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HELP YOU WORK And help you get from here to there Pg 04
Discover the EP Solution to INTERNAL POWER POLLUTION And learn why legacy solutions do not work Pg 36
In the Spotlight
the latest in LED technology From our Lighting & Control segment Pg 43
SPRING & SUMMER 2016
10 APPS WE LOVE THAT
A SHEALY ELECTRICAL WHOLESALERS PUBLICATION
CAMPBELL
UNIVERSITY
28
Realizes a 65% energy savings worth $20,500 annually
Contents
*
MOVE
ON COVER
LEARN YOUR LESSON
IN THE SPOTLIGHT
04
10 APPS WE LOVE From apps
that help you on the job, to the ones that help you get from here to there ...
10
TESTIMONIAL Mike Kerns explains what it is like to work with Shealy Electrical Wholesalers ...
16
MOTOR FAILURE Being armed
with the knowledge to avoid costly downtime and improve asset uptime...
24
LEARN YOUR LESSON Don't
repeat the same mistakes - learn how to improve shutdown process ...
28
PROJECT PROFILE Gore Arena
lighting upgrade yields great savings for Campbell University ...
for internal power pollution
28
18
NEW LED RETROFIT
with our Lighting & Control segment
24
takes 3 minutes or less
34
43 32
45
36
46
EASY LED RETROFIT converts
your existing fixture into energy-saving LED in 3 minutes or less ...
DISCOVER THE EP SOLUTION to internal power pollution and learn why legacy solutions do not work ...
40
ETHER NETWORKS Upgrade, integrate and migrate to industrial ethernet networks ...
42
IN THE SPOTLIGHT The latest in
44
LED technology and trends from our Lighting and Control segment ...
LIMIT SWITCHES Enter the wireless era, saving you time and money by eliminating cabling ...
50
THE EP SOLUTION
Campbell University experiences a 65% energy savings ...
to improve shutdown process
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TOWN DOWN TON ES L CHAR ION A LOC T S PAGE
SOUTHWIRE BLITZ makes the way through customer job site throughout NC and SC
SHEALY STRATEGIC SOLUTIONS Meet the newest solutions arm of Shealy Electrical
50
HABITAT BUILD Dates have been set for the next Habitat for Humanity build in Columbia SC ...
HABITAT DEDICATION
making a house a home
51
testimonial
“Downtime with Shealy as the supplier is unheard of.”
from
Michael Kerns
our locations SOUTH CAROLINA
from the president
A
CHARLESTON (843) 879-0232
ll too
CHARLESTON DOWNTOWN (843) 853-7044
often, we hear
the phrase “you can’t teach an old dog new tricks.”
This proverb suggests that it is impossible to change people’s habits, traits or mindset. One of our associates, Cecil Greene (respectfully known as Mr. Greene to all of us) challenges that expression. Mr. Greene attended Clemson in the days when it was all male, all-military ROTC, and strictly regimented. After graduating from Clemson Agricultural College in 1941, he spent a few months working for Westinghouse Electric; waiting to reach the age of 21 and serve in WWII. After stops in Italy and France, Mr. Greene resumed civilian life. He married his wife, Mary Frances (a marriage that would last 61 years until she passed), and began his engineering career with McCall-Thomas Engineering firm in Orangeburg, SC. It was at McCall-Thomas where he was assigned the task of designing and staking the power distribution on Hilton Head Island…and he delivered. In May of 1960, Mr. Greene joined Shealy Electrical’s Utility department as an outside salesman. He served in many roles during his tenure. This May we will celebrate his 56 years of tremendous contribution and his much deserved retirement. (He will celebrate his 96th birthday on July, 30th 2016). Throughout the years as the times have changed, Mr. Greene has consistently changed with them.
When one of our manufacturers stopped supplying cutout-arrester combination units, he took it upon himself to to fill the void. Since 1993, he has assembled and provided over 25,000 combination units to Shealy utility customers. When Microsoft Office programs became mainstream, Mr. Greene did not shy away with intimidation. He enrolled himself in night school classes at a local technical college and mastered the programs in his 70s.
COLUMBIA & CORPORATE (803) 252-5668
FLORENCE
(843) 656-0088
GREENVILLE (864) 242-6880
GREENWOOD (864) 223-4210
NORTH AUGUSTA (803) 278-1504
SUMTER
(803) 934-8350
Mr. Greene is responsible for helping mold Shealy into what it is today. We have so much to learn from his never-ending desire to keep learning, keep moving, and keep changing. Tom Brokaw wrote a well-known book entitled The Greatest Generation – in that book he described characteristics that defined that generation of Americans as follows: a sense of responsibility, commitment to marriage and family, a strong work ethic, faith in God and the future. If Mr. Greene is any indication of the Americans from that generation, Mr. Brokaw got it 100% correct. We can’t all be part of the Greatest Generation…that ship has sailed. We can, however, aspire to be more like Mr. Green; serving a purpose higher than ourselves, making a positive impact in the world, and inspiring future generations.
NORTH CAROLINA CHARLOTTE (704) 372-3040
CLINTON
(910) 592-5776
CONCORD (704) 782-7006
DUNN
(910) 892-0132
GASTONIA
(704) 864-8721
KERNERSVILLE (336) 992-2329
MONROE
(704) 225-8988
MOORESVILLE (704) 799-3444
RALEIGH
(919) 390-7039
"Now, with information at their fingertips, electrical pros at all levels are armed with ever more powerful on-demand IT capabilities. Tasks that used to demand laborious hand calculations or time-consuming diversions to consult hefty code books — and the conveyance of information via face-to-face meetings, phone conversations, and e-mails that are becoming the equivalent of smoke signals as expeditious means of communication — are being sped up and simplified." From apps that help you on the job, to the ones that help you get from here to there ... Here are a few of our favorites!
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THE CIRCUIT SPRING & SUMMER 2016
This app is quick, easy, and accurate.
FLIR Tools Mobile
Sean Rickard
Charlotte, NC location
FLIR Tools Mobile lets professional thermographers use their mobile device to see and capture live,
Electrical Code Tables Electrical Code Tables is an all in one application for NEC code
Stanley Level App
streaming infrared video and stills from select FLIR cameras. With FLIR Tools Mobile the camera
tables. Tables include: Motor FLA,
The STANLEY®’s Level App
NEMA Enclosures, Conductor
for the gives you a portable
Ampacity, Conductor Area,
level in the palm of your hand.
Conduit Area, Minimum Cover,
– highly useful for IR inspections
The app asks you to calibrate
of energized equipment or
your device for the first use.
performing IR surveys in hard-to-
and much more! Great for a quick check in the field or for use in the office. Simple to use and simple
Once completed, the digital
to understand, just electrical code
level is available anytime,
tables!
anywhere. Just like a real level,
Features: NEC 2011 and NEC 2014 selectable code references.
can be stationed in one area and operated wirelessly from another
reach locations and harsh working environments. Streaming video and remote access also gives decision makers and others on
the bubble will indicate when
your team a valuable opportunity
you’re straight. For ease of
to observe and collaborate in the
use, numbers indicate how
thermal imaging process
Step-by-step help section to guide you through the calculation.
close to center you are - the
Features:
Lots and lots of searchable electrical code tables.
farther from 0°, the farther from straight you become.
Import images from your infrared camera
Perfect for a quick reference in the field.
The Stanley level app is very simple. It turns your phone into a level. Once you download
With the app available in two styles, you can choose the look that fits your mood. Pick from
Read out temperature measurements
the classic STANLEY® cherry
Zoom in on images
wood level or the modern
Remotely take snapshots when a camera is connected
yellow FATMAX® Level.
the app, you calibrate the level with a simple procedure that the app will walk you through, then you’re up and running. I first discovered it when looking at some recessed lights for a sloped ceiling in a church. Some recessed fixtures have a slope kit that must be ordered separately and you must specify the degree of slope in the ceiling. I just climbed a ladder stuck my phone on the ceiling and the app worked perfectly, 20 degree slope.
Kyle Murray
Gastonia, NC Location
Lay out and move measurement tools on the image
The digital level makes hanging objects a breeze. For fast projects or unexpected needs, you will always have the level device right in your pocket. Perfect for hanging, building, mounting, creating and more.
On the camera, take snapshots that will automatically be saved on your mobile device Display an image’s GPS coordinates on maps Create and e-mail image sheets and reports Print image sheets and reports to any AirPrint-enabled printer and send images to FTP sites and other file sharing services
THE CIRCUIT SPRING & SUMMER 2016
7
CFE Media's Apps for Engineers CFE Media’s Apps for Engineers is an interactive directory of more than 110 engineering related mobile applications that were created by various companies. This app will help users to do their jobs better and save time, providing a “pre-sort” of relevant mobile engineering applications loaded with various calculators, catalogs, file viewers, measurement tools, and more. Apps for Engineers is useful for engineers working in industrial, automation, manufacturing and building We use Google Earth on a regular basis to determine the usable south facing area of roofs, etc. for solar, issues of shading and taking measurements for potential module capacity Jim Woods
Columbia, SC location
Google Earth
systems industries. Users can sort through the apps by “Category” or “Type,” navigate to a list of apps, view a profile description for each, and link to the App Store to download the app or get more information. The app is designed so engineers can review and post comments about the apps they downloaded.
Southwire SIMpull Solutions Configurator
Fly around the planet with a
Southwire SIMpull Solutions Configurator allows the user
swipe of your finger! Search for
to load a wire feeder schedule following a step by step
cities, places, and businesses.
process that will build paralleled runs with SIMpull heads.
Browse layers including roads, borders, places, photos and more. Visit the Earth Gallery to find exciting maps such as real-time earthquakes, planes in flight, hiking trails, city tours, and more. Features:
The user can then stack like runs or different runs on a reel and see accurate weight and reel size dimensions. If job restrictions limit the size reel on a job, the user can define those restrictions when building their reels. If A Frames and/or a SIMpull Truck is needed on the job, the stack reels can be configured on a SIMpull Truck easily, allowing the user to define the wire payoff direction, and A Frame position on the bed of a trailer, eliminating
Integrated Google Maps Street View allows you to explore the world at street level.
all potential delivery errors. Once the feeder schedule
Use the new “tour guide” to easily discover exciting new places to explore.
to Southwire's system for a seamless quotation or order
Updated directions let you visualize transit, walk, bike and drive directions in 3D while updated search result list will let you browse search results quickly.
is loaded, the entire bill of materials can be submitted placement and provides a visual aid and hard copy for all parties involved in the order and delivery process. This app enhances the communication process of the SIMpull Solutions experience and is one of many great apps provided by Southwire.
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THE CIRCUIT SPRING & SUMMER 2016
Waze
Waze is the best app for directions! It gives you real time updates on traffic and accidents on your route. Jim Shoemaker
Kernersville, SC location
Waze is the world's largest community-based traffic
You can also actively
and navigation app. Join
report accidents, police
drivers in your area who
traps and other hazards
share real-time traffic &
you see on the road.
road info to save time, gas
Get road alerts along
money, and improve daily
your route and find the
commuting for all.
cheapest gas prices
Just by driving with Waze
around you shared by the
open, you're already
community. Plus, you can
contributing tons of real-
add friends, send locations
time traffic information
or keep others posted on
to your local community.
your arrival time.
Features: Live routing based on community driven, real-time traffic & road info Community reported alerts including accidents, hazards, police traps, road closures, and more Turn-by-turn voice guided navigation Live maps, consistently edited and updated by Waze community map editors Automatic rerouting as conditions change on the road Send your ETA & real-time drive to update those you’re meeting Find the cheapest gas station on your route Add information on local places and businesses
LIGHT ON WEIGHT. HEAVY ON SAVINGS. IMC and Kwik-Couple® IMC Switch to Intermediate Metal Conduit and you have a lot to gain. Lower cost and lighter weight than Rigid Steel, IMC can be used for the same applications while saving you money. Save even more with Kwik-Couple® IMC by eliminating the need for separate couplings and reducing the time of installation. There are some savings that can’t be taken lightly. Visit alliedeg.us to learn more.
©2016 Atkore International, Inc. All rights reserved.
Every electrician uses NEC Code App
Leviton 2 Go
the NEC Code Book.
Leviton 2 Go helps electricians,
This is the full book, not
Stay up-to-code with the 2014
contractors and homeowners
just the tables to do the
NFPA 70®: National Electrical
discover and research switches,
calculations like others.
Code! Now you can access the
dimmers, outlets, occupancy sensors, GFCI’s and the entire
Sean Rickard
Charlotte, NC location
Leviton line of products directly
NEC® whenever you need! Adopted in all 50 states, the NEC® is the benchmark for safe electrical design, installation, and inspection
from their mobile device. The
to protect people and property
app simplifies the purchasing
from electrical hazards.
process, enabling all users to search for products through the
The NEC® 2014 Edition app is
app or scan bar codes in-store to
your mobile companion to the code. Browse the articles or search
create a product list that is emailed directly from the mobile device. Users can also scan Leviton or competitor bar codes to generate the corresponding Leviton part number.
I have checked the app against the code book and it is spot on. It is a handy app to have on your hip, especially when you don’t have a code book readily available.”
by keyword, and access important electrical safety news and code development information from the NFPA.
Kyle Murray
Gastonia, NC location
Users will be able to access all product information including instruction sheets, how to videos and product drawings directly from their mobile device. Leviton
Southwire Conduit Fill
Southwire has created this great tool to help
2 Go also keeps customers up-
electricians, engineers and contractors answer the
to-date on the latest information,
question, “What size conduit do I use” per the NEC®,
news and tips from Leviton through push notifications
includes fill percentages and jam probability. If you
and/or directly from the app’s
do not have the NEC book handy or do not want to
“News” button. Other Leviton 2 Go functions include keyword
spend time manually calculating the Conduit Fill %,
searches that will enable users to
this is the right app for you. The app provides quick
find the corresponding Leviton part number, identification of product families or products as “favorites,” and access to the Leviton print catalog in an easy to use intuitive interface.
and easy navigation. Enter the Conduit Type and Size and specify your conductors. The App will calculate the Conduit Fill % as per NEC Guidelines. With one click, you can email your results.
THE CIRCUIT SPRING & SUMMER 2016
“ It’s amazing what the
“
10
Shealy team can do.
THE CIRCUIT SPRING & SUMMER 2016
11
“WE’VE GOT YOU COVERED” A TESTIMONIAL FROM MICHAEL KERNS
M
y experience with Shealy Electrical began in the spring of 2010. At that time I was having trouble with my current supplier’s inability to provide materials to the projects I was managing. Working near Eastover, SC and not knowing many suppliers in the area was a bit daunting also. Al Howell came by for a visit
while I was in the field back in March 2010 and asked if he could help supply our needs. I spoke with Al for some time discussing the Tier1 supplier issues at the site and mentioned that this would be an uphill battle all the way. However, I liked the line card that Al presented and stated to Al that I would give it a try. I spoke with the client’s purchasing department concerning the high quality and the large quantities of materials I regularly require to be successful with our site projects. I also outlined the inability of current suppliers to provide mass quantities at the level of quality which was very critical to my (our) success. I also mentioned that the current supplier had no inventory from which to draft, and that they would not answer the phone on Fridays and weekends. Now, the purchasing agent at the time seemed very aware of the issues and wanted to help us curb the problems. The purchasing agent asked me to obtain three control quotes from each supplier so we could compare pricing and have back up support for shifting suppliers. This is when Al brought Michael George to the site for introduction, and we began listing known common materials and established a Hi-Low matrix in the event Shealy could begin stocking the free issue bins in my warehouse. Free issue is nothing more than a supply room of materials for ease of access thus minimizing downtime. The Shealy quote was well put together and accepted quite readily by purchasing. The other suppliers didn’t even bother to answer the call for quote. Hence, Shealy is now on board as my chief supplier, and this is how we officially met.
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THE CIRCUIT SPRING & SUMMER 2016
Michael Kerns
F
ast forward now to the project in question at Lumberton, North Carolina. Prior to this project, Shealy had supplied me all over the country at my various job sites. Their ability to do this was quite simple. Al and Michael invited me to their warehouse some time ago and presented me with an area of the warehouse that was
then, and I assume now, dedicated to the needs of Zachry. Almost any common material in the electrical trade was in this area, and they would adjust the inventory to accommodate changes in the different sites and their specifications. Outstanding customer relations are what keep us together as a team. No other supplier would even think about doing such for us, and it is much appreciated. Downtime with Shealy as the supplier was unheard of. I must say that if there was a short coming in the supplies, I would likely be the one at fault. I have had so many companies tell me, “I’m not sure I can help you with that.” Not so with Shealy. I can quote John Younginer so many times saying, “We’ve got you covered.” The attitude of the customer’s needs coming first is paramount with John, and you can see this down through the entire Shealy team. Both Al and Michael have been so supportive, and when they didn’t have the answers I would call John, and he would find the answers immediately. At the Lumberton site, we were starting up and had just tied the generator to the main grid. We suffered a catastrophic main buss failure. Of course everyone looked to me to provide any essential supplies to get this repaired and back online. Getting all the guys (Al, Michael, and John) on the phone was the only recourse I had. The materials were identified; Michael and Al took their part and ran with it. John, being so resourceful, was able to get all the buss materials in route that day. It’s amazing what the Shealy team can do. The Lumberton site was so dynamic with changes and discovery work, and there is no way this project could have completed on time without the support of our Shealy team.
Shield_White_2013
THE CIRCUIT SPRING & SUMMER 2016
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13
Version 1.1 – 25 October 2013
WE CARE ABOUT Your timE and we realize that life is more than work. We create customized solutions that save you time and money.
WHERE do you want to be right now? let us help you get there faster.
www.shealyelectrical.com
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THE CIRCUIT SPRING & SUMMER 2016
O F MO T O R F A IL U R E Motors are used everywhere in industrial environments and they are becoming increasingly complex and technical, sometimes making it a challenge to keep them running at peak performance. It’s important to remember that the causes of motor and drive issues are not confined to a single domain of expertise–both mechanical and electrical issues can lead to motor failure–and being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. Article from Fluke Corporation
P OW E R Q UA L I T Y 1.Transient Voltage 2. Voltage Imbalance 3. Harmonic Distortion
VARIABLE FREQUENCY DRIVES
Drive and drive output
4. Reflections on drive output PWM signals 5. Sigma current 6. Operational overloads
M E CHAN I C A L 7. Misalignment 8. Shaft imbalance 9. Shaft looseness 10. Bearing wear
I M P ROP ER I N S T A L L A T I O N 11. Soft foot 12. Pipe strain 13. Shaft voltage
Motor and drive train
THE CIRCUIT SPRING & SUMMER 2016
17
Transient Voltage __________________________________ Transient voltages can come from a number of sources either inside or outside of the plant. Adjacent loads turning on or off, power factor correction capacitor banks or even distant weather can generate transient voltages on distribution systems. These transients, which vary in amplitude and frequency, can erode or cause insulation breakdown in motor windings. Finding the source of these transients can be difficult because of the infrequency of the occurrences and the fact that the symptoms can present themselves in different ways. For example, a transient may appear on control cables that don’t necessarily cause equipment damage directly, but may disrupt operations. Impact: Motor winding insulation breakdown leads to early motor failure and unplanned downtime Instrument to measure and diagnose: Fluke 435-II Three-Phase Power Quality Analyzer Criticality: High
Voltage Imbalance __________________________________ Three-phase distribution systems often serve single-phase loads. An imbalance in impedance or load distribution can contribute to imbalance across all three of the phases. Potential faults may be in the cabling to the motor, the terminations at the motor, and potentially the windings themselves. This imbalance can lead to stresses in each of the phase circuits in a three-phase power system. At the simplest level, all three phases of voltage should always have the same magnitude. Impact: Imbalance creates excessive current flow in one or more phases that then increases operating temperatures–leading to insulation breakdown Instrument to measure and diagnose: Fluke 435-II Three-Phase Power Quality Analyzer Criticality: Medium
Harmonic Distortion _______________________________ Simply stated, harmonics are any unwanted additional source of high frequency AC voltages or currents supplying energy to the motor windings. This additional energy is not used to turn the motor shaft but circulates in the windings and ultimately contributes to internal energy losses. These losses dissipate in the form of heat, which, over time, will deteriorate the insulation capability of the windings. Some harmonic distortion of the current is normal on any part of the system serving electronic loads. To start investigating harmonic distortion, use a power quality analyzer to monitor electrical current levels and temperatures at transformers to be sure that they are not overstressed. Each harmonic has a different acceptable level of distortion, which is defined by standards such as IEEE 519-1992.equipment damage directly, but may disrupt operations. Impact: Decrease in motor efficiency results in added cost and an increase in operating temperatures Instrument to measure and diagnose: Fluke 435-II Three-Phase Power Quality Analyzer Criticality: Medium
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THE CIRCUIT SPRING & SUMMER 2016
Reflections on drive output PWM signals ___________ Variable frequency drives employ a pulse width modulation (PWM) technique to control the output voltage and frequency to a motor. Reflections are generated when there is an impedance mismatch between the source and load. Impedance mismatches can occur as a result of improper installation, improper component selection or equipment degradation over time. In a motor drive circuit, the peak of the reflection could be as high as the DC bus voltage level. Impact: Motor winding insulation breakdown leads to unplanned downtime Instrument to measure and diagnose: Fluke 190-204 ScopeMeter速 fast sampling 4 channel portable oscilloscope, Fluke 1587 Insulation Resistance Tester. Criticality: High
Sigma Current ___________________________________ Sigma currents are essentially stray currents that circulate in a system. The sigma currents are created as a result of the signal frequency, voltage level, capacitance and inductance in conductors. These circulating currents can find their way through protective earth systems causing nuisance tripping or in some cases excess heat in windings. Sigma current can be found in the motor cabling and is the sum of the current of the three phases at any one point in time. In a perfect situation, the sum of the three currents would equal zero. In other words, the return current from the drive would be equal to the current to the drive. Sigma current can also be understood as asymmetrical signals in multiple conductors that can capacitively couple currents into the ground conductor. Impact: Mysterious circuit trip due to protective earth current flow Instrument to measure and diagnose: Fluke 190-204 ScopeMeter isolated 4 channel portable oscilloscope with wide bandwidth (10kHz) current clamp (Fluke i400S or similar). Criticality: Low
Operational Overloads __________________________ Motor overload occurs when a motor is under excessive load. The primary symptoms that accompany a motor overload are excessive current draw, insufficient torque and overheating. Excessive motor heat is a major cause of motor failure. In the case of an overloaded motor individual motor components including bearings, motor windings, and other components may be working fine, but the motor will continue to run hot. For this reason, it makes sense to begin your troubleshooting by checking for motor overload. Because 30 % of motor failures are caused by overloading, it is important to understand how to measure for and identify motor overloading. Impact: Premature wear on motor electrical and mechanical components leading to permanent failure Instrument to measure and diagnose: Fluke Ti400 Infrared Camera, Fluke 289 Digital Multimeter Criticality: High
THE CIRCUIT SPRING & SUMMER 2016
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Misalignment _____________________________________ Misalignment occurs when the motor drive shaft is not in correct alignment with the load, or the component that couples the motor to the load is misaligned. Many professionals believe that a flexible coupling eliminates and compensates for misalignment, but a flexible coupling only protects the coupling from misalignment. Even with a flexible coupling, a misaligned shaft will transmit damaging cyclical forces along the shaft and into the motor, leading to excess wear on the motor and increasing the apparent mechanical load. In addition, misalignment may feed vibration into both the load and the motor drive shaft. There a few types of misalignment: Angular misalignment: shaft centerlines intersect but are not parallel, Parallel
misalignment: shaft centerlines are parallel but not concentric, Compound misalignment: a combination of parallel and angular misalignment. (Note: almost all misalignment is compound misalignment, but practitioners talk about misalignment as the two separate types because it is easier to correct a misalignment by addressing the angular and parallel components separately.) Impact: Premature wear in mechanical drive components that leads to premature failures Instrument to measure and diagnose: Fluke 810 Vibration Tester to identify potential misalignment issues, Fluke 830 Laser Shaft Alignment Tool to diagnose and correct misalignment Criticality: High
Dirt Accumulation _________________________________________________________ Imbalance is a condition of a rotating part where the center of mass does not lie on the axis of rotation. In other words, there is a “heavy spot” somewhere on the rotor. Although you can never completely eliminate motor imbalance, you can identify when it is out of normal range, and take action to rectify the problem. Imbalance can be caused by numerous factors, including: Dirt accumulation, Missing balance weights,
Manufacturing variations, Uneven mass in motor windings and other wear-related factors. A vibration tester or analyzer can help you determine whether or not a rotating machine is in balance. Impact: Premature wear in mechanical drive components that leads to premature failures Instrument to measure and diagnose: Fluke 810 Vibration Tester Criticality: High
Shaft Looseness __________________________________________________________ Looseness occurs when there is excessive clearance between parts. Looseness can occur in several places: • Rotating looseness is caused by excessive clearance between rotating and stationary elements of the machine, such as in a bearing. • Non-rotating looseness happens between two normally stationary parts, such as a foot and a foundation, or a bearing housing and a machine.
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THE CIRCUIT SPRING & SUMMER 2016
As with all other sources of vibration, it is important to know how to identify looseness and resolve the issue to avoid losing money. A vibration tester or analyzer can determine whether or not a rotating machine is suffering from looseness. Impact: Accelerated wear on rotating components resulting in mechanical failure Instrument to measure and diagnose: Fluke 810 Vibration Tester Criticality: High
Bearing Wear_____________________________________________________________ A failed bearing has increased drag, emits more heat, and has lower efficiency because of a mechanical, lubrication, or wear problem. Bearing failure can be caused by several things:
A heavier load than designed for, Inadequate or incorrect lubrication, Ineffective bearing sealing, Shaft misalignment, Incorrect fit, Normal wear, Induced shaft voltages. Once bearing failure begins, it also creates a cascade effect that accelerates motor failure. 13 % of motor failures are caused by bearing failure, and more than 60 % of the mechanical failures in a facility are caused by bearing wear, so learning how to troubleshoot this potential problem is important. Impact: Accelerated wear on rotating components resulting in bearing failure Instrument to measure and diagnose: Fluke 810 Vibration Tester Criticality: High
Soft foot ________________________________________________________________ Soft foot refers to a condition in which the mounting feet of a motor or driven component are not even, or the mounting surface upon which the mounting feet sit is not even. This condition can create a frustrating situation in which tightening the mounting bolts on the feet actually introduces new strains and misalignment. Soft foot is often manifested between two diagonally positioned mounting bolts, similar to the way that an uneven chair or table tends to rock in a diagonal direction. There are two kinds of soft foot: • Parallel soft foot: parallel soft foot occurs when one of the mounting feet sits higher than the other three • Angular soft foot: angular soft foot occurs when one of the mounting feet is not parallel or “normal” to the mounting surface. In both cases, soft foot can be caused either by an irregularity in the machine mounting feet, or in the mounting foundation upon which the feet rest. In either case, any soft foot condition must be discovered and remedied before proper shaft alignment can be achieved. A quality laser alignment tool can typically determine whether or not there is a soft foot problem on a particular rotating machine. Impact: Misalignment of mechanical drive components Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool Criticality: Medium
THE CIRCUIT SPRING & SUMMER 2016
21
Pipe Strain_______________________________________________________________ Pipe strain refers to the condition in which new stresses, strains, and forces, acting on the rest of the equipment and infrastructure transfer backward onto the motor and drive to induce a misalignment condition. The most common example of this is in simple motor/ pump combinations, where something applies force to the pipeworks such as:
A shift in the foundation , A newly installed valve or other component, An object striking, bending, or simply pressing on a pipe, or broken or lack-of pipe hangers or wall-mounting hardware. Those forces can put an angular or offset force on the pump, which in turn causes the motor/pump shaft to be misaligned. For this reason it is important to check machine alignment more than just at the time of installation–precision alignment is a temporary condition that can change over time. Impact: Shaft misalignment and subsequent stresses on rotating components, leading the premature failures. Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool Criticality: Low
Shaft voltage ____________________________________________________________ When motor shaft voltages exceed the insulating capability of the bearing grease, flashover currents to the outer bearing will occur, thereby causing pitting and grooving to the bearing races. The first signs of this problem will be noise and overheating as the bearings begin to lose their original shape and metal fragments mix with the grease and increase bearing friction. This can lead to bearing destruction within a few months of motor operation. Bearing failure is an expensive problem both in terms of motor repair and downtime, so helping to prevent this by measuring shaft voltage and bearing current is an important diagnostic step. Shaft voltage is only present while the motor is energized and rotating. A carbon brush probe attachment allows you to measure shaft voltage while a motor is rotating. Impact: Arcing across bearing surfaces create pitting and fluting resulting in excessive vibration and eventual bearing failure Instrument to measure and diagnose: Fluke-190-204 ScopeMeter isolated 4-channel portable oscilloscope, with AEGIS shaft voltage carbon brush probe. Criticality: High
1. Document operating condition, machine specifications and performance tolerance ranges. 2. Capture and document critical measurements at installation, before and after maintenance and on a routine basis. 3. Create an archive reference of measure ments to facilitate trend analysis and identify change of state conditions. 4. Plot individual measurements to establish a baseline trend. Any change in trend line of more than +/- 10 % to 20 % (or any other % determined, based on your system performance or criticality) should be investigated to root cause to understand why the issue is occurring.
THE CIRCUIT SPRING & SUMMER 2016
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Conduct a post-mortem after every major scheduled and unscheduled event to avoid repeating the same organizational and fundamental mistakes.
M
any organizations spend millions on
readable report that shows what you learned (both
shutdowns and not a penny on learning
positive and negative, and always constructive) and
what there is to learn and preserving it
how to avoid problems.
for future shutdown teams. Remember
what Winston Churchill said, (although not in reference
Timing
to shutdowns): “Those who do not study history are
Most post-mortem activities should wait for 30 to
doomed to repeat it.”
90 days. People just completing a shutdown are
We must preserve lessons learned or we are doomed to
to get back to their lives. A second reason to wait
repeat the same mistakes. The fastest way to develop
is to try to allow some emotional space to develop.
your organizational muscle in shutdowns is to conduct
Post-mortems go more smoothly if no one feels
a post-mortem after every major scheduled and
defensive or blamed for mistakes.
usually tired, frequently upset, and need some time
unscheduled event. There are some post-mortem activities that can You’ll learn:
and should be done during the last few days of the
What worked well and should be repeated
actual shutdown. Specifically, you want to interview
Where problems occurred, which can be used to
key contractor personnel before they leave the
initiate problem-solving sessions if the problems
site and go to their next job. Ask them to name
were not solved during the event
three things that worked for them and three things
Who needs more training before the next shutdown
that did not work for them from this shutdown. If
What to include in the checklist to make future
possible, ask someone not directly involved in the
shutdowns more successful.
shutdown to conduct these interviews. This person will be more likely to be a neutral party who can
The shutdown post-mortem is a series of document
effectively capture the lessons learned without
reviews and meetings with the endpoint being an easily
being defensive.
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THE CIRCUIT SPRING & SUMMER 2016
www.sylvania.com
those who do not study history are doomed to Preparing for the post-mortem In preparation for post-mortem meetings and report-writing, team members should refresh their memory of what actually happened by reviewing the shutdown documents: Any scope documents, mission statements and estimated budgets generated by top management The list of jobs (It’s important to keep this because it will save you time when you do another shutdown in the same area.) Minutes and personal notes from shutdown meetings Closed work orders with materials used, labor expended, other resources used, and closing comments (These should be entered into CMMS and become part of the unit histories.) Contract documents, contractor lists and any completed evaluations. (This usually includes reviewing the main contracts and interviewing someone from Purchasing.) Schedules, schedule compliance reports and minutes from compliance meetings. These can be put into a book form to make them easy to review.
SYLVANIA ULTRA LEDTM PAR HO first to market with highest lumen at lowest wattage package.
Get the project team together and discuss the shutdown
— Great replacement for high power halogen & HID lamps
write what were the lessons learned with references to the minutes from the meetings
— Save time & money — Reduce maintenance & energy costs
Contact your SYLVANIA Sales Representative for more details.
Have an initial meeting and generally discuss what worked and what did not work. Keep meeting minutes from this whole process. Assign one person or small teams to and to source documents where that is appropriate. Remember to be alert for both negative lessons (things to avoid or remember) and positive lessons (things to make sure you repeat). Here are ideas for areas to discuss in the subsequent post-mortem meetings. Subgroups could be assigned related topics. What worked and what didn’t work? Did the shutdown policies impact the shutdown for better or worse? Did the shutdown meet Operations’ needs and expectations? Be specific.
© 2016 SYLVANIA Inc. SYLVANIA is a registered trademark
Considering the activities of engineering, what happened? Considering the activities of planning and scheduling, what happened?
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How much did the shutdown change between the time it started and when it finished? How close were the budget and the baseline schedule? What worked and did not work about communications? What worked and did not work about the shutdown team allocation of responsibilities? What techniques or technologies helped this shutdown? Which ones should we drop in the future?
- Work scope
- Cost performance
- Shifts and work schedule
- Work completed compared to work scheduled - Scheduling compliance
- Safety and environmental compliance - Contractor performance - Vendor performance
Writing the report Start with a one-page summary that includes an executive summary of the shutdown, KPIs measuring shutdown performance, and a summary of recommendations for future shutdowns. Suggestions for chapters in a shutdown report include: Environmental, safety and health issues including accidents, near misses, issues with permits, PPE Issues with start-up and shutdown Completeness, accuracy and usefulness of engineering Effectiveness of job planning and scheduling. Work assignments, including a review of assignments, resource issues and execution issues. Schedule compliance including schedule breaks, logistics issues, and mobile equipment issues.
- Was everything done that was supposed to be completed? - Added work
- Emergent work (how could we have known in advance?) Support from outside
- Contractor performance, quality, cooperation
- Vendor performance, quality and accuracy, cooperation Site logistics, stores, rentals, delays and excessive waiting time Any specific things that caused delays Any specific things that really worked well and should be repeated.
To get better at shutdowns the results of your post-mortem have to be accessible to future shutdown team members. Make sure your lessons-learned document is updated, supplemented,read and discussed before every shutdown. In fact, the first activity of every shutdown should be to review this document. Joel Levitt is the director of international projects with Life Cycle Engineering (LCE). Levitt can be reached at jlevitt@LCE.com.
CAMPBELL UNIVERSITY
GORE ARENA LIGHTING UPGRADE PROJECT PROFILE
OVERVIEW Campbell University is a historic but progressive school situated in rural Buies Creek, NC. While most attention is given to their larger university neighbors in the Research Triangle Park, Campbell has consistently grown over the years and is currently in the process of launching a new school of engineering. This, just three years after opening the Jerry M. Wallace School of Osteopathic Medicine, the first new medical school in North Carolina in thirty-five years. Campbell has also received national recognition for their sports programs as a member of the NCAA Division 1 Big South Conference. In 2015, Campbell was notified by the BSC that they would be hosting the 2016 men’s basketball tournament. And, they would be evaluated as a possible host for the next 3 years.
THE CIRCUIT SPRING & SUMMER 2016
29
- ARTICLE AND PICTURES BY JOHN PEELE, DUNN NC LOCATION
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THE CIRCUIT SPRING & SUMMER 2016
G
ore Arena, the
to reduce power consumption
To expedite the installation, the
home of Campbell
and utilize newer technology
project was divided into two
basketball, was
that would make the arena a
phases. Phase I involved just the
opened in 2008.
real showplace for all of the
court lighting and Phase II will
The court area was lit with 48
fans attending the game and
include the seating area, controls
1000W metal halide sports
watching live on ESPN.
and an option for color. Phase II
fixtures with an additional 48 1000W metal halide fixtures to indirectly light the seating area. Obviously, this lighting was using an enormous amount of energy as well as producing a huge amount of heat. In addition, the control system was out of date and the manufacturer was not supporting the system any more. With the conference tournament just four months away, the administration at Campbell approached Shealy to provide a turn-key solution to upgrade the lighting in the facility to LED technology. The two main factors behind this upgrade were
will be done in the summer. The following issues were raised by Campbell University:
Shealy engaged with Ephesus Lighting to design a lighting
Lighting must meet ESPN/
layout to meet the needs of
NCAA Tournament play
the ESPN/NCAA requirements.
lighting requirements
The system utilized a total of 38 Ephesus Arena Series light
Installation of new lights
engines in 600W, 300W, and
must be completed before
190W configuration. The lights
March to accomodate
were prewired with DXM ports
the Big South basketball
for individual control functions
tournament
to be added later.
Installation must take
For installation of the lighting,
place during regular
Shealy contracted a licensed
basketball season and may
electrical contractor with
require working around the
experience in indoor sports
team's practice and game
lighting. Ephesus required that
schedule
an Environmental Potentials
THE CIRCUIT SPRING & SUMMER 2016
EP2000 be installed in the electrical panels. The EP2000 uses waveform correction technology to protect the electronic circuitry in LED fixtures from surges and also filters out unwanted “noise” on the incoming power. The fixtures arrived ahead of schedule during the first week of January. Due to the early arrival, the contractor was able to schedule the installation during a week when both the men’s and women’s basketball teams had away games and practice could be held in another facility.
BEFORE
At 6am on January 20, the Campbell facilities electrical team began removal of the old lighting while the contractor began installing the mounting brackets for fixtures. By 3:30pm, the LEDs were aimed and the switch was flipped to turn them on. After some final aiming adjustments, the
installation of Phase I was complete….in ONE DAY. Campbell played their first game under the new LED lights the following week. As a result of this upgrade, Campbell is realizing a 65% energy savings worth $20,500 annually.
AFTER
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THE CIRCUIT SPRING & SUMMER 2016
LED RETROFITS from
GET UP TO 60% ENERGY SAVINGS AND SAVE ON INSTALLATION
THE CIRCUIT SPRING & SUMMER 2016
Designed for Quick and Simple Installation Powerful rare earth magnets (pictured to the right) allow hands-free installation. Now, in less than the time needed to change a ballast, you can convert your existing fixture into energy-saving LED that lasts up to 20 years!
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THE CIRCUIT SPRING & SUMMER 2016
INSTALL IN 3 MINUTES OR LESS 1 Turn off the power. Remove the existing fluorescent tubes.
3 With the magnets facing the housing, place LED RetroFit into position; it will attach magnetically. Align as needed.
5 Attach the quick connect to the incoming electrical line.
7 Cover the disconnect wires, and the electrical connection with the provided magnetic junction box cover.
9 Apply both included labels to the fixture. Restore the power and you are done.
2 Remove ballast cover and disconnect the ballast.
4 Secure with two of the self-tapping screws diagonally, in opposite corners.
6 Connect both ends of the quick connects securely.
8 Secure with the remaining two small self-tapping screws.
THE CIRCUIT SPRING & SUMMER 2016
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Litetronics® Adds Two New 2x2 Models to its State-of-the-Art LED Retrofit Family - Allowing Easy Conversion from Linear Fluorescent Troffers to LED Litetronics® 2x2-ft LED Retrofit Kit delivers superior energy savings and operating life compared to linear fluorescents. It provides the evenly distributed, flicker-free luminous white-light output sought for today’s office and other commercial buildings, retail stores, manufacturing plants, medical facilities, schools and warehouses, for professional specification and installation. A single Litetronics® three-lamp 2x2-ft LED Retrofit Kit consuming a mere 32 total watts, replaces typical U-shape linear fluorescent T8 lamp systems using 56 - 60 watts, while matching lumen output and light distribution. With a rated operating life of 85,000 hours per Litetronics® unit, facility owners and operators enjoy near 50% energy savings or more compared to T8 U-shape linear fluorescents, throughout more years of use. Litetronics® 2x2-ft LED Retrofit Kit is UL listed, DLC recognized and backed by a 7-year factory warranty. Installation of the Litetronics® 2x2-ft LED Retrofit Kit is swift (three minutes typical retrofit, start to finish) and easy. It greatly reduces labor cost of complete fixture replacements or other LED retrofit kits. After removing lamps, ballast cover and ballast, Litetronics® one-piece 2x2-ft LED Retrofit Kit literally pops securely into the existing troffer housing. It is permanently held in place with Litetronics® patent-pending “rare-earth” magnetized system, allowing a hands-free completion of installation and connection. Litetronics® 2x2-ft LED Retrofit Kit takes the guesswork out of fluorescent troffer retrofitting for professional lighting specifiers, lighting distributors and contractors alike. This 2x2-ft LED Retrofit Kit is a completely autonomous one-piece unit, suited for 120v to 277v systems. It avoids all time and costs of removing and recycling perfectly good ceiling fluorescenttroffer housings. The Litetronics® Retrofit unit is UL and DLC (Design Light Consortium) listed, RoHS compliant and available in 3500K, 4000K or 5000K color temperatures.
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THE CIRCUIT SPRING & SUMMER 2016
discover the EP solution for internal power pollution
& learn why legacy solutions do not work
Just 50 years ago the biggest threat to electrical equipment was catastrophic surge events. Now, equipment is smaller, faster and extremely sophisticated. Computerized, digital and electronic equipment all generate high frequency noise. This noise is responsible for ballast failures, equipment malfunctions, nuisance tripping of breakers and VFDs and shortened asset lifecycles. Approximately 85% of power pollution is generated inside facilities in the form of A1 & B3 ring waves. Environmental Potentials developed a product capable of dealing with this 21st century problem. Standard surge testing does not reveal how a product combats the threat of internally generated noise. A real test of how a device can protect sophisticated equipment is how well that device deals with A1 and B3 Ring Waves.
THE CIRCUIT SPRING & SUMMER 2016
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- ARTICLE BY JIM SHOEMAKER, KERNERSVILLE NC LOCATION
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THE CIRCUIT SPRING & SUMMER 2016
Figure 1: An A1 ring wave at 180 degrees. The green line represents EP. The blue line represents Cutler Hammer and the yellow line represents Psytronics. The higher the line goes the more danger there is to equipment.
Figure 2: A B3 ring wave at 180 degrees. Notice the yellow and blue lines go above 1200V on both the positive and negative half cycle. This dangerous energy goes directly to expensive electrical equipment.
Let through voltage is the amount voltage let through
as noise. Every other company focuses on protecting
EPcompetitors let through enough voltage to cause
not the 85% of the surges that disrupt the production
the device and into the electrical system. Both of the
equipment malfunctions, waste energy and shorten the asset lifecycle.
from only the 15% of catastrophic surge events and process.
Environmental Potentials’ patented waveform
Protect your LED investment
that protects facilities from the 15% of external threats
has revolutionized power quality for the past 15 years.
correction technology is the only technology available
with this patented waveform correction technology that
such as lightning and the 85% of internal threats such
Previously, power quality devices focused on protecting
THE CIRCUIT SPRING & SUMMER 2016
equipment from extreme events. Extreme events were
defined as more than 20% above or below the peaks of
the sine wave. These extreme events are created by events
such as lightning, utility switching, transformer failure, large
faults and the Environmental Potentials’ waveform correction technology will remove electrical noise and suppress voltage transients.
However, the proliferation of electronics, computers and digital equipment is creating pollution on the waveform which rarely, if ever, exceeds the 20% “envelope”. The
processes of rectifying AC to DC, and inverting DC to AC, are responsible for generating 85% of power pollution.
Environmental Potentials patented waveform correction
technology focuses on tracking the waveform and filtering all of the pollution generated by continuous power
conversion. Environmental Potentials converts this pollution
into heat within the unit rather than relying on ground, other system conductors, or even loads to provide the required attenuation. This eliminates harmful and unusable energy from your system. Installing EP ensures the waveform
delivered to your high dollar business process assets is as sinusoidal as possible.
For more information, contact Jim Shoemaker, Lighting and Automation Specialist - jshoemaker@shealyelectrical.com
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THE CIRCUIT SPRING & SUMMER 2016
NO NEW CABLING OR MAJOR SHUTDOWN REQURED U P G R A D E , I N T E G R AT E & M I G R AT E TO I N D U S T R I A L E T H E R N E T N E T W O R K S
ethernet networks over existing wire
S
healy now carries PCN High-Performance Industrial Ethernet Upgrade Products for Factory, Oil & Gas, Energy and other Industrial IP network upgrade applications. PCN Technology Inc. (PCN); is a leading communications technology and products
company that designs, manufactures and markets Industrial Internet connectivity products that meet the needs of automation & control engineers. Designed for the most demanding applications, PCN products are focused on repurposing some, part or all of a legacy serial infrastructure; not just providing a point solution. PCN products allow the repurposing of existing automation copper to operate as high-speed multi-drop infrastructures. PCN products support multi-drop, peer to peer, and other point to multi-point topologies over thousands of feet. Each PCN product also comes equipped with an integrated 4-port Ethernet switch eliminating the need for additional IT equipment costs. All PCN products boot-up at power and begin working. No software or configuration is required.
THE CIRCUIT SPRING & SUMMER 2016
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PCN offers a suite of products to meet the needs of customers including “migration” products that allow customers to operate both serial and IP networks simultaneously, but independently, on the same wiring. This allows customers trying to break free from proprietary or legacy serial networks and allows them to begin to move into industrial Ethernet without completely shutting down serial operations. Additional PCN products completely repurpose the legacy serial cabling into industrial Ethernet network infrastructure allowing customers to rapidly reuse the existing copper as if they had run thousands of feet of multi-drop structured cabling. They can then immediately deploy their state of the art preferred industrial Ethernet equipment from their favorite supplier. PCN products have been used in: • Factory Automation & Control • Process Automation & Control • Oil & Gas Facilities • Chemical Plants • Grain Facilities • Solar & Wind Energy Farms • Transportation Systems • And more… - ARTICLE BY DANIEL DROLET, EVP OF PCN
For industrial applications such
as manufacturing facilities, oil and gas refineries, etc.; it can be both costly and complex to deploy ethernet networks when having to effectively rip out and replace the legacy wiring infrastructure. To do so requires tremendous capital expense, planning, prolonged interruption to operations and the risky prospect of revenue impact. These factors all contribute to the likelihood of not having the needed budget, mounting concerns about dealing with unplanned surprises and ultimately pushing out the project’s implementation – ultimately losing business competitiveness by delaying the move from old technology to a new Industrial Internet enabled network. PCN products provide industrial network operators with the capability of repurposing their existing wiring to facilitate the accelerated deployment of Industrial Internet networks by simply reusing all of the existing cabling currently in operation. With over 35,000 products installed to date in the most adverse of environments, PCN continues to demonstrate its leadership in Industrial Ethernet technologies. For more information, contact Terry Hudson, Automation Specialist - thudson@shealyelectrical.com
IN THE FROM OUR LIGHTING & CONTROL SEGMENT LED technology has transformed the lighting industry ... it has emerged over the past 5 or so years to deliver incredible energy savings, much longer life than traditional technology, and high quality deliverable lumens. Legislation, code changes, utility/tax deduction incentives, and lower LED prices all have helped entrench LED technology as lighting source of the future. The US general lighting industry is an almost $14b market of thich almost $11b (or 75%) are fixtures. The remaining market consists of $2.4b in light source replacements and $.6b in lighting controls. McKinsey forcasts the overall lighting fixture market to grow 13% from 2016-2020. With our top tier LED vendor alignments in place, combined
THE CIRCUIT SPRING & SUMMER 2016
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with our value add services, Shealy Electrical is well positioned
reach locations where re-lamping is difficult and costly. The fixture
to support our customers with lighting design, energy audits,
is ideal for industrial sites that require frequent wash-downs, car
savings & ROI analysis (to include any utility and/or tax deduction
washes, tunnels and stairwells. SHARK comes in two sizes: 2' version
incentives)."
available in 18 and 25 Watts, 4' version available in 36 and 50 Watts.
utility & tax deduction incentives Don't leave money on the table - Help your customer capture lighting rebates. In the Carolinas, the largest utility companies are Duke Energy, Duke Progress and SCE&G. All three offer rebates to customers who upgrade existing lighting to energy efficient lighting. Qualifying measures include T8 and T5 lamps/fixtures, interior and exterior LED fixtures and lighting controls. For Duke Energy customers, new construction projects can qualify for a rebate when LED 2x4 panel fixtures and occupancy sensors are installed. Incentive programs can help offset up front cost, shorten payback time and increase overall energy savings. Federal lighting project tax deductions have been renewed through December of 2016. Most customers can take advantage of a tax deduction (EPACT 179D) of up to $.60/sq foot, once qualifying events occur. Call Shealy Electrical's lighting specialist team for support in processing utility incentives and the tax deductions, if applicable.
product highlight interior
protect your led investment Environmental Potentials patented waveform correction technology has revolutionized power quality for the past 17 years. Previously, power quality and surge protective devices focused on protecting equipment from extreme events. These extreme events are lightning, utility switching, transformer failure, and large faults. SPD's simply react after an event and then try clamp the voltage peak, unfortunately the initial voltage rise has already caused damage. EP's patented Waveform technology is the only device that attacks a voltage spike or surge as it begins to rise, it then slows that voltage rise and absorbs the energy without shunting it to the ground or neutral of the power system. EP's waveform
Over 50% of exterior lighting applications are now changing
correction technology also absorbs and removes high frequency
over to LED technology ... whether it's an existing retrofit or a new
noise by giving it a termination point and converting it to heat. This
application. Pole lights, wall packs, flood lights, canopies and
will provide conditioned and transient free power to $1500 (EP200
parking garages, all with up to 75% energy saving possibilities and
device) investment be installed on every lighting panel after any
more if integral controls are used. Most 'traditional technology'
LED project retrofit. RESULT - Dramatic reduction in LED Failures.
exterior lighting has a life rating from 10-20,000 hours where it's LED replacement can last up to 100,000 hours ... saving on maintenance costs. This cost savings can sometimes be greater than the energy savings enjoyed in the wattage change itself. Another benefit of LED exterior lighting is the improved perception of increased security and safety due to the quality of light placed where you want it, and typically with increased foot candles. Call Shealy Electrical today for help in your exterior lighting design needs.
exterior led RAB Lighting introduces SHARK, a high efficiency, impactresistant and watertight linear LED fixture. SHARK provides a maintenance-free alternative to fluorescent lighting in hard-to-
takeaway of the day ...
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THE CIRCUIT SPRING & SUMMER 2016
LIMIT SWITCHES ENTER THE WIRELESS ERA
Telemecanique Sensors unveils OsiSense XCKW, a powerful new wireless and battery-less limit switch THE OSISENSE XCKW RANGE SAVES CUSTOMERS TIME AND MONEY BY ELIMINATING CABLING
T
he new OsiSense XCKW range from Telemecanique Sensors brings easy connectivity to machine configurations where cabling is difficult, expensive, or unwanted. The range of wireless, battery-less limit switches is designed to serve a vast number of industries,
from hoisting, elevators and escalators to mills, foundries, process machinery, and handling & packaging. The new limit switch range is offered in out-of-the-box compatible packs comprising an OsiSense XCKW limit switch and a receiver. Simplified, cost-effective installation and maintenance OsiSense XCKW limit switches simplify machine connectivity. Planning a wireless machine solution doesn't involve cables, which significantly reduces the cost of the system. Furthermore, a wireless solution doesn't use contacts, so maintenance costs are also reduced. OsiSense XCKW switches come in a plug-and-play kit, so only electro-mechanical skills are needed to install it. It's equally easy to replace an earlier-generation limit switch because the OsiSense XCKW is 100% compatible with XCKS & XCKM switches. Long-distance communication OsiSense XCKW has a wireless range of up to 100 m. The range can be doubled using an active antenna, also offered by Schneider Electric. Energy efficiency and environmentally friendliness OsiSense XCKW is self-powered, so there is no need to worry about battery replacement or battery recycling costs. Schneider Electric’s optimised design and production process has also reduced the amount of raw material used per device, making it even more environmentally friendly.
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IN SHEALY NEWS
Take a look at what is going on within the company. More company and product news can be found on our facebook page and at www.shealyelectrical.com/resources/news
southwire blitz spring 2016 travels through nc and sc In March we hit the ground running with Southwire and their team, bringing along two trailers filled with the latest and greatest in labor savings Maxis Products. We saw over 30 different customers at different jobsites and shops in North and South Carolina. Southwire offers a large range of labor savings and jobsite safety products that help you get the job done quicker and safer. If you missed it and want to see the Southwire Trailer, talk to your Account Manager to set something up or look for our next blitz in Fall 2016!
SHealy electrical makes donation for sc flood relief and REbuild Shealy Electrical donates $40,000 to the Central South Carolina Habitat for Humanity. This donation is ear-marked for Flood Relief rebuilding in the midlands. Many families are not receiving enough insurance and FEMA to cover the cost of rebuilding their homes. Shealy Electrical held ‘jeans days’ and sold special edition flood relief T-shirts to raise money. Also a friendly out-of-state electrical distributor (that prefers to remain anonymous) donated $10,000 toward the cause.
Pictured from left to right: Talisha Beha - Volunteer Projects Manager | Roy Kramer - Executive Director Bill DeLoche - Shealy Electrical Wholesalers CEO | David White - Shealy Electrical Wholesalers President Karen McLeod - PluggedIn Committee Administrator
Shealy Electrical has a special relationship with Habitat and we are confident they will be able to maximize our gift to have the most impact.
SUPER
CAPACITOR Meet THE new "solutions Arm" of Shealy Electrical
shealy strategic solutions Q What is Shealy Strategic Solutions?
Shealy Electrical continues to add solutions to grow our industrial markets in the Carolinas. Shealy Strategic Solutions provides OEM/Direct spend customers an array of services and products to handle their complex manufacturing and assembly operations. Our focus is to understand what is important to our customers and identify their supply chain headaches. We are not trying to sell products but understand the customer’s challenges and needs. By conducting customer interviews and assembly line tours, we gather necessary information about their supply chain operations and specific challenges. Once identified, we work with the customer to provide creative solutions that help eliminate headaches while reducing overall cost.
Q What are examples of some customer “headaches” you have encountered? Headaches vary depending on the person we are interviewing and their role within the organization. OEM purchasing professionals often spend 80% of their time and resources managing 20% of overall spend. This is due to the large number of suppliers and transactions they are tasked to manage. With the wide range of both electrical and non-electrical products we offer, we help our customers with reduction in transactional cost, supplier consolidation and inventory reduction. Single handedly eliminate the need to reprogram or replace batteries! Remain unstoppable in the event of a power outage. The supercapacitor in our new ET Basic+ Series Electronic Controls makes you a super hero by easily maintaining the scheduling of a facility’s interior and exterior lighting, plus other load-bearing equipment like bell ringing, water features, signage, and more. Better control at a better price. Find out more at Intermatic.com/ET2000
Connect with us
Logistics managers are challenged with providing component parts to the assembly line at the precise time parts are needed. When managing hundreds and sometimes thousands of vendors, this can become a daunting task. Smaller spend suppliers can create the largest challenges for OEM’S because the vendor’s spend doesn’t afford the same level of service some larger vendors provide. By consolidating several of these vendors, we are able to elevate the level of services to surpass that of larger spend suppliers. Production managers are tasked with efficiently producing product at the pace their customers demand. Non-value added assembly tasks can erode production efficiencies and tie up valuable manufacturing space and resources. By outsourcing these non-value added assemblies to SSS, the customers can reallocate space and resources for additional production throughout. In addition, SSS manages all the vendors and components necessary to build the assembly providing additional value for purchasing and logistics.
Q How will you work with current Shealy customers? We will work with existing Shealy account managers to identify potential OEM/Direct Spend opportunities at both current and new customers within their service area. Utilizing their strong working relationships where they are providing MRO solutions, account managers will reach out to direct spend personnel in purchasing, logistics and production to set up assembly line tours and plant interviews with the SSS team. We are here to broaden Shealy’s service offering at the OEM/Direct Spend customers while making the overall experience seamless.
THE CIRCUIT SPRING & SUMMER 2016
are some of the services that Q What Shealy Strategic Solutions offers? Vendor managed inventory: These programs leverage the strengths of lean organizations and eliminate waste associated with detail forecasting and scheduling processes. Just in Time: The just in time inventory model allows companies to reduce their overhead expenses while insuring that parts are available to manufacturer their products. Third party logistics: These services can include warehousing, transactional and transportation solutions for items in which the customer prefers to maintain ownership. Vendor consolidation: Vendor consolidation reduces an OEM’S point of contact. Rather than managing dozens or even hundreds of vendor relationships, they can narrow the field to just a few. Those vendors become more than simple suppliers or service providers; they become partners. Kitting: The process of kitting is often used in manufacturing as a way of reducing material handling and processing time. Assembly/Pre-Assembly: By outsourcing non-value added assemblies the customers can reallocate space and resources for additional production throughout. This also facilitates supplier consolidation and inventory reduction.
Q Tell us about your team. Mark Gamble – Mark is SVP of Shealy Strategic Solutions. He is a UNCC graduate. He started out in the warehouse for a national distributor and moved to inside and outside sales. He became branch manager in 1990 in Charlotte. In 1996 he became a district manager and had 6 branches in the Carolinas. In 1998 the district started focusing on OEM solutions. Mark joined
47
Shealy in 2015 and is leading the team at Shealy Strategic Solutions. He is responsible for and developing the strategy and initiatives of this segment. Paul Hearn - Paul graduated from the University of Houston and worked for a national MRO integrator based in Houston, Texas for 10 years. He joined up with Mark in 2000 and helped advance the OEM services in the Carolinas. He came to Shealy late last year. Paul’s title is Director of Operations but has a dual role of sales and operations. Paul and Mark work together to find opportunities and develop solutions. Both Paul and Mark also work on developing the supplier base that is outside the typical electrical distributor field. That is an important piece of this operation. Tyler Klein – Tyler worked for 9 years as a project manager on assemblies and engineered products for his previous employer's largest customer. He was an integral part in growing the OEM business model at this customer. Tyler will be in outside sales for Shealy Strategic Solutions and is working to generate opportunities in the OEM marketplace. He also may be used in the MRO world. Madison Hammel – Madison’s background started in the training program at the same national electrical wholesaler. He moved to inside sales in Asheville handling the largest customer in the branch. He briefly went into outside sales in the Asheville market and has now moved to Charlotte to join Tyler in outside sales for Shealy Strategic Solutions.
Mark Gamble
Paul Hearn
Madison Hammel
Tyler Klein
Tanner Reische– Tanner’s responsibility is to create a seamless data interface between SSS and our OEM customers. In addition, he works on internal processes to make sure we are running as efficiently and error free as possible. We call him our “Secret Weapon.” Tanner Reische
THURSDAY, MAY 5TH SPRINGHILL SUITES 511 LADY STREET, COLUMBIA, SC 29201
CLEAR YOUR CALENDAR - RESERVE YOUR SESSIONS NOW! THIS SHEALY ELECTRICAL EXPO KICKS OFF ON THURSDAY, MAY 5TH IN COLUMBIA, SC AND YOU’RE INVITED TO TAKE PART IN THE EXTENSIVE LEARNING EXPERIENCE!
Join us as we shed light on leading edge technology that will empower your business! Learn more about LED and energy efficient lighting, the safest and most efficient ways to run your facility, and the latest trends in clean energy practices! Choose from 3 different seminar sessions per hour! Stick with the same subject focus, or mix it up between Lighting, Industrial, or Solar/Clean Energy topics. There are only 50 seats available per session, so be sure to reserve your spot ASAP!
8:30AM until 9:30AM SESSIONS
The State of Solar
Grounding Systems in Your Facility
Protect Your LED Investment/Shealy Solutions
Christian Siebens - Backup Power Source
Albert Honan - Power Consultant Specialist - Schneider Electric
Darrin Leroy - Power Quality Specialist | Bill Hurd - Shealy SVP
Energy Storage and Microgrids The electric utility industry is now transitioning into a model that will change how we use energy. This session will introduce you to Solar Energy, Energy Storage and other Clean Energy Solutions that are shaping our future energy landscape.
How to Install, Maintain & Troubleshoot
Is your facility properly grounded and how do you know? What options do you have to identify, troubleshoot and upgrade your grounding system? Is a high resistance grounding system right for you? Find out all of these things in this session.
Power Quality Issues/Shealy Lighting Support We will discuss the effects of high efficiency noise and transients on LED technology and how you can protect that technology. Learn how you can add value to your projects through lighting audits, LED and controls product options, and financial payback analysis.
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9:30AM until 10:30AM SESSIONS
South Carolina’s Solar Programs
Industrial Control Panel Standards
EnergyWise for Your Business
John Raftery - SCE&G | Emily Felt - Duke Energy
Tom Fowler - Product Launch & Business Development, Schneider
Bruce Helwig - SCE&G | Randy Lucas - Tax & Energy Consultant
Incentives from the Utility Perspective You’ll get a clear understanding of available solar programs and incentives, as well as solar system payback potential from our state’s Investor Owner Utilities.
Control Panel Design & Electrical Standards
Learn about the new electrical standards and industry trends that impact the layout of control panels. There’s a transition underway regarding UL 508 of which customers and control panel builders should be aware: UL 508 will soon be phased out and replaced by UL 60947-4-1.
Energy Efficient Tax & Utility Incentives
An update on the available Federal tax incentives for energy efficiency projects, and an update from SCE&G’s ‘EnergyWise for Your Business’ incentive program. Learn how to take advantage of these incentives and apply them to a specific project.
10:30AM until 11:30AM SESSIONS
Electric Vehicle Charging Stations
Switchgear Solutions & Upgrades
LED - Bridging Technology
David Lenoir - Leviton Manufacturing
Rich Hicks - Southeast Services Manager, Schneider Electric
Rick Gottlieb - LED Product Innovation - Cooper Lighting
For the Workplace and Home
As Electric Vehicles (EV) become more prevalent in our world, we’ll address the question: Why should I consider and EV Charging Station for my workplace or home and what’s in it for me?
Increase the Life of Your Switchgear
Maintaining aging switchgear in a facility is a common one. Upgrading and maintaining the switchgear to keep it current with the ever-evolving National Electric Code can only add to the complication. Upgrading to new gear may not be a viable option. We will go over your options.
Past, Present, and Future
New technologies and advancements result in major changes in the lighting industry, and keeping pace is becoming more difficult. This course focuses on market shifts as well as some of the most significant new technologies in the lighting industry. This presentation is AIA accredited.
11:30AM until 12:30PM SESSIONS
The Business Side of Solar PV
Arc Flash - Start an Effective Program
LED and Controls
Roger Locke - SolarWorld
Albert Honan - Power Consultant Specialist, Schneider
Erik Feus & David Feus | Controls Engineers
Solar’s Affect on a Company’s Bottom Line Whether you’re a contractor that needs to grow your business, or a commerical customer looking to reduce cost, we will explore how solar can make your company more money.
Maintaining a Program in Your Facility
This seminar gives an overview of NFPA70E code on Arc-Flash and an overview of the requirements, will outline a path on how to get started, and what needs to be considered to get a safe and successful plan implemented in your facility.
Compatibility Issues
Learn about the variety of ways to control LED lighting, the importance of the NEMA410-2011 specification for LED drivers, and how you can use what you learned to eliminate costly call backs.
RESERVE YOUR SESSIONS AT WWW.ENERGYEXPO.SPLASHTHAT.COM
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THE CIRCUIT SPRING & SUMMER 2016
DOWNTOWN CHARLESTON LOCATION MOVES! Shealy Electrical Wholesalers is pleased to announce their move to a new location in downtown Charleston at 1553 King Street Extension – Suite B. Shealy Electrical Wholesalers is pleased to announce their move to a new location in downtown Charleston at 1553 King Street Extension – Suite B. Shealy moved the downtown location for two primary reasons….the old location was not going to be viable long term due to the eventual sale of the property and the location did not have adequate parking for the amount of customers and amount of business Shealy was experiencing. The old location was built around 2000 and it operated as an independent electrical supply house until 2011, when Shealy purchased the location to further service the growing Charleston market. The Ladson store is located 25 miles away from downtown Charleston, so purchasing the downtown location made sense to help serve the entire Charleston market. The old location was a very problematic building. It was two-story and in effect Shealy was only utilizing about 3000 square feet. – basically, just the first floor. The new facility is 9000 square feet total. There is an abundance of parking and increased lay down yard area for our pipe. Racking was also added to handle 130150 pallets of material for jobsite storage solutions. Since the downtown area has such a storage problem on jobsites due to the closeness of everything, the storage solutions will be a viable option for many of Shealy’s customers. The new location will have three full-time associates on staff. Charlie Reid will be the site manager, along with the help of two other associates. We will be reintroducing deliveries at this location to help our customers manage their time better. Shealy’s inventory will be doubling, reintroducing the deliveries thru a van service. Having three associates man the facility will greatly increase service to customers. Most of Shealy’s customers do and will continue to work in downtown Charleston as the entire area continues to grow. Thanks to the new location, Shealy will be able to provide better service and response time to areas in downtown, Mount Pleasant, James Island, West Ashley, and Johns Island.
dates are set for Shealy's next habitat build At the heart of Shealy Electrical’s charitable giving is the idea that being a good corporate citizen by giving back to our communities is both a responsibility and privilege Shealy is committed to improving the quality of life in the communities where we live and work by supporting organizations that address vital community needs. Check out the events that we have lined up for the year so far! For more details on these events and how you can be involved, contact Karen McLeod at our Corporate office and keep up with us on social media for updates of our community efforts!
THE CIRCUIT SPRING & SUMMER 2016
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making a house a home On Saturday February 13th the dream of home ownership became a reality for Hinh Rahlan, his wife Blem Rocham and their two children. Rahlan and Rocham are Montagnard people who came to Charlotte as refugees from Vietnam. Shealy Electrical Wholesalers partnered with Habitat for Humanity of Charlotte to build and sponsor the three bedroom home. The project started in the parking lot of the Shealy Charlotte branch in October where associates, vendors, and volunteers worked for 4 full days building the home. After that the house was moved to its permanent location in Reid Park in West Charlotte. Habitat Charlotte has made a commitment to Reid Park by not only building new homes, but also performing critical repairs on current owner-occupied homes, and refurbishing abandoned homes. They have also added a playground to the neighborhood. Habitat for Humanity of Charlotte has been named 2015-2017 Affiliate of Distinction.
Thinking LEAN Construction? Think T&B. Improve your productivity and profitability with eFab by Thomas & Betts. TM
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by Thomas & Betts
© 2016 Thomas & Betts Corporation. All rights reserved.
• Prefabricated electrical rough-in assemblies • Pre-built trapeze systems and cable tray • BIM downloads in all the popular software formats • A dedicated engineering support team that can assist you with design and pre-planning • Online cloud-based configuration design tool For more information about Thomas & Betts and ABB Low Voltage Products LEAN Construction services, contact your Shealy or T&B/ABB representative.
WE CARE ABOUT YOUR TIME AND WE REALIZE THAT LIFE IS ABOUT MORE THAN WORK. We create customized solutions that save you time and money.
WHERE DO YOU WANT TO BE RIGHT NOW? LET US HELP YOU GET THERE FASTER.