger assures positive shutoff. NS201 and NS211 series are piloted diaphragm valves; NS201 series valves also can operate under zero pressure differential. AutomationDirect www.automationdirect.com Input #209 at www.plantengineering.com/information

3 Expedited turnaround available 3 Custom design and reverse engineering services 3 Over 65 years in manufacturing equipment protection 3 We have the correct OEM parts in stock to rebuild your cover WAY COVERS

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A new series of insulation resistance testers is capable of safely testing both high- and low-voltage equipment. The MIT515, MIT525, MIT1025 and MIT1525 feature testing techniques that provide valuable diagnostic information to the user. Rated at 5 kV and 10 kV, the MIT515, MIT525 and MIT1025 are engineered to ensure the highest precision possible. The MIT525, MIT1025 and MIT1525 perform spot tests, step voltage tests, dielectric discharge tests, ramp tests and dielectric absorption tests for QA testing in manufacturing processes, diagnostic tests to isolate faulty components for repair, as well as routine preventative/predictive maintenance. Each unit has a noise filter that can reject up to 3 mA on the 5 kV and 10 kV models and 6 mA. Megger www.megger.com

FOR MORE INFORMATION: 800-298-2066 sales@dynatect.com Dynatect.com/Repair-Services input #21 at www.plantengineering.com/information

Input #210 at www.plantengineering.com/information

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Pressure calibrator The 729 series automatic pressure calibrator simplifies the calibration process by automatically generating precise test pressures, improving calibration integrity by compensating for leaks, and automatically documenting the pressure calibration process to help meet compliance and regulatory requirements. With the rugged, portable 729, technicians simply input a target pressure and the calibrator automatically pumps to the desired set-point while the internal fine adjustment control stabilizes the pressure at the requested value, delivering more accurate results and speeding the calibration process. It also features automatic pressure generation and control for multiple tests to 300 psi and measurement of mA signals on transmitter outputs and sourcing and simulation of mA signals.

Quality Service Expertise Save Time and Money by Using Ultima Series &OKPZ UIF FDPOPNJD NBDIJOF BOE MVCSJDBOU MJGF CFOFÃ¦UT PG VTJOH UIF SJHIU 4VNNJU TZOUIFUJD PJM JO UIF SJHIU BQQMJDBUJPO 4VNNJUnT TZOUIFUJD 6MUJNB 4FSJFT BJS DPNQSFTTPS MVCSJDBOUT PGGFS ESBJO JOUFSWBMT PG QMVT IPVST VOEFS OPSNBM PQFSBUJOH DPOEJUJPOT 5BML UP PVS FYQFSUT BOE Ã¦OE PVU JG 6MUJNB JT UIF SJHIU MVCSJDBOU GPS ZPVS DPNQSFTTPS

Fluke Corporation www.fluke.com Input #211 at www.plantengineering.com/information

800.749.5823 KlÃ¼ber Lubrication NA LP

PLANT ENGINEERING

June 2017

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Olive oil is good for you. Compressor oil is not.

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input #23 at www.plantengineering.com/information

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Level switches The G Series level switches are specifically designed for special problem applications that involve extremely light or fluffy products, or for heavier bulk solids that tend to pack or bridge easily. It provides consistent results on applications of pharmaceutical powders, powder materials for coating beads and tablets, fillers and other substances that vary widely in bulk density or particle size and many other materials with a tendency to pack. The uncovered paddle is free to vibrate, producing an output signal. This signal operates a relay indicating the paddle is uncovered. When the paddle is covered a dampening of the oscillations occurs and the relay indicates that a high level exists. DYNATROL www.dynatrolusa.com Input #212 at www.plantengineering.com/information

input #25 at www.plantengineering.com/information

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input #26 at www.plantengineering.com/information

INNOVATIONS By David Manney, L&S Electric

Soft starters an option when VFDs donâ&#x20AC;&#x2122;t work

RWRU GDPDJH WDNHV SODFH DV D UHVXOW RI PHFKDQLFDO ZHDU DQG WHDU DQG KXJH LQUXVK FXUUHQWV 7\SLFDOO\ YDULDEOH IUHTXHQF\ GULYHV 9)'V KHOS SUHYHQW ZHDU DQG WHDU WR PHFKDQLFDO FRPSRQHQWV 9)'V VORZ VWDUWLQJ DQG VWRSSLQJ RI WKH GULYH WUDLQ A soft starter is a viable option if it is impossible to use a VFD with a motor. A soft starter minimizes the initial impact that a motor receives upon starting.

How do soft starters work? Motor-driven applications rely on VFDs or soft starters. These devices prevent damage, or a significant amount of stress, to the product transported by the machine. Among the types of equipment that benefits from a soft starter are pumps, fans, and conveyors. This equipment stops and starts on an automatic basis when necessary. Soft starters increase the voltage in steps, depending on the application. There are thyristors such as silicon controlled rectifiers (SCRs), or a pattern of solid state switches in a soft starter. These components allow the voltage to increase at a slower rate and cause the motor to run at full speed at differing intervals.

One, two, and three phases

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Three-phase motor applications use SCR-SCR and SCR-diode designs. The SCR-SCR offers a full wave control. The SCR-diode tends to generate undesirable harmonics and requires a higher start current. In a single-phase unit, it fails to reduce the start current, although it controls the start torque. This issue is why this unit is not suitable for applications that handle high inertial loads or frequent cycling. For a two-phase unit, a motor needs a circuit breaker or thermal relay for protection. Moreover, this unit does not isolate all the phases of the motor. Unlike the single- and two-phase unit, three-phase units can provide full and maximum control. Thus, these units provide the best control of both the torque and the current.

Working with open or closed loops A soft starter either runs an open or closed loop. An open loop design does not pro-

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vide any current feedback loop. The open loop controls the starting phase with a pre-selected voltage profile without protecting the motor. On the other hand, a closedloop design provides current functions and motor protection. This combination allows users to select the preferred start current level. The start voltage profile on openloop systems follows a pre-determined ramp regardless of the motor speed or the current drawn. The most suitable setting offers the breakaway torque to the electric motor upon starting. Although these starters make the motion gentler, they are not capable of producing any specific torque. In the case of a closedloop starter, it monitors the output and adjusts the input voltage automatically to reach the target voltage. Other closed-loop units only adjust the voltage to maintain the constant acceleration. There are voltage ramp systems that monitor the input current on one phase. The next step is a comparison to a set point. The final step includes ramping once there is a higher amount of current generated. When it comes to machines that require varied onset torque such as load conveyors, a current-ramping type of soft starter is advisable. This device takes the current from the start value to a predetermined limit over a specific length of time. For the most part, applications that use 75 HP or more benefits from soft starters. Some of these include grinding mill machines and paper manufacturing machinery. This equipment needs to reach the full load within a defined period to prevent damages to certain equipment located in the drive train. A limited level of acceleration is necessary to avoid too much gear teeth stress on heated cylinders on paper dryers, as an example.

Other reasons to install a soft starter in a motor include improved efficiency and controlled acceleration. These benefits translate to increased productivity due to fewer breakdowns in motors and unplanned downtimes. PE

David Manney is a marketing administrator at L&S Electric. This article originally appeared on L&S Electricâ&#x20AC;&#x2122;s â&#x20AC;&#x153;Watts Newâ&#x20AC;? blog. L&S Electric is a CFE Media content partner.

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 guaranteeâ&#x20AC;&#x201D;itâ&#x20AC;&#x2122;s more than a cleaning system; itâ&#x20AC;&#x2122;s a business asset.

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Why install soft starters There are several advantages linked with the installation of soft starters working with motors. As a primary benefit, these devices promote the smooth starting of a motor without glitches or jerks. This method of starting motor results in controlling the starting current in steps by altering the initial voltage. PLANT ENGINEERING

June 2017

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input #28 at www.plantengineering.com/information

INNOVATIONS By Kevin Goodsell, Valin Corp.

The ABCs of VFDs Find the right application to match the motor need.

nside of plants today, ac motors are becoming the industry standard. Many plants are shifting to ac motors from hydraulic motors and in some cases dc motors when powering heavy loads, which were more popular in the past. This shift can be attributed to a variety of reasons and most have to do with cost. AC motors are more compact and require less maintenance than a hydraulic motor or a dc motor with brushes. With cost being a driving factor, operators need to have more precise control over the ac motor. It is important to understand the practical applications of a variable frequency drive (VFD) to an ac motor. Among the questions to be asked: t 8IFO JT B 7'% CFOFGJDJBM t 6OEFS XIBU DPOEJUJPOT TIPVME B 7'% CF VTFE t 8IBU T UIF EJGGFSFODF CFUXFFO B 7'% BOE B TPGU TUBSUFS 6OEFSTUBOEJOH UIF BOTXFST UP UIFTF RVFTUJPOT XJMM NBYJNJ[F UIF VTF BOE NJOJ NJ[F UIF DPTU PG PQFSBUJOH BO BD NPUPS JO a plant setting.

Full voltage starters, soft starters, and VFDs 5IFSF BSF TFWFSBM XBZT UP QPXFS BOE DPO trol an ac motor. In addition to a VFD, one could alternatively apply a full voltage starter or a soft starter. The most basic motor control involves using a full voltage starter. With this approach, full voltage is applied to the motor and it ramps up to NBYJNVN TQFFE BT RVJDLMZ BT JU DBO 5IF QSPCMFN PQFSBUPST SVO JOUP XJUI B full voltage starter is the inrush of current can be up to seven times the full load current of the motor. For a very short period of time, a very high in rush of current is applied to the motor and its control components. If a large motor needs to do a frequent amount of starting and stopping, JU DBO XFBS PVU FRVJQNFOU GBTUFS BOE CF B DPTUMZ CVSEFO PO UIF GBDJMJUZ T VUJMJUJFT In contrast, a soft starter eliminates this burden by reducing the load and torque PVUQVU UP UIF NPUPS 5IJT BQQSPBDI BMMPXT the motor to ramp up at a speed that is determined by a setting on the soft starter itself. An operator can set a specific rampinput #29 at www.plantengineering.com/information

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up time, and from the time it is turned on to the time designated, the motor runs at full speed. This allows reduced current inrush, reducing the risk of premature failure and additional burden on the facilityâ&#x20AC;&#x2122;s utilities. A VFD takes this concept a step further by allowing the operator to always control the inrush current and the speed of the motor. The VFD can control the motor both during the start/stop cycle and throughout its runtime. A VFD is necessary where complete speed control is required and a key concern is energy consumption. A soft starter will be the less expensive option, but in large horsepower situations, savings can be realized over time with a VFD.

output current on the motor. This desired outcome is completely driven by process. There is a need to protect whatever it is that the motor is driving, and many pieces of equipment in the plant setting have mechanical limitations. Because of this,

exceeding these limits by over torqueing can lead to heavy damage or costly malfunction. Most VFDs are manufactured to be extremely flexible so they can be configured to use the inputs and outputs (I/O)

Basic VFD applications Flow control is one of the most common applications of a VFD inside of a plant setting. The ability to change the speed of a pump to control flow is paramount. System conditions will often require a reduced flow rate. Dampers and valves often are used to accomplish this reduction, but this strategy does not help energy conservation. Conversely, a VFD can control flow rate while at the same time optimizing the energy required to do so. There may be a situation where an operator needs to run the motor at less than maximum speed at certain times of the day, but then crank it up faster at other times. This is the real driver with the popularity of VFDs in todayâ&#x20AC;&#x2122;s environment: saving energy and reducing operational costs. If an operator is simply looking to run an ac motor at a constant speed that is less than the motorâ&#x20AC;&#x2122;s full speed rating, a gearbox can be used. However, if an application is such that it is a variable torque load, a VFD is a fitting solution. On a very basic level, for example, imagine an ac motor is used to run a fan on a cooling tower. The faster the operator wants the fan to run, the more horsepower and energy it will require.

Additional benefits In addition to cost savings due to energy conservation, most VFDs will allow the operator to set different parameters to limit torque. This is done by limiting the PLANT ENGINEERING

June 2017

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INNOVATIONS that are integrated into them. These I/O can be used for any number of different functions, including start/stop functionality, direction change, constant speed selection, macro selection, speed adjustment, etc. Additionally, VFDsâ&#x20AC;&#x2122; ana-

log outputs can be configured to provide feedback to the plant control system for parameters, including power consumption, actual speed, frequency, torque, etc. If a process changes, for example, and it now needs to be run at a different speed,

TSUBAKI TOUGH. TSUBAKI BACKSTOPS ARE JUST AS TOUGH AND RELIABLE AS THEIR CHAIN. The top companies in the world use Tsubaki products. Tsubaki Backstops, just like the full range of Tsubaki products provide the winning combination: UNMATCHED QUALITY, DURABILITY, RELIABILITY, AND SERVICE & SUPPORT. Tsubaki has been making backstops for over 50 years. They know whatâ&#x20AC;&#x2122;s at stake if equipment is down for any length of time. So why wouldnâ&#x20AC;&#x2122;t you use the best? Eliminate that weak link by ordering Tsubaki backstops today!

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input #31 at www.plantengineering.com/information

the plant control system can adjust the signal to the driveâ&#x20AC;&#x2122;s designated speed input. In the case of flow control, VFDs have evolved to the point where many of them can be integrated with a pump right out of the box using a pre-defined macro. In this case, a flow meter would connect directly to a driveâ&#x20AC;&#x2122;s analog input. An operator may adjust the desired flow remotely and the drive will maintain that flow by executing an internal PID loop. Some drives allow the operator to set up flow schedules and may also be set up to bring additional pumps online as demand requires. A VFDâ&#x20AC;&#x2122;s built-in I/O is not the only way to control a drive. Many drives offer flexibility that allows for a variety of different communications protocols that can control the VFD from most manufacturersâ&#x20AC;&#x2122; controllers. All standard protocols are available for most VFDs. This allows the operator to have bi-directional communications with one communications cable as opposed to multiple wires. Why is this important? By utilizing a single cable, as opposed to multiple wires, installation costs are kept at a minimum and a much larger amount of data can be transmitted. This data does not just apply to advanced control, but monitoring as well. Typically, operators are looking to monitor the speed, torque, current, and temperature of the drive. Far more data can be communicated over this one cable than a VFDâ&#x20AC;&#x2122;s built-in I/O can accommodate. When a situation calls for multiple pieces of data, involving numerous I/O, many VFDs today can handle the requirement. Finally, the maintenance benefits are a major part of the appeal of effectively utilizing a VFD for an ac motor in a plantâ&#x20AC;&#x2122;s operation. Maintenance costs can be lowered significantly due to reduced wear and tear on the equipment because of controlled starts. VFDs are continuing to gain popularity in the industry as the different benefits they provide grow, most of which will be associated in one way or another with cost and energy savings. PE

June 2017

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ABB is a leader in power and automation technologies that enable customers to improve performance while lowering environmental impact. ABB Inc.

Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.

Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems. Rogers Machinery

aitkenproducts.com

Dynatect designs and manufactures a complete line of components to protect equipment and people. Dynatect

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

atlascopco.us Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco

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

avotraining.com For almost 50 years, AVO has been helping organizations create safe and reliable electrical systems. AVO Training Institute

dynatect.com

emaint.com eMaint improves the way over 50,000 users worldwide manage, monitor, and control assets for a connected world. eMaint Enterprises

flexicon.com Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.

vac-u-max.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

lubriplate.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.

mhia.org MHIA is the leading non-profit trade association representing the U.S. material handling and logistics industry. Material Handling Industry of America

camfilapc.com

Noria is a worldwide leader in providing lubrication consulting services and training. Noria Corp.

centuryspring.com

www.plantengineering.com

uecorp.com UEC provides innovative, customizable power distribution and monitoring solutions. Universal Electric Corp.

us.kaeser.com

baldor.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.

solonmfg.com Solon Manufacturing Co. engineers and manufactures Solon Belleville Springs and pressure switches. Solon Manufacturing Co.

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.

Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co. 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

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

yaskawa.com

noria.com

orival.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.

PLANT ENGINEERING

June 2017

CONTACTS

Advertiser Contacts for plant engineers

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If 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. Page

Reader Service #

Phone #

AutomationDirect

C-2

800-633-0405

Baldor Electric Company

C-4

800-828-4920

www.baldor.com

CALLING ALL SYSTEM INTEGRATORS…

630-571-4070

www.plantengineering.com/SIYApplication

Camfil APC

800-479-6801

www.camfilapc.com

CENTURY SPRING CORP

800-237-5225

www.centuryspring.com

Advertiser

Web site www.automationdirect.com

PlantEngineering.com 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph. 630-571-4070, Fax 630-214-4504

CFE Edu

630-571-4070

http://CFEedu.cfemedia.com

CFE Media, Engineering Is Personal

630-571-4070

www.plantengineering.com

CFE Media’s Global System Integrator Database

630-571-4070

www.plantengineering.com/global-si-database

CFE Media’s New Products for Engineers Database

630-571-4070

www.plantengineering.com/NP4E

Donaldson Co., Inc

800-365-1331

www.DonaldsonTorit.com

DYNATECT

800-298-2066

www.dynatect.com

ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com

EPICOR

800-999-1809

www.epicor.com

KRISTEN NIMMO, Marketing Manager 630-571-4070 x2215, KNimmo@CFEMedia.com

Eruditio, LLC

843-375-8222

www.Eruditiollc.com/PE

Flexicon Corp

888-353-9426

www.flexicon.com

MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com

www.fabtechexpo.com

KATIE SPAIN, Art Director 630-571-4070 x2218, KSpain@CFEMedia.com

GAMS at FABTECH 2017

GKR Industries, Inc

800-526-7879

www.gkrindustries.com

GTI Spindle Technology

603-669-5993

www.gtipredictive.com

HARVARD CORPORATION

500-523-1327

www.harvardcorp.com/ml

IEX 2017

203-840-5847

www.iexusa.com

IIoT Webcasts

630-571-4070

www.plantengineering.com/lloT

Kaeser Compressors, Inc

866-516-6888

www.us.kaeser.com/PE

Lubriplate Lubricants Co

800-733-4755

www.lubriplate.com

LUDECA, Inc

305-591-8935

www.ludeca.com

MAPCON

800-922-4336

www.mapcon.com

MIL-COMM

201-935-8561

www.mil-comm.com

MOVINCOOL

800-264-9573

www.movincool.com

Orival, Inc

800-567-9767

www.orival.com

13, 23

7, 12

800-322-3225

www.phoenixcontact.com/confidence_HESI

54, 77, 78

630-571-4070

www.plantengineering.com

Plant Engineering Electronic Newsletters

630-571-4070

www.plantengineering.com/newsletters

Plant Engineering Webcasts

630-571-4070

www.plantengineering.com/webcasts

PRUFTECHNIK Inc.

856-401-3095

www.pruftechnik.com

Reimagining Plant Engineering

630-571-4070

www.plantengineering.com

Rogers Machinery

800-394-6151

www.knw-series.com

Schneider Electric

SEW-EURODRIVE, Inc.

864-439-7537

www.seweurodrive.com

Phoenix Contact Plant Engineering Digital Reports

www.schneider-electric.us/smartmachines

Siemens

SPM Instrument

800-505-5636

www.spminstrument.us

Sullair Industrial Products

219-879-5451

www.sullair.com

Summit Industrial Products

800-749-5823

www.klsummit.com

U.S. Tsubaki

800-443-4216

www.ustsubaki.com

Vac-U-Max

973-759-4600

www.vac-u-max.com

Yaskawa America, Inc

C-3

800-927-5292

www.yaskawa.com

June 2017

PLANT ENGINEERING

www.sea.siemens.com

www.plantengineering.com

PUBLICATION SERVICES JIM LANGHENRY, Co-Founder & Publisher 630-571-4070 x2203, JLanghenry@CFEMedia.com STEVE ROURKE, Co-Founder 630-571-4070 x2204, SRourke@CFEMedia.com TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com

PAUL BROUCH, Director of Operations 630-571-4070 x2208, PBrouch@CFEMedia.com MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.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

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JPreston@CFEMedia.com Tel. 602-369-3037

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stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588

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.

Discover how to easily integrate Yaskawa drives into the PLC environment: http://budurl.me/YAI1039

input #32 at www.plantengineering.com/information YASKAWA AMERICA

DRIVES & MOTION DIVISION

YASKAWA.COM

1-800-YASKAWA

Keeping Industry Up and Rolling

Nothing is more frustrating than shutting down a machine, even an entire production line because of a bearing failure. BaldorÝDodge® bearings represent the best quality and reliability industry has to offer. From punishing mining applications to corrosive washdown environments, and everything in between, there’s a BaldorÝDodge bearing perfectly suited for the task at hand. Keep your machinery healthy, strong and efficiently rolling along with the widest choice of industrial bearings in the world…only from BaldorÝDodge. baldor.com

479-646-4711

Ý Unmatched Quality

Ý Superior Reliability

Ý Energy Efficient

Ý Stock and Custom Orders

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input #33 at www.plantengineering.com/information