AutomationDirect carries a full line of AC and DC motors from trusted brands like Toshiba®, U.S. Motors®, WEG®, Leeson®, IronHorse® and Marathon®, at some of the best prices in the industry. In-stock motors are shipped quickly with free shipping on orders over $49*.
Toshiba EQP SD (Severe Duty Motors)
Starting at $376.00
• 230/460 VAC 3-phase from 1/2 - 100 hp
• 1200, 1800, 3600 rpm
• Inverter duty
• Oversized 300-series bearings
• Heavy-duty cast iron construction
• TEFC enclosure with IP55 protection
• Class I, Division 2, Groups A, B, C, D
• NEMA premium efficiency
• UL, UR, CSA
• 3-year warranty
U.S. Motors
ACCU-Torq Motors
Starting at $370.00
• 230/460 VAC 3-phase from 1/4 - 10 hp
• 1800 rpm
• Constant torque operation; zero to base speed on vector drives
• 5000:1 speed range
• Constant horsepower operation to 2X base speed
• Optimized for operation with variable speed drives (VFDs)
• Compatible with encoder installation
• NEMA premium efficiency ratings on certain models
• 3-year warranty (1hp and larger)
WEG S-Series Rolled Steel Motors and Brake Motors
Starting at $194.00
• Three-phase 208- 230/460 VAC and single-phase 120/240 VAC from 1/4 to 3 hp
• 1200, 3600 and 1800 RPM
• TEFC enclosure with IP55 rating
• Class F insulation
• Premium and Standard Efficiency available
• Certified Class I, Div 2, Groups A,B,C,D
• Brake motors include spring set, solenoid actuated AC brake with manual release lever
• UL, CSA
• 18 month warranty
IronHorse MTS
Stainless Steel Washdown-Duty
Starting at $401.00
• Three-phase 208-230/460 VAC from 1/3 to 20 hp
• 1200, 3600 and 1800 RPM
• TEFC or TENV enclosure
• IP69K protection
• Premium Efficiency (EISA Compliant)
• BISSC Certified
• TEFC enclosure
• Class F winding insulation
• 304 stainless steel frame, end bracket, junction box and hardware
• Class I, Div 2 hazardous locations
• In accordance with NEMA, CSA, UL, and CE
• 2 year warranty
IronHorse MTRJ Series Jet Pump Motors
Starting at $167.00
• 3600rpm
• Single-phase 120/230 VAC from 1/3 to 2 hp
• Three-phase 208- 230/460 VAC from 1/3 to 3 hp
• Built-in thermal protection on single-phase models
• 56J frame with threaded shaft for connection to a jet pump
• 2 year warranty
BLITZDUCTORconnect series combined lightning current and surge arresters feature a low-cost, modular, compact design for system protection. The internal LifeCheck monitoring function helps ensure the arrester is able to prevent costly equipment damage from lightning strikes and surges.
DEHNpatch Series
Starting at $120.00 (929121)
DEHNpatch surge protectors protect Ethernet, Industrial Ethernet, and Power over Ethernet devices up to the Gbit range.
DEHNpipe Series
Starting at $110.00 (929963)
DEHNpipe series are IP67-rated corrosion-resistant protectors ideally suited for process environments, 4-20 mA circuits, or bus systems up to 30VDC.
at $54.00 (953202)
New!
Simple product selection through PT Wizard
Easy on-site setup for reliable lubrication without interrupting operations
Remote lubricator health monitoring and inventory management with OPTIFY ™ , the Dodge ® condition monitoring platform
VIEWPOINT
5 | Trends to watch in 2024 focus on ‘sustainable’
INSIGHTS
7 | How electrical, power trends are affecting manufacturing facilities
Electrical and power systems have changed in many ways over the years
SOLUTIONS
12 | How to look at energy efficiency through demand-side management
Industries are shifting to DSM, using strategies like smart energy storage systems for energy efficiency
17 | When, how to improve energy efficiency through boiler tuning
Industrial plant engineers can achieve proper fuel, steam and air flow to improve energy efficiency
22 | Three ways big data can realize sustainability, digital transformation initiatives
Real-time data provides business insights into sustainability and digital transformation
SOLUTIONS
24 | Know the pros, cons when selecting a motor starter
Knowing common motor starting methods and the differences ensures optimal selection
30 | To pick the right drive, ask the right questions
Selecting a drive for a new application or to replace an existing one
34 | Does your facility need a pipe stress audit?
Learn to identify potential pipe stress or thermal growth problems
44 | How to choose the right arc flash PPE
Emphasize the importance of personal protective equipment in safeguarding workers
48 | Developing an effective PPE program for long-term success
PPE serves as the last line of defense between most hazards and employees
52 | Developing a successful PPE blueprint for plant managers
PPE plays a pivotal role in ensuring worker safety across various industries
CHRIS VAVRA, Web Content Manager CVavra@CFEMedia.com
MICHAEL SMITH, Creative Director MSmith@CFEmedia.com
AMANDA MCLEMAN, Director of Research AMcLeman@CFEMedia.com
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Efficient motor management
• Electrical safety
• Expert Q&A: Hazard protection and hazardous environments
• Lubrication
• Material handling
• Pneumatic and hydraulic controls
• Predictive maintenance
• Process piping
CFE Media Contributor Guidelines Overview
Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about — engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
* https://tinyurl.com/PlantEngineeringSubmissions gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.)
* If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online.
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LEARN MORE AT: https://tinyurl.com/PlantEngineeringSubmissions
TM Technology and
Trends to watch in 2024 focus on ‘sustainable’
What will it take to make your plant sustainable?
The dictionary definition of “sustainable” is “able to be maintained at a certain rate or level.” Every manufacturing plant wants to see its numbers remain sustainable regarding output, profit and safety days.
Taking a slightly different view, sustainable also refers to maintaining the planet, its resources and future viability. That means using recyclable materials, conserving water or designing more energy efficient products.
tasks or to use technology to improve the process even further.
Robots also reduce mundane tasks (read: fewer ergonomic problems) and improve efficiency. Plus, using a robot achieves safety improvements because humans no longer have to handle hazardous materials or other dangerous tasks.
Amara Rozgus, Editor-in-Chief
With the word “sustainable” in mind, I realized there are three trends I’m watching in 2024.
Energy efficiency
“Energy can be a profit center” is even more true today as energy efficiency becomes a larger consideration for facility owners. Whether you deem it energy efficiency, sustainability, green or some other phrase, it’s no longer a trend, it’s a reality.
Companies with a strong environmental, social and governance (ESG) plan often incorporate renewable energy options, waste reduction and energy efficiency initiatives. These ESG campaigns codify a company’s goals, and set examples for the rest of us.
Robotics
Robots do a good, consistent job of material handling, process operations, assembly or inspection. This leads directly to a sustainable manufacturing line, and allows human workers to take on the more intricate
Waste and energy consumption are reduced when robots are on a manufacturing line, accelerating sustainability. All of this wraps into a more sustainable manufacturing sector.
Artificial intelligence
Artificial intelligence (AI), like robots, can minimize repetitive or complex processes, such as analysis of intricate manufacturing processes. This might include optimizing a production line or improving quality control.
When used correctly, AI has the ability to change every process from the C-suite to the entry-level technician. Value can be added through innovation and improved customer experience, or by supporting remote work or supply chain transparency. While still in its infancy with a lot of trial and error, the opportunities for efficiency, sustainability and transformative change are gigantic. Truly at the forefront of digital transformation, AI will increase in use by leaps and bounds. Use of AI will require shifts in the workforce, which will force companies to train and retrain for a different skillset. PE
How electrical, power system trends are affecting and impacting manufacturing facilities
Electrical and power systems have changed in many ways over the years and their impact is felt throughout the plant floor in many ways
QUESTION: What’s the current trend in electrical and power systems for industrial and manufacturing facilities?
Scott Dowell: Sustainability is one of the largest trends in electrical and power systems today, but manufacturers are increasingly looking to marry sustainable energy efforts with three key factors — safety, cost effectiveness and uptime.
Manufacturers have already been reporting on their efforts towards sustainability, sharing information on their carbon footprint or producing annual sustainability reports. Much of their focus today is on ensuring they are meeting the goals already established and figuring out how to get the right mix of power consumption needed to do the manufacturing process, in the most economical way possible, as they move forward.
To do so, they need to take stock of what power sources are available and what already exists. With an aging workforce that is headed into retirement, maintaining institutional knowledge is critical. For example, many plants are operating with aging equipment. Perhaps there is a dated electrical panel that is finicky due in part to a historically minimal maintenance schedule. Understanding the existing limitations as well as current and future power consumption needs helps to shed light on reliability and uptime, as well as one of the most pressing concerns — employee safety.
Following the COVID-19 pandemic, there is an increased awareness about the role organizations must play in keeping their employees safe on the job. Reevaluating the safety of the building and electrical equipment within, the plant floor infra-
structure and your employees is a must. For many this includes replacing aging electrical equipment and outdated electrical power systems. In tandem, as OSHA’s rules have continued to change, manufacturers must keep pace when it comes to electrical risk. In the past, you could conduct an arc flash study to evaluate and identify risks and that was considered sufficient.
Today, you must conduct the study, perform testing to ensure the equipment reacts appropriately in the event of an arc flash, as well as conduct regularly scheduled maintenance. Otherwise, that could be a serious violation. There is a lot of cost associated in these instances as organizations invest in updating equipment and mitigating safety concerns, but without it out they face substantial risk — financial and otherwise.
All of these efforts coincide with the demand for greater reliability of the power network itself.
Eaton recently opened a specialized Innovation Center focused on digital technologies for distributed energy resources near Montreal in Brossard, Quebec. The work the company will do here will break traditional boundaries of what electrical systems can do and enable far more flexibility in how electricity is generated, distributed and used. Courtesy: Eaton
At the Eaton Experience Centers in Pittsburgh and Houston, full-scale demonstration and testing facilities, visitors can get a hands-on look at how microgrids support sustainable, resilient and affordable energy. The controlled environment has a fully functioning microgrid that interconnects multiple onsite energy sources. Courtesy: Eaton
Q: Is your facility implementing microgrid or renewable power systems? Describe the project.
Ken Crawford: We are planning to install a 175 kWdc rooftop solar photovoltaic (PV) system, Utilizing 350, Trina Solar 500W Solar Panels. This system will produce approximately 218 MWh/year and has a maximum efficiency at >98.5% for inverter and 99.5% for optimizers. Installation is planned for late 2024. The system is expandable up to 650.5 kWdc, providing 845 MWh/year in the future.
‘
Following the COVID-19 pandemic, there is an increased awarenes about the role organizations must play in keeping their employees safe on the job.
’
In a competitive global marketplace, uptime has never been more important. As such, manufacturers are exploring the power of data capture to glean better insights about system uptime. Today it’s possible to quickly gather digital data about everything that is happening on the plant floor and power systems are a primary source of information.
Solutions can identify how specific equipment and power systems are performing in certain instances and over time. By gathering that data in a continuous real-time cycle, manufacturers can identify areas of concern, prioritize new equipment investment and improve their uptime. This directly impacts their goal of providing a manufacturing environment that is as sustainable, safe and reliable as possible.
Marc Elliott: Industrials the world over are focused on safety, sustainability, efficiency and controlling energy costs. Electrical safety is a primary consideration, longtime focus and ongoing continuous improvement effort vital to achieving organizational objectives. Sustainability and environmental, social and governance (ESG) goals are driving the desire to integrate renewables, which adds complexity to energy systems. As electrification takes off, finding ways to drive efficiency and control energy costs is vital. The best energy is the energy you don’t use. At Eaton, we’re making sustainability gains with improvements to safety, electrical resiliency and cost in our operations and for our customers.
Marc Elliott: At Eaton, we have a longtime commitment to sustainability and are focused on accelerating the energy transition. We’re simplifying the safe integration of renewables — at our facilities and for customers. For example, a nearly decadeold solar installation at our Beaver, Pennsylvania, plant continues to provide reliable and clean power. In Puerto Rico, we’re building microgrids at manufacturing plants in Arecibo and Las Piedras. These clean energy projects will reduce emissions by 8,345 metric tons in the first year of operations, while strengthening resilience with the ability to withstand extreme weather emergencies.
Q: Tell us about a recent project you’ve worked on that’s innovative, large-scale or otherwise noteworthy.
Scott Dowell: We’ve helped multiple manufacturers address their most pressing demands for energy sources. For example, one of our customers had the goal of becoming the first to market in their carbon capture venture. To do so they needed to have a test/demo facility supported by 15kv energy. Unfortunately, the project site that they purchased had an existing 35-year-old switchgear line up that had been out of commission for five years. Given their go-to-market plan, the customer could not wait for the new Switchgear line up as they faced a 70-week lead time. We were able to refurbish, repair, retrofit, test and re-engineer aspects of the switchgear in 12 weeks, saving them valuable time and supporting their primary business objective.
Q: What tips would you offer to someone tasked with ensuring the power system is flexible?
Marc Elliott: While there is no one-size-fits-all approach, flexibility requires greater control over infrastructure through digitalization and decarbonization strategies enabling more possibilities for
affordably integrating energy sources. Microgrid systems are a powerful lever to increase resiliency and helping prepare for the unexpected by balancing where, when and how electricity is obtained. Getting started requires an understanding of your goals and existing infrastructure; a power system study performed by microgrid experts provides vital insights on how to balance power demand, utilize existing assets and plan for new onsite energy resources over time. Note an energy-as-a-service financing shifts microgrid investments from CapEx to OpEx.
Q: What power technologies within the manufacturing plant are you helping implement?
Scott Dowell: Wesco helps to implement power technologies from the meter all the way through each piece of equipment, to automate the entire power distribution system. From electrical safety programs to low voltage communications to cutting edge industrial internet of things (IoT) applications, we understand the nuances of electrical power systems.
This is especially critical as the landscape for how to best stay safe on the plant floor continues to evolve. For instance, OSHA recently put in place a new requirement (NFPA 70B), which targets electrical equipment maintenance and specifically electrical switching. Built off the standard from NFPA, the goal is to ensure that electrical switching mechanisms aren’t just in place but truly work the way in which they were designed. It’s about protecting the overall safety of the systems as well as the employees who work with them. While 70B was already a recommended practice, the newly minted requirement reinforces the importance of identifying electrical safety risks on the plant floor.
As manufacturers evaluate how to best achieve
Weidmuller USA’s new engineering and production facility will feature solar panels and be expandable over time. Courtesy: Weidmuller USA
electrical power safety in their factories, many come to us to help replace or retrofit older technology. Smart metering is one example. By leveraging sensors, IoT technology and data analytics, we can identify how and when power is being consumed so manufacturers can in turn leverage power consumption outside of peak times to create a much more sustainable flow of power. A byproduct of the newer systems is better safety for the employees as they aren’t forced to contend with outdated and potentially dangerous systems.
Justin Mitchell: We oversee the implementation of electrical safety programs and standard operating procedures. As online grocery shopping continues to gain popularity across the nation, the need for additional storage space becomes increasingly imperative. To address this, we propose expanding the freezer capacity in our manufacturing plants. This will enable us to augment the existing square footage of the freezer storage facilities. PE
Equipment and software used to measure, predict, and control Power Factor. Courtesy: Weidmuller USA
What’s Your 2024 Compressed Air Resolution?
Take a look UP
Your piping system could be key to big savings. With an air leak estimated to cost you in the region of $2,500 per year, those pipes are a potential goldmine when it comes to savings. Keep in mind that not all air leaks are audible, and so ultra-sonic equipment might well be needed to inspect those pipes thoroughly. If you’ve never had an AIRScan, then make 2024 the year to put that right. www.atlascopco.com/tagit
Energy Recovery
Did you know that an air compressor could also be the key to reducing your fossil fuels usage? By reusing the heat of compression you can get a head-start on the need for warm water, as one example, and save thousands on your heating bill. In many instances, Energy Recovery systems can also be fitted to existing compressors and don’t require much space. www.atlascopco.com/ER
Control Systems
In simple terms, do you have the tools to make your equipment work perfectly in harmony? A central control system will do the critical thinking for you and ensure your system is working efficiently. Most control systems can also work with multiple brands of air compressors. Remote connectivity, diagnostics, and early detection of any issues is a must for any production site as we embark on 2024. www.atlascopco.com/optimizer
Make Your Own Gases
Your make your own compressed air, so what about nitrogen or oxygen too? The good news is that if you have a compressor, you are likely already 50% of the way there. By adding a small generator, you have built the system you need to enable you to take control of your gas availability, delivery, purity and price! www.atlascopco.com/nitrogen-usa
Have a Plan
‘What if’ is a question we have all asked ourselves on multiple occasions. Since compressed air is critical to any site, what happens if your compressor is not working? Do you have a backup? Do you have a plan to allow essential predictive maintenance to happen? How will I cope if my production doubles or if I need to reduce my capacity? A compressed air plan is essential to your production facility and let us help you make one.
www.atlascopco.com/air-usa
Process Cooling
It’s a well known fact that chillers are an essential part of the manufacturing process and effectively removing excess heat is essential to a wide-variety of industrial applications and ensuring product quality. Atlas Copco has brought their own, unique innovation stamp to the range, including remote connectivity, advanced controllers, and exceptional efficiency – with multiple ranges to meet the exact needs of every customer. The chiller ranges follow the principle of “integrated design”. Meaning the hydraulic and refrigerant circuits, condensers, compressors, fans, and superior control systems are always included. Our products are easy to install, with “plug and play” connections.
Process Filtration
and applications and stamp to the – with the condensers, are easy to
The process filtration range is focused on liquid, steam, and sterile air, extending our filter product portfolio by increasing its reach into multiple industries, including pharmaceutical, electronics, life sciences and food. The product portfolio includes bags, filters, and cartridges with the goal of preventing microbial contamination and ensuring that the quality of the final product is protected. These filters can be steam sterilized and used with a wide-range of mediums. The stainless-steel housings holding these products are sanitary, and therefore inhibit the growth of bacteria and allow for easy disassembly for inspection and cleaning.
Aeration Blowers
Atlas Copco offers a complete range of aeration blowers, with multiple technologies on offer, including positive displacement technologies (screw blowers and lobe blowers) and centrifugal technologies (high-speed turbo blowers and multistage blowers). All our oil-free air blower technologies are designed to offer you quality air and maximum uptime of your process, safeguarding the quality of your end product. Having a complete range ensures customers can selecting the best blower technology for their application over its lifetime; when the cost of purchase, electricity usage, and service is all factored in.
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Michael Wrinch, Ph.D., PEng, FS Eng, PMP, Hedgehog Technologies, Burnaby, British Columbia
How to look at energy efficiency through nontraditional demand-side management
Industries are shifting to DSM, using strategies like smart energy storage systems and solar installations for improved energy efficiency
In recent times, with the rise of artificial intelligence, advanced communication, storage technology and the commercialization of solar technology, nontraditional demand-side management (DSM) options have emerged. These innovative techniques can produce significant results in distinct ways.
The energy markets have changed in four ways over the years, with smart metering enabling the billing of total energy, time of use and peak power.
1. Transforming stranded assets into renewable energy generators
Stranded assets such as parking lots and rooftops can be converted into valuable energy-producing areas by installing solar photovoltaic panels. These solar panels have the capacity to generate megawatts of electricity on-site, reducing the need to purchase energy from the grid — particularly during peak daylight hours when energy prices may be higher. Recently, Six Flags Magic Mountain initiated a groundbreaking 12.37-megawatt solar carport, described as California’s largest solar energy project.
2. Leveraging energy storage to reduce peak demand and charges
The challenge with solar is that it's not always sunny and the energy may not be needed when solar production is at its highest. This lack of dispatchability in solar production can be addressed by coupling it with energy storage systems, such as batteries or thermal storage. These systems can be charged during periods of low energy demand and discharged during peak demand periods This helps shave off the peaks of energy demand, optimizing load levels to achieve a higher load factor (the load factor is calculated as peak power divided by average power), which can result in lower utility bills. Many utilities charge higher rates during peak times for both peak power and energy. By reducing peak demand, facilities can avoid or minimize demand charges, which are calculated based on the highest level of power drawn (typically over a 15-minute rolling window) during a bill-
FIGURE 1: Example of a stranded asset parking lot that was converted into a solar energy facility in Shanghai. Courtesy: Hedgehog Technologies
Objectives Learningu
• Explore the integration of smart meters, communication networks and data management systems for comprehensive energy monitoring.
• Gain an understanding of the challenges associated with nontraditional demand-side management (DSM).
• Develop a new perspective on stranded assets, such as parking lots and rooftops.
ing period. Energy storage can further enhance the reliability of the power supply and provide backup power during outages, which is critical for many industrial processes or to prevent brownouts.
3. Participating in demand-response programs
Nontraditional DSM often involves integration with smart grids, which can provide real-time data on energy consumption and enable more sophisticated energy management strategies. Facilities can participate in demand-response programs, wherein they agree to reduce their energy consumption or deploy battery-stored solar energy during periods of high demand on the grid in exchange for financial incentives.
This may involve automated systems that respond to signals from the utility to temporarily limit energy consumption by dispatching batteries, using stored thermal energy on-site, dimming lights, adjusting heating, ventilation and air conditioning settings or temporarily shutting down nonessential equipment.
4. Optimizing energy use through monitoring, analytics and time-based dispatching
Energy monitoring involves the full integration of smart meters, communication networks and data management systems. For example, in industries attempting to electrify their fleets with forklifts, cars and trucks, the demand can potentially exceed the main service capacity. Energy monitoring and control can monitor the services on the main feed and can dispatch or curtail charging infrastructure based on the loading of these lines, thereby enabling more efficient use of existing assets.
Additional considerations for DSM
While nontraditional DSM strategies can yield significant benefits, there are some pitfalls to consider before proceeding. The first challenge lies in the high initial investment costs associated with
many of these technologies. Although this aspect can be stifling, it is important to note that there are continually new incentives, rebates and financing options that can help offset the initial costs. Additionally, exploring options such as energy service companies that offer performance contracting and front-load the costs can be a viable approach.
The second challenge concerns the complexity of integrations. Nontraditional DSM methods are often more intricate than jobs such as a simple lighting retrofit. They demand thorough planning and consideration of the variables. For instance, solar installations on rooftops or parking lots
FIGURE 3: Graphic recreation of a stranded asset being repurposed for solar energy generation. Courtesy: Hedgehog Technologies
FIGURE 2: Example of a stranded asset parking lot that was converted into a solar energy facility in Shanghai. Courtesy: Hedgehog Technologies
ENGINEERING SOLUTIONS
may need a seismic and geotechnical assessment to ensure the surface can support the additional weight.
The third challenge is investing in the wrong technology or opting for a technology that may become obsolete and is costly to upgrade. While all technology eventually becomes obsolete, careful consideration is essential to ensure it can be managed in a manner that won't require a complete overhaul shortly after the project is complete.
Nontraditional DSM is the future
Overall, nontraditional DSM techniques hold the promise of achieving energy reduction and efficiency, resulting in cost savings on production and a reduced carbon footprint. Regardless of the goal, these options are going to play an increasingly important role in addressing the energy efficiency and conservation needs of a plant. PE
Michael Wrinch, Ph.D., PEng, FS Eng, PMP, is the founder of Hedgehog Technologies.
Insightsu
Demand-side management (DSM) insights
uThis article explores examples of nontraditional demandside management (DSM) techniques, comparing them to traditional methods and highlighting the associated risks and benefits.
uThere are four key areas in which the energy market has changed, giving the consumer more power over the use of electricity.
Decarbonize with Confidence
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Products is decarbonization
With a $15 billion commitment to near-term clean energy projects, we’re ready to empower you to decarbonize efficiently, sustainably, and confidently—leading you from now to net zero. To learn more, call 800-NEED-GAS (800-633-3427).
The world’s largest hydrogen producer and a first-mover in the low- and zero-carbon hydrogen economy, Air Products is helping industrial manufacturers, OEMs, and EPCs navigate the complexities of decarbonization with safe, reliable clean hydrogen solutions; advanced carbon capture and storage; and new ways to recover, blend, and purify hydrogen.
first-mover in the low- and zero-carbon manufacturers, OEMs, with safe, reliable and storage; and new
FIGURE 4: Photo of Hedgehog Technologies' electrical engineer Aileen Maynard standing near a large solar installation. Courtesy: Hedgehog Technologies
MANUFACTURED IN AMERICA BUILT FOR THE WORLD
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But our reach doesn’t end at our factory doors. We understand the global nature of business, and that’s why we’ve built a robust network of partners and distributors around the world. No matter where you are, FS-Elliott is there to support your compressed air needs.
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When, how to improve energy efficiency through boiler tuning
Industrial plant engineers can achieve proper fuel, steam and air flow to improve energy efficiency through boiler tuning activities
Modern boiler control applications are inherently challenging. Trying to maximize combustion efficiency while adhering to the boiler manufacturer’s recommendations, along with NFPA and ASME codes and simultaneously satisfying emissions permit requirements via the U.S. Environmental Protection Agency, is practically a study in diametrically opposed methodologies.
Still, the most common way to carry heat through a plant is with steam, making it an integral aspect for plant manufacturing operations. So it is left to the boiler tuner to pull a rabbit out of a hat each year when the boiler gets it scheduled tuning. Let’s dive into some ways to approach the different issues commonly encountered with newer boiler/ burner applications during scheduled tuning.
Air flow control/characterization
Gone are the simple days where a damper with a single speed fan controls air flow. Today’s modern boiler systems can have a variety of different air flow control devices and drives installed, including:
• Fresh air damper: The first damper before the fan and flue gas recirculation (FGR) duct that regulates the amount of fresh air entering the process.
• Fan inlet and outlet dampers: The dampers after the FGR combines before the windbox to help control airflow.
• Boiler outlet damper: Often referred to as the stack damper, it properly directs water vapor and combustion gases out of the system.
• FGR damper: Controls the recirculation of flue gases to lower nitrogen oxides (NOx) emissions.
• Motor variable frequency drives (VFD): Motor speed controllers that automatically lower the motor speed when operating at lower loads to save energy. Here are the steps of a normal air flow control tuning strategy:
1. Use the boiler outlet damper to control the pressure, either just ahead of it in the boiler outlet or in the furnace. This pressure is the critical driver of flow through the FGR ducts making it critical for good NOx control.
2. Position the FGR according to a curve based on the fuel flow. There are times when FGR flow is measured, then the curve gives the setpoint for the FGR flow controller.
Learningu
Objectives
•Learn how to best optimize oxygen for efficiency and coordinate fuel and air tuning.
• Understand boiler control final elements such as dampers and variable frequency drives, and how they work together in a modern boiler.
• Review the effect of feedwater temperature on drum level control.
FIGURE 1: Air damper output curves without variable frequency drive. Courtesy: Novaspect
Tom Marsh, Novaspect, Schaumburg, Illinois
ENGINEERING SOLUTIONS
3. Then, group the other dampers and fan speed together, each with its own characterization curves to control air flow.
The critical tuning step for this is configuring the characterization of all the various air flow controlling dampers (usually three dampers and a motor speed). The best way to accomplish this is with the boiler offline while just running the fan. This gives the person tuning a chance to adjust each curve by simultaneously monitoring the air flow while stepping up the output of the flow controller in 5% or 10% increments.
Any proportional-integral-derivative control requires linearity to work throughout the control range and this is particularly critical in a boiler that will operate flows through the whole control range.
With a VFD, the cost savings can come from opening the air dampers first and then ramping up the fan speed, but keeping the fan running as slow as possible.
Be aware: turning the fan too slow can lead to pulsations caused by the fan blades passing the fan scroll. Usually, 25-30 Hertz works as a minimum, but some boilers may require 40 Hertz or higher as a minimum. It really is a function of how the fan is designed, but pulsations in the outlet duct expansion joints will be an indicator the fan speed is too slow.
O2 control and boiler efficiency
Controlling the oxygen (O2) close to the setpoint is an essential element that leads to efficiency and cost savings, and the trick is getting the fuel and air controllers to operate in conjunction with each other. However, it is not as simple as characterizing the outputs and giving both loops the same gain and reset.
The key really lies in the different dynamics of the two flow controllers. Fuel flows, whether liquid or gas, tend to be very close to the controlling valve so they can operate rather quickly. Air flow ducts are sized for low velocities and pressure drop to prevent buying a bigger fan than necessary. So, the feedback dynamics between the two loops can be quite different.
Ensuring that the closed loop response time between the air and fuel controllers match is critical to the efficient tuning of the boiler. This can be done with boiler master step changes and calculating the response time back to setpoint in a trend for each controller. Or a more advanced tuning scheme can be used that predicts closed loop response time like some auto tuners or the lambda tuning method. Either way, when a step change is made in load, the fuel and air should arrive at the new setpoint at the same time and the O2 should stay right on the setpoint curve as the transition takes place.
The largest loss in the sum of losses method of efficiency calculation is the dry flue gas loss (the heat that is going up the stack). As the air comes in at an ambient temperature it is heated up several hundred degrees and goes up the stack, carrying the unburned oxygen and 78% nitrogen with it.
Determining the normal operating range of the boiler and improving O2 at that point could lead to significant savings. A general rule of thumb is that
FIGURE 2: Air damper output curves with variable frequency drive.
for every 1% you save in flue gas O2 will save you 0.5% in efficiency. The savings can be significantly greater when going from 5%-4% O2, than from 3%-2% O2.
Depending on how good the O2 control is and how your air and fuel flow controllers are characterized and tuned, the result may not be lowering the O2 throughout the entire control range as that may adversely affect carbon monoxide or NOx at high loads. Many plants operate multiple boilers at a 40%-60% load range with the hopes that if one trips the others can make up for the load loss, but this is typically below the O2 design point from the manufacturer’s O2 curve. If testing and tuning can be done in the normal 40%-60% operating range, a 1% or even 2% O2 reduction is possible. The key to this is better air and fuel flow control allowing the O2 to always stay on setpoint.
One final warning for taking O2 readings: It is critical to close off the O2 calibration port during normal operation because any leaks in the calibration lines or from the valves on the calibration tanks can cause erroneous readings, which can be dangerous. It is always important to ensure that O2 calibration lines have no leaks and that all valves are closed when a boiler is operating.
Drum level control in boilers
Effective drum level control is critical to the safe operation of the boiler and the widely recommended three-element drum level control has been the standard for decades. Controlling the water/vapor interface can be fickle and is often fraught with challenges.
However, another common problem has surfaced in recent years with the deaerator temperature. The deaerator is the tank that mixes feedwater with steam before it goes to the boiler to remove the noncondensable gases. The deaerator’s ability to heat the water is essential for drum level control. Recent trends like flue gas condensable heaters and dumping trap discharge directly to the deaerator has caused plants to operate the deaerator at a lower pressure.
Historically, the deaerator operated at 15 psig with the feedwater temperature at 250°F, but now many are operating at 5 psig and are lucky to get feedwater to 225°F. The issue involves the feedwater initiated shrink/swell affect, where the drum level
is going down, so you raise the feedwater flow, but the cold feedwater comes in and collapses the steam bubbles, which results in a decrease in level. This is a classic inverse acting loop where the effect gets drastically worse when the feedwater temperature is lowered.
There are some shrink/swell compensator circuits that can be added to the three-element drum level control and derivative can be used for offsetting some of the lag in the loop, but lower feedwater temperatures make this less effective. Boilers can change load just as fast as drum level will let it and by doing things that compromise drum level control (like using lower deaerator pressure), which only impede the ability to safely react to load changes.
Boiler header pressure control
Plants will often have a pressure controller per boiler and the operator will assign each of them different setpoints so that one ramps up to full first and then the second one comes off minimum and starts to control pressure. This works, but by controlling all the load swings with one boiler, it increases the chances of that boiler tripping. It is better to have a coordinated plant master that sends the demand to each boiler and allows all boilers to operate together to control swings.
Like a three-element drum level control, the coordinated plant master is a common standard that should be easy to implement for any control
FIGURE 4: Determining lag time from the process variable measurement (e.g., pressure, temperature, flow, pH, speed, etc.) change in direction. Courtesy: Novaspect
Insightsu
Boiler insights
uBoiler tuning can be used to optimize operation and thermal efficiency in industrial steam systems.
uBoiler tuning includes combustion setup (curve setting), optimized flue gas oxygen control, boiler loop tuning coordination and drum level control best practices.
ENGINEERING SOLUTIONS
‘ An important fact to consider about plant master and drum level is that they often interfere with each other because they are both integrating processes with similar time constraints.’
system. Even with boilers that have their own standalone control system, they will have a “remove” mode to accept a signal from a remote source, which can be a good upgrade as it only takes a few input/ output per boiler to configure this control.
An important fact to consider about plant master and drum level is that they often interfere with each other because they are both integrating processes with similar time constraints — i.e., one will start to swing and then the other will as well, especially if the integral times are too tight. Like with air and fuel, the best way to combat this is to use a tuning method to determine their close loop
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response time. This can help you gain some separation from the interference through separating response time.
Another approach is to use a little derivative on the plant master. Many times, this will break that interaction and stabilize the entire process. To pick the derivative time, use a manual bump test to make the pressure first go down and then go back up. From the trend, take the difference from the time when the pressure starts to change its upward direction and the time when it has completely leveled out in the new direction. This should be the lag time and it is first order. If you divide that time by four, it should give you a good derivative time (shown as tau, or time, in Figure 4).
Achieving proper boiler system control and optimal thermal efficiency through tried and tested tuning methods requires a delicate balance between science and art amid myriad constraints facing industrial manufacturing plants. PE
Tom Marsh is an Application Engineer at Novaspect.
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Weighing equipment and software that is increasing the accuracy, efficiency and quality
The highly automated processes used to produce skin care, hair care, make-up, perfumes, toiletries and deodorants require accurate weighing of the precious ingredients to ensure the promised quality and effectiveness. Minebea Intec offers precise industrial weighing solutions together with dosing, formulation, sorting, filling and packing solutions.
Three ways big data can realize sustainability, digital transformation initiatives
Real-time data provides business insights
into sustainability and digital transformation gains in three key areas and can help companies realize their goals.
Technological advancements have evolved at a rapid pace, enabling manufacturers to innovate and change operational processes to satisfy consumer demand for new products that enable how people live and communicate. In turn, society has fully realized the potential benefits these advancements provide thanks to manufacturers’ innovation and investment. From mass production of automobiles to personal cell phones and customized medicines, manufacturing has changed the world by making modern products affordable, safe and available to consumers.
Objectives
• Learn how manufacturers are striving to evolve and become more efficient.
• Learn how big data can help companies be more sustainable and achieve digital transformation.
• Learn how energy management, waste management and regulatory compliance can help manufacturers be more sustainable and efficient.
It is hard to imagine modern daily life without the foundational products and services provided by the manufacturing community. However, over time, the success manufacturers have achieved in delivering these desired commodities to consumers also has come with the unintended consequences of long-term production, including a higher level of waste, more demand for resources and increased carbon emissions.
A real-world example is the “pop top,” an invention of the early 1960s. An aluminum tab was developed so people could easily pop open canned beverages without a can opener or “church key.” They could detach and discard the tab. The pop-top can was pervasive on into the 1970s, but by then, the aluminum tabs were being discarded on beaches
and in other community areas, which created a litter problem and safety concerns. Not only could people “step on a pop top” and cut their heel as Jimmy Buffett said in his song “Margaritaville,” but they also faced a more serious medical issue. Consumers would sometimes push the loose tab back into the can and inadvertently swallow it. Innovators and manufacturers stepped in to change the mechanism used to open canned beverages. They developed the “Sta-Tab,” a safe opening device that remains attached to a recyclable can after opening.
Technological advancements are great, but no one wants to harm people or the environment in the production process. That is not the kind of change manufacturers set out to make in the world. When a company first sets up production, personnel safety and environmental impact are top of mind.
The processes are defined and constrained based on current industry knowledge, best practices and available technologies. For example, a plant or mill built in the 1970s does not have the same technological advantages of a modern-day greenfield plant. However, it still must continue to operate and meet production goals.
Balancing sustainability and production strategies can be a tall order for manufacturing facilities that were not initially designed nor equipped to support a circular economy. Modern digital transformation (DX) solutions enable these companies to strike a delicate balance by harnessing the power of big data to achieve environmental, social and governance (ESG) initiatives.
Three ways to harness the power of big data
In this era of smart manufacturing, the accessibility and visualization of complex data supports
Companies must digitally transform their operations now to meet modern customer demands while still becoming more sustainable and efficient.
Courtesy: Rockwell Automation
integrated production and sustainability planning. The convergence of information technology (IT) and operational technology (OT) allows access to real-time process and enterprise data, prompting new business insights and revealing opportunities for sustainability gains in three key areas: Energy management, waste management and regulatory compliance.
Energy management
A knowledge-driven management strategy is a big step along the path to net zero emissions. Viewing operational data and how it relates to energy and resource data provides valuable energy efficiency insights. Aligning process control with energy consumption information will reveal areas with higher or lower usage of resources like steam, electricity and water. With data available down to the machine level, analyses can be conducted by asset, product or process. System modifications can be implemented to automate optimization procedures to streamline energy use based on real-time control parameters. Using advanced tools such as model predictive control (MPC) also allows operators to see resource usage and tighten up parameters or make necessary adjustments to save energy or reduce waste.
Waste management
Using the digital thread early in the design and development phases can help manufacturers bring new products to market with less production waste and lower anticipated consumer waste. Digital twin technology enables manufacturers to design products that are environmentally friendly and profitable. Digital twinning shows the virtual product and processes, helping to identify and correct envi-
ronmental impact issues and other problem areas before production ever begins. Artificial intelligence (AI) technology also enables the control system to learn about the process and adjust during continuous operation. This saves resources, reduces waste and supports optimization. In the same way, machine learning (ML) technology helps machines learn how to be more efficient over time, using less energy or producing less waste.
Regulatory compliance
DX provides the right data to the right people at the right time across the enterprise, supporting faster, more accurate emissions reporting. The intelligence derived from the overlay of production and emissions data will reduce non-compliance risks by indicating areas with potential compliance gaps so corrective action can be taken quickly. Using realtime data ensures compliance information is always up to date and accessible. Required reports can be automated using verified traceable data to lower the risk of non-compliance. As regulations become more complex and pervasive, programming compliance parameters into the system will help companies keep up with compliance reporting and required procedures. It also frees operators so they can perform higher level knowledge-based tasks.
Manufacturers have always wrestled with the complicated engineering and operational challenges of reaching compliance and productivity. Companies must digitally transform operations now to meet customer demands for personalized and recyclable products while becoming more sustainable for the future. PE
Carol M. Schafer is a global senior marketing manager for LifecycleIQ Services at Rockwell Automation.
‘A knowledgedriven management strategy is a big step along the path to net zero emissions.’
Insightsu
Sustainability insights
Technological advancements enable manufacturers to innovate, meeting consumer needs, yet the unintended consequences demand a balance for sustainability and innovation.
Leveraging big data through digital transformation helps manufacturers optimize energy, reduce waste, ensure compliance, and achieve sustainable operations.
Know the pros, cons when selecting a motor starter
Knowing common motor starting methods and the differences between them ensures the optimal selection for any given process
Induction motors convert electrical energy into mechanical energy (i.e., motion). In the process of conversion, the electrical supply connects to the motor stator, producing a rotating magnetic field that rotates the rotor and starts the motor. When the motor starts, it draws a very large starting current.
Objectives
• Understand the purpose of motor starters.
• Learn about the common types of motor starters.
• Review the advantages and disadvantages of different motor starters
This starting current, which is also known as the inrush current, is typically five to eight times higher than the rated current of the motor. The high inrush current can easily damage or burn the windings of the motor and cause a huge dip in the supply voltage, which can damage other loads connected to the same power supply. As such, it is important to protect the motor from the inrush current by providing motor starters or drives.
An essential component for any motor, whether an exhaust fan, blower or compressor, is the motor starter. To start and run motors, there are several options available, including across-the-line starters with a contactor, reduced-voltage with autotransformer (RVAT) or reduced-voltage soft starters (RVSS) with solid-state control and variable frequency drives (VFD). Each method has its own advantages and disadvantages regarding cost, size and capabilities.
Across-the-line (full voltage)
One of the most basic motor starting methods is an across-the-line motor starter, which is also known as full-voltage or direct-online. An acrossthe-line motor starter typically includes three components: the contactor, the motor circuit protector and the overload relay. Figure 1 details a generic wiring diagram of an across-the-line motor starter. Contactors are normally open contacts that close the circuit when the contactor coil is energized. The contactor coil is typically connected to a control relay in the 120-volt control logic such that the motor can turn on/off depending on application.
For example, if the water level in a pumping well is high, the submersible motor needs to turn on to pump the water to another location. Or if the water level is low, the motor needs to turn off to prevent dry running, which will cause damage to the motor.
Overload relays protect the motor from excessive heat caused by overloading or stalling situations. An overload relay, either thermal or electrical, will monitor the heat or current flowing through the circuit. If the heat or current is
FIGURE 1: A generic across-the-line motor starter wiring diagram.
Courtesy: CDM Smith
above a limit over a certain period, the overload relay will trip, which will operate an auxiliary contact that interrupts power to the contactor coil and de-energize the motor. The motor circuit protector shown in Figure 1 is an overcurrent protective device (OCPD) that provides protection for the motor circuit. This OCPD can be a circuit breakertype or fuse.
Figure 2 shows a National Electrical Manufacturers Association (NEMA) size 1 motor starter in a control panel for three pumps (triplex) in a wastewater lift station.
As shown in Figure 1, the motor starter is connected directly to the power supply, meaning full voltage, current and torque are applied instantaneously when starting the motor. Due to this, the motor accelerates to full speed quickly and will also have a high inrush current of short duration. The current reduces as the motor speeds up and when the motor is at full speed, the current will be at the rated motor current.
Because of their simplicity, across-the-line starters do not create switching that causes harmonics like VFDs. The motor will run constantly and consistently at 0% or 100% speed with an acrossthe-line starter, which is not ideal for applications where speed control is necessary (e.g., odor control blowers, etc.).
When stopping the motor, the power is instantly cut from the motor. The motor then spins down on its own, which can lead to hard or fast stops. For bigger motors, this can damage the motor windings due to the heat.
Due to motor heating, voltage drop, large current demand and strain on the other connected electrical equipment, across-the-line starting is not recommended for larger motors. The inrush current will be largest with this starting method, which for a large motor can create a need for an oversized generator or power system supply. However, compared to other motor starting methods, the full voltage motor starter can be the cheapest and most compact option for smaller motors.
Soft starters
Soft starters are devices used to temporarily reduce the torque and current provided to an alternating current (ac) electrical motor during startup. These devices are meant to reduce mechanical stress on the motor, electrical distribution equipment and any generator systems supplying power.
Soft starters can come in the form of mechanical or electrical devices. Two common electrical devices used for soft starting are RVSS and RVAT soft starters.
RVSS are a type of soft starter designed to control the starting voltage to provide smooth, controlled starting to a motor by reducing the motor torque. For stopping, the motor can also be gradually slowed down instead of having to hard stop. Figure 3 shows a picture of an RVSS in a control panel for a 75-horsepower submersible well pump.
The method of voltage control comes from silicon-controlled rectifiers, also known as thyristors, operated with a controller to set starting torque and current and slowly ramp a motor up to speed. Once a motor is at full speed, many modern RVSS will use internal bypass contactors to provide power to the motor. This is done to reduce the wear and tear on the starter, increasing its life span.
Some disadvantages of RVSS over full-voltage starters are the increased heat generation during startup, the increase amount of spaced required and the increased initial cost for the device.
RVAT are a type of soft starter that uses the secondary of an autotransformer to provide reduced voltage to a motor by using preset output taps.
‘ Because of their simplicity, across-the-line starters do not create switching that causes harmonics like VFDs.’
FIGURE 2: Three NEMA 1 starters in a triplex control panel at a wastewater lift station. Courtesy: CDM Smith
ENGINEERING SOLUTIONS
SPECIFYING MOTORS AND DRIVES
These taps are usually at 50%, 65% and 80%. During startup, the reduced voltage is used to get the motor spinning, until a set time or line current has been reached and then the motor bypasses the RVAT to operate at 100% voltage. During shutoff, there is no soft stopping and the motor is immediately disconnected just like a full-voltage starter.
Other disadvantages compared to RVSS are the increased footprint of this device, the increased weight of this device, increased heat generation from the transformer and limited control over starting speed because the limited number of output tap options. With all these disadvantages and the fact that RVAT soft starters are roughly the same cost, it is no surprise that RVSS are generally the preferred solution.
The only advantage RVAT has over RVSS is the simple and robust design that requires a limited number of parts.
Variable frequency drives
VFDs are a type of soft starter that are used to not only start and stop a motor slowly, but also to control the speed of ac motors. VFDs operate by converting input ac to direct current (dc) power, smoothing the dc power using an inductor capacitor filter and, finally, converting the dc power into a simulated, through pulse-width modulation, sine wave using an inverter consisting of insulated-gate bipolar transistors (IGBT).
The exact method of power conversion will depend on whether the VFD uses a pulse rectifier, such as 6-, 12- or 18-pulse, or an active front end drive. See Figure 4 for a 6-pulse wiring diagram and Figure 5 for an active front end wiring diagram.
Each type has its advantages and disadvantages, especially when dealing with the disadvantages associated with VFDs. Some disadvantages are harmonics, reflected waves, heat generation and increased initial cost.
Harmonics are a concern for the line-side of the VFD created by the rectifier and inverter and have various negative effects, such as causing capacitor banks to fail, burn out motor windings, trip circuit breakers and cause transformer overheating. Some VFDs produce more harmonics than others, for instance, a 6-pulse drive will produce more than an 18-pulse drive and an 18-pulse drive will produce more harmonics than an active front end drive.
FIGURE 3: Reduced-voltage soft starter in a submersible pump control panel at a well. Courtesy: CDM Smith
FIGURE 4: A generic 6-pulse variable frequency drive circuit wiring diagram. Courtesy: CDM Smith
‘
The best method of preventing overheating is to use heat sinks and fans to dissipate heat through vents in the VFD enclosure.’
However, a 6-pulse drive is the cheapest VFD, while an 18-pulse drive and active front end drive costs roughly the same. Note, even if a 6-pulse drive is selected, there are methods to reduce harmonics, such as in-line reactors or external harmonic correction units.
Reflected waves are a concern for the load-side of the VFD caused by the quick switching of IGBTs and can create overvoltages that damage cable insulation, motor windings and motor insulation. For this reason, it is important to consider inverter duty motors, which are made to handle larger voltage differentials. Another solution is to install either a load reactor, dv/dt filter or sine wave filter or locate the VFD close to the motor, as the reflected waves get worse with distance.
Heat generation comes from the many parts of the VFD required to convert the ac current to dc and from the switching of IGBTs to produce a simulated sine wave. While the switching frequency can be lowered to reduce heat generation, it is not always advisable because it can increase harmonics from the VFD and noise from the motor.
The best method of preventing overheating is to use heat sinks and fans to dissipate heat through vents in the VFD enclosure. Ideally, VFDs would be installed inside a climate-controlled electrical building or room, but many vendors do provide external VFDs with air conditioning units. See Figure 6 for a VFD internally installed into a motor control center.
The last disadvantage is an important one as VFDs cost more than a RVAT or RVSS option. However, the increased initial cost and other disadvantages do come with some great benefits and capabilities. Some of these benefits are improved
power factor, speed control and reduced energy consumption.
Power factor improvement is caused by the dc bus capacitors within the VFD. The dc bus capacitors provide reactive current to the motor, which is required to induce the rotor’s magnetic field. This means the input supply current from the utility only needs to be real power. This benefit can help avoid power factor penalties from the utility, reduce current on the distribution network and reduce demand charges from the utility.
Speed control is an ability that allows the motors speed to be controlled by varying the output voltage and current of the VFD to achieve the required torque and desired speed. This can be done using an open-loop control method or a closed loop control method based on the application required. In the open-loop system, the VFD is tuned to ensure accurate speed control, while the closed-loop system monitors the voltage and current of the motor to read the motor speed and adjusts accordingly.
Reduced energy consumption is a product of reducing the speed of a motor and therefore the motor load. This is often a major advantage and can provide large energy savings. The reason such large energy savings can be gained is because of the relation between speed and power consumption.
For instance, a 50% reduction in motor speed reduces power demand to 12.5% of the original power demand, 42% power demand for 75% motor speed and 73% power demand for 90% motor speed.
FIGURE 5: A generic active front end variable frequency drive circuit wiring diagram. Courtesy: CDM Smith
ENGINEERING SOLUTIONS
Conclusion
When it comes to choosing a motor starting method, there are many choices depending on the desired motor application and motor size. The across-the-line starting method may be preferred for smaller motors that do not require speed control. Soft starters become important considerations for larger motors to reduce inrush current but does not offer speed control.
VFDs are a great option for large motors and/or motors that require or benefit from speed control. However, they introduce harmonics to the electrical system, which may need to be mitigated. Choosing the ideal method can ensure an efficient and cost-effective system at any facility. PE
Lilly Vang, PE, is an electrical engineer at CDM Smith, focusing on the design of electrical power systems.
Joshua Hunter, PE, is an electrical engineer at CDM Smith, experienced in the design and analysis of electrical power systems.
FIGURE 6: A 6-pulse variable frequency installed in a motor control center at a water reclamation facility. Courtesy: CDM Smith
The Importance of a Proper Lubrication Program
David Reh | Director of field engineering and training services, Lubriplate Lubricants Company
Proper lubrication is essential to maintaining the bottom line, but starting a lubrication plan can seem to be an overwhelming proposition. Not having an effective program can result in hundreds of hours of downtime and lost production. Where does one begin faced with such a daunting task? This article will discuss methods to implement a comprehensive lubrication program, or how to possibly improve one already in place.
The first thing that should be done is to define the program’s goals and objectives. Many plants want to consolidate inventory, reduce costs, and to ensure that the correct products are being used in the right places, especially in regard to any applicable legislation or food grade lubrication requirements. A qualified lubrication expert can assist with each of these goals, and advise you on what may or may not be a practical plan based on their experience.
Even a seemingly small accomplishment can be crucial. Some examples might include consolidating multiple gear oils into a single one, inventory reduction, or identifying an opportunity to save money through the advantages of using a superior lubricant. A few successes like these along the way help to keep the ball rolling.
Implementing a color coding plan, tagging equipment, and employee training are also smaller sized goals that can be accomplished fairly quickly with a moderate effort and reap much larger benefits in the long term. Another example of this is oil analysis. Oil analysis can be a good place to start, because it can be started on critical equipment without a lot of effort, and carries with it a potentially large return on the initial investment.
With each small part of the project that is completed, employees become more invested in the continuance of the program as it builds towards the conclusion a comprehensive lubrication program that saves money in the long run.
Lubriplate provides it’s customers with a complete extra services package. These services include a technical support hotline and e-mail, complete plant surveys, customized, color coded lubricant tags, lubrication maintenance software, plant user training and no charge oil, fluid and grease analysis. For more on this subject and customer assistance call 1-800-733-4755 or e-mail LubeXpert@lubriplate.com
Download the paper at: www.lubriplate.com/Resources/White-Papers/
ENGINEERING SOLUTIONS
MOTORS, DRIVES
Don Congdon, SEW-EURODRIVE, Wellford, South Carolina
To pick the right drive, ask the right questions
Selecting a drive, whether for a new application or to replace an existing one, doesn’t have to be a traumatic experience
If an electrically powered industrial machine moves, chances are that a drive — an electronically controlled gearmotor — orchestrates that motion. While ordinary gearmotors have moved industry for over a century, inexpensive electronic drives have been mainstream technology for just a few decades.
Consequently, plant engineers and maintenance personnel may feel uncomfortable about selecting a drive. Traditionally, drive manufacturers guided this process through their sales engineers, but many now offer online selection tools or smartphone apps as an alternative. While these certainly make the selection process more convenient, they can be daunting to use correctly.
Happily, there’s a simple solution to this problem: Ask the right questions before sitting down to the selection tool. Thoughtfully defining the
problem and organizing the application’s requirements paves the way to a smooth and successful selection experience.
The drive train
The drive train contains everything that powers the application, including the drive itself. The drive (see Figure 1) has three core components: a gearbox, an electric motor and a variable frequency drive (VFD). It may connect directly to the application or it may deliver power through additional transmission elements, such as a belt, chain or spindle. In either case, the drive must have appropriate coupling and mounting devices. These include flexible couplings, flanges, feet or torque arms.
The motor may require a brake, either to stop the load or hold it in place. If the application requires precise speed control or accurate positioning, a motor encoder will be necessary. When a programmable logic controller (PLC) or other industrial controller manages the application, the VFD will probably need a suitable fieldbus interface or some extra inputs and outputs.
• Recognize the core components and optional accessories making up a drive train.
• Identify an application’s key electromechanical and electronics requirements.
• Review the various items to consider for drive selection.
‘ The drive has three core components: a gearbox, an electric motor and a variable frequency drive (VFD). ’
The following questions define the drive. They flesh out the main components and tease out the specialized accessories required. The questions broadly divide the drive into its electromechanical and electronic components.
Core electromechanical questions
Begin by identifying the application’s motion. Is it rotary or linear? With linear motion, is it horizontal, vertical or angled? Vertical and angled applications usually require a brake, while horizontal ones may or may not. Be sure to identify the motion’s duty cycle too. Continuous duty applications, like simple conveyors or a blower, can work well with an ordinary alternating current (ac) induction motor. Cyclic applications performing repetitive sequences, such as packaging machines, may benefit from a more dynamic permanent magnet synchronous motor.
While thinking about the application’s motion, identify the expected loads. Besides their magnitude, also determine whether they’re predominantly static or dynamic. Sizing a drive for an application with relatively static loads is simple. If the load varies widely or can change abruptly, the drive will need a larger service factor. Be sure to identify the application’s acceleration requirements too. In cycling applications, the motor must deliver sufficient torque to accelerate the load within the time constraints. Permanent magnet synchronous motors can handle aggressive acceleration better than ordinary induction motors.
Determine the application’s speed, torque and horsepower requirements. These help size the motor and gearbox. The speed and torque requirements also determine the appropriate gearbox ratio. Be sure to identify how the drive will connect to the application. List appropriate details like shaft diameter, flange and feet requirements and coupling type. Finally, if the application needs a brake, identify the required braking torque.
Application efficiency has progressively become more important in recent years due to rising energy costs and legislation mandating efficient motors. Questions that you’ve already answered may steer the selection tool toward a particular motor efficiency rating. For example, a continuous duty application requires a premium efficiency (IE3) motor.
You can improve efficiency even further by requesting a particular gearbox style and mounting position. Gearboxes based on helical and/or bevel gears tend to be much more efficient than those containing worm gears, so they’re preferable when efficiency is paramount.
Similarly, the gearbox mounting position influences efficiency because position determines how much oil the housing must contain to keep the gear stages lubricated. Vertical mounting positions often require more lubricant, which leads to higher churning losses as the gears plow through the oil.
Whenever possible, select a mounting position that requires the least lubricant. Every manufacturer has its own mounting position identification scheme (see Figure 2). Be sure that you understand it, so you can correctly specify the gearbox mounting position.
FIGURE 2: Gearbox mounting position identifiers vary among manufacturers. This is SEW-EURODRIVE’s system. Courtesy: SEWEURODRIVE
ENGINEERING SOLUTIONS
MOTORS, DRIVES
Environmental questions to select a drive
You’re past the most difficult electromechanical questions. Those that remain help identify additional factors needed to ensure a good match between the drive and the application. Begin by describing the application’s operating environment. Is it indoors or outdoors? Clean or dirty? Wet or dry? Are there harsh or corrosive chemicals involved? Will the drive require regular wash-down?
The answers to these questions determine the drive’s materials, protective coatings, seals and cabling. A drive operating in a poultry processing plant, for example, requires multiple wash-downs per day with hot water and caustic cleaning agents. Ordinary protective coatings won’t survive these conditions for very long. A stainless-steel drive with potted motor windings and conduit box connections is a much better choice.
On the other hand, the environment can be dry but still very harsh. Drives powering ore- or rockcrushing machines must endure heavy dust and abrasive grit. These will probably require multiple shaft seals or ones specifically designed to keep abrasives out. The drive may also need bearing relubrication fittings to make regular grease changes simpler. Identify the application’s expected temperature range. Is it unusually hot or cold? Temperature affects lubricant choices. Mineral oils and greases perform well at everyday temperatures, where-
as specialized synthetics are better choices for hot and cold extremes. The gearbox and motor may require auxiliary heat in a cold environment or more aggressive cooling in a hot one. While you’re thinking about lubricants, remember that food processing and pharmaceutical machines often need food-grade lubricants.
Core electronics questions
At this point, you’ve asked enough questions to specify the motor and gearbox. The remaining questions help select the VFD and its accessories. These may be unfamiliar territory if you’ve not worked with VFDs before. While all VFDs do much the same thing — control the motor — they vary widely in their features and intended applications. Again, asking the right questions will help you decide which one is right for you.
You’ve already answered an electromechanical question that is equally important for selecting the VFD — the application’s horsepower requirement. Additionally, determine the available power supply voltage and phase (single- or three-phase). These answers size the VFD and identify possible models. In most cases, a drive manufacturer will offer several VFDs that will satisfy your application’s basic electrical requirements. Listing additional application requirements will help you choose from among these.
Begin by identifying the application’s operating mode — whether it’s speed-, position- or torquebased. Speed-based applications are the simplest, so almost any VFD can handle them capably. Do determine the accuracy required, however. Entry-level VFDs can handle applications with modest requirements — fans, pumps and blowers, for example.
Applications requiring higher accuracy must use a VFD that supports closed-loop control via a motor encoder. While many VFDs can operate in closed-loop mode, not all come with built-in encoder interfaces. Those that don’t will require an add-on interface board. This must match the motor encoder’s communications standard. By their very nature, positioning applications require a more advanced VFD. It must run the motor at a specific speed while monitoring one or more encoders to determine the application’s position. Upon reaching the specified position, it must stop the motor cleanly and accurately. If an appli-
FIGURE 3: Control cabinet (left) and decentralized (right) variable frequency drives perform the same task but in completely different ways. Courtesy: SEW-EURODRIVE
cation requires positioning, determine its type (linear or angular) and the required accuracy. These answers will also influence the encoder selection. Precise positioning will require an expensive, highresolution encoder, while basic positioning can get by with a more economical choice.
Applications requiring torque-based control are the least common, so not all VFDs support this mode. They require the VFD to maintain a specific tension on the load by adjusting the driving torque. A wire winder is an example, as is the paper feed system in a web printing press. In each case, the VFD monitors the tension on the wire or paper with a sensor, such as a dancer potentiometer. The VFD uses this feedback to generate the torque required to maintain the target tension. If the application is torque-based, be sure the VFD supports this mode and can interface with the required sensors.
For the final core electronics question, determine how the VFD will integrate into the application. Many VFD manufacturers offer their products in two styles: control cabinet and decentralized (see Figure 3). A control cabinet VFD, as its name implies, lives in an electronics cabinet. Wires enter and exit the cabinet, connecting power, the motor and any sensors to the VFD. The cabinet protects the VFD from the environment, especially important when operating under harsh conditions.
Decentralized VFDs approach control differently. They mount either on the motor itself or very close to it. Because they’re exposed to the application’s operating environment, decentralized VFDs usually have relatively high ingress protection ratings, such as IP66 or higher.
A decentralized VFD integrates more seamlessly into the application and typically requires less wiring because it mounts very close to the motor. Decentralized VFDs are becoming increasingly popular in many industries. Some drive manufacturers even offer “electronic gearmotors” — an all-in-one gearbox, motor and VFD (see Figure 4). These offer an especially elegant solution to many drive challenges. As a bonus, some are exceptionally efficient because they combine a super premium efficiency (IE4) motor with an efficient gearbox and VFD.
Secondary electronics questions
Once you’ve identified the core electronics requirements, ask questions that will reveal spe-
cial features affecting the VFD. For example, many applications include controls or sensors that the VFD must monitor. These may be digital devices like toggle switches, pushbuttons, limit switches or a referencing cam. Alternatively, they may be analog devices, like temperature sensors, a speed-control potentiometer or a voltage that represents a process variable. Most VFDs include at least a few digital inputs and outputs (I/O), but not all support analog signals. In some cases, the VFD may require an expansion card to augment its built-in I/O.
Finally, consider the control method that the application will use to manage the VFD. Simple applications like fans and pumps may rely on the VFD’s front panel for control and status display. More sophisticated applications might operate the VFD in terminal control (binary) mode via switches, a potentiometer and digital indicators.
The most sophisticated applications use a PLC or similar industrial controller to manage the VFD. These usually communicate with the VFD over a fieldbus — a robust industrial network. Fieldbus control provides maximum flexibility and sophistication but adds an extra layer of complexity.
If the application requires fieldbus control, you’ll need to identify the controller brand and model, as well as the fieldbus standard it uses. Newer controllers use Ethernet-based fieldbuses such as EtherNet/IP, Modbus TCP or PROFINET. Older controllers use legacy standards such as PROFIBUS or DeviceNet. Most VFD manufacturers support multiple fieldbus standards. The VFD may have a built-in fieldbus interface or may require an add-in card.
Selecting the drive
At this point, you’ve gathered everything necessary to use the drive manufacturer’s selection tool. Fire it up and answer its questions, supplying the information that you’ve gathered. You’ll discover that thinking things through in advance will give you confidence as you work your way through the selection process, as well as afterward when the tool generates its recommendations. Far from being a worrisome experience, drive selection will become a routine task that gives plenty of satisfaction. PE
Don Congdon is a corporate trainer at SEW-EURODRIVE.
FIGURE 4:
A highly efficient electronic gearmotor integrating a motor, a helical gearbox and a variable frequency drive. Courtesy: SEW-EURODRIVE
‘ A decentralized VFD integrates more
seamlessly into the application and typically requires less wiring because it mounts very close to the motor.
’
ENGINEERING SOLUTIONS
PIPES AND PIPING SYSTEMS
Chris Mach, PE, and Brandon Grodi, PE, Matrix Technologies Inc., Maumee, Ohio
Does your facility need a pipe stress audit?
Learn to identify potential pipe stress or thermal growth problems using an explanation of pipe stress and thermal expansion
HObjectives Learningu
• Understand how thermal expansion of piping affects connected equipment.
• Learn how to spot common indications of high thermal stress in the field.
• Review how changing process conditions or pipe routings can cause thermal movement issues.
eat up a run of pipe, and it gets longer. That’s simple physics and of itself isn’t necessarily a problem. But piping rarely runs from point A to point B without being connected to something, usually a piece of equipment. Consider a straight run of pipe that connects two pressure vessels. How much force can a straight pipe heated to 300°F, fixed at both ends, generate? With perfectly stiff anchors, a 6-inch diameter pipe can generate nearly 250,000 pounds of force, limited only by the structural buckling of the pipe itself.
Where thermal growth meets a fixed object, like a piece of equipment, force is generated. Forces acting over an area result in stress. Pipe stress analysis calculates thermal growth and resulting forces and stresses. Good pipe stress design adds flexibility to the system and keeps forces and stresses manageable.
Flexibility isn’t just about routing but also supports and restraints designed to control the movement of expanding pipe. When this step in the design process is skipped or not given adequate attention, issues can result in the field. Below are some common indications that a thermal growth problem may exist at a plant.
Piping indications
Here are several piping and support issues in the field that may indicate the need for a pipe stress audit:
Bent or “squirming” pipe runs: This happens when a long run of pipe has grown thermally but is bound in the axial direction, the resulting force buckles the pipe. In long runs of pipe or piping runs with an expansion joint, you may see this as “squirming” of the pipe or lateral bends outside of the centerline of the pipe.
Bent elbows or tee connections: Another common indicator is excessive bending at a piping elbow or tee connection. Pay attention to elbows that seem extended too far (bent to an angle greater than 90 degrees) or compressed too far (bent to an angle less than 90 degrees). Look for piping connections that are no longer square.
Leaking flanges: Leaking flanges can have many causes, including improper bolt tightening, over pressure, corrosion and gasket failure. While leaking flanges may not be directly related to thermal growth issues, a poorly designed piping system can put excessive lateral or bending forces on a flange, resulting in leaks.
FIGURE 2: Pipe shoe lifted off steel. Courtesy: Matrix Technologies Inc.
FIGURE 3: Pipe shoe slid off steel. Courtesy: Matrix Technologies Inc.
FIGURE 1: Buckled section of piping. Courtesy: Matrix Technologies Inc.
Pipe support issues: Pipe supports are meant to support the weight of the pipe and, in some cases, direct the movement of the pipe or restrict excessive movements. Pipe shoes that have lifted or slid off support structures may indicate thermal growth issues. Pipe shoes, guides, line stop lugs or supporting steel that has been bent or broken are also good indicators.
Bent support steel or rod hangers: While it’s not uncommon to see rod hangers that are somewhat tilted, a rod that’s obviously bent or with a large rotation could point to thermal growth problems that need to be addressed. Bowed rods can also point to piping that has grown in unexpected directions.
Spring cans
Most spring cans and hangers have an indicator showing the relative position of the spring in relation to maximum allowed travel for the hanger. This same indicator typically shows both hot and cold positions. Indicators outside of the cold-tohot range or completely topped- or bottomed-out can indicate thermal growth issues.
Spring hangers should always hang vertically. Most manufacturers specify that spring hangers be installed within 4 to 5 degrees of vertical. Significant lateral tilt or rotation of the hanger indicates unplanned thermal movement. Significant tilt to the spring shaft can indicate the same issue in base cans.
Equipment indications
Rotating or reciprocating equipment: Pumps or other rotating equipment with a poor maintenance history, worn seals, worn bearings or alignment issues during routine maintenance can indicate high nozzle loads, which could be due to
FIGURE 4: Bent piping rod hanger vertical load.
Courtesy: Matrix Technologies Inc.
FIGURE 5: Bent piping rod hanger lateral loads. Courtesy: Matrix Technologies Inc.
FIGURE 6: Laterally skewed spring hanger support. Courtesy: Matrix Technologies Inc.
thermal loading. Rotating and reciprocating equipment nozzles are typically sensitive to high loads and are often found to be overstressed in the field.
Fixed equipment nozzles: Bent or cracked nozzles are sometimes seen on fixed equipment; if the bend is slight it may be seen as a distortion in the shell around the nozzle. More rarely, cracks around the nozzle or nozzle repad can form after long periods of high nozzle load or thermal cycling.
‘ Rotating and reciprocating equipment nozzles are typically sensitive to high loads and are often found to be overstressed in the field.’
Management of change indications
Some pipe stress problems are easier to spot from the office; plant documentation can sometimes show issues more clearly.
Process modifications: Equipment that has changed service or operating conditions can hide thermal stress issues. Changes to process fluid temperatures often manifest as thermal growth problems over long runs of attached pipe. Vessels operating at modified temperatures may impart new thermal movements to attached piping, lifting pipes off support steel or changing spring hanger loadings.
Piping and instrumentation diagram (P&ID) revisions: Clouded sections of P&IDs often indicate a change in the process conditions or piping interconnects. Does the change indicate equipment operating at new temperatures? Has a
Continued on page 38
u By knowing what to look for, a pipe stress audit can help a facility increase savings and production down the road.
uUnidentified safety and operational issues can be rectified after identification.
a few of our many abilitites
We constantly work to ensure both the availability of raw material and manufacturing capacity to provide our distributors with critical products needed.
ENGINEERING SOLUTIONS
Continued from page 35
new bypass line or piping interconnect recently been installed? Even small changes in piping connections or process conditions can result in thermal growth issues.
Construction or maintenance actions: Not every change to the structure or piping is planned; field conditions often require that adjustments be made. When this happens, it’s important to compare field piping to piping isometrics. Be particularly aware of construction or maintenance activities that cause changes to stress analyzed piping or adjacent support steel. Isometrics for stress analyzed piping are often clearly marked and should not be modified without additional analysis.
Next steps in a pipe stress audit
So, you’ve spotted a shoe that’s off the support steel, a bent section of pipe or bottomed-out
‘Be particularly aware of construction or maintenance activities that cause changes to stress analyzed piping or adjacent support steel.’
spring can. Maybe that pump with maintenance problems sounds all too familiar. Maybe a dozen little maintenance items suddenly came into focus after reading this article. Now what? It is time to contact a pipe stress professional and have them conduct a pipe stress audit. PE
Chris Mach, PE, is a senior consultant and team lead in the Analytical Services Group at Matrix Technologies Inc.
Brandon Grodi, PE, is the department manager of the Mechanical Group at Matrix Technologies Inc.
FIGURE 7: Stress analyzed piping tag for piping isometrics. Courtesy: Matrix Technologies Inc.
Atlas Copco Compressors is an industry-leader in compressed air technology and service. Nowhere is this more evident than in our extensive range of compressed air products and service plans. From oil-free & oil-injected compressors, to quality air products, to our nationwide parts & service network, we take our role as a reliable provider of all things air extremely seriously.
Our promise to you is we do more. What does that mean? Simply, we go further and deeper in every aspect of our offering to you. That promise extends way beyond just products. In each category where we compete— compressors, dryers, chillers, blowers, controls and more—we add our own unique innovation stamp and deliver outstanding value.
No other company offers more technologies to produce and manage air, but we don’t try to be a total solutions provider and we’re not a ‘one-stop-shop’.
Instead, we innovate in the focused areas where we are confident, we can provide a complete solution that has the lowest cost of ownership, maximizing efficiency and, most importantly, offer a complete service package that is second to none.
We have a presence in over 180 countries, but more importantly we are present where you are. We serve hundreds of thousands of customers globally with many household products and brands you know. But rather than list them all, we think you should be the focus. Let’s work together. Let’s find your savings level or productivity number and develop a plan to achieve it.
Though we’re most well-known for our air compressors products, Atlas Copco is by no means a compressor-only company. In fact, we have an extremely diverse product portfolio and service portfolio. Other items in our repertoire include:
• Nitrogen and Oxygen Generators
• High Pressure Air and Gas Compressors
• Industrial and Aeration Blower Technologies
• Industrial Cooling Equipment
• Quality Air (Dryers, Air Receivers, Aftercoolers, Filters)
• Service and Parts
Our solutions are made to work together. More importantly, they’re made to work for you.
“Our mission is to save U.S. manufacturers over $1 billion in annual electricity costs, while reducing CO2 emissions by 9 million metric tons.”
Atlas Copco Compressors LLC in Rock Hill, South Carolina
Robert Eshelman General Manager/ President
Atlas Copco Compressors
Rooted in principles of innovation and excellence, FS-Elliott has become a leading force in American manufacturing and a global authority in designing, manufacturing, and servicing centrifugal compressors. With a rich six-decade history, the company consistently raises industry standards by delivering solutions tailored to evolving customer needs.
Headquartered in Export, Pennsylvania, USA, FS-Elliott proudly produces a diverse range of centrifugal compressors. Whether customers require an engineered PAP Plus model tailored to API and customer specifications or a pre-engineered, industrial Polaris model, our units range from 250 to 6,000 HP, offering up to four stages of compression and pressures reaching 350 psig. As a testament to FS-Elliott’s confidence, the Polaris compressors are backed by an industry-leading warranty, providing peace of mind for our customers. The company’s flexibility extends to warranties, exemplified by a recent 10-year warranty supplied to a contractor in conjunction with a preventative maintenance program to support a US automotive manufacturer’s project requirements.
As a customer-centric company, FS-Elliott prioritizes understanding unique requirements and tailoring solutions to address specific challenges, whether new apparatus, controls, OEM upgrades, or service. Our team consistently strives for excellence, ensuring that FS-Elliott remains synonymous with reliability, performance, and energy efficiency.
“
Building on a 60-year
tradition of excellence, FS-Elliott’s commitment to providing exceptional value is the cornerstone of our vision. We don’t take a standard product as others do and try to make it work; instead, we analyze our customer’s requirements and create high-efficiency solutions specific to their application.”
—
Albert Gomez, Vice President of Global Services
From day one, FS-Elliott’s commitment to customer value is evident—from listening to requirements and quoting processes with dedicated engineers to continuous support during manufacturing, testing, and a culminating training school for partners and operators. FS-Elliott proudly offers lifetime support for its compressors, recognizing the critical importance of a positive customer experience.
With a global network of partners and distributors, coupled with factory direct services, FS-Elliott is not just a local success but a reliable partner for businesses worldwide. Whether seeking a trustworthy ally for compressed air needs or aiming to enhance facility efficiency, FS-Elliott stands ready to deliver unparalleled solutions and support.
Albert Gomez Vice President of Global Services
Building the machines that power industry; Hitachi Global Air Power, formerly Sullair, is a leading, global industrial compressed air solutions manufacturer. Known the world over for its reliable and durable air compressors and legendary air end, the company has been building Sullair brand compressed air solutions in Michigan City, Indiana since 1965.
In 2017, Hitachi Industrial Equipment Systems Co., Ltd. (“HIES”), a whollyowned subsidiary of Hitachi, Ltd. purchased Sullair, bringing together two innovation-forward titans in the compressed air industry. Since the acquisition, Hitachi has invested more than $45 million in Hitachi Global Air Power and added more connected capabilities that help customers achieve added energy savings and operational efficiencies.
“Our customers want reliable air power, period,” explains John Randall, Hitachi Global Air Power President and CEO. “Everything we do focuses on that simple concept. Our customers know they are getting decades of proven innovation so they can turn on their compressor and not worry whether their facility will have air power – it’s a legacy we are extremely proud of.”
“The acquisition by Hitachi has been transformational to our business,” said Randall. “Our customers are looking for more safety features, more energy efficiency — and with fewer experts on hand at their facilities due to workforce constraints, more reliability. Hitachi’s investment in our business is helping us answer these needs in new and innovative ways.”
Sullair compressors come in a full range of power and type — oil free, portable, rotary screw, centrifugalfor a variety of applications including food and beverage, pharmaceutical, construction, oil and gas, and more. New in 2023, the company launched an expansion of the popular LS Series
and added the DS Series - oil free compressors built on the proven legacy of the company’s oil free expertise. On the portable side, the company launched the E1035H electric portable compressor.
“We are working on some really innovative projects particularly around efficiency,” Randall continues. “With our sustainability goal of a carbon neutral value chain by 2050, our engineers are designing some next-level compressed air solutions; It is a very exciting time to be at Hitachi Global Air Power.”
“Our customers want reliable air power, period. Everything we do focuses on that simple concept.”
Telephone: 1-800-SULLAIR
hitachiglobalairpower.com
John Randall
Hitachi Global Air Power President and CEO
See better. Move quicker. Build smarter. Today’s world is lined with complexity. With each passing day digital transformation beckons with new technology and solutions. But through it all, one constant remains. Expertise leads the way. iBase-t has developed technology that identifies and augments the path ahead. But we’re more than a platform, we’re a people.
“We work hand in hand with our customers to embark on successful builds that enable critical projects all over the world. Whether it’s protecting interests at home or abroad, supplying hospitals with life-saving medical equipment, or sending spacecraft to explore the cosmos; we deliver today to determine tomorrow.”
We make the world’s most complex operations more productive, efficient, and intelligent. Our customers are the leading experts in their fields and depend on iBase-t’s industry expertise to not only navigate – but to thrive in – a critically complex age of manufacturing.
Since 1986, our team has been providing the digital operations tools necessary to drive innovation and our team’s domain knowledge spans aerospace and defense, electronics, industrial equipment, medical device, nuclear, space and ship building industries.
necessary our knowledge
Naveen Poonian
iBase-t President & CEO
Our technology is Solumina.
• It replaces paper-based processes and siloed applications with a digital solution that supports your critical processes and your model-based enterprise journey.
• Solumina is the only complete, integrated system that connects manufacturing operations, supplier quality, and sustainment management. All with embedded quality features to create a seamless flow of data across the value chain and product lifecycle.
• Now, with the first cloud-native manufacturing operation system on the market, we’re offering a scalable, reliable, and cost-effective approach to digital transformation.
We heard our customers when they said; “When it comes to information technology in manufacturing, they are on the leading edge. They are beating out everyone. But they’re the industry’s best-kept secret.”
So, we’re reaching out to you, to share that our industry experience is unmatched. Our platform is battle-tested. And our daily pursuit of better, safer, and smarter is infinite.
We are the custodians of what comes next. Your guide through the chaos. Together, we’ll arrive at a simpler tomorrow.
For more information, visit www.iBaset.com
When there seems to be limitless machinery component options, or in other cases, hard-to-find replacement parts, how are you to know which is best for the job? Narrowing it down to a single item for application is more difficult than ever due to the increasing number of industrial products in the marketplace. Continuous technological advances can make decisions either easier or more challenging.
Partners. The Best Part of All.
It can be overwhelming to consider all the different equipment types and their diverse applications. Often, it is most feasible to engage a specialized third party for the best bottom-line results. Our expert team at Motion is eager to partner with you to find the best product, design, build or repair solution for any application. These special partnerships are exemplary of the saying, “Two heads are better than one.”
Knowing the part that needs to be replaced or fixed is only half the equation, the other half being how quickly the needed part or service can be accessed. Replacement part availability is crucial with unexpected downtime, which can add up to significant costs. Today, more than ever, the bar has been set high for distributors and suppliers to satisfy customers’ delivery expectations. To effectively achieve this, one cannot be complacent and do business as usual because “it’s always been done this way.”
In recent years, we at Motion have effectively transformed our delivery and finalmile process with automated goods-to-person systems, regional fulfillment centers, data trend and technology leveraging, and other value-added capabilities—all with the goal of same- or next-day delivery to customers. We continually evolve our strategy to focus on exceeding your experience with a partner.
When our customers need complementary expertise, especially for a particular issue or specialized project, Motion is here to collaborate. Together, we will arrive at the best solution. Partners, the best part of all.
Visit Motion.com.
Limbaugh Executive Vice President & Chief Operations Officer at Motion
Joe Limbaugh is Executive Vice President & Chief Operations Officer at Motion. Serving the Company since 1983, he is responsible for product procurement and inventory, distribution and fulfillment centers, branch operations support, headquarters campus operations, marketing, productivity improvement, automation intelligence, conveyance, repairs/services, and company-wide lease management.
Joe
ENGINEERING SOLUTIONS
Jarred Richter, Hedgehog Tech, Burnaby, British Columbia
How to choose the right arc flash PPE
Emphasizing the critical importance of proper personal protective equipment (PPE) in safeguarding workers from the risks of arc flash events is critical.
When thinking about personal protective equipment (PPE) used for arc flash protection, many would first imagine it being used in a high voltage setting such as a substation or generation facility. The truth is given the right conditions, an arc flash event can occur inside any business. Selecting the right arc flash PPE is critical for keeping workers safe who are exposed to electri-
cal hazards. Without a good process, an arc flash event can cause serious injury or death. Therefore, taking note of a process to get the right equipment helps ensure a safer workplace.
Understanding three important PPE factors
Arc flash PPE requirements are difficult to navigate if the information is not readily available. To start, you can often find this information displayed in a high-voltage electrical panel. The arc flash and shock hazard label outlines three important factors:
1. Working distance - Refers to the distance between the person’s head and chest area from the potential arc source.
Objectives
• Learn three important factors for arc flash and shock hazard labels in high voltage electrical panels.
• Understanding the break-down of arc flash equipment.
• Learn best practices for maintenance and inspections of arc flash PPE.
2.Incident energy - Measured in calories per square centimeter (Cal/Cm^2) which is the amount of thermal energy exerted on a surface, positioned a specified distance from the source, produced during an electrical arc event.
3. Arc flash boundary - The distance at which a person without PPE may get a second-degree burn from an arc flash occurrence.
If the above information is unavailable on the arc flash equipment, it is recommended an arc flash hazard and risk assessment is conducted to establish the incident energy and boundary at a specific location. This can be completed by consulting an electrical engineer to perform the analysis or using software tools that calculate arc flash energy and working distance.
Using standards for verification
With those three pieces of information, verify them using relevant standards such as NFPA 70 (America), CSA Z462-21 (Canada) or IEEE 1584. These standards will support the decision in selecting PPE based on the incident energy levels.
For example, using CSA Z462-21 incident energy analysis will provide insight into the appropriate PPE from Table 3, 6A, and 6B. Once the PPE category is determined, refer to Table 6C which outlines the required PPE to be used.
FIGURE 2: Chart representing the difference between four different PPE categories. Courtesy: Hedgehog Technologies
Prioritize buying arc flash gear that provides an acceptable fit for every team member. It’s pivotal to invest in multiple sizes because loose or tight-fitting equipment can become a safety risk. It is recommended all workers using arc flash PPE should have their own pair of flame-resistant coveralls, balaclava, approved safety footwear, safety glasses and hearing protection. Inspecting these items should become part of the regular maintenance routine to identify any potential risks. For example, parts of the arc flash equipment have a shelf life which requires inspection.
Arc flash PPE best practices
It is recommended an inspection checklist is filled out before each use of arc flash PPE and
Insightsu
Arc flash PPE insights u Arc flash incidents can happen in diverse workplaces, necessitating proper personal protective equipment (PPE) selection crucial for safeguarding workers from potential serious harm.
uUtilizing specific standards, regular equipment inspections, diverse gear sizes, and fostering safety culture are pivotal in ensuring effective arc flash protection.
FIGURE 3: Example of an equipment testing interval with recommendations for inspection. Courtesy: Hedgehog Technologies
ENGINEERING SOLUTIONS
other isolated equipment. Like fall protection requirements, If any damage is spotted, employees should tag it, remove the PPE from service, and report it to management.
Training is another crucial factor. Ensure the team follows a detailed and regular training schedule to educate on the hazards associated with arc flash and how to properly use the equipment. This is a good place to revisit the equipment selection criteria, especially after there has been any upgrades or changes to the electrical system.
Lastly, fostering a company culture towards safety can greatly improve employee safety. Each person is their own safety critic and having safe operations top of mind is going to mitigate the risk of serious injury or death on any job site. PE
Jarred Richter is an electrical technologist at Hedgehog Technologies, a CFE Media and Technology content partner.
FIGURE 4: Jarred Richter providing training on arc flash PPE safety. Courtesy: Hedgehog Technologies
Optimizing Efficiency: Navigating Automation Operations in Food and Beverage
The food and beverage industry plays a critical role in our daily lives, providing essential resources worldwide. To ensure top performance, companies in this industry need to stay ahead by continuing to improve efficiencies through automation, process improvements, and to ensure they are doing the very best in health and safety. With the growing demand for items such as fruits, dairy products, and other resources in the food and beverage industry, the requirement for increased production becomes more pronounced.
The complexity of designing and operating automation can pose significant challenges, particularly for enterprises with a diverse range of customized products. Adapting to fluctuating customer demands, evolving regulations, and dynamic market conditions can also necessitate a level of flexibility that is needed in automation. It is crucial to approach automation with a clear understanding of its complexities and a commitment to navigating them successfully. Operations stand to gain benefits in terms of scale, scope, and speed with the help of automation.
They can increase their output, improve product quality and efficiency, expand their product range, and market reach, and respond swiftly to customer demands and changes in the market. Norgren and Bimba offer engineering resources to help educate and tackle customized needs, big or small. This white paper discusses the automation journey among food and beverage operations, discussing challenges, benefits, needs, and solutions. Furthermore, this white paper shows the many ways movement, control, and speed are heightened through automated systems.
Register to download the paper at: http://tinyurl.com/35ajhztn
Developing an effective PPE program for long-term success
Personal protective equipment (PPE) serves as the last line of defense between most hazards and employees and requires innovative strategies to improve PPE program success as companies strive for zero injuries in the workplace.
The Occupational Safety and Health Administration’s (OSHA) top 10 most frequently cited standards for 2023 reveal a concerning trend: there were 2,074 violations cited for inadequate eye and face protection alone, marking an increase of almost 700 violations compared to the previous year. Aside from this, respiratory protection was cited more this
year with nearly 300 violations more compared to last year. This sharp rise may indicate a pressing need for more effective personal protective equipment (PPE) programs.
In this article, we will address the challenge of getting employees to consistently wear PPE properly by examining two contrasting approaches to implementing PPE programs: compliance-driven versus employee-driven. As we delve into the dynamics of PPE usage in the workplace, it becomes evident the path to enhanced safety lies not only in strict adherence to OSHA standards, but also in fostering a culture where employees take ownership of their personal safety.
Importance of PPE in the workplace
PPE is more than just a compliance requirement; it is a vital line of defense against workplace hazards, reducing the risk of injuries, and fostering a more productive work environment. PPE includes protective gear such as gloves, respirators, hard hats, goggles, and protective clothing that act as a barrier between workers and potential dangers. Each type of PPE is designed to mitigate specific risks, such as physical impact, chemical exposure, electrical hazards, and environmental elements. The proper selection, use and maintenance of PPE are essential in creating a safe workplace, underscoring the need for effective PPE programs.
Navigating PPE & OSHA standards
The Occupational Safety and Health Administration (OSHA) requires employers to protect their employees from workplace hazards. Having the hazard eliminated or controlled at its source is the most ideal way to protect employees, however, when these are not possible or do not provide enough protection, employers are mandated by OSHA to provide appropriate personal protective equipment (PPE) to their workers at no cost. This is
FIGURE 1: An infographic showing the different types of PPE such as head protection, respiratory protection, foot and leg protection, eye and face protection, hand and arm protection, and body protection. Courtesy: TradeSafe
‘ Compliance-driven PPE programs primarily focus on meeting the set standards and regulations as mandated by OSHA.’
in line with the hierarchy of controls wherein PPE is placed at the bottom as the last resort for protection against hazards.
Employers are responsible for conducting a thorough hazard assessment to identify and control physical and health hazards, providing appropriate PPE, training on its correct use and maintenance, replacing worn or damaged PPE, and updating the effectiveness of the workplace’s PPE program. Providing PPE is not enough; employers must also enforce its use and evaluate the adequacy of the equipment in relation to the evolving workplace hazards.
While employers are responsible for providing and maintaining PPE, employees also play a crucial role in ensuring their own safety. OSHA standards emphasize that employees must wear PPE correctly to protect themselves from injuries and exposure to harmful substances in hazardous environments. Employees are also required to attend training sessions on PPE use, covering aspects like donning and doffing procedures, and understanding what to do in case of PPE malfunction. Moreover, workers are responsible for cleaning and maintaining their PPE, and informing their supervisors when there is a need to replace or repair the protective equipment.
Although employers and workers have different responsibilities required by OSHA, they are both involved in a critical aspect of PPE programs: the PPE assessment process. This involves identifying potential hazards in the workplace and determining the appropriate type of PPE needed to mitigate these risks. The assessment should be comprehensive, involving employer and employee input, and should be regularly updated to reflect changes in work processes, equipment, and external regulations.
Understanding the distinct roles of employer and employee in PPE programs and assessment sets the stage for a deeper understanding of two contrasting approaches to PPE programs: compliance-driven and employee-driven. While these
approaches are aimed at ensuring safety, they differ in their execution and impact on workplace culture and safety efficacy.
Compliance-driven PPE programs
Compliance-driven PPE programs primarily focus on meeting the set standards and regulations as mandated by OSHA. These programs, governed by strict adherence to rules and guidelines, prioritize legal conformity and a top-down approach to safety management, often centering on the employer's responsibility to provide and enforce the use of PPE. This approach, while effective in meeting regulatory requirements, brings into question the level of employee engagement and long-term effectiveness in fostering a comprehensive safety culture.
Benefits of compliance-driven programs include ensuring organizations meet the minimum safety standards set by OSHA, thereby reducing the risk of legal penalties and enhancing the basic safety of the workplace. By following these guidelines, employers can systematically address a range of workplace hazards and equip workers with the necessary protective gear. This approach provides a structured framework for PPE management, streamlining the process of hazard identification, PPE selection, and training, which is crucial in large and complex industrial settings.
However, a compliance-only approach to PPE can lead to a superficial understanding of workplace safety, where the focus is on ticking boxes rather than addressing the specific needs of the workforce. Such programs may fail to adapt to unique or changing conditions in the workplace, potentially leaving gaps in worker protection.
FIGURE 2: An infographic of the Hierarchy of Controls in an inverted pyramid to show the most effective to least effective control. Courtesy: TradeSafe
Objectives Learningu
• Understand the employer and employee responsibility for PPE & OSHA standard and how to perform PPE assessments.
• Learn about compliancedriven programs and how they can provide positive results as well as understand the potential dangers and unintended consequences of a program.
• Understand how employee-driven programs can be effective with proper communication and training to help ensure long-term success.
ENGINEERING SOLUTIONS
‘ The long-term success of employee-driven PPE programs lies in their ability to adapt to changing workplace conditions and employee needs. ’
Furthermore, this approach can cause a complacent attitude towards safety, where the presence of PPE is equated with a safe working environment, even if the equipment is not adequately suited to the tasks or not used correctly by the employees.
While compliance-driven PPE programs are intended to provide a baseline of safety, they can sometimes lead to unintended consequences, such as a disconnect between workers and management regarding the practicality and comfort of the provided PPE. However, an intended positive consequence is the establishment of a clear and consistent safety protocol, which is important in industries with high risks. Yet, the rigidity of such programs can inhibit employee feedback and participation, potentially overlooking innovative and more effective safety solutions employees might suggest based on their on-the-ground experience.
Employee-driven PPE programs
In contrast to the structured compliance-driven approach, employee-driven PPE programs offer a more dynamic and participatory model of safety management. This approach leverages the insights
and experiences of employees to create a more adaptable and effective PPE program. By involving employees in the decision-making process, these programs enhance compliance and foster a sense of ownership and responsibility toward workplace safety. Consider these three PPE programs that take on this approach:
1. Participatory PPE selection committees: By forming committees that include representatives from various employee groups, companies can ensure the PPE selected is both suitable for the specific hazards of the job and comfortable for daily use. This inclusive approach leads to higher employee satisfaction and compliance with PPE usage.
2. Peer-led safety training sessions: Utilizing knowledgeable and experienced employees to lead safety training sessions can create a more engaging and relatable learning experience. Peer trainers can share real-world experiences and tips, making the training more practical and impactful.
3. Employee-led safety audits: Empowering employees to conduct regular safety audits allows for continuous feedback and improvement of PPE programs. These audits, led by the employees themselves, can identify unseen hazards and practical challenges, ensuring PPE programs evolve with the changing needs of the workplace.
When it comes to the success of any employee-driven PPE program, effective communication is crucial. Regular, open dialogues between management and employees ensure PPE programs remain
Table 1: Employers' Versus Employees' Responsibilities
relevant and effective. Training, in this context, goes beyond mere instruction on how to use PPE; it involves educating employees about the rationale behind PPE choices and encouraging them to voice their concerns and suggestions. This level of engagement not only enhances understanding, but also builds a culture of safety where employees feel valued and heard.
The long-term success of employee-driven PPE programs lies in their ability to adapt to changing workplace conditions and employee needs. By involving employees in the continuous assessment and improvement of PPE programs, companies can ensure these initiatives remain effective and relevant. This approach also fosters a proactive safety culture, where employees are active contributors to the safety dialogue. This leads to heightened safety awareness, reduced accidents and a more harmonious relationship between management and employees regarding workplace safety.
The challenge of ensuring consistent use of PPE in the workplace calls for innovative strategies that strike a balance between the structured approach of compliance-driven programs and the participatory nature of employee-driven programs. Such a combination approach would include the strengths of both models for legal compliance while also fostering a workplace culture where employees feel involved and invested in their safety.
For instance, a combined strategy could involve setting up a compliance framework based on
OSHA standards, within which employees participate in selecting and evaluating the PPE. This could be facilitated through joint committees comprising both management and employee representatives to make sure the selected PPE is not only compliant with regulations as well as practical and comfortable for the workers. Training programs could also be designed to blend formal compliance education with peer-led sessions, where experienced workers share practical tips and insights, making the learning process more relatable and effective.
Incorporating technology, such as digital feedback tools or apps, can bridge the gap between compliance and employee-driven approaches. These tools can provide a platform for employees to report issues, suggest improvements, and receive updates on PPE usage and safety protocols. This ongoing dialogue creates a sense of ownership among employees, encouraging them to adhere to PPE protocols not just as a compliance requirement but as an integral part of their daily work routine.
By combining the structure of compliance-driven programs with the adaptability and employee engagement of employee-driven approaches, organizations can create a robust and resilient safety culture that not only meets regulatory standards, but also protects and values its workforce. PE
Herbert Post is VP of safety and health at TradeSafe, a CFE Media and Technology content partner.
uThe surge in violations for inadequate eye and face protection, plus increased respiratory protection citations, signals a critical need for more effective PPE programs.
uPPE isn't just about compliance; it's a frontline defense. Effective programs involve comprehensive hazard assessment, employee training, and a culture of shared responsibility.
uContrasting compliancedriven and employeedriven PPE approaches highlight the importance of blending structure with participation for legal compliance and a safetyfocused culture.
ENGINEERING SOLUTIONS
Eric Whitley, L2L, Salt Lake City
Developing a successful PPE blueprint for plant managers
Personal protective equipment (PPE) plays a pivotal role in ensuring worker safety across various industries. Nine future PPE trends in manufacturing are highlighted.
Personal protective equipment (PPE) is a universal foundation of safety in facilities. It's not merely a compliance hurdle — PPE represents an organization's dedication to the well-being of its workforce. In industries where risks are inherent, the right PPE can mean the difference between a regular workday and a life-altering incident.
In specialized areas like electrical, mechanical, and automation engineering, PPE takes on heightened significance. Electrical engineers, for instance, need PPE that guards against electrical shocks and arcs. Mechanical engineers might require protection from moving parts, while those in automation need safeguards against the unique risks posed by automated machinery. In maintenance and management, PPE ensures that routine checks and repairs can be conducted safely, without exposing workers to undue risks.
Industry regulations’ role in PPE selection
u
Objectives Learning
• Gain a comprehensive understanding of the importance of Personal Protective Equipment (PPE) in safeguarding workers from workplace hazards.
• Get familiar with key industry regulations and standards governing PPE selection and compliance, ensuring worker safety and legal adherence.
• Acquire insights into best practices for conducting comprehensive risk assessments, balancing cost-effectiveness with safety and effectively sourcing PPE to enhance workplace safety and overall operational efficiency.
Plant managers face a number of challenges when it comes to PPE. The task isn't just about finding equipment, but also finding the right equipment that meets industry standards, suits specific task requirements and fits budgetary constraints. Ensuring quality and timely delivery adds another layer of complexity.
Understanding the basics of PPE
PPE serves a singular, vital purpose: to shield workers from workplace hazards. It’s a barrier that mitigates the risk of injury or health complications arising from specific job functions or environments. Whether it's protection from chemicals, electrical currents or physical impacts, PPE ensures workers return home in the same health they arrived in.
The spectrum of PPE is vast, tailored to the myriad risks workers might encounter. Headgear protects against falling objects, while specialized footwear might offer resistance against electrical hazards or chemical spills. Each piece of equipment is designed with a specific threat in mind, ensuring comprehensive protection.
Industry regulations form PPE standards, ensuring that equipment meets specific safety criteria. These regulations, often developed by industry experts and safety organizations, provide a benchmark for PPE quality and performance.
Among the most prominent regulation in force today includes:
• OSHA Standards (U.S.): The Occupational Safety and Health Administration (OSHA) sets and enforces standards to ensure safe working conditions for employees in the U.S. Its regulations cover a wide range of PPE including eye and face protection, respiratory devices, and protective clothing.
• Personal Protective Equipment at Work Regulations (UK): This UK-specific regulation mandates employers to provide appropriate PPE for their workers. It covers the assessment, provision, maintenance, and correct use of PPE to protect workers from health and safety risks.
• PPE Regulation (EU) 2016/425 (European Union): This EU regulation outlines the requirements for PPE design, production, and marketing to ensure a high level of protection for users. It emphasizes the responsibilities of manufacturers, importers, and distributors.
• ANSI/ISEA Z87.1 (U.S.): Defined by the American National Standards Institute and the International Safety Equipment Association, this standard pertains to the requirements for eye and face protection devices, ensuring they provide adequate protection against specific hazards.
• AS/NZS 2210.1 (Australia/New Zealand): This standard, set by the joint Australian/New Zealand committee, focuses on safety, protective, and occupational footwear. It ensures footwear meets specific requirements to protect against various workplace hazards.
• CSA Standard Z94.3 (Canada): The Canadian Standards Association's regulation for eye and face protectors. It outlines criteria related to the design, construction, testing, and use of eye and face protection devices.
• NFPA 70E (U.S.): Developed by the National Fire Protection Association, this standard addresses electrical safety-related work practices. It provides guidance on PPE selection for workers exposed to electrical hazards.
• ISO 20345 — Safety Footwear (International): An international standard set by the International Organization for Standardization, ISO 20345 specifies requirements for safety footwear, ensuring protection against various risks like impact, compression, and chemical exposure.
Compliance with PPE regulations isn't just a matter of legality, but a commitment to worker safety. Non-compliance can lead to severe repercussions, both in terms of worker health and legal consequences. Beyond the immediate risk of injuries or fatalities, organizations might face hefty fines, lawsuits, and reputational damage if they fail to adhere to established standards.
Another important consideration: PPE regulations are not one-size-fits-all. They vary based on the specific risks associated with different industries and are often tailored to address those unique challenges.
Regional differences also come into play with countries or even states having their own sets of
rules based on local risks, industry presence, and historical data.
Conducting comprehensive risk assessments
Conducting a risk assessment is a systematic process. It begins with identifying potential hazards in the workplace, whether they're related to machinery, chemicals, or processes. Once identified, these hazards are evaluated based on their likelihood and potential severity. Finally, appropriate measures, including the selection of suitable PPE, are implemented to mitigate these risks.
Different manufacturing areas come with their own set of challenges. For instance, the assembly line might pose risks related to moving machinery, while the chemical processing unit could expose workers to toxic substances. It's crucial
‘ Personal protec-
tive equipment
(PPE)
is a universal foundation of safety in facilities.
’
FIGURE 1: Connected worker platforms, leveraging technologies like the Internet of Things (IoT) and artificial intelligence (AI), can further enhance personal protective equipment (PPE) management. Courtesy: L2L
ENGINEERING SOLUTIONS
‘ Industry regulations form PPE standards, ensuring that equipment meets specific safety criteria."’
for plant managers to dissect each area, understand the specific hazards present, and ensure that workers are adequately protected.
Once hazards are identified and evaluated, the next step is to determine the appropriate PPE. This decision is based on the risk level associated with each hazard. For high-risk scenarios, PPE with rigorous protective features might be required, while lower-risk environments might necessitate more basic protection.
Balancing cost-effectiveness with safety considerations
While the upfront cost of PPE is a tangible figure, plant managers must also consider the potential costs of skimping on protection. Non-compliance or accidents can lead to financial liabilities far exceeding the initial investment in quality PPE. It's important to view PPE not just as an expense but as an investment in safety and longterm financial prudence.
Insightsu
Personal protective equipment (PPE) insights
uChoosing the right PPE is beyond compliance; it's safeguarding lives. Identifying hazards, adhering to industry standards, and balancing costs ensure comprehensive protection.
uPPE regulations aren't universal. Compliance isn't just legal; it's a commitment to safety. Regional variations and evolving standards necessitate continuous monitoring.
uThe future of PPE transcends traditional gear. From IoT-integrated equipment to AI-driven risk assessment, innovations prioritize worker well-being and operational efficiency.
The lifespan of PPE is a crucial factor in its overall cost-effectiveness. Durable equipment that can withstand the rigors of daily use without frequent replacements offers better value in the long run. Regular maintenance checks ensure PPE remains in optimal condition, maximizing its protective capabilities and lifespan.
Balancing safety and budgetary constraints requires a strategic approach. This might involve bulk purchasing, negotiating with suppliers for better rates, or investing in durable PPE that, while more expensive initially, offers longer service life and better protection. Regular maintenance and timely replacement also can ensure PPE remains effective without incurring unnecessary replacement costs.
Best practices and recommendations for sourcing PPE
Identifying the right PPE supplier is almost as crucial as selecting the right equipment. Managers should seek suppliers with a proven track record, verified testimonials, and industry certifications. Engaging in pilot testing or requesting samples can also provide insights into product quality before making a bulk purchase.
Quality assurance is non-negotiable when it comes to PPE. Given the critical role PPE plays
in worker safety, ensuring that products meet or exceed industry standards is paramount. Regular audits, third-party certifications, and adherence to international safety standards can provide confidence in a supplier's product quality.
Local sourcing often offers faster delivery times and easier communication, but it may come with a higher price tag. International suppliers, on the other hand, might offer competitive prices but could pose challenges in terms of shipping delays, customs issues, or quality inconsistencies. Weighing these pros and cons based on specific needs can guide the sourcing decision.
Bulk purchasing can lead to significant cost savings, as many suppliers offer discounts for large orders. Forming partnerships or joining consortiums also can provide collective bargaining power, leading to better pricing and terms. These strategies not only reduce costs, but also can streamline the sourcing process.
Implementing PPE protocols and training
Even the best PPE can fail if not used correctly. Comprehensive training ensures that staff understand the importance of PPE, know how to wear and maintain it, and are aware of its limitations. Regular refresher courses can reinforce this knowledge, ensuring consistent and correct PPE usage across the board.
Routine checks and maintenance are vital to ensure PPE remains in optimal condition. Protocols should be established for regular inspections, cleaning, and, if necessary, replacements. Such proactive measures can prevent equipment failures and ensure workers are protected at all times.
Connected worker platforms, leveraging technologies like the Internet of Things (IoT) and artificial intelligence (AI), can further enhance PPE management. These platforms can monitor PPE usage, send alerts for maintenance or replacement, and even provide data-driven insights to improve safety protocols. Integrating such technologies can elevate the effectiveness of PPE programs.
Nine future PPE trends in the manufacturing sector
The PPE industry, like many others, is undergoing a transformation driven by rapid technological advancements. Innovations like smart helmets
with augmented reality or wearables that monitor vital signs are reshaping the PPE landscape. These advancements not only offer better protection, but also enhance worker efficiency and comfort.
Let’s look into some exciting trends to watch out for in the near future (some of which are already being implemented):
1. Work exoskeletons: Work exoskeletons are wearable devices that amplify a person's physical capabilities by providing external support and augmentation, allowing them to lift heavy objects with minimal effort and reducing the risk of musculoskeletal injuries. These devices reduce the risk of musculoskeletal injuries, helping ensure workers can perform physically demanding tasks without compromising their health.
2. Smart fabrics: Smart fabrics represent the next frontier in adaptive wearables. These advanced textiles come embedded with sensors that can detect and respond to environmental conditions. Whether it's regulating temperature to keep workers comfortable or changing texture to provide better grip, smart fabrics are set to redefine how we think about clothing in the workplace.
3. IoT-integrated PPE: The fusion of IoT with PPE is a game-changer. Such equipment can continuously send real-time data about its condition, wear, and tear. This ensures timely maintenance or replacement and provides insights into environmental conditions, alerting workers to potential hazards in their vicinity.
4. Drones for safety inspections: Drones are revolutionizing safety inspections. They can swiftly and safely inspect hard-to-reach or potentially hazardous areas, ensuring environments are safe before workers set foot in them. This enhances safety while saving time and resources at the same time.
5. AI-powered risk assessment tools: Predictive tools use AI to analyze vast amounts of data to foresee potential hazards, allowing for proactive safety measures. These tools can recommend tailored PPE solutions based on specific tasks, environments, and individual worker profiles.
6. Virtual reality (VR) training: VR can simulate a range of hazardous situations, allowing workers to practice safety protocols in a risk-free environment. This immersive training helps ensure workers are prepared and know the right actions to take when faced with real-world dangers.
7. Biometric monitoring wearables: Health monitoring goes beyond the doctor's office with these wearables. Devices that continuously monitor vital signs, fatigue levels, and other health indicators can provide real-time feedback to workers. If any anomalies are detected, alerts can be sent to both the worker and supervisors, ensuring timely interventions and reducing health risks.
8. Augmented reality (AR) maintenance guides: Wearable AR devices can overlay digital information on the physical world, providing real-time guidance on equipment maintenance and repair. This ensures tasks are performed safely, efficiently, and correctly, reducing the risk of equipment malfunctions.
9. Environment-sensing devices: These devices are like a sixth sense for workers. Wearables equipped to detect harmful gases, radiation, or extreme temperatures can provide immediate alerts. By doing so, they ensure workers can take timely precautions, avoiding exposure to potentially harmful conditions.
Keep in mind that as industries evolve, so do the risks associated with them. This will lead to changes in PPE regulations and standards. Plant managers should stay on top of industry trends, participate in relevant forums and engage with regulatory bodies to anticipate and prepare for these shifts.
Continuous learning and adaptability are key for plant managers. Subscribing to industry journals, attending seminars, and participating in workshops can provide insights into emerging risks and PPE solutions. Building a network of peers and experts also can offer a platform for knowledge exchange and collaboration.
Developing a strong PPE approach
An informed approach to PPE is the bedrock of worker safety. Aside from buying the equipment, it’s about understanding the unique risks of an environment and sourcing the best protective solutions. With the right strategies and a proactive mindset, plant managers can ensure their teams are not only protected, but empowered to perform their best. PE
Eric Whitley is the director of smart manufacturing at L2L, a CFE Media and Technology content partner.
‘ Identifying the right PPE supplier is almost as crucial as selecting the right equipment. Managers should seek suppliers with a proven track record, verified testimonials, and industry certifications.’
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