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NOVEMBER 2019

Editorâ&#x20AC;&#x2122;s Insight 5 | CAD in the cloud is an inevitability

SOLUTIONS 7 | Double up on solenoid safety Adding two solenoid valves to a safety instrumented system keeps equipment, facility and personnel safe and the system online

13 | Eight selection criteria for actuation components Electromechanical systems offer advantages over hydraulic and pneumatic actuators

17 | Eliminate leaks to enhance plant safety, profitability How to avoid common causes and costs of fluid system leaks

PRODUCT OF THE YEAR FINALISTS 29 | Advance manufacturing through innovation Manufacturing is the process by which raw materials become finished goods. This simplistic statement describes what can be complex, diverse operations involving human effort, machines, tools and processes that go together to produce everything from consumer goods to industrial devices and more. Regardless of the industry, all manufacturers share a universal need: New products. Welcome to the 2019 Plant Engineering Product of the Year Finalists.

22 | Control system connectivity update Digitalization requires communication hubs, a role well-suited to PCs and HMIs

25 | Understand the PRICE of nitrogen Generating your own may be the best way to go

INSIDE: IIoT FOR ENGINEERS 1 | Device revolution 2 | Ascent to the cloud 6 | Interfaces & convergence

PLANT ENGINEERING (ISSN 0032-082X, Vol. 73, No. 9, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2019 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. E-mail: PE@omeda.com. Postmaster: send address changes to PLANT ENGINEERING, PO Box 348, Lincolnshire, IL 60009. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60009. Email: PE@omeda.com. Rates for non-qualified subscriptions, including all issues: USA, $165/yr; Canada, $200/yr (includes 7% GST, GST#123397457); Mexico, $200/yr; International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 USA, $35.00 Canada/Mexico and $40.00 Other International. Please address all subscription mail to PLANT ENGINEERING, PO Box 348, Lincolnshire, IL 60009. 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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EDITORIAL ADVISORY BOARD H. LANDIS “LANNY” FLOYD, IEEE Life Fellow H.Landis.Floyd@gmail.com JOHN GLENSKI, President, Automation Plus jglenski@processplus.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 JOHN MALINOWSKI, Senior manager of industry affairs (retired), Baldor Electric Company 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

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INSIGHTS

By Kevin Parker, Editor

CAD in the cloud is an inevitability On November 1, the computer-aided design (CAD) and product lifecycle management (PLM) supplier PTC completed its acquisition of Onshape, for which it paid about $470 million. Onshape software will become a software as a service (SaaS) product development platform. Short-term, it positions PTC to capitalize on what it describes as the “inevitable” industry transition to SaaS. Inevitable it is. SaaS already has rejuvenated several enterprise software markets. According to Allied Market Research, enterprise resources planning (ERP) markets today are growing at more than 10% per year, for example. A survey study conducted by IDC and sponsored by Amazon Web Services indicates 19% of the IT professionals surveyed said their discrete manufacturing companies have or are considering investment in cloudbased mechanical CAD software, while 54% said they have a two-year adoption plan for same. This was the highest combined percentage for all software categories, although quality control, computer-aided engineering and manufacturing execution systems scored highest in terms of companies taking immediate action. Given the centrality of CAD/PLM to many enterprise functions, from product design to manufacturing to data management, it’s not surprising that messing with CAD, and CAD users, takes forethought and planning. PLM is an electronic means to get work instructions onto plant floors. Also relevant to plant floors, the IDC study reveals that today about 10% of enterprise asset management software resides in the cloud with about 56% preparing to “lift and shift” to the cloud.

Wealth of systems

Respondents to IDC’s 2019 Product and Service Innovation survey indicated almost half their PLM licenses are cloud based — a rapid upward trend. According to IDC’s Jeffrey Hojlo, many goods makers still want to maintain a native set of design files for either IP protection or regulatory compliance www.plantengineering.com

purposes while leveraging cloud for collaboration. In its most recent fiscal year, PTC saw 9% growth in its traditional CAD business, while average industry growth for CAD in recent years has been in the 4-6% range. Since introducing the first parametric, feature-based, solids-modeling CAD software in 1988, PTC’s revenues have grown to about $1.3 billion in its latest fiscal year ending September 30. A series of interesting, even novel acquisitions made over the years suggest integration and enhancement points from Onshape to existing PTC products, IDC said, including: • ThingWorx, for connecting design information and knowledge with other data models and applications • Frustum, for cloud-based generative design • Vuforia, for augmented reality authoring of 3D data • Windchill, for PLM. Onshape is a SaaS, cloud CAD tool with PDM capabilities and a collaborative environment for design and engineering. Hojlo said it is not a full-fledged PLM platform with ideation, product portfolio management, supplier relationship management, and quality management, but added that expectations are that the product can evolve into a product innovation platform.

Full steam ahead

This intention was recently affirmed by Jim Heppleman, president and CEO, PTC, “Based on the successful approach we took with our ThingWorx Internet of Things and Vuforia Augmented Reality platforms, we expect the increased investment and market reach that PTC brings to Onshape will lead to an even stronger position in the high-growth SaaS market. We also intend to integrate breakthrough capabilities, such as our recently acquired Frustum generative design technology, into Onshape, to further advance PTC’s position as the market transitions to the SaaS model.” PE

PLANT ENGINEERING

November 2019

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SOLUTIONS SAFETY INSTRUMENTED SYSTEMS

By Joseph D. McHugh II

Double up on solenoid safety Adding two solenoid valves to a safety instrumented system keeps equipment, facility and personnel safe and the system online

Figure 1: In this typical emergency shutdown scenario, the shutdown valve stops the flow of hazardous fluids upon detecting dangerous conditions. The solenoid valve responds to the ESD controller to vent the actuator to a fail state. All images courtesy: Emerson

n the context of an entire production facility, such as an oil refinery, exercising the solenoid valve might not be at the top of your priority list. But the reality is all valves experience stiction if they remain inactive for too long. (Note: Stiction is the friction that tends to prevent stationary surfaces from being set in motion.) Although periodic exercise is crucial for any valve, the stakes are higher when it comes to the solenoid: if this valve experiences stiction-related failure, the emergency shutdown valve won’t be able to stop the flow of a flammable or even explosive fluid — leading to possible catastrophe. Though critical for valve maintenance, the problem with exercising the solenoid valve is that it may entail downtime. Fortunately, there’s a simple solution. Consider a two-solenoid safety methodology that allows exercising the solenoid valve online, protecting the plant, improving uptime and enabling adherence to functional safety requirements.

The solenoid valve’s role

The emergency shutdown (ESD) block valve is part of the final element in a safety instrumented system (SIS), which is required by law on any equipment processing hazardous chemicals. While the basic process control system is designed to prevent incidents by way of process alarms and operator intervention, the SIS provides an additional layer of protection to prevent and mitigate potential dangers (see Figure 1). An SIS typically consists of the following components: • Sensors, which measure process parameters, including pressure, temperature, flow, level and gas concentration. • Logic solvers, or controllers that read the signals from the sensors and execute preprogrammed actions to prevent or mitigate a process hazard.

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• Final elements, which bring the process to a safe state. In addition to the ESD valve, they can include a pneumatic, electric or hydraulic actuator and solenoid valve. In many SIS applications, the solenoid valve remains energized in the open position during normal operation. (Note: This indirectly acknowledges energize to trip applications.) However, if the system detects overpressure or other dangerous conditions, the valve moves to the closed position, activating the ESD valve to stop the process flow. But despite its critical role in ensuring the safety of the facility, equipment and nearby personnel, the solenoid valve

A word with Dr. Angela Summers Dr. Angela Summers designed the technology behind the redundant control system (RCS). She has nearly 30 years of experience in instrumentation and controls, process design and environmental pollution controls and is currently the president of SIS-TECH, a consulting and engineering firm that specializes in safety instrumented systems. “At the time of my design, you really only had two choices for using solenoids to actuate block valves,” Summers said. “You either used a simplex architecture, which provided you with a good level of safety, but it was inherently less reliable because you depended on the one solenoid. Your second option — two-out-of-two (2oo2) — wasn’t quite as safe because it required two devices to work, but it was much more reliable. The product I designed was a mix of the two: you get extremely high safety, as well as high reliability. “Emerson spent a lot of time working to maximize the flow pathways of the manifold to achieve the fastest closure time possible while producing the smallest, lightest box for installation,” Summers said. “The company evolved the manufacturing process to create a product that minimized my design’s footprint, cost and weight.” PLANT ENGINEERING

November 2019

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SOLUTIONS

SAFETY INSTRUMENTED SYSTEMS

Architectural constraints and considerations

Figure 2: More frequent testing of the solenoid valve lowers the average PFD, even without adding more complex architecture.

Over the years, the safety integrated system (SIS) architecture has evolved to increase overall safety and improve process reliability, but each emerging solution had its advantages and disadvantages (see Figure 5): • One-out-of-one (1oo1). This basic architectural design features only one element.

rarely gets used. In fact, it can remain in the same position for months or even years, increasing the chances that it will fail to close on command. The most prevalent cause of this failure is stiction.

The dangers of neglect

Figure 3: Featuring a low average PFD and spurious trip rate (STR), the RCS provides both safety and reliability in one package.

Figure 4: Over the years, SIS architecture has evolved to increase overall safety and improve process reliability, but each design has its advantages and disadvantages when it comes to the average PFD and STR.

“Mechanical devices, like the human body, work well when they’re regularly exercised,” said Dr. Angela Summers, president of SISTECH Solutions. “When you don’t exercise the valve, you’re increasing the potential that it could stick, which could prevent the valve from closing when it needs to.” (see sidebar, “A word with Dr. Angela Summers.”) In a typical solenoid valve, O-rings remain in direct contact with the chamber walls, creating a seal while the plunger is in motion. The plunger must first overcome the stiction between the O-rings and walls to move. If the valve is at rest for an extended period, the stiction increases beyond its normal level until the forces generated by the solenoid coil can no longer overcome it, preventing the valve from closing properly. In addition, the presence of water or oil can cause a sticky residue inside the valve. Because chances of stiction increase incrementally over time, infrequent testing raises the probability of valve failure on demand (PFD). Even without changing the architecture of the valving, more frequent testing will reduce stiction, lowering the average PFD (see Figure 2).

• November 2019

PLANT ENGINEERING

• 1oo2. This design adds redundancy for better safety. Although it reduces the average probability of design failure on demand (PFD), it does increase the spurious trip rate (STR), in which failure of either solenoid valve will trip the system. • 2oo2. This architecture adds redundancy for better process reliability. Although it reduces the STR, it increases the average PFD. • 2oo3. This design adds advanced redundancy for better safety and process reliability, while reducing both the STR and average PFD. However, because this architecture involves more components, it leads to higher input/output (I/O) requirements, increased power consumption while adding complexity. • 2oo2D. The RCS features 2oo2D, one of the newer architectures that incorporates diagnostics for improved safety and high process availability. Its fault-tolerant design has no single point of failure and provides a much lower STR than 1oo2 and 2oo3 architectures.

In addition to the potentially life-threatening safety concerns, including the risk of fires or explosions, solenoid valve failure is a condition that has vast productivity implications — especially if it leads to a plant shutdown. Not only would a shutdown disrupt uptime, but significant costs could be incurred.

Double-solenoid redundancy

Periodically testing solenoid valves serves two mechanical purposes: It prevents stiction, and it proves it isn’t there to begin with. Bringing the valve through a single cycle is all that’s necessary. Deenergize the solenoid coil so the valve fully closes, and then reenergize the coil to return the valve to the open position. But as simple as it is, cycling the solenoid requires taking the SIS offline, which creates downtime. For many plant owners, this disruption to productivity outweighs the threat of hypothetical catastrophe. Fortunately, the solution is simple: By adding a second solenoid valve to the design of the ESD valve, each solenoid can be tested individually. www.plantengineering.com

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SOLUTIONS

SAFETY INSTRUMENTED SYSTEMS

You can even program the controller to run periodic tests automatically, preventing valve stiction, lowering the average PFD and avoiding plant accidents — without ever taking the system offline. Installing a second solenoid valve isn’t time-consuming. Nor is it mechanically complex. Within a

prepackaged solution, the redundant control system (RCS) is a proven pilot valve arrangement that has no single point of failure and provides builtin redundancy and diagnostics to optimize plant safety and reliability while maximizing uptime (see Figure 3). The RCS incorporates a 2oo2D architecture and consolidates many components, including a maintenance bypass switch, pressure switches and redundant solenoid valves, into one easy-to-configure package that meets critical safety requirements. Some of the benefits of this redundant system include: • Automated online testing allows detection of 98% of dangerous failure points, including solenoid valve and partial stroke tests, as well as continuous monitoring and diagnostic feedback from pressure switches; no bypassing is required. • Easy online maintenance allows replacing the solenoid valves, coils and pressure switches quickly and easily with no process interruption. • No nuisance trips. Thanks to its fault-tolerant, redundant solenoid valve architecture, the RCS has no single point of failure that could lead to unplanned closure of the process valve.

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• Stainless-steel construction, i.e., the system’s optional 316L stainlesssteel valves and pressure switches, are suitable for use in corrosive environments, such as the Gulf Coast, where oil and gas equipment is regularly exposed to salt, humidity and fluctuating temperatures. • High safety availability, with the RCS being SIL 3-certified and meeting IEC 61508:2010 requirements for functional safety (see “Following functional safety guidelines”). PE Joseph D. McHugh II is business development manager, process, hydrocarbon, fluid and motion control at Emerson. He has more than 35 years of experience in the process instrumentation industry.

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SOLUTIONS MOTION CONTROL

By Chad Carlberg and Chris Diak

Eight selection criteria for actuation components Electromechanical systems offer advantages over hydraulic and pneumatic actuators

hen deciding between fluid-driven and electromechanical linear actuators, close consideration of long-term benefits to the intended end user can help original equipment manufacturer (OEM) system designers maximize both product value and return on investment (ROI). Fluid-driven actuators translate electric energy motion through a column of air, gas, oil or other media. While the motion they provide is simpler than with other type actuators, the infrastructure required to support them is not. Hydraulic actuators require an external system of pumps and valves; Pneumatic actuators require complex air delivery systems. For both, stroke length is defined by a mechanical hard stop. Electromechanical systems can handle more complex operations with a much simpler design. Figure 1: Packaging lines benefit from the increased controllability of electromechanical actuators as they often eliminate the need for changeover when switching from one product to another. All images courtesy: Thomson Industries Inc.

An electric motor — through a belt gear, a worm gear, a planetary gear or via a direct coupling — rotates a ball screw, which translates the torque into axial force through an extension tube. All key motion components are, or can be, self-contained. Motion is controlled by a programmable electronic signal. System designers should consider the following eight criteria when choosing between fluid-driven and electromechanical actuators.

1. Motion profile control

As business volatility and complexity increase, users of actuator-driven machinery and equipment demand greater control over position, velocity or force throughout the range of motion. Fluid-driven actuators cannot provide this easily. It is difficult for them to achieve the slow, controlled speeds that may be needed in many applications. To some extent, fluid-based actuators can gain control using external systems such as proportional regulators, valves and encoders, but this adds cost and further complexity. Because electromechanical motion is controlled electronically, the device can be programmed to stop at any point along the stroke. Force and motion profiles can be changed in software without having to shut down and reconfigure the machine. The increased controllability of electromechanical actuators often can eliminate the need for changeover when switching from one product to another. In applications such as packaging lines, where numerous package sizes may run in a single shift, this can result in significant savings (see Figure 1). Electromechanical actuators also can be networked, enabling functionality such as synchronization, making it easier for end users to work with unbalanced loads.

2. Impact on cleanliness and safety

In addition to limiting control over the motion profile, fluids make for a grimier, potentially dangerous work environment. For example, hydraulic fluids must be transported and stored. Ever-present leaks www.plantengineering.com

PLANT ENGINEERING

November 2019

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SOLUTIONS

MOTION CONTROL

wear. Infrastructure components must be monitored and replaced as needed. However, electromechanical actuators run longer with no maintenance intervention, providing consistent performance for the entire actuator lifetime.

4. Ambient noise

Figure 2: Electromechanical actuators are ideal for use in sanitary applications that require ultra-clean, energy efficient operation.

must be cleaned and can contribute to slip-and-fall accidents on the plant floor. Various filtration methods must be used to reduce contaminants. When the fluid has fully degraded, it must be changed and disposed of carefully. Pneumatic actuators present similar issues due to the presence of oil and other impurities in compressed air supplies. The exhausted air must be filtered to remove impurities before it is released into the environment. Electromechanical actuators have no such issues. Motion is in precision-fit metal parts, which require only routine lubrication â&#x20AC;&#x201D; or in some cases no lubrication at all. Given that, electromechanical actuators are especially appropriate for use in sanitary applications that require ultraclean operation such as in the food, beverage, packaging, medical and electronics manufacturing industries (see Figure 2). Because all components are contained in sealed modules with high ingress protection, electromechanical actuators also are more suitable for environments with higher contamination risk: chemical plants, paper mills, welding operations and outdoor applications.

3. Durability and maintenance

Just avoiding the grime and contamination of fluids reduces pressure on maintenance resources, but the greatest contributor to the maintenance workload is the complexity of fluid-based systems. Routine, break/fix-style maintenance is essential for fluid-based systems. Oil loses efficacy and must be checked. Gaskets and seals are subject to damage and

â&#x20AC;˘ November 2019

PLANT ENGINEERING

Noise is a significant issue with both hydraulic and pneumatic actuators. A hydraulic system consists of an electric motor, bearings, rotor/stator assembly and a fan. The motor drives a pump, which pressurizes hydraulic fluid in the cylinder via a valve. The fluid is transmitted through a system of tubing, hoses and fittings. To maintain the pressure, this system must be kept idling continually, which produces additional baseline noise that often can be heard throughout the plant, adding to ambient environmental noise levels. This is such a concern that products offering noise mitigation on hydraulic systems are an industry in itself. With pneumatic actuators, noise is mostly the result of air leaks, which are frequently present. Pressure losses and impurities found in compressed air supplies impact pneumatic actuators, causing increased energy usage and noise levels. By contrast, the design of electromechanical actuators makes their operation quiet. This technology is continuously advancing to achieve quieter operation for use in applications not possible for the other media actuators. For example, there is an electromechanical actuator on the market that operates with a sound level of less than 45 dB â&#x20AC;&#x201D; about the same as a typical library.

5. Energy efficiency

Fluid actuators use energy very inefficiently because they go through a two-step energy conversion process. Hydraulic systems have the advantage of being able to hold constant pressure without having to apply additional amounts of energy, but this requires keeping a pump running continuously, even when the actuator is not performing any work. With pneumatic actuators, escaping air through leaks increases energy usage and ambient noise levels. In contrast, electromechanical technology uses energy only when doing work, and does so with high efficiency. More than 90% of the energy applied to an electromechanical ball-and-roller screw assembly is converted to work. An electromechanical device also can hold a load in place without expending additional energy or complex system assemblies.

6. Space efficiency

The fact that everything in an electromechanical actuator can be self-contained in a compact unit means that OEMs can make smaller machines. This size www.plantengineering.com

reduction helps end users add automation to smaller spaces, improving efficiencies for both operation and space utilization (see Figure 3). Certain manufacturers have gone one step further in making actuators with a single-mount capability, making it easier for OEMs to deliver smaller systems.

7. Integration with other applications

As industrial systems become smarter and more connected, opportunities to optimize production to new levels of quality, efficiency and cost control are emerging. Many of these involve exchanging operational data across workplaces via the cloud. Fluid actuators are not as equipped to play in those applications, as additional hardware often is required to provide what is integrated in electric actuators. This additional technology requirement makes integrating fluid actuators into process optimization or modernization strategies more costly and difficult at times. Electromechanical actuators connect to networks with only a few wires, making it easier for them to exchange performance information among actuation devices as well as with optimization software.

8. Total cost of operations

While each selection criteria discussed thus far translates into end user value to some degree, an electromechanical actuatorâ&#x20AC;&#x2122;s greatest contribution is most likely its role in reducing total cost of operations. Greater control over the motion profile means there is no need to buy complex add-on components, servo valves or other components to control operations. Cleaner operation and reduced maintenance contribute to the bottom line by reducing the labor otherwise needed to monitor and repair systems. Using electromechanical actuators eliminates the expense of hydraulic oil associated with traditional hydraulic systems. Because electromechanical actuators run longer without needed maintenance, manufacturers save on replacement purchases and inventory management. The ability for electromechanical actuators to convert 90% of energy to work allows a plant to save thousands in energy costs. In energy intensive industries, energy cost savings can justify upgrades to electromechanical actuators with system paybacks as quickly as one year. More efficient space utilization can have a significant financial benefit, especially in areas where real estate values are high or on offshore and remote operations. Going forward, it may be that the greatest financial benefit of using electromechanical actuators is in their readiness for integration into the digital age. Companies are making gains by pulling device www.plantengineering.com

data into asset management software, enabling greater predictive management of processes and assets. A key aspect for system designers is ensuring that the right components are selected and integrated to deliver accuracy, efficiency, precision, noise level and other performance characteristics. Many companies manufacturing electromechanical actuators offer online self-service sizing and selection tools that enable designers to accurately size and select linear motion systems and other components.

Sharing the benefit

Most of the same features that make electromechanical actuators more valuable than fluid-based systems to end users also make it easier for OEM system designers to deliver that value. Pneumatic or hydraulic technology requires working with complex, space-consuming infrastructures. Electromechanical actuators are simpler and easier to size. In a few steps, designers can determine the required load and duty cycle, and specify stroke and retraction length. Modern configuration tools make this process even easier. Once an actuator is determined, the end user determines a location, mounts and wires it with a few wires and the actuator is up and running. Designers of fluid-based systems do similar calculations but must consider the additional system requirements of how to locate and sustain the fluid supply to the actuator. Because they deliver so many benefits to end users, electromechanical actuators can help OEMs field a more competitive offering. As they are easier to work with and more versatile, electromechanical actuators also can reduce design and development costs.

Maximizing value and ROI

In addition to providing system designers with an easier and more versatile motion component than fluid

PLANT ENGINEERING

Figure 3: Electromechanical actuators take up less space and improve efficiencies of both operation and space utilization.

November 2019

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SOLUTIONS

MOTION CONTROL

Selecting motion control components As industrial technology advances, and electromechanical actuators and other motion control components expand in capabilities for heavy duty applications, system designers are faced with a wide variety of options for their projects. Application and selection tools make it easier for design engineers to select the right product for their specific application needs, providing an effortless navigation experience to help identify the ideal actuator solution quickly. To ensure the best fit, they should take into account a handful of end-user considerations when making their selections: • How much control will the end user have over motion profiles? • How clean is the operating environment? What are the potential hazards? • What is the stated life cycle? How much maintenance is required? • How quiet is the system? • How energy-efficient is it? • How much space is required for operation? • How easy is it to integrate with other applications? • What is the impact on total cost of operating?

Harvard.indd 1

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actuators, electromechanical linear actuators provide significant advantages to both end users and OEMs. They are cleaner, easier to integrate, control and maintain, quieter and more energy efficient. In addition, they take up less space — all of which contribute to a lower total cost of operation and longer lasting operation without maintenance. Hydraulic and pneumatic alternatives have their place, but best practice is to consider all alternatives when deciding which actuation technology would be best for the application. PE Chad Carlberg is product line manager, Linear Actuators-Americas with Thomson Industries. He is responsible for all aspects of the short- and long-term strategies of the linear actuator business, including product road maps and product development. He earned his Bachelor of Science in Marketing at Butler University and has been with Thomson for 15 years. Chris Diak is the Automation Product sales manager at Motion Industries and has worked in the electrical/automation field for 24 years, with the last 22 at Motion Industries. He earned a BSEE from Clemson University.

input #11 at www.plantengineering.com/information

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SOLUTIONS FLUID SYSTEMS

By Stacey Phillips

Eliminate leaks to enhance plant safety, profitability How to avoid common causes and costs of fluid system leaks

luid system leaks are common throughout the miles of tubing, valves and other components that span most industrial plants. Such leaks represent increased operating costs at best and potential safety issues at worst. Even the smallest leak can present an issue. A simple drip of fluid on a walkway could cause a slip or fall that can become a lost-time accident. A minor release of toxic gas may result in evacuations and costly fines. A trivial bleed of expensive argon gas could drastically affect a plant’s bottom line. These are just some of the many reasons to address leaks quickly and develop a plan to prevent future ones (see “Adding up losses from leaks”). To help maintain plant safety and profitability, a plant’s leak mitigation plan should include training personnel about leak detection and prevention. Effective tactics include focusing on how and why leaks occur, how to locate and test for them and

Figure 1: Assemblers can use a gap inspection gauge to ensure they have sufficiently tightened a fitting. If the gauge will not enter the gap between the nut and fitting body (left), the fitting is sufficiently tightened. If it will (right), additional tightening is required. All images courtesy: Swagelok

how to develop a strategy to address and reduce leaks plantwide.

Recognizing common leak causes

Surprisingly, most leaks occur due to human error, not substandard parts. Errors may be due to the design and installation of a component or even the component choice. Therefore, it is important to select the right components at the outset and install them correctly. To better understand how to choose the right parts, it is helpful to understand the following top three common causes of leaks: Unreliable metal-to-metal seals. “Packless” metalto-metal seals are difficult to make and maintain reliably, especially over time. Installers must follow manufacturer’s guidelines precisely to avoid leaks. To enable a more reliable long-term seal, they may want to replace the component with one featuring an adjustable packing. Improperly installed tube fittings. To reduce the likelihood of leaks and enhance plant safety, installers must properly assemble tube fittings. Technicians should be trained in how to make up a fitting by orienting the ferrules properly, tightening the assembly to specifications and using a gap inspection gauge to verify their work (see Figure 1). Poor tubing selection and preparation. When tubing materials are incompatible with process fluids or the external environment, they will be prone to corrosion, premature failure and leaks. In addition, tubing preparation is critical, as unevenly cut tubing or tubing that has not been deburred may compromise a fitting’s sealing ability.

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PLANT ENGINEERING

November 2019

•

SOLUTIONS

FLUID SYSTEMS

leak out of those components as system concentrations shift (see Figure 4). In addition, fluids may become entrapped in cracks or stuck in deadlegs and then leak into the fluid stream, potentially changing its composition. One strategy for avoiding virtual leaks is to eliminate deadlegs (see Figure 5).

Figure 2: A real leak allows system fluid to escape via cracks or gaps between sealing surfaces.

Understanding leak types

The type of leak will influence a technician’s troubleshooting and repair steps. By understanding the following three most common types of leaks, the technician will be able to determine the appropriate corrective measures to address them: Real leaks. A leak that results from a pressure barrier failing to contain or isolate a system fluid from the surrounding environment is called a real leak (see Figure 2). Such leaks commonly occur due to cracks or gaps between sealing surfaces. At a minimum, a technician may need to simply tighten a valve packing to correct a real leak. However, it is possible the technician may need to replace valve components, such as the packing or O-rings (see Figure 3), or the valve altogether. Virtual leaks. Fluid trapped within a system can unintentionally get released into other areas of the fluid system. Such virtual leaks may occur due to material outgassing (i.e., when gas escapes from a material under test in a vacuum) or from fluids that absorb or adsorb into components and later

• November 2019

Adding up losses from leaks Plants waste millions of gallons of fluid each year due to leaks. At roughly $40 for one gallon of hydraulic fluid, for example, those leaks can add up to significant losses. Furthermore, leaks can account for: • Lost production: Every process shutdown taken to fix a leak reduces a plant’s production output potential. • Equipment damage: Loss of lubrication can lead to premature wear and machine failure. • Off-specification product: A plant may inadvertently produce an off-spec product due to improper instrument calibration or operation caused by a leak. That material must be reworked, sold at a reduced price or discarded. • Degraded work environments: Leaks in traffic areas can cause slip/fall accidents. In addition, fugitive emission leaks can be expensive and dangerous.

Figure 3: When addressing a real leak, a valve that swings open in line permits a simple packing replacement compared to uninstalling and reinstalling (or replacing) the entire valve.

Permeation. Permeation occurs when a fluid passes into, through and out of a pressure barrier that does not have holes large enough to permit more than a small fraction of the molecules to pass through any one

• Fines for noncompliance: Costly fines may result from systems and equipment that violate regulations. • Cleanup needs: Locating and repairing leaks takes time and money and may even require a special team to manage leaks of toxic chemicals. Additionally, a plant may face the cost of shutting down a system to thoroughly clean it following a leak. PLANT ENGINEERING

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Since 1923

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Cleveland Brothers

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SOLUTIONS

FLUID SYSTEMS Figure 4: A virtual leak releases fluid trapped within a system into other areas of the system.

hole (see Figure 6). It is a common occurrence when using fluoropolymers for valve seats and seals or flexible hose cores, as fluids or gases can penetrate the polymer surface, migrate through the material and desorb on the other side. The best way to avoid permeation is to choose components featuring sealing materials that mitigate Figure 5: Within a deadleg, old material trapped in the tee formation becomes a virtual leak into the main fluid stream, contaminating it.

the phenomenon, including harder plastics such as polyether ether ketone (PEEK).

How to detect leaks

Learning how to detect leaks is a key strategy for enhancing worker safety and decreasing operational risks. A good leak detection program will encompass the five primary nondestructive test (NDT) methods, including bubble testing, pressure leak testing, airborne ultrasonic testing, mass spectrometry testing and pressure change measurement testing.

Figure 6: With permeation, fluid penetrates and moves through and out of a pressure barrier.

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PLANT ENGINEERING

Bubble testing is a quick and easy way to detect and locate gas leaks. During bubble testing, a technician pressurizes a component to create a pressure differential. Next, the technician either immerses the pressurized component in a solution or applies a soapy film to the exterior of the component and watches for leaks, which will be indicated by bubbles. With bubble testing, technicians can evaluate an entire component at once, which can save time. In addition, the test enables technicians to determine whether a leak is a real or virtual leak. Pressure leak testing is especially helpful for determining the location of a gas or fluid leak. The two techniques that offer the best results are hydrostatic and pneumatic tests. For either test, the operator gradually pressurizes the component with water or air to a specified pressure and then holds that for a predetermined length of time to measure any loss. This test allows operators to evaluate an entire assembly at once to detect leak rates. Operators perform airborne ultrasonic testing using a handheld device that can sense medium to large leaks. The test is used mainly to locate leaks in compressed air systems and relies on measuring the magnitude of ultrasonic noise produced when fluid or air leaks with enough velocity to cause turbulence. The test is especially helpful for quickly scanning large areas for leaks and for locating leak sources from a distance. In mass spectrometry testing, a technician first inserts a sealed component or assembly into a pressure chamber and injects tracer gas (usually helium) into the chamber. Next, the operator transfers the component quickly to a mass spectrometer and applies a pressure differential to measure the amount of tracer gas that has penetrated the component or assembly. If the operator detects tracer gas inside the mass spectrometer, the component has a leak. Pressure change measurement testing is used to calculate and evaluate a leak rate to ensure the amount of leakage is within acceptable limits. It can determine total leakage in a simple, inexpensive manner by following one of four common techniques, which include pressure decay, pressure change absolute, pressure change reference and volume or flow measurement. For example, www.plantengineering.com

using the pressure decay technique, operators pressurize a component with air and use a pressure transducer to monitor that pressure. Any pressure drop indicates leakage.

Prioritizing leak maintenance

safer, more cost-effective operations (see Figure 7). PE Stacey Phillips is the field engineering regional area manager for the Americas at the Swagelok Co.

Figure 7: Training personnel on proper tube fitting tightening and testing procedures can help plants maintain safety and profitability.

Leaks are ubiquitous throughout nearly all plants. However, it is not feasible to address every leak right away. Instead, it is helpful to categorize leaks and prioritize which ones to address first, including fixing the following leaks in order: Dangerous leaks. Any leak that presents a safety issue should be a plant’s top priority. Such leaks may include releases of noxious gases and caustic chemicals or fluid leaks onto floors and walkways that create slip/fall hazards. A plant’s risk managers should identify these safety issues first and then send their top maintenance technicians to fix them right away. Costly leaks. All the leaks in a plant will collectively add up to a significant loss. However, sometimes the smallest leaks can contribute the most to that loss. For example, a small leak of expensive argon gas should be prioritized even above a large leak of lower cost compressed air. Stopping the more expensive leak first may drastically help the plant’s bottom line. Maintenance technicians can later address the air leak. Nuisance leaks. Minor leaks that don’t present safety hazards and are not responsible for major losses can be left for later. Such nuisance leaks should not be ignored, but plants often can wait to address these lowpriority leaks when their maintenance staff is not facing other more critical duties.

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Addressing leaks It is helpful to train — and retrain — engineers and technicians in leak detection and prevention to enhance their skills. Training may include educating them on proper material selection, as well as holding hands-on, skill-building courses that cover tube bending and tube fitting installation procedures. By focusing on identifying and stopping leaks, these skilled professionals can help plants realize rogers-kseries.com

November 2019

input #13 at www.plantengineering.com/information

SOLUTIONS PLANT AUTOMATION

By Don Pham and Linda Htay

Control system connectivity update Digitalization requires communication hubs, a role well-suited to PLCs and HMIs

any industrial plants and facilities are executing asset digitalization projects by incorporating Industrial Internet of Things (IIoT) elements and implementing other Industry 4.0 initiatives. A key enabler for these efforts is connectivity between field devices, such as sensors and instruments, and higher-level computing platforms. Connectivity usually is via company intranets and the Internet. Field devices typically use operations technology (OT) communication protocols and traditional wired signals, while intranets and the Internet use IT protocols. A bridge between OT and IT is required in the form of a communication hub, a role well-suited to newer programmable logic controllers (PLCs) and human machine interfaces (HMIs).

Controller connectivity

PLCs must connect to a wide variety of field devices and other components to perform traditional control and monitoring tasks. Discrete devices providing inputs to PLCs include limit switches, position switches, photoelectric sensors and other components that indicate on-off status. Discrete PLC outputs provide on/off commands to motors, Figure 1: Newer on/off valves and other on/off equipment. Analog PLCs typidevices providing inputs to PLCs include analyzcally support a multitude of communication protocols for connecting to plant-floor field devices via OT protocols, and to upper level computing systems via IT protocols. All images courtesy: IDEC

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PLANT ENGINEERING

ers, instruments, RTDs/thermocouples and other components with varying inputs. Analog PLC outputs drive variable frequency drives (VFDs), control valves and other equipment operating over a range of speeds or positions, typically scaled as zero to 100%. These traditional discrete and analog connections are common to almost every type of PLC application, with digital communication links added in many instances. Instead of installing a bundle of wires and cables from a VFD to a PLC, a single digital communication cable can be used to exchange information. A group of drives often can be linked to a PLC via some type of Ethernet-based network, such as Modbus TCP, further reducing required wiring and cabling. Smart instruments and analyzers generate many data points, and for this reason are also commonly linked to a PLC via a network. Less common methods of communication, but critical in some applications, are serial via RS232C/ RS485 networks. Many older field devices, such as weigh scales, may only offer this type of digital communication link. Bluetooth and other forms of wireless connectivity are provided by some PLCs for networking to compatible devices. Specialized industries, and applications such as building automation, often require support for the BACnet/IP communication protocol, a feature found in many newer PLCs (see Figure 1). Another specialized protocol is J1939, typically used for connections to in-plant vehicles such as forklifts. PLCs use these methods of communication to gather data for monitoring and control, and this data also can be manipulated and stored. SD memory ports and mini-B USB ports often are provided for expanded data storage, and data stored there or in PLC memory can be exchanged with higher level computing platforms via company intranets and the Internet, both typically via Ethernet. A PLC works well as a communication hub for applications where only a single controller is used www.plantengineering.com

to concentrate many field devices, but applications with multiple PLCs and other controllers are often better served by an HMI.

HMI hubs

HMIs typically don’t connect directly to field devices, but instead exchange data with these devices via an intermediate PLC or some other type of controller. For applications with a small amount of input/output (I/O), an HMI with real-time control capabilities can be used to provide a space saving all-in-one automation solution. An HMI often is required to communicate with many different controllers simultaneously, requiring support for a multitude of protocols (see Figure 2). Some of the most common types of controllers connected to HMIs via digital data links include PLCs, VFDs and weighing systems. Modern HMIs typically provide support for more than 100 serial and networking industrial protocols, such as BACnet/IP, Modbus RTU Master/Slave and Modbus TCP/IP. Users should look for an HMI capable of supporting multiple protocols simultaneously as this allows ongoing data exchange with many sources and systems. Not only can an HMI connect to many different sources of data, it also can provide onboard data storage, as well as additional storage via devices plugged into its USB and SD memory card ports. This stored data can be formatted for exchange with asset management systems, enterprise resource planning systems and other higher-level computing platforms. These communications are typically via Ethernet for real-time data exchange. For periodic transfers of accumulated data, file transfer protocol (FTP) functionality enables copying or moving files between local memory, external memory devices or cloud-based files, databases or data storage platforms. FTP provides a convenient and effective remote file transfer method and is supported by most upper-level computing platforms, as well as by some newer HMIs.

In these instances, it’s often helpful to use a combinat ion PLC/ HMI unit so the driver can view operational st atus det ai ls and receive messages. Interlocks and other programming can be added so only certain types of critical information are displayed while the vehicle is in motion, such as a warning to reduce speed, with other information only accessible while the vehicle is stationary. The PLC/HMI unit can be connected to an asset management system for data exchange via either a wired or a wireless link. In another type of application, a vehicle would be manually connected to a PLC via J1939 communications at the end of a shift. This would allow the vehicle to transmit its operational status, including mileage, battery life and other operating parameters to the PLC. The PLC would in turn send this information to an asset management system, usually via an Ethernet link. If wireless communications are added between a vehicle and a PLC, data can be sent via the J1939 protocol while the vehicle is mobile, adding another level of functionality.

Figure 2: Up to four communication protocols, including leading IT protocols such as Modbus TCP/ IP and FTP, can be used simultaneously with human-machine interfaces (HMIs).

Figure 3: Forklifts and other industrial vehicles typically used in production plants and facilities often provide support for the J1939 protocol, allowing data exchange with PLCs supporting the same protocol.

Monitoring mobile assets

Many plants and facilities use forklifts, trucks and other industrial vehicles to move personnel, equipment, raw materials and supplies from one location to another (see Figure 3). These industrial vehicle assets naturally come with their own automated systems to monitor and control operations. These systems typically provide support for the J1939 protocol, as do some PLCs. In a typical application, a PLC can be added directly to a vehicle and communicate with its vehicles’ local control systems via the J1939 protocol. www.plantengineering.com

PLANT ENGINEERING

November 2019

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SOLUTIONS PLANT AUTOMATION Figure 4: Controllers for filtration, cooling and other packaged systems usually provide support for the BACnet/IP protocol, offering a convenient means for digital communication with HMIs and PLCs.

BACnet for buildings Commercial and industrial facilities typically contain many packaged units such as for HVAC, air purification, water softener, boiler, chiller, cooling and filtration (see Figure 4). Each of these

units usually has its own local control system, with all units normally connected to a central control and monitoring system. Connections from these units to the central system can be hardwired, but this only provides limited data exchange and requires extensive wiring and cabling. A much better approach is to exchange data digitally using BACnet/IP, a protocol supported by almost every building automation packaged unit, and by many HMIs and PLCs. This allows an HMI, a PLC or both to be used for monitoring and control, and for coordination among multiple packaged units. Integrating various systems with this type of solution is a substantial improvement compared to proprietary building management systems, which typically lack flexibility and features. As with other applications, the HMI or a PLC can interface subsystems up to higher-level computing platforms, such as a building’s asset management system, usually via an Ethernet connection.

Looking ahead PLCs and HMIs, with the right connectivity and communication features, are an excellent fit for linking field devices and equipment to higher level computing systems, providing double duty in addition to their regular monitoring and control roles. When used this way, no new communication hardware or software is required, reducing costs and complexity. PE

WHEN OIL FREE AIR IS CRITICAL Count on Sullair for reliable Air compressors

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Don Pham is a senior product marketing manager at IDEC Corp., with more than 15 years of experience with industrial automation products including PLCs, HMI touchscreens, machine safety and sensors. He is responsible for product positioning and marketing strategies for these products and works with a research and development team to identify and add features that customers and OEMs are looking for. He is proficient in several industrial programming languages. Linda Htay is a product marketing specialist at IDEC Corp., responsible for touchscreens and display products. She has experience working with automation and industrial products such as HMIs, PLCs and more. Linda has a BSEE from San Jose State University.

input #14 at www.plantengineering.com/information

November 2019

SOLUTIONS PLANT UTILITIES

By Brett Maiorano

Understand the PRICE of nitrogen Generating your own may be the best way to go

f a business is a regular consumer of nitrogen, it’s likely aware (and perhaps even painfully aware) of what a hassle nitrogen-tank rental and delivery can present. Moreover, bulky nitrogen cylinders take up a lot of floor space in a facility. Given their weight, and that the vessels contain gas under high pressure, they amount to an ever-present safety risk. Further, the rental and delivery service can be expensive. Tank replacement regularly leads to downtime and added labor costs. Opting out of the gas company’s strict contracts can be a challenge. The list goes on. If any of the issues mentioned above sound familiar, don’t feel alone. As many business owners, managers and workers in similar situations have already discovered, it may be time to consider onsite nitrogen generation.

The good news about generating on-site nitrogen is that if an air compressor is available, that’s half the battle. From that point all that’s needed to generate nitrogen in-house is a connected nitrogen generator unit. Two main types of on-site nitrogen generators are available: PSA (pressure swing adsorption) and membrane. Before getting into the details, let’s focus on the benefits of on-site nitrogen generation in general. When the time comes to ditch the gas contract (and all the hassles that come with it), take a close look at the current nitrogen situation — and consider the many “PRICE-related” benefits that on-site generation delivers.

Purity control

Tanked nitrogen is 99.99% pure, which is great — when it’s needed. Nitrogen is delivered at that ultra-high purity level because the gas company produces a single variety for all its customers, regardless of what purity level each individual customer needs. But for approximately 75% of the c onsu me rs buy i ng t an ke d nitrogen, this high level of purity isn’t required for their applications. One reason for the high cost of 99.99% pure bottled nitrogen is that a very large system is required to produce this level of purity, so the output gas tends to follow a one-purity-fits-all formula. With on-site nitrogen generation, consumers can get nitrogen at the purity level needed, often at a cost savings when compared to the cost of highly pure tanked nitrogen. Image courtesy: Atlas Copco

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SOLUTIONS

PLANT UTILITIES

“Tanked nitrogen is 99.99%

pure, which is great — when it’s needed. Nitrogen is delivered at that ultra-high purity level because the gas company produces a single variety for all its customers, regardless of what purity level each individual customer needs.

”

With on-site nitrogen generation, consumers can get nitrogen at the purity level needed, often at a significant cost savings when compared to the cost of the highly pure tanked nitrogen. In fact, the tank needed to produce nitrogen at a 99.99% purity level is roughly 10 times as large as the tank needed to produce nitrogen at a 95% purity level. The bottom line is that if the application’s oxygen tolerance is high, paying a premium for nitrogen that is nearly 100% pure isn’t necessary. A lower purity level will do. Applications for which lower-purity nitrogen might be perfect include tire filling, fire suppression, some food packaging, laser cutting, electronic soldering, plastic extrusion and others. In fact, most applications don’t require 99.99% pure nitrogen. However, let’s be clear — even with a 99.99% purity level, on-site nitrogen still offers a clear payback and a return on investment that makes perfect sense for the business plan. Of course, the lower the required nitrogen quality, the bigger the payback — but there is a significant payback regardless of the purity level needed.

Reduced efforts

When a business implements on-site nitrogen generation, the reductions it can realize include: • Reduced downtime: Because a nitrogen generator is constantly available and its tank is always being refilled, there’s no need to switch out cylinders, resulting in downtime reductions.

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• Reduced labor: On the same note, because the need to switch out tanks regularly is eliminated, the labor costs involved in doing so are also eliminated. • Reduced injuries: Since there is no longer a need to switch out and move the heavy nitrogen cylinders, the risk of injuries is greatly reduced. • Reduced need for storage space: With just a single tank on-site that is constantly being refilled, there’s no longer any need to store extra tanks in the facility, freeing up space for other purposes. • Reduced waste: Because on-site generation can produce nitrogen at exactly the needed pressure and flow rate, no gas is bled off in efforts to get the gas to these required levels. Also, with cylinder-rental services, the tanks are often returned with some gas left in them — which can add up to large amounts of wastage over time, especially for businesses that utilize nitrogen in high quantities. Further, when a tank is not being used for long stretches of time, the pressure builds — creating a need for the relief valve to bleed off nitrogen gas, wasting a costly (and already paid-for) resource in the process.

Increased safety

Typical nitrogen-delivery services use cylinders that weigh over 100 pounds and that are filled with gas under high pressure — so it’s not hard to imagine why safety directors can’t help but see a recipe for a highly dangerous projectile, especially should a valve be broken off. Further, when nitrogen is delivered in liquid form, a high risk for burns can exist. When nitrogen gas is produced on-site, the risks of both burns and projectiles is greatly decreased. On-site nitrogen generation can pro duce cost savings in several ways. The most obvious example is that generating nitrogen allows business owners to eliminate rental fees on cylinders. These can add up, as most shops generally have three rented cylinders in-house — one in use, another an empty tank awaiting pickup, and a third one full and waiting to be rotated into use. With on-site generation, of course, just one owned cylinder is needed on-site, and it’s constantly being refilled. Next, when cylinders are rented, there will inevitably be cases when the tanks are returned www.plantengineering.com

with unused nitrogen remaining inside — representing waste losses in gas that was paid for but never used. Another consideration, as mentioned above, is that cost savings can be realized when nitrogen of lower purity levels is used for applications with higher levels of oxygen tolerance. More opportunities for cost savings include avoiding any combination of the following: the uncontrollable price increases that can come with purchased gas, avoiding costly contract negotiations, eliminating or reducing hazardous material fees, avoiding delivery surcharges, and reducing the amounts of local and state taxes paid.

Efficiency/environment

A green/eco-friendly practice that also helps the bottom-line, on-site nitrogen generation represents a win for both the environment and the company bank account. The practice creates efficiencies and environmental benefits by effectively eliminating both the production and delivery phases needed for each delivered cylinder, as it eliminates the need to burn energy in converting nitrogen gas to liquid, and it reduces the carbon dioxide emis-

sions generated by delivery vehicles. In addition, by avoiding the return of partially filled tanks, as well as any necessary gas bleed-off/venting before tank return, on-site nitrogen generation reduces waste right at the facility. If you’re still having nitrogen cylinders delivered to your business — and especially if you’re a heavy nitrogen consumer who sees regular tank drop-offs/pickups at your facility — it may be time to consider all the PRICE-related benefits that on-site nitrogen generation can bring. For many businesses, the return on investment reaped from on-site generation can cover the initial equipment investment very quickly, all while introducing a range of benefits and conveniences. Escape the gas contract by generating nitrogen on-site — while both saving money and reducing downtimes related to waiting for cylinder/ dewar tank delivery. Reliable gas generators that can efficiently and effectively meet nitrogen and oxygen on-site-production needs. PE Brett Maiorano is business development manager industrial gases, Atlas Copco Compressors.

Heavy-Duty Industrial Vacuum Cleaner Disintegrates Safety Concerns, Unscheduled Downtime, and Wasted Manpower in Abrasive Blasting Operation Today’s manufacturing environment focuses more and more on safety, compliance, and productivity. According to OSHA, effective safety and health programs mean a world of difference between organizations operating “in the black and those running in the red.” Learn how a heavy-duty, continuous-duty industrial vacuum cleaner disintegrated safety concerns, unscheduled downtime, and wasted manpower in an abrasive blasting application for a leading manufacturer of structural steel beams. By replacing the manual ‘brooms and shovel’ removal of heavy steel shot with an industrial vacuum cleaning system, unscheduled downtime was reduced by 80 percent, manpower was reduced by 50 percent, providing more efficient plant maintenance and a cleaner working environment. Eliminating manual material handling has some of the biggest potential to improve a company’s productivity, product quality, and overall business competitiveness. Download the paper at: www.vac-u-max.com/case_histories.cfm?case=48 input #15 at www.plantengineering.com/information pe201911_whitePprrHlf_vacumax.indd 1

www.vac-u-max.com

10/16/2019 10:30:14 AM

Smart Software for Smart Maintenance

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Smart Software... MVP Plant, smart software, ensures precise CMMS data with:

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• Automated Workflows • Mobile CMMS (Automatic Work, Parts & Time Tracking) • OData APIs • User-Friendly Interface Smart Maintenance... With precise CMMS data, smart maintenance results: • Improved Mechanical Uptime • Increased Reliability, Capacity, Productivity & Profitability • Mitigated Risk to Quality, Safety & Property Loss • Optimized Inventory To learn more, visit www.CMMSDataGroup.com/2019 CMMS Data Group (866) 360-1912 www.CMMSDataGroup.com Info@CMMSDataGroup.com © 2019 CMMS Data Group. All rights reserved. MVP Plant and Smart Software for Smart Maintenance are registered trademarks of CMMS Data Group. input #16 at www.plantengineering.com/information

INNOVATIONS

2019

PRODUCT Year of the

Advance manufacturing through innovation

FINALISTS

By Jack Smith, Managing Editor, and Amanda Pelliccione, Project Manager

anufacturing is the process by which raw materials become finished goods. This simplistic statement describes what can be complex, diverse operations involving human effort, machines, tools and processes that go together to produce everything from consumer goods to industrial devices and more. Regardless of the industry, all manufacturers share a universal need: New products. Welcome to the 2019 Plant Engineering Product of the Year Finalists. From the emergence of sensors and software that drive greater plant floor connectivity to energy management and motors and drives, this year’s 96 Product of the Year submissions are evidence that the finalists have continued to make their devices smarter and more intuitive. From the smallest sensor and logic controller to the largest motor and compressor, the innovative plant pro-

Asset Management Mounted bearings smart sensor The ABB Ability Smart Sensor for Dodge mounted bearings enables “health checks” for bearings. The smart sensor technology provides an early indicator of potential problems by assessing the condition of bearings from vibration and temperature information. ABB Ability Smart Sensor for mounted bearings use the latest algorithms to assess, manage and ensure performance of components. The smart sensor easily mounts to the bearing and communicates wirelessly via a smartphone or other device. This capability keeps employees safe, enabling easy access to the health data of bearings in locations that may be difficult or dangerous to reach. ABB Motors & Mechanical www.baldor.com www.plantengineering.com

vides a free flow of data and knowledge to everyone involved in plant operations. All this leads to greater productivity, more flexible manufacturing, better maintenance practices and a better sense of how raw materials and energy are being used. This year’s 13 categories offer the latest innovations in every area of the plant — from asset management to safety (if you’re looking at it alphabetically) and from material handling to lighting (if you’re looking at the plant from floor to ceiling). Taken individually, they are the result of research and development at the world’s top industry suppliers. To cast your Product of the Year vote, go to: www.plantengineering.com/NPE Voting is limited to Plant Engineering subscribers ONLY. Voting deadline is Jan. 10, 2020.

Predictive maintenance vibration, temperature node A complete end-to-end solution featuring wireless sensors, configurable hardware architecture and an intuitive user interface, the Predictive Maintenance System is designed to curb unplanned downtime and provide a swift return on investment. The batterypowered GraceSense Temperature Node monitors the surface temperature of any asset. In addition, the GraceSense Panel-Mount/ CloudGate collects data wirelessly from the nodes and transmits to the remote cloud using either an LTE or plant Wi-Fi connection. GraceSense also offers a complementary nonconductive temperature monitoring device called the Hot Spot Monitor (HSM). Grace Engineered Products www.graceport.com PLANT ENGINEERING

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INNOVATIONS Asset Management Device manager with HART-IP support The HART-IP interface improves implementation of the AMS Device Manager with third-party systems. Traditionally, multiplexers and protocol converters are needed, such as an RS-485/232 to Ethernet converter to access HART data for use in AMS Device Manager. Now, with HART-IP, an Internet Protocol (IP)-enabled version of HART, AMS Device Manager can access HART devices through existing plant IP networks such as Ethernet, Wi-Fi or fiber optic networks. Emerson Automation www.emerson.com

Mobile EAM CloudSuite EAM Mobile v11.4.11.1 connects with CloudSuite EAM, giving field technicians valuable access to information where they need it the most — on the job. By allowing technicians to access critical information when and when they need it most, CloudSuite EAM Mobile helps boost first-call resolution rates, increase technician productivity, empowers informed decision-making and increases accuracy of data capture, parts used, fail codes and details about resolutions. Improving asset data is the first foundation step in the EAM maturity model, leading to best practices. Infor www.infor.com

Cloud-based condition monitoring system

•

Safe alignment system

The SDT340 is the latest ultrasound solution to detect, trend and analyze ultrasound and vibration — designed for monitoring asset condition. SDT340, together with UAS4.0, is a cloud-connected condition monitoring solution that combines the power of ultrasound, vibration, temperature and RPM in one diagnostic package. Ultrasound and vibration are the two most relevant indicators of asset condition; especially where the assessment of bearing and gear health are concerned. In addition, the SDT340 can tackle air and steam leak management as well as electrical fault monitoring and mechanical inspections.

Maintenance technicians in the oil & gas, petrochemical and chemical processing industries will now be able to use the PRUFTECHNIK singlelaser technology and a ruggedized tablet with touchscreen to perform laser shaft alignment. With a single laser alignment system, the measurement setup is faster, and the machine prealignment is not necessary, saving hours of work. No matter the distance or length of the spacer shaft, the measurement accuracy remains consistent. Even over short distances, where accuracy may become a problem in double laser systems, the dual detectors inside the single sensor ensure high accuracy.

Ludeca www.ludeca.com

Pruftechnik www.pruftechnik.us

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2019 Product of the Year Asset Management Maintenance connection solution By combining Accruent’s Maintenance Connection with the document management solution, Meridian, users can maximize the combined strength of the products to ensure faster, more accurate access to their dynamic asset information. Comprehensive and accurate asset information enables maintenance teams to complete work more quickly and costeffectively, increase asset uptime and help assure worker safety. By providing a single source of truth for all engineering documentation, teams can eliminate duplicate data entry into different systems. Maintenance Connection users have direct access at a click of a button to the related technical documentation. Maintenance Connection, an Accruent Company www.maintenanceconnection.com

Motor management system SIMOCODE pro is a motor management system for full-voltage motor applications. This system is used to measure voltage, current and power, helping to protect, monitor and control motors to reveal potential motor problems before they occur. It also can be fitted for direct-on-line, reversing and star-delta (wye-delta) starters and for controlling soft starters by monitoring and protecting constant-speed motors with predictive maintenance functions. SIMOCODE pro is designed to communicate via various networks such as PROFIBUS, PROFINET, Modbus RTU, EtherNet/IP and OPC UA, helping users take advantage of the cloud and various features. Siemens Controls https://usa.siemens.com/controls

High feature energy meter Compared to the standard versions, the energy meters of the “High Feature” function class offer many additional functions, such as network analysis, current measurement via current-voltage transformers or Rogowski coils, use in IT networks, 24 V dc electronic supply, measurement of the neutral conductor current, time stamping of MINMAX values, power factor of the fundamental wave and more. Siemens www.usa.siemens.com

Bluetooth sensor, mobile application SKF Pulse combines an easy-to-use, portable, Bluetooth sensor with a free mobile app, allowing users to quickly monitor rotating equipment and machine health to predict issues before operations are affected. The sensor acts as a smart vibration tool, transmitting data wirelessly via the mobile app for instant machine diagnostics and insights. The vibration and temperature data can be stored and shared for further analysis. Designed for maintenance, repair and operations (MRO) managers and staff in a wide range of industries — including food and beverage, cement, marine, oil and gas and other industries — SKF Pulse provides a cost-effective entry point for a do-ityourself, preventive maintenance program. SKF www.skf.com/us

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INNOVATIONS Automation & Controls Electric bench top press

Pneumatic gripper system

Bimba's IntelliPress Bench Top Electric Press offers all the benefits of electric motion (reduced energy costs, greater control of force and speed, an infinitely variable stroke and less mess associated with oil and hydraulic operations). The IntelliPress provides complete control over process speed, pressing force and home position. It contains a networkable color human-machine interface (HMI) to monitor production data and empower the operator to change production settings quickly and easily for faster changeover and setup times. With an oversized internal ball screw, users can choose among three force output ratings for 3,000, 6,000 or 12,000 pounds of pressing force.

Bimbaâ&#x20AC;&#x2122;s Pneumatic Gripper System (BPGS) provides a versatile yet rugged gripping solution for a wide range of applications. This gripper series offers a high gripping force solution for various industries due to multiple jaw options. Bimba offers angular, regular, chisel, flange and shovel jaw types along with hot metal gripper options. This gripper series features a high gripping force that allows for picking up large heavy objects in demanding environments. The hardened steel chassis ensures that the gripper can withstand hard impacts with the work piece and other items within the environment without breaking. Bimba www.bimba.com

Bimba www.bimba.com

Actuator The PA Series NFPA actuator from Bimba offers versatile solutions to a wide range of applications requiring the conversion of pneumatic energy to linear force and motion. The PA Series actuator offers 12 NFPA mounts for flexible mounting configurations and several standard features such as auto-cushioning and magnetic pistons. Equipped with an auto cushioning system, this uniquely designed internal air cushion auto-adapts to changing loads and conditions. The PA Series NFPA actuators are ideal for everyday pneumatic linear motion applications, such as packaging, food processing, material handling and industrial automation equipment. Bimba www.bimba.com

Electromechanical kit The Smart Function Kit from Bosch Rexroth is an easy to select and program electromechanical kit for a variety of applications, allowing for fast, productive and smart pressing. The Smart Function Kit combines preselected mechanical and electrical components to create plug-and-produce solutions designed for forces between 2 kN and 30 kN. The modular system consists of perfectly synchronized hardware and software components: an electromechanical cylinder and force sensor, servomotor, drive controller, industrial PC and browser-based HMI software based on HTML 5. The installed software with auto-parametrization requires no programming knowledge for commissioning and operation. Bosch Rexroth www.boschrexroth.com/en/us

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2019 Product of the Year Automation & Controls Embedded control system

Standalone vision system

Ideal for PLC, CNC, motion control, robotics and hydraulics, the XM-42 embedded control combines high-level performance with numerous communications interfaces to cover a wide range of applications. It supports all major communication protocols and with the integrated OPC UA server and Rexroth’s Open Core Interface, it is ready to use in connected environments. The control is specifically designed for use in tough environments and is not sensitive to shock or vibration and boasts a high degree of electromagnetic compatibility. Together with the expandable communication, function and input/ output (I/O) modules, it forms a universal end-to-end control system.

The In-Sight 9000 is a rugged, ultra-high-resolution line of standalone vision systems. With its ability to acquire and process exceptionally detailed images, the In-Sight 9000 delivers high accuracy part location, measurement and inspection over a large area — even when mounted at longer distances. Line scan and area scan image acquisition options are available for imaging continuously moving or stationary objects. In addition, a full suite of vision tools configurable through the In-Sight EasyBuilder interface solves a wide range of applications across industries. Cognex www.cognex.com

Bosch Rexroth www.boschrexroth.com/en/us

Fixed-mount barcode reader DataMan 370 series fixed-mount barcode readers solve challenging direct part mark (DPM) and labelbased multi-code, multi-symbology applications using Cognex’s latest decoding algorithms, a multicore processor and new integrated lighting. With twice the performance and power of conventional readers in the same class, DataMan 370 delivers superior read performance for the broadest range of applications, including: high-speed lines, difficult-toread parts, small codes, multi-code, multi-symbology applications and multi-sided scan tunnels. Cognex www.cognex.com

Graphic design human-machine interface A modern, built-for-purpose operations experience that makes graphics design easy, DeltaV Live provides a world-class operations experience, designed for today’s high-performance operator requirements. The highly customizable HMI is Emerson’s first to natively support HTML5 — laying the foundation for easy to design and configure universal, crossplatform graphics. A new graphics studio simplifies graphics configuration that increases productivity and removes reliance on scripting for common tasks. Experience single-click access to graphics, built-in hierarchical navigation, directories and other applications. Emerson Automation www.emerson.com

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INNOVATIONS Automation & Controls HMI/PLC operator interface With a removable front display and touchscreen and one universal ¾-inch hole for mounting all HMI size models from 7-inch, 8-inch, 10.4-inch and 12-inch HMIs, the EZTouch EZ7 Series is ideal for plants upgrading the display size on their machines or replacing a damaged HMI from a forklift at half the cost of a new HMI, or original equipment manufacturers (OEMs) looking to offer multiple size interfaces without altering the cabinet enclosure. With universal connectivity to more than 95% of all PLC manufacturers, the EZTouch EZ7 Series works for all plant machines. EZAutomation www.ezautomation.net

Industrial Ethernet node The P2M Industrial Ethernet node design is optimized to be cost effective with the intention of providing the opportunity for users with traditionally hardwired networks to migrate to an Ethernet solution. It features easy connectivity to three core valve products, Moduflex, H Micro and H Series ISO with flow range 0.18 Cv (flow coefficient) to 6.0 Cv with 19 digital outputs on Moduflex valves and 24 outputs on H Series Micro and H Series ISO valves. Easy integration is enabled by an embedded webpage for monitoring and configuring. Simple diagnostic input data is provided over the network for easy troubleshooting and predictive maintenance. Parker Hannifin – Motion Systems Group www.parker.com

PLC compact touchscreen controller The EZTouch mini.PLC can function as a standalone machine controller or smart HMI with local I/O for existing PLCs. EZTouch mini.PLC is a compact touchscreen controller that saves space, time and money for various control applications. The 3.5-inch or 5.7-inch thinfilm-transistor (TFT) color HMI touchscreen with advanced programmable logic controller (PLC) comes equipped with 27 I/O points including 12 digital inputs, one configurable quadrature high speed counter input, eight digital outputs, four relay outputs, two analog inputs and one analog output. EZTouch mini.PLCs have extremely compact profiles ideal for tight fit applications with a depth of only 1.78 inches and 2.54 inches respectively for the 3.5-inch and 5.7-inch models.

Terminal block PTV has conductor insertion on the side for improved connection and conductor marking recognition. This is especially valuable in cramped spaces. PTV features clearly arranged wiring without bending radii, and time-saving conductor connection, due to tool-free Push-in direct connection technology. The connection principle and conductor routing are simple to understand. PTV terminal blocks are compatible with CLIPLINE complete standard accessories, simplifying inventory requirements. Phoenix Contact www.phoenixcontact.com/us

EZAutomation www.ezautomation.net

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2019 Product of the Year Automation & Controls Data acquisition protocol converter Red Lionâ&#x20AC;&#x2122;s Data Station protocol converter and data acquisition system is designed to act as a nexus for next-generation industrial data collection and management. Built-in message queue telemetry transport (MQTT) connectors accelerate industrial Internet of Things (IIoT) projects with pointand-click simplicity, while embedded OPC UA server functionality eliminates the need for separate system hardware to gather and exchange data with upstream systems. The optional SQL queries capability simplifies activities like quality control, production scheduling and batch and recipe management.

Logic and motion controller The Modicon M262 controller is IIoT-ready for logic and motion applications. It offers intuitive, scalable and reliable machine integration into Industry 4.0 environment, machine to device, machine to human, machine to machine, machine to plant or machine directly to cloud. The Modicon M262 controller embeds cybersecurity features and encryption protocols to provide direct cloud connectivity and digital services thanks to its two ready-to-work and independent embedded Ethernet ports. The M262 is the latest controller released from Modicon. Schneider Electric www.schneider-electric.us

Red Lion Controls www.redlion.net

Human-machine interface

Three-port interface module

Red Lion Graphite 12.1-inch HMI offers a UV-protected brilliant display with widescreen format 1,280 x 800 resolution, making it easily viewable even in direct sunlight. Unlike other HMIs available in the market with 1,000 nits or lower brightness, the new 12.1-inch outdoor Graphite model features a bright 1,600 nits display, enabling users to easily monitor and control production equipment in any lighting condition.

SIMATIC ET 200SP, PROFINET three-port interface module IM155-6PN/3 High Feature, two slots for SIMATIC BusAdapter, max. 64 Periphery modules and 16 ET 200AL modules, S2 redundancy, Multi Hot Swapping, 0.25-millisecond isochronous mode, optional PN strain relief and inclusive server module. Siemens www.usa.siemens.com

Red Lion Controls www.redlion.net

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INNOVATIONS Automation & Controls Industrial PC

3-phase starter

SIMATIC IPC647E is an industrial PC in a 19-inch design (2U). With the latest 8th generation (Xeon, Core i7, Core i5 and Core i3) Intel processor architecture, it offers the most powerful PC technology in a newly developed industrial design. In addition, the advanced housing design of the IPC647E is compatible for mounting with its predecessors. This means that it also can be used in existing systems without additional expense. Due to its low height (2U) and installation depth, it is particularly suitable for space-saving realization of fast computing and visualization tasks.

The 3-phase controlled 3RW55 starter covers a power range from 7.5 to 1,700 hp and is available with a variety of options to fit the requirements of any application. The starter supports five communication protocols to ensure seamless data exchange with almost any automation system. Intelligent functions, such as autoparameterization, pump cleaning and advanced pump stopping, optimize plant processes, save time and reduce wear on pumps and piping. Siemens Controls https://usa.siemens.com/controls

Siemens www.usa.siemens.com

Neural processing unit

Virtualized computing platform

The S7-1500 TM NPU (Neural Processing Unit) contains the Intel Movidius Myriad X Vision processing unit, which enables the efficient processing of neural network structures and the use of machine learning algorithms. The installed VPU, Intel’s new Myriad X VPU chip, is the first in its class to have a dedicated hardware accelerator for deep neural network structures. With the S7-1500 TM NPU, users can connect compatible sensors such as cameras or microphones via the integrated USB 3.1 and Gigabit Ethernet port interfaces included onboard the card. The data collected from the connected sensor systems can be processed using neural networks then evaluated in the CPU program.

The ztC Edge is a zero-touch, fully virtualized and selfprotecting computing platform, specifically designed for industrial edge environments. By using ztC Edge, operators at the edge with limited IT resources can deploy, manage and maintain highly secure, reliable and efficient edge computing systems by themselves, unlocking the true potential of their digital transformation initiatives, and helping them improve productivity while lowering risk. Since the release of the product in 2018, ztC Edge has helped users reduce unplanned downtime and ensure availability of business-critical industrial applications. Stratus Technologies www.stratus.com

Siemens www.usa.siemens.com

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2019 Product of the Year Compressed Air Oil-free air compressor The ZR VSD+ is available with an integrated MDG rotary drum dryer, which provides a stable and guaranteed pressure dew point of -40 F at almost zero energy cost. The design and sealing of the venting chamber ensure physical separation between the oil and air circuits, eliminating any possibility of oil entering the compressed air chamber and guarantees Class 0 oil-free air. Its design maximizes service efficiency with everything accessible. All components in the compressor element, such as the rotor profiles, smart inlet and rotor coating, have been redesigned for maximum durability and improved efficiency. Atlas Copco www.atlascopco.com/en-us

Antistatic ionizing bar The Gen4 Ionizing Bar eliminates static electricity 25% better than previous models by eliminating larger static charges faster. It has improved range and is effective when mounted up to 4 inches from a charged surface. Production speeds, product quality and surface cleanliness can improve dramatically. It eliminates static on plastics, webs, sheet stock and other product surfaces where tearing, jamming or hazardous shocks are a problem. A high concentration of positive and negative ions produces fast static decay, neutralizing surfaces causing production, quality or safety problems. The electrical ion source is shockless and there is no radioactive element. Exair www.exair.com

Soft grip back blow safety air gun EXAIR's Soft Grip Back Blow Safety Air Gun uses the smallest back blow nozzle available to deliver a blast of air to effectively blow debris and liquids from inside small pipe or hose diameters, channels, bores, holes, internal threads and other internal part features. The air gun’s ergonomic design keeps the operator’s hand in a comfortable position so it can be used for hours of continuous use without fatigue. An array of holes on the Model 1004SS M4 Back Blow Air Nozzle provides a forceful back-facing 360-degree airflow to clear out coolant, chips and light oils from machining processes. Exair www.exair.com

Electrical Safety Compact circuit protector The 200-amp Bussmann series Compact Circuit Protector (CCP) with Class CF CUBEFuse is a UL 98 Listed branch circuit disconnect switch that delivers the smallest footprint compared to any Class J disconnect — requiring up to 69% less space. Although the footprint is smaller than any Class J disconnect, and comparable to a circuit breaker of a similar current rating, the 200-amp CCP manages to provide a 200 kA short-circuit current rating (SCCR), with the current limiting ability of fuses, to help increase equipment SCCR. Additionally, front and side rotary operated versions are available, along with a variety of accessories. Eaton www.eaton.com

www.plantengineering.com www.plantengineering.com

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INNOVATIONS Electrical Safety Data access port The Data Access Port from Panduit is designed to provide programming port and electrical outlet access to equipment without the risk of exposure to electrical safety hazards. This product provides personnel a safe and secure way to maintain and monitor performance of PLCs, variable frequency drives (VFDs) and industrial networks to promote overall safety at the work site, resulting in reduced costs and increased efficiency. The circular frame design allows data access ports to be installed quickly and effortlessly by using a standard panel punch. Panduit www.panduit.com

Arc flash mitigation motor control center Schneider Electric’s patented ArcBlok technology in the Square D Brand Model 6 Motor Control Center (MCC) for arc flash mitigation is designed to improve worker safety and protect equipment from damage. Not just a barrier, the design prevents arc flash from originating and extinguishes and contains the arc energy if a problem occurs. Schneider Electric www.schneider-electric.com/ww/en

Electrical diagnostic test

Magnetic lock-out/tag-out device

Ramsay Corporation has designed a new diagnostic test for electrical jobs with questions in 10 categories to better gauge the knowledge and abilities of an incumbent workforce. Plants can Save time and money by using this test to quickly and effectively find areas of weakness in their workforce. Users also can use this test to help tailor their training programs to be as efficient as possible.

Lock-out/Tag-out (LOTO) is a safety practice used in industrial settings to ensure that potentially dangerous equipment is properly shut off, isolated or rendered inoperable prior to maintenance or other work, and is mandated by law in many jurisdictions. When locked out, the switchable magnet’s handle is inoperable, thus preventing removal of the device and operation of the intended switch, push button, valve or other equipment. Switchgear Safety offers LOTO Pro devices for all types and styles of equipment (both electrical and nonelectrical) and can design and configure the products for any custom or specialized applications where standard hard-mounted LOTO devices aren’t available or practical.

Ramsay Corp. www.ramsaycorp.com

Switchgear Safety www.switchgearsafety.com

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November 2019

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2019 Product of the Year Electric Motors & Drives Food safe bearing

Servo cable

Dodge Food Safe bearings solve two of the most prominent industry challenges when it comes to bearings: grease washout and corrosion. Food Safe bearings feature a patented lubrication protection system, superior coating and smooth design to improve cleanability and maximize life in applications that require high pressure, caustic washdown. All Food Safe bearings are IP69 rated for water, and with product registration, offer an unprecedented one-year warranty against failure due to water ingress.

ÖLFLEX SERVO FD 7TCE is a continuous flex and oil resistant servo cable suitable for mounting either in equipment or in cable tray. The FD 7TCE is a single cable solution that eliminates the need for these connectors and multiple cables. Additionally, using the FD 7TCE with its low capacitance insulation reduces voltage drops over long cable runs. The TC-ER rating means installations do not require expensive and labor-intensive conduit. A specially formulated thermoplastic elastomer (TPE) jacket, and cross-linked XLPE insulation can withstand temperatures of 221 F (105 C).

ABB Motors & Mechanical www.baldor.com

Lapp USA https://lappusa.lappgroup.com

Free-standing drive

Frame motor

M600 and M700 drives are now pre-engineered and packaged into robust, highly configurable Drive Free Standing (DFS) solutions. Save engineering cost, resources and time through easy configuration of quality packaged drive systems that are highly adaptable for stand-alone applications, or ready to integrate into a broader system suite. The Control Techniques’ Drive Freestanding is ready for fast deployment to minimize downtime in emergency situations, or short lead time project requirements.

The SH718 frame provides an industry leading power output with up to 22,000 hp in a frame smaller than what is typical in the industry. This modular frame size provides more than 20% more power in the same shaft height. With a smaller frame and a higher level of efficiency, users will save more money on energy, reduce their carbon footprint and realize an increased return on their investment. Siemens Industry www.usa.siemens.com

Control Techniques www.controltechniques.us

www.plantengineering.com

PLANT ENGINEERING

November 2019

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INNOVATIONS Electric Motors & Drives

Energy Management

Passive harmonic filter

Solid-state circuit breaker

The HGP filter is a drive-applied 5% passive harmonic filter. High quality components and a robust design allow this passive filter to deliver best-in-class performance under the harshest conditions and in the most challenging applications. The HGP filter is suitable for all industry applications. The addition of PQconnect allows users to remotely access their filters to monitor and control specific functions. HGP with PQconnect is the first intelligent passive filter that monitors power quality and controls the contactor. The HGP with PQconnect also features Bluetooth technology with Android App capabilities or Modbus RTU communication.

The Atom Switch is a solid-state circuit breaker that uses silicon carbide (SiC) semiconductors instead of traditional mechanical switches to control the flow of current. Every Atom Switch is autonomous with its own firmware and identity, which allows users to digitally adjust power sources based on individual needs and requirements. It enables circuit interruption capabilities up to 100,000 amps, reducing the risk of arc flash. This gives users the freedom to make changes based on their energy needs from any computer or smart device. Atom Power www.atompower.com

TCI https://transcoil.com

Energy Management Modular circuit monitoring system The modular circuit monitoring system (MCMS) is redefining circuit monitoring with next generation technology that simplifies installation and connectivity while providing instant access to data in a userfriendly format. The versatile core module system is a single monitoring solution with peripherals optimized for branch circuit and multi-circuit monitoring applications designed to reduce the cost and complexity associated with legacy systems. It also features options for new build, retrofit and thirdparty legacy branch circuit monitoring systems. It also features an HTML web interface for real-time and historical data plus configuration and commissioning.

Lithium-ion uninterruptible power supply The 5P lithium-ion uninterruptible power supply (UPS) provides a dependable, integrated solution with enhanced network security, extended battery life and remote management capabilities that make it the ideal solution for distributed IT and edge computing environments. The 5P lithium-ion UPS uses lithiumion batteries that provide enhanced performance compared to lead-acid batteries, with extended service life up to eight years and reducing the need for mid-cycle battery replacement. The onboard battery management system (BMS) provides up-todate insights into battery performance, charge cycles and active temperature monitoring to keep the user informed of the life cycle of their UPS battery. Eaton www.eaton.com

Anord Mardix USA http://anordmardix.com

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2019 Product of the Year Energy Management Arc reduction transformer The Cooper Power series AR-VFI transformer is integrated with the technology needed to reduce incident energy in downstream equipment and enhance safety when work on energized equipment is necessary. The Arc-Reduction VFI (AR-VFI) transformer reduces incident energy in the transformer secondary compartment by a factor of eight. The transformer is designed with fully integrated medium-voltage vacuum interrupter (VFI), differential relay protection package, system control power transformer and 24-hour battery backup system capable of logging/ sending/receiving data through the duration of an outage. Anomalies are sensed and transmitted through the integral control package to isolate the downstream equipment in less than four cycles clearing time â&#x20AC;&#x201D; maximizing electrical safety and system reliability. Eaton www.eaton.com

Power busway

Extreme temperature uninterruptible power supply The SSG-RP-1H is an extreme-temperature online UPS with ruggedized features specifically designed for applications in harsh environments. The rackmount models (800 VA to 2 kVA) are tested and designed with robust components and materials. The SSG-RP-1H operates reliably from -40 F to 158 F (-40 C to 70 C), has standard environmental protection features including conformal coating of circuit boards, a powder-coated chassis and encapsulated fans. The UPS also includes extreme-temperature batteries capable of minutes to many hours of runtime. Options include NEMA 3R-rated outdoor enclosures, remote UPS management, environment sensors and relay cards.

The Pow-R-Trak busway delivers power to any location without sacrificing uptime. The Pow-R-Trak is designed for mission critical, industrial and commercial markets and is easy to install, eliminating the need for specialized labor. The continuous track design delivers power along the entire length of the busway for quick expansion and reconfiguration. Pow-R-Trak sections are reusable and can be added, removed or repositioned per user requirement. Bus plugs also are available with optional circuit protection configurations for higher available fault currents. All Pow-R-Trak busway ratings and configurations have been tested and listed to UL 857 safety standards. Eaton www.eaton.com

Industrial heating application input/output system The Siplus HCS4200 is an input/output (I/O) system for industrial heating applications that always controls the electrical heating elements with the required accuracy. The intelligent heating controls can reduce the overall costs for commissioning, operation and maintenance by up to 70% compared with a solution comprised of individual components. Integrated diagnostics and high reproducibility facilitate an improved heating process with enhanced product quality. The Siplus HCS4200 controls heating elements up to 20 amps with voltages of 45 V, 70 V and 110 V in 230/277 or 400/480 V ac networks.

Falcon Electric www.falconups.com

Power distribution unit

The High Density rack power distribution unit (PDU) offers improved outlet counts and the addition of 11 color options for easy identification of A/B power feeds. Providing 11 different outlet module options allows configuration for up to 54 outlets per PDU and more than 20,000 configurable options for users. Alternative phase outlets simplify load balancing and improve airflow by putting outlets where they are needed. It also has an improved cord entry position, which reduces interference in racks and potential hazards by configuring the input cord for front or end entry. Eaton www.eaton.com

Siemens www.usa.siemens.com www.plantengineering.com

PLANT ENGINEERING

November 2019

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INNOVATIONS Energy Management

Fluid Handling

Load management system

PTFE sheet gasket

TeSys island is a load management system that brings the benefits of digitalization to the next generation of motor control up to 40 hp/80 amps. Early detection and alerts allow machines to operate efficiently, resulting in decreased downtime. Design and configuration effort are dramatically reduced using avatars (digital twins). Programming, commissioning and maintenance are streamlined due to intuitive tools and interfaces. Control wiring and device installation is simplified significantly using a bus coupler interface and easy ribbon control cable “click” installation. With TeSys island, OEMs and system integrators can design more intelligent equipment with greater design-to-commission efficiency.

The ChemLon Eclipse 7576 is a PTFE sheet gasket with features including universal chemical compatibility, low load to seal, creep resistance and strong rigidity. PTFE gasket materials are used primarily in chemical service in process plants. Pure PTFE must be restructured and/or filled with additives to give it stability under system load and temperature. Available bolt load, chemical mixture, space limitations and temperature/ pressure variations can affect which type of PTFE can be used, which is crucial because system conditions vary within a process plant. The ChemLon Eclipse 7576 is designed to withstand these conditions.

Schneider Electric www.schneider-electric.us

A.R. Thomson Group www.arthomson.com

Wireless energy management control system Sm@rtGear Mobile allows users to remotely monitor, configure and control low voltage switchgear, switchboards and power panels using a mobile phone or tablet (wireless or hardwired). It lets users remotely open and close breakers from outside the arc flash hazard zone, which removes the need for a dedicated control panel. Users also can remotely activate breaker maintenance mode from outside the arc flash hazard zone and view the breaker status from the outside arc flash hazard zone. Local security is enabled via a WPA2 Wi-Fi network, which only allows local access. Siemens Energy Management www.usa.siemens.com

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PLANT ENGINEERING

Hydraulic power unit With an energy-efficient and compact design, the CytroBox hydraulic power unit (HPU) is an IIoTequipped solution for hydraulic machine applications up to 30 kW. With CytroConnect IIoT service, operators can monitor operating status and plan maintenance cost-effectively. Data is transferred to a web dashboard where key status indicators can be read on any end device. The upright HPU can be integrated like a control cabinet and the drive unit is equally compact. The asynchronous servomotor has been replaced by a synchronous servomotor. Preset controllers in the variable-speed pump drives adjust energy requirements on an individual basis. Bosch Rexroth www.boschrexroth.com/en/us

www.plantengineering.com

2019 Product of the Year Fluid Handling Extra-large flow pumps

Storm drain filter

The CR 95, CR 125 and CR 155 pumps feature a hydraulic design that improves everything from impeller and guide vanes to inlet, discharge port, sleeve and diffuser, giving users improved energy efficiency and pump reliability. CR pumps include three additional extralarge flow sizes of up to 580 psi pump pressure with a maximum flow of 1,400 gpm at the best efficiency point. CR pumps up to 30 hp can be fitted with either integrated drives (CRE) or stand-alone drives (CUE). For the large CR/CRN range, plug-and-play drives are offered and can be preconfigured and tested to suit specific needs.

The PIG Storm Drain Filter guards drains with improved filtering of oil, sediment and debris from stormwater runoff. Using a four-stage filtration process and patent-pending filter ring, the filter ensures every ounce of water that enters is clarified, removing oils and sediment. Stormwater flows through the drain grate onto the fabric shelf, passes over the filter ring, into the collection bag and over four sets of filter strips (stage 4). The Storm Drain Filter features a stainless-steel adjustable frame to secure the filter in place, and holds up to 60 lb. of oil, sediment, debris and trash — even when the grate is not installed. New Pig www.newpig.com

Grundfos https://grundfos.us

Y-strainer with rare-earth magnet

Water-absorbent mat pad

The LPD-Mag Y-strainer provides a strong pressure drop and a high debris capacity at the same time. The Neodymium rare-earth magnet installed within the strainer assists in removing iron oxide buildup, helping assure the system runs smoothly. The magnet is installed into the collection vortex of the LPD, maximizing the magnet’s ability to catch iron oxide. The blowdown port is designed to allow for a thorough blowdown of the strainer to remove metallic and nonmetallic debris while in service.

The PIG Water Absorbent Mat Pad is designed and engineered with a durable top layer to hold the mat together (even when soaked and handling for disposal). Each high-capacity pad is specially treated for instant wicking on contact. The mat pad absorbs faster, uses less product and creates less waste. It is effective for fast cleanup of spills, puddles, pooling, equipment breakdowns, and roof leaks. It also is useful for situations where sump pumps or wet vacs are not necessary or available. New Pig www.newpig.com

Metraflex Co. www.metraflex.com

www.plantengineering.com

PLANT ENGINEERING

November 2019

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INNOVATIONS Fluid Handling

Lighting

Proof hygienic valves

High bay lighting application

The D4 Series of proof hygienic valves are used for the reliable separation of dissimilar products. This is useful in fulfilling today’s customer demands for production flexibility, maximized productivity, rapid return on investment and reduced product and personnel risk across the food and beverage, dairy, personal care and brewing process industries. All D4 valves are fully balanced for dependable operation against pressure spikes and flow in any direction. The assurance of genuine automated processing is enhanced with the option of a unique, state-of-the-art control unit with integrated seat lift detection and no external sensors. The double seat mix proof valves efficiently process two different fluids through the valve simultaneously.

The Reliant High Bay is designed for lighter duty applications. Built for maximum energy efficiency and value, Reliant carries an L-70 rating at 131 F (55 C) and L-90 rating at 77 F (25 C) for 100,000 hours of performance. The Reliant's rectangular, modular design enables both single-unit and tandem installation — configurable onsite for maximum flexibility. This modular option delivers up to 72,000 total lumen output. The Reliant fixture also is designed to shed dust and moisture. This contractor-friendly lightweight chassis, along with easy access to wiring and simple four-corner mounting, make Reliant safer and easier to install with less resources compared to heavier fixtures. Dialight www.dialight.com

SPX Flow www.spxflow.com

Press fittings

LED lighting fixture

The MegaPress Stainless XL fittings for 2-1/2-inch, 3-inch and 4-inch pipe complete a comprehensive lineup of press fitting technology for a broad variety of applications. MegaPress fittings reduce installation times by up to 90% compared to traditional pipe joining methods. They are available in 304 and 316 stainless steel and are approved for use with Schedule 10 to Schedule 40 pipe. Designed for iron pipe size (IPS) stainless steel, MegaPress Stainless XL fittings make secure connections in seconds, which helps keep a project on time or ahead of schedule. MegaPress Stainless XL fittings allow installers to easily identify unpressed connections during pressure testing.

The Crouse-Hinds series PVMA low bay LED lights help industrials improve productivity in the most demanding environments. The next generation lighting provides reliable, maintenance-free illumination that can yield substantive cost savings for harsh and industrial applications. The lights also are designed for 50,000+ hours of operation from -40 F (-40 C) to 131 F (55 C). It also has field replaceable drivers for reduced waste and costs. Its rugged design makes it useful for complex environments and its copper-free aluminum and sealed LED housing protects against water, dust and corrosive atmospheres. Eaton www.eaton.com

Viega www.viega.us

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November 2019

PLANT ENGINEERING

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2019 Product of the Year Lighting LED-connected luminaire

Ambient lighting system

The Crouse-Hinds series Champ VMV LED Connected luminaires, are certified for operation in harsh and hazardous environments. The technology incorporates remote monitoring and control technologies to help industrial customers increase energy savings and reduce maintenance costs. Modern industrial environments demand connected lighting platforms that can adjust lighting conditions for specific space and usage requirements without sacrificing performance in hazardous areas. Users can transform the capabilities of integral lighting technology in harsh environments to help reduce energy over-usage while driving dramatic improvements in operating efficiencies and costs. The Champ VMV LED Connected technology is certified for use in Class I, Division 2 hazardous rated areas, and incorporates SmartMesh WirelessHART technology.

SpectraClean is a portfolio of troffers, vaportight and striplight luminaires that leverage developments in the disciplines of lighting science and microbiology to combine white and narrowband 405 nm visible light to meet ambient and task lighting requirements while providing a continuous, unobtrusive disinfection option for commercial applications. The product family offers a complete disinfection solution to address common lighting applications in vertical markets, such as education, commercial office, industrial food manufacturing and commercial kitchens. SpectraClean is designed to provide continuous environmental disinfection and complement cleaning and disinfection strategies. Hubbell Lighting www.hubbelllighting.com

Eaton www.eaton.com

Wireless connected lighting system The WaveLinx Wireless Connected Lighting System includes integrated industrial sensors and is ideal for small and large applications. The connected system enables sensing and communication capabilities within the lighting fixture, allowing building owners to increase operating efficiency through controls and data. With insights into facility data, such as light level, occupancy, power consumption and device status, the system helps leverage lighting to make more informed decisions. The fixtures provide out-of-the-box functionality, allowing easy setup, programming and control through the intuitive mobile application, saving on installation costs. WaveLinx commissioning enhancements also include automatic firmware updates as devices join the network, further reducing installation time.

LED high bay lighting fixture The Harris Lumen Selected LED High Bay allows users to change the fixture’s light output with a few simple adjustments using easily accessible switches. This feature enables use in low-bay and high-bay environments while addressing a facility’s unique lighting needs today and as they evolve. Available in 2- and 4-foot fixture lengths, the 2-foot version is adjustable to deliver 9,000 to 15,000 lumens and the 4-foot version is adjustable to deliver 18,000 to 30,000 lumens. Orion Energy Systems www.orionlighting.com

Eaton www.eaton.com www.plantengineering.com

PLANT ENGINEERING

November 2019

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INNOVATIONS Maintenance Software Internet of Things maintenance solution

Industrial workforce management platform

Connected Maintenance is an Internet of Things (IoT) solution for maintenance organizations looking to transform operations, improve reliability and uptime and move from a traditional time-based preventive maintenance (PM) strategy to become predictive. By leveraging the systems and data that organizations already have in place, Connected Maintenance aggregates all of those data sources into one platform and creates intelligent real-time condition monitoring/ anomaly detection to identify failures before they happen. It can then dispatch maintenance through a seamless integration into the organization’s enterprise asset management (EAM) system to generate a work order or service request in real time.

Digital STO V19.1 industrial workforce management platform digitalizes complex and collaborative work processes, focused on owner operators in assetintensive industries, with a focus on shutdowns, turnarounds and outages. With Digital STO, managers can gain real-time visibility, dramatically improved manageability and enhanced decision-making capabilities. Workers receive optimized access to essential data, ensuring maximum productivity, quality, safety and compliance. The cloud platform is implemented in days, without disruption to the business, enabling customers to digitalize their unique know-how and work processes while complementing their existing enterprise information and OT systems. Mobideo Technologies www.mobideo.com

Aquitas Solutions www.aquitas-solutions.com

Computerized maintenance management system MVP Plant is a computerized maintenance management system (CMMS) that supports inline and batch editing, enabling quick edits in the List view for single and grouped items. Instead of having to load each record individually, users can now instantly update multiple items simultaneously. Calendar functionality gives users a visual tool to efficiently manage their organization’s maintenance tasks. Within the calendar, users can schedule work orders by drag and drop, edit work order data and view work order schedules by day, week or month. The GIS asset management mapping feature also lets users view a work order’s physical location on a map. CMMS Data Group www.cmmsdatagroup.com

Maintenance Tools & Equipment Plant monitoring system for operations, maintenance AMS Inspection Rounds digitizes information collected during inspection routes to drive operations and maintenance action. By integrating information with automation systems, users have accurate, realtime information that enables better decision making. Graphical dashboards deliver insight into plant condition, helping prioritize action and highlighting critical safety issues. AMS Inspection Rounds delivers condition data to other plant systems via a wired or secure Wi-Fi connection, eliminating the need for manual entry. It also provides automated workflows to operations and maintenance personnel while they are in the field, ensuring complete, consistent and repeatable collection of condition data. Emerson Automation www.emerson.com

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PLANT ENGINEERING

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2019 Product of the Year Maintenance Tools & Equipment Industrial vacuum cleaner

Thermal camera

The 30-Gallon Heavy Duty HEPA Vac industrial vacuum cleaner is designed for less frequent or lower volume applications and can move more material with less wear. It is engineered to filter contaminants to HEPA requirements in dusty environments requiring frequent cleaning. It is extremely quiet at 82 dBA (half the noise of electric vacs), making it suitable for a wide variety of environments. An economical, easily maintained prefilter stops larger particles, while the HEPA filter handles the smaller matter. All filters are tested for minimum 99.97% filtration at the 0.3-micron level to meet HEPA standards in strict accordance to IEST-RPCC-007.

The PTi120 pocket thermal imager is a professional tool built for use in rough industrial environments. The rugged thermal imager stands up to dirt and water and can survive one-meter drops. It is a radiometric, 120 x 90 thermal imager with advanced features designed to help accelerate troubleshooting and reporting. The 3.5-inch LCD touchscreen offers IR-Fusion to blend a visible light image with an infrared image to more easily locate problems and can be adjusted by sliding a finger across the screen. It features asset tagging that eliminates the tedium of sorting and organizing infrared images. Send via Wi-Fi or automatically upload once connected to the network or computer via USB.

Exair www.exair.com

Fluke www.fluke.com

Sonic industrial imager

Industrial vacuum for harsh, explosive applications

Equipped with an array of microphones for an expanded field-of-view, the handheld Fluke ii900 Sonic Industrial Imager enables maintenance teams to quickly and accurately locate air, gas and vacuum leaks in compressed air systems. SoundSight technology is simple to learn and designed specifically for noisy production facilities. The 7-inch LCD touchscreen overlays a SoundMap on a visual image for quick leak location identification. The interface allows technicians to isolate the sound frequency of the leak to filter out loud background noise. In a matter of hours, the team can inspect the entire plant. Images can be saved and exported for reporting purposes. Fluke www.fluke.com

The VAC-EX-120-9-SS is a powerful, yet compact industrial vacuum designed for collecting dry, combustible powders, such as flour, sugar and additives. Many nutraceuticals, food and beverage and pharmaceutical manufacturers are uniquely susceptible to the danger of explosion through their high use of powdered substances. Explosion-proof vacuums, certified for their specific applications, are vital to employee and plant safety. The portability and performance of the VAC-EX-120-9-SS make it perfect for production environments with flammable dust production. The 115 V ac electric dry industrial vacuum is certified explosion-proof (Class II, Division 2, Groups F and G). Goodway Technologies www.goodway.com

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PLANT ENGINEERING

November 2019

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INNOVATIONS Maintenance Tools & Equipment Ergonomic tightening system

Continuous-duty industrial vacuum

The QX Series Ergonomic Tightening System (ETS) is designed to deliver short pulses of energy into the fastener during tightening, so the operator safely retains control of the tool. The ergonomically enhanced motor control algorithm minimizes the average force experienced by the operator, protecting workers from injury. Workers no longer have to manipulate the fastening tool and a stationary reaction device. ETS tools increase mobility and access for tasks requiring one-handed tool operation or when optimum operator agility is paramount.

The Model 1050 is a continuous-duty industrial vacuum cleaning system designed for high volume recovery of highdensity materials such as steel shot, grit, cement, foundry sand and other similar materials. The Model 1050 vacuums up to 10,000 lb. (4,500 kg) per hour and is well-suited for high-volume recovery at local pickup point areas such as debris under conveyor belts or in bucket elevator pits, as well as a “breakaway” central system for long-distance cleaning via piping networks for applications including cleaning mezzanines and hard-to-reach areas. The vacuum pump provides airflow that never diminishes for quick recovery of material from large piles and over long distances.

Ingersoll Rand https://company.ingersollrand.com

VAC-U-MAX www.vac-u-max.com

Ultrasound camera The BATCAM is an ultrasound camera that anyone can use conveniently because of its intuitive visualization technology. Even nonexperts can easily use the BATCAM since it is simple to operate and provides visualization of ultrasound occurrence location. In addition, the user can quickly diagnose and easily view and share measurement results by image or video, since BATCAM is filming a wide range in real time and shows multiple noise sources. It has ultrasonic sensors in 30 channels and a high-resolution optical camera. Its detection frequency range is 20 Hz to 60 kHz, with a detection distance of up to 20 meters. SM Instruments www.smins.co.kr

Laser shaft, pulley alignment system The Easy-Laser XT770 allows users to know their machine from every angle. Align to ANSI or user-defined tolerances, measure misalignment of horizontal and vertical machines including soft foot check, unlimited machine trains, track machine movement like thermal growth and pipe strain, and document alignment results to a PDF, which can be stored, emailed or attached to the work order in the CMMS. The XT770 gives users the freedom to perform shaft and belt alignment with ease and precision with tablets, phones or XT11 display. Its easy-to-use app-based platform requires less training and implementation time. Ludeca www.ludeca.com

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Grease for extreme temperature conditions The 880 Crown & Chassis Extreme greases offer lubricant consumers the protection and the pumpability they need in sub-freezing temperatures without compromising viscosity and equipment protection. Testing has shown 880 Crown & Chassis Extreme remains pumpable and operational well below -40 F (-40 C). The beauty of 880 Crown & Chassis Extreme is that it maintains the thick consistency of an NLGI #2 grease and carries all the same properties of the original 880 Crown & Chassis Grease. Extreme maintains an unmatched 100 lb. Timken OK Load, industry leading 1.3% water washout and terrific 0.33-millimeter Wear Scar — all from a grease that will pump below -40 F. Texas Refinery Corp. www.texasrefinery.com

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2019 Product of the Year Material Handling Systems Closed-deck shoe sorter

Spherical roller bearing

The VanRiet HC sorter is the fastest closed deck shoe sorter in the world, with a maximum speed of 590 feet/minute (3 meters/second). The sorter has a fully closed deck to prevent dirt and debris from falling into the sorter and to prevent cartons and other packaging from getting stuck. Single or double-sided shoe configurations give the sorter greater versatility and allows it to serve a higher number of chutes in the same footprint. Users can accommodate a variety of packaging types due to narrow slats and a fully closed sorter deck design.

The Sealmaster unitized spherical roller bearing (USRB) is now available with the Klamploc tapered adapter lock. The Klamploc tapered adapter lock design reduces installation time for users in two ways. First, key installation steps now are printed on the collar, giving the installer the ability to know how far to turn the locking collar without having to refer to the guide (though directions should still be read fully prior to attempting an installation). Second, with nothing to remove or bend, Klamploc eliminates several steps during installation compared to other market offerings.

MHS www.mhsglobal.com

Regal Beloit America www.regalbeloit.com

Hybrid actuation system

Lithium-ion battery pack

The HAS500 Hybrid Actuation System design combines the controllability of traditional electromechanical actuators with the power density, longer life and failsafe conditions commonly found on traditional hydraulic systems. The result is an improved actuation solution for 1-2 axis of motion control. Bore sizes ranging from 2 inch through 8 inch bore with no limit on stroke, mount or rod modifications. System features include all-in-one design, plug-and-play actuator, easy to apply, easy to install, easy to control, space savings, energy savings, reduced leak points and reduced oil reservoir volumes.

The Raymond Model 8250 pallet jack with lithiumion has a 24-V, 156 ampere-hour light EV battery pack. Built specifically for the Raymond Model 8250, this doublepower-capacity lithium-ion battery pack has been UL 2271 listed. The Model 8250 with lithium-ion battery is an intelligent truck and pack offering, providing CAN communication that allows data exchange between truck and lithium-ion battery pack. In addition, the onboard battery management system allows the operator to schedule charge times, manage charging notifications and monitor charge and usage to prevent discharging events.

Parker Hannifin â&#x20AC;&#x201C; Motion Systems Group www.parker.com

The Raymond Corporation www.raymondcorp.com

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November 2019

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INNOVATIONS Material Handling Systems Robotic reach truck The Yale dual-mode pantograph robotic reach truck is an industry first product, expanding the capability of robotic lift trucks to lift more than 30 feet high and reach into double-deep storage. This capability allows operations to maximize the facility’s cubic volume, ideal for operations looking to accommodate expanding inventories while facing challenges finding and retaining labor. For consistent performance at height, sensors and 3-D cameras enable precise fork placement and guidance. Switch from automatic to manual mode at the touch of a button with dual-mode functionality, giving operations the flexibility to take control. Yale Materials Handling Corp. www.yale.com/north-america/en-us

Plant Analytics & Design Industrial display screen The RXi Industrial Display Portfolio’s modular line of displays features industrial monitors, panel PCs and web panels that are built tough and can run effectively in extreme temperatures. The vivid displays deliver clear images and feature intuitive touch interfaces as responsive as the latest smartphones. The displays are available in many configurations and offer advanced features like the ability to run web-hosted applications or operate interconnected to each other. The new RXi Industrial Display Portfolio helps designers and engineers deliver the best possible user interface experience to their customers and choose the best display size, physical characteristics and computing options for their application. Emerson Automation www.emerson.com

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November 2019

Plant Analytics & Design Process manufacturing analytics software R21 is an advanced analytics solution for process manufacturing customers. It enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate and share insights to improve production outcomes. R21 features reflect the growing use of publishing analytics-based views. Scorecards are used for tabulated metrics, measurements and other summary data, and may be presented in tables with conditional formatting support and userdefined columns. R21 also adds frequency analysis capabilities, often referred to as “FFT,” to transform segments of a time-series signal into the frequency domain. Seeq Corp. www.seeq.com

Production cockpit TrendMiner 2019.R3 allows process manufacturing enterprises to build an analytics-driven production cockpit. The production cockpit analyzes the live production process; compares its progress to historical production runs; and displays diagnostics, quality status and predictions to production operators or management through individually designed dashboards. It also streamlines the flow of information between shifts, from shift teams to engineers and can provide live production views and historical analysis from the most remote factory to expertise located anywhere, giving them the power to make informed decisions rapidly. It is designed for users in the chemicals, oil & gas, water/wastewater, utilities, pharmaceuticals, food processing and metals & mining sectors. TrendMiner www.trendminer.com

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2019 Product of the Year Safety Spherical roller bearing

Modular busway system

The Dodge Safety Mount spherical roller bearing uses a patented built-in mounting system to reduce installation time up to 75%. Best suited for bulk material and air handling applications, the bearing mounts by tightening fasteners instead of using a hammer and other tools. The system also allows simple installation and removal from the same side of the bearing, which means only one person is needed for the task. It also features a triple-lip contact seal and corrosion-resistant flinger sealing system, which prevents contamination from entering the product during installation and operation.

DATABAR is a unique open channel modular busway system designed for mission-critical rack power distribution in data centers. The system is designed to be compact and features patent-pending design innovations in the integral plug-and-play coupling system. This allows simpler and faster installation and tap-off actuator mechanisms. It is available in ratings from 160 to 800 amps and is UL 857 listed. It also has tap-off interlocking for improved operator safety and comes with 100% ground path via a onepiece extruded aluminum housing. It also has tap-off options for multi-outlet, drop cords and monitoring.

ABB Motors & Mechanical www.baldor.com

Anord Mardix USA http://anordmardix.com

Containment bag for leaking transformers

Remote switch actuator

The Transformer Containment Bag safely contains leaking transformers, allowing complete access to lifting lugs for easy lifting, moving and storing. The bag allows 100% OSHA-compliant lifting by providing access to the transformer manufacturer’s lifting lugs through the integrated primary and secondary reinforced access ports during every stage of use in which an electric utility line crew would need to lift, move and store a transformer. The primary and secondary reinforced access ports are used to access the transformer manufacturer’s lifting lugs while the Transformer Containment Bag’s duffle is up and designed with a built-in weather cover flap to prevent weather from entering the bag. Andax Industries www.andax.com

www.plantengineering.com

The RSA-152G remote switch actuator (RSA) is designed to operate the Boltswitch T Series of bolted pressure switches (BPS) with no modification to existing electrical equipment, thanks to the magnetic latching system. Optional features include a radio remote with a range up to 300 feet, a 24 V dc LED light, a wireless video camera system with an LCD monitor and a rugged protective case assembly. All RSA units are portable with fast and easy setup. They offer mechanical and/or electrical safety protection, adjust to fit unique electrical equipment configurations, reduce requirements for personal protection equipment and meet NFPA 70E arc-flash safety compliance standards. CBS ArcSafe www.cbsarcsafe.com

PLANT ENGINEERING

November 2019

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INNOVATIONS Safety Safety border mat The PIG safety border mat is designed to provide a no-slip path for foot traffic. The mat has adhesive backing to minimizes trip hazards and to make sure it stays in place with no shifting, bunching or flipping over. The hi-viz yellow and black pattern provides safer walkways. The absorbent, hightraction top layer allows for a safer walking surface. The safety border mat is built to last up to three months and peels up easily. Its absorbent top traps dirt, salt and moisture to keep it from being tracked around. It will stick to most commercial floor surfaces, including concrete, VCT, linoleum, ceramic tile, quarry tile and laminate flooring. New Pig www.newpig.com

The PSRswitch is an RFID coded, noncontact safety switch. Integrated RFID transponder technology and intelligence ensure maximum protection against tampering and outstanding safety in accordance with EN ISO 14119. With compatible evaluation units and SAC cabling, it provides a costeffective, complete solution for flexible safety door and position monitoring for the digital factory. The PSRswitch provides safe series connection of up to 30 sensors, comprehensive IO-Link diagnostic information with the PSR-MC42 safety relay, and maximum protection against tampering with three RFID encoding levels. Encoding levels are here and ready for approval. Phoenix Contact www.phoenixcontact.com/us

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November 2019

The Operational Risk Management (ORM) Digital Twin can help operators by delivering a real-time, digital replica of the asset that simulates the operational reality. It automatically brings all system, sensor and human-derived inputs together in a joined-up way to see their cumulative impact. The ORM Digital Twin can make process safety risk visible, prominent and available for all in real time. It also helps improve operational awareness through the ability to understand what’s happening, when it’s happening and what’s driving the risk. This lets operators make better and more informed decisions that manage risk against productivity. Sphera https://sphera.com

RFID coded, non-contact safety switch

Digital twin for operational risk management

PLANT ENGINEERING

Toxic and combustible gas detector The Vanguard is a WirelessHART toxic and combustible gas detector designed to augment gas detection coverage for brownfield and greenfield sites with minimum financial outlay and maintenance. Vanguard can improve monitoring capability at 10% of the cost of a wired system. The Vanguard is easy to operate and calibrate, is interoperable with existing WirelessHART networks and asset management systems and can be dropped anywhere in the mesh network to provide an instant gas monitoring point. Calibration and bumptesting also is made simple with the push of a button to activate the calibration process. United Electric Controls www.ueonline.com

www.plantengineering.com

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