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VIEWPOINT
5 | Predictive or preventive maintenance: Which strategy is right for you?
Learn to lend predictive, preventive maintenance to achieve the right business balance.
INSIGHTS
8 | How manufacturers utilize asset management for better maintenance, management results
Asset management is a critical aspect for manufacturers and it helps turn data into actionable information that can change operations
SOLUTIONS
12 | How do NFPA 70E-2024 updates improve electrical safety?
Learn about the NFPA 70E “point of work” concept, which focuses on proactive electrical safety measures where the work is performed
18 | Know how to identify, recognize electrical and unapparent hazards
The purpose of this article is to help identify a variety of workplace hazards and provide basic electrical safety
SOLUTIONS
| Back to basics: How to reduce electrical hazards in industrial workplaces
Electrical safety in industrial workplaces begins with awareness of potential electrical hazards and the strategies that are available to mitigate them
28 | How to create a culture of electrical safety at a manufacturing facility
More awareness and education are needed to create a culture of electrical safety
31 | Building a world-class predictive maintenance foundation
E. & J. Gallo’s World Class Maintenance initiative builds a predictive maintenance foundation. 34 | Evolution of copper corrosion testing for electric vehicle lubricants
New copper corrosion test methods are being developed to make electric vehicle (EV) lubricants better.
| Chain lubrication considerations for extreme conditions
Chain lubrication is useful for extreme applications for equipment or situations that are dangerous for humans to enter while in production.
MAY/JUNE
Portable test instrument taking a reading through a UL 61010 test point permanent electrical safety device (PESD).
is
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AMANDA PELLICCIONE, Marketing Research Manager APelliccione@WTWHMedia.com
SUSIE BAK, Staff Accountant SBak@WTWHMedia.com
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
• Compressed air systems
• Efficient motor management
• Expert Q&A: Automation
• Fall protection
• Gears and bearings
• Material handling
• Preventive maintenance
• Transformer efficiency
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Content For Engineers. WTWH Media focuses on 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.
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Predictive or preventive maintenance: Which strategy is right for you?
Learn to blend predictive, preventive maintenance to achieve the right business balance
In today’s high-tech manufacturing facilities, maintenance emerges as a linchpin of operational success.
It is the meticulous attention to detail, the strategic planning and the technical expertise of plant managers and engineers that ensure the seamless functioning of machinery and the uninterrupted flow of production.
Within this realm, two distinct yet complementary strategies — predictive and preventive maintenance — stand as indispensable methodologies, demanding both oversight and strategic allocation of resources.
Amara Rozgus, Editor-in-Chief
Predictive maintenance, the mark of forward-thinking engineering, relies on a sophisticated blend of data analytics, sensor technology and machine learning algorithms to anticipate and preempt potential failures. Plant managers and maintenance engineers orchestrate the deployment of sensor networks across critical equipment, capturing real-time data on performance metrics, such as temperature, vibration and fluid levels. This data serves as the essence of predictive maintenance, fueling predictive models that forecast impending issues with remarkable accuracy.
However, predictive maintenance alone cannot solve all a facility’s operational problems. It requires a synergistic partnership with preventive maintenance to strengthen manu-
facturing operations. Plant managers and engineers collaborate to establish comprehensive maintenance schedules based on historical performance data, manufacturer recommendations and industry best practices. It is the seamless integration of predictive and preventive maintenance strategies that unlocks the full potential of maintenance excellence in manufacturing plants. Plant managers and engineers navigate the intricate interplay between these methodologies, leveraging predictive information to inform preventive actions and finetuning maintenance schedules based on real-time performance data. This holistic approach not only minimizes downtime and maintenance costs but also fosters a culture of continuous improvement, where each maintenance activity serves as a catalyst for operational excellence.
Maintenance in manufacturing plants transcends the realm of routine tasks, emerging as a strategic imperative demanding the expertise and foresight of plant managers and engineers. Through the meticulous implementation of predictive and preventive maintenance strategies, these professionals uphold the operational integrity and resilience of manufacturing operations, navigating the complex terrain of technological advancements and operational challenges with precision and efficiency. PE
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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. 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.
How manufacturers utilize asset management for better maintenance, management results
Asset management is a critical aspect for manufacturers and it helps turn data into actionable information that can change operations.
Question: What’s the current trend in asset management for industrial and manufacturing facilities?
Pratibha Pillalamarri: An important trend in asset management for industrial and manufacturing facilities is the integration of advanced technologies. Embracing industrial artificial intelligence (AI) and machine learning (ML) strategies has emerged as an important component for optimizing asset performance. This shift reflects a broader recognition among companies and our customers that operational efficiency is intrinsically tied to asset management efficacy.
‘ Artificial intelligence (AI) and machine learning (ML) serve to augment the fundamentals, allowing asset management teams to monitor more assets, improve planning and execution accuracy and make more strategic decisions based on data.’
Central to this framework is the imperative of proactive monitoring of process health and performance. Leveraging the abundance of data available, predictive analytics and AI algorithms provide realtime insights, enabling preemptive actions to avoid potential disruptions. This departure from traditional reactive approaches signifies a strategic shift towards proactive maintenance strategies.
Additionally, there is a growing focus on sustainability, emphasizing environmentally-friendly operational practices to enhance resource efficiency and environmental stewardship.
The combination of these trends signals a new era of efficiency and cost-effectiveness in asset management. By prioritizing continuous operations, reducing downtime and adopting sustainable practices, organizations can achieve significant improvements in productivity and cost savings.
Question: What future trends should engineers, plant managers and designers expect for asset management? (Looking ahead one to two years.)
Chris Barnes: Three megatrends are shaping the future of asset management in the near- to medium-term.
The first is technological and tends to get the most hype — and that’s the accelerating accessibility of consumer-grade AI. Asset management is ripe for AI adoption thanks to the investments made over the past decade-plus equipping assets with sensors connected to the Internet of Things (IoT). With the vast and diverse datasets available from IoT-connected assets, we expect to see routine asset management tasks shift to autonomous workflows performed by AI.
The second megatrend is an increasingly hybrid workforce — both in terms of skills and work environments. AI support tools and IoT-connected sensors enable hybrid operating models for asset management teams that bring together local and remote experts, both equipped with real-time digital asset monitoring and proactive alerting. Making effective use of these tools requires a hybrid of digital and mechanical skills, driving a competitive landscape for hiring the right skills mix to match future ways of working. In fact, 94% of manufacturers
expect to maintain or grow their workforce to keep up with AI adoption, according to Rockwell Automation’s 2024 State of Smart Manufacturing report.
The third megatrend is a focus on decarbonization and sustainable outcomes. As organizations prioritize sustainability goals and regulatory requirements become more stringent, asset management teams must integrate environmental considerations into their asset management practices. This includes optimizing energy usage, reducing carbon emissions and extending the lifespan of assets through proactive maintenance and eco-friendly upgrades. Investments in renewable energy sources, energy-efficient technologies and circular economy principles will become central to asset management strategies, driving innovation and reshaping industry standards.
Brian Fortney: The biggest trend should be the increasing integration and the work into the ecosytem of tools. This will drive new thinking about storerooms/spares supply and even workforce training. Increased visibility to lifecycle also will drive new approaches to obsolescence risk.
Pratibha Pillalamarri: A growing emphasis on sustainability is reshaping operations and highlighting the interconnectedness of design decisions with operations and maintenance. Looking ahead, sustainable practices will intertwine more deeply with operational frameworks, requiring alignment between design intent and operational realities. Moreover, there is a surge in the adoption of IoT and predictive analytics for real-time monitoring, alongside the rise of digital twins and cloudbased solutions for improved asset optimization. AI and ML will be adopted to enable more data-driven decision-making, as resilience and risk management become more important. By embracing these trends, stakeholders can navigate the changing landscape with agility, promoting efficiency, sustainability and resilience.
Question: Describe the successes from using programs and systems that incorporate asset management. This may include Internet of Thingsbased systems, Industry 4.0, etc.
Pratibha Pillalamarri: YPF's implementation of Aspen Mtell has led to substantial successes in asset management. Initially monitoring 11 critical pieces of equipment across three refineries, the program expanded to oversee 49 assets, including pumps, compressors, heat exchangers and reactors. Leverag-
ing advanced machine learning capabilities, Aspen Mtell tracked 3,000 sensor tags, facilitating proactive detection of equipment abnormalities.
For example, it identified issues in a vital compressor six months before traditional methods would have, saving almost five days of production. Additionally, the solution detected increased temperatures in the hydrocracking unit, enabling timely maintenance to prevent potential damage and production loss. This success prompted a cultural shift towards proactive maintenance and efficient work prioritization within YPF.
YPF focuses on safeguarding additional assets, optimizing energy efficiency and addressing issues related to fouling and corrosion. In a significant step towards sustainability, YPF introduced agents to monitor emissions from one refinery, with plans to expand this monitoring to all 26 discharge sources. This dedication to sustainability showcases YPF's proactive stance towards environmental responsibility and drives innovation in Argentina's oil and gas industry.
Question: What tips would you offer to someone newly tasked with asset management duties?
Brian Fortney: The best advice for someone newly tasked with asset management responsibility would be to get your "blinders" off as quickly as possible and create visualizations to answer: What do you have? What do you need? Where is your risk? Think of it like a map where you have to identify current state to know the distance of your journey to desired state. Once you have these visualizations, identify your strategy to get to desired state and leveraging the information at your fingertips to support investment and action.
Question: How has the integration of artificial intelligence (AI) and machine learning (ML) impacted traditional asset management strategies?
Chris Barnes: AI and ML serve to augment the fundamentals, allowing asset management teams to monitor more assets, improve planning and execution accuracy and make more strategic decisions based on data.
There are three types of problems where AI/ML can be applied:
1. Known problems with known solutions — AI agents pre-trained on asset management principles serve as a force-multiplier for human experts. By
Chris Barnes, senior manager, AI & IoT – maintenance & reliability, Kalypso, a Rockwell Automation business, Los Angeles
Brian Fortney, global capability manager, asset optimization services, Rockwell Automation, Cleveland
Pillalamarri, former senior product marketing manager, Aspen Technology, Houston
Pratibha
INSIGHTS
Objectives Learningu
• Understand and learn about the current maintenance trends manufacturers are dealing with.
• Learn how different thought leaders are developing their maintenance strategies to evolve with a changing manufacturing landscape.
monitoring a very large number of assets to detect and prioritize known problems, human experts are freed up to focus on only the most pressing issues.
2. Known problems needing customized solutions — ML can help tailor existing asset management strategies using both real-time operational inputs and statistical analysis learned over large historical datasets from in-field assets. By accounting for operational disturbances and learned failure patterns, AI agents can advise improvements to current strategies.
3. Complex problems with to-be-discovered solutions — Specific ML techniques like deep reinforcement learning can identify asset management strategies that yield optimal system-wide results. These techniques accelerate data-driven workflows like root cause analysis, leveraging large and diverse datasets of operational inputs and human decision-making, to recommend strategies that would take human operators years of analysis to achieve.
Pratibha Pillalamarri: The integration of AI and ML has transformed traditional asset management
strategies, bringing in a new era of efficiency and effectiveness. Traditional practices involved a combination of reactive maintenance practices, often treating equipment and processes in isolation. However, with the emergence of AI and ML technologies, customers are realizing the interconnectedness of equipment and processes.
Advanced technologies enable customers to optimize processes by identifying optimal operat g process and maintenance data. By analyzing vast amounts of data, AI and ML can predict equipment and process issues ahead of time, providing prescriptive guidance on how to address them, including adjustments to operating regimes. This predictive and prescriptive approach shifts asset management from reactive to proactive, leading to improved reliability, efficiency and cost-effectiveness.
Question: How does effective asset management contribute to improved maintenance practices?
Brian Fortney: An effective asset management strategy will set the rules of the road for maintenance programs. You can be the hero of your epic journey, but you will need allies and you will face obstacles. Maintenance partners can be great allies in the journey, but you may have to train them to enable support of your strategy. The obstacles to be vanquished include poor documentation, outdated systems, mismanagement of storerooms, required training, and inconsistent repair quality. Communicating strategy and outcomes is key to enabling improved maintenance practices to support effective asset management.
Pratibha Pillalamarri: Effective asset management improves maintenance practices by enabling proactive strategies and optimal resource allocation. Through predictive maintenance techniques, organizations can prevent equipment failures, minimizing downtime and optimizing asset reliability. Comprehensive asset management solutions complement existing condition-based maintenance, allowing maintenance activities
to be triggered based on asset condition rather than fixed schedules. Not just that, leading solutions provide users with actionable insights allowing for intervention.
They also notify users of an optimal window by considering the financial impact of various scenarios. By integrating with enterprise asset management (EAM) and computerized maintenance management systems (CMMS), these asset management solutions can request work orders, allowing for timely interventions. Maintenance personnel can also document their learnings or effectively utilize inbuilt FMEA libraries. By analyzing performance data, equipment and process, organizations can optimize asset performance and utilization, reducing energy consumption and maximizing efficiency. By implementing proactive strategies, organizations can optimize resource allocation, ensure regulatory compliance and enhance asset reliability and performance. PE
‘ Effective asset management improves maintenance practices by enabling proactive strategies and optimal resource allocation.’
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How do NFPA 70E-2024 updates improve electrical safety?
Learn about
the NFPA 70E “point
of work” concept, which focuses on the need for proactive electrical safety measures where the work is performed
1: A qualified worker using a portable test instrument to test for voltage through a UL 61010 test point permanent electrical safety device (PESD). Courtesy: Grace Technologies Inc.
Staying ahead of the latest standards and technologies is not just about compliance — it's about protecting lives. The 2024 updates to NFPA 70E: Standard for Electrical Safety in the Workplace bring to the forefront the “point of work” concept, emphasizing the need for proactive safety measures right where the work is performed. This concept underscores the importance of assessing risks and implementing controls before any electrical work begins, ensuring that safety is not an afterthought but a fundamental part of the work process.
How NFPA 70E ensures electrically safe work conditions
The process for establishing and verifying an electrically safe work condition, as outlined in NFPA 70E Article 120.6, is a comprehensive procedure aimed at ensuring the safety of workers handling electrical equipment. It involves identifying all electrical sources, opening the disconnecting device(s) for each source, ensuring disconnection, verifying the disconnection visually, releasing stored electrical and nonelectrical energy, applying lockout/tagout (LOTO) procedures and using a test instrument to verify the absence of voltage. These seven steps, followed in sequence, are critical for maintaining a safe work environment and are aligned with the principles of NFPA 70E, which emphasizes the importance of safety in electrical work practices.
Permanent electrical safety devices (PESDs) listed to UL 61010: Safety Requirements for Electrical Equipment For Measurement, Control, and Laboratory Use can play a vital role in this process by providing a means to verify the absence of voltage without direct exposure to electrical hazards, thereby supporting compliance with NFPA 70E's approach to electrical safety.
Specifically, when used with an adequately rated portable test instrument, test point PESDs help in the verification process of the absence of voltage, complementing step seven of the LOTO process by allowing for safer and more efficient verification before and after work is performed. This enhances compliance with NFPA 70E by integrating technology that makes the verification process less invasive and reduces the risk of exposure to electrical hazards.
Compliance with NFPA 70E language: ‘point of work’
PESDs comply with NFPA 70E-2024 language and its emphasis on the “point of work” by providing strategically designed solutions that enhance safety directly at the work site. Their proper placement, compliance with safety standards, role in LOTO procedures and facilitation of safe voltage testing embody the principles of electrical safety at the point of work, ensuring a safer environment for electrical maintenance and repair activities.
Here's how PESDs align with the “point of work” concept as articulated in NFPA 70E-2024:
• Proper placement and accessibility: PESDs should be installed in locations that are both practical and precise, ensuring that they are readily accessible at the point where electrical work is conducted. This placement is pivotal for maximizing their effectiveness in promoting electrical safety and aligns with the “point of work” concept by mitigating risks directly where the electrical work occurs.
FIGURE
• Compliance with NFPA 70E requirements: PESDs and other test point devices are recognized as compliant with the safety standards set by NFPA 70E. They provide a safe and efficient method for verifying the absence of voltage, which is a crucial step in establishing an electrically safe work condition. Their design and application are in harmony with the NFPA 70E's emphasis on verifying an electrically safe work condition at each point of work, underscoring their role in adherence to updated safety protocols.
• Enhanced safety during LOTO procedures: Incorporating visible PESDs such as voltage presence indicators and absence of voltage test points can significantly reduce risks during LOTO procedures. By enabling effective and reliable verification of voltage status within an electrical panel or system, PESDs serve as an additional layer of protection, ensuring that workers can make informed decisions about the safety of their work environment. This is particularly relevant to the “point of work,” where ensuring the absence of hazardous energy is paramount.
• Facilitating safe and accurate absence of voltage testing: The NFPA 70E revisions validate the use of impedance-protected test points, a feature of many PESDs, for absence of voltage testing. This functionality is critical for safely establishing an electrically safe work condition, directly supporting the “point of work” philosophy by enabling precise testing at the location of the electrical work.
As industries continue to evolve and electrical systems become more complex, the need for comprehensive safety standards that address the realities of modern electrical work is paramount. The NFPA 70E 2024 updates, with their focus on “point of work” safety, PESDs and enhanced LOTO procedures, represent a significant step forward in meeting this need. By adhering to these standards and embracing the technologies and practices they advocate, employers and safety professionals can ensure that their electrical safety programs are not just compliant, but truly effective in protecting workers from harm.
Rethinking risk with the hierarchy of controls
One of the cornerstones to any electrical safety program is the approach to the hierarchy of controls. Traditionally, this hierarchy has guided employers and safety professionals to prioritize elimination and substitution over administrative controls and personal protective equipment (PPE).
FIGURE 2: Voltage verification using a handheld testing device through a UL 61010-certified permanent electrical safety device (PESD) test point, ensuring an efficient and compliant procedure.
Courtesy: Grace Technologies Inc.
‘ PESDs comply with NFPA 70E-2024 language and its emphasis on the “point of work” by providing strategically designed solutions that enhance safety directly at the work site. ’
PESDs are an essential part of the engineering controls within the hierarchy of controls in industrial safety. The hierarchy of controls is a system used in occupational health and safety to minimize or eliminate exposure to hazards. It is represented as a pyramid with the most effective methods of control at the top and the least effective at the bottom. Here's where PESDs fit in:
1. Elimination: Physically removing the hazard and is the most effective control method. While PESDs don't eliminate electrical hazards, they significantly minimize the need for interaction with live circuits, indirectly contributing to elimination.
2. Substitution: Substituting hazardous situations with less hazardous ones can be partly achieved by using PESDs, as they can replace more hazardous voltage testing methods that require direct interaction with live circuits.
3. Engineering controls: This is where PESDs are directly applicable. They are designed to isolate workers from electrical hazards by providing a way to verify the presence or absence of voltage without exposing workers to live electrical components. For example, PESDs allow verification from outside a closed electrical panel, reducing the risk of arc flash and shock.
Learningu
Objectives
• Grasp the updates in NFPA 70E-2024, particularly the emphasis on “point of work” safety practices.
• Understand the placement and importance of permanent electrical safety devices (PESDs) in enhancing electrical safety and compliance.
• Learn about the advancements in lockout/ tagout (LOTO) safety procedures and their critical role in preventing workplace electrical hazards.
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4. Administrative controls: These involve changing the way people work and include safety training and procedure modifications. While PESDs themselves are not administrative controls, they are often incorporated into safety procedures, thus supporting these controls.
5. Personal protective equipment (PPE): This is the last line of defense and the least effective control method. PESDs can reduce the need for PPE by minimizing exposure to hazards, although PPE may still be required during certain operations for additional safety.
By integrating PESDs into electrical safety protocols organizations can significantly enhance their safety measures, align with best practices and comply with standards such as NFPA 70E. These devices are a proactive measure that aligns with the philosophy of designing safety into work practices and the working environment.
Integrating enhanced electrical safety program measures
The integration of PESDs into an electrical safety program represents a significant shift toward safer and more reliable electrical maintenance practices. By providing a means to verify the absence of voltage without exposing workers to live components, PESDs align perfectly with the NFPA's increased emphasis on “point of work” safety. This approach not only enhances compliance but also significantly bolsters the overall safety and productivity of electrical maintenance operations.
NFPA 70E 2024 places a strong emphasis on training and competency. It mandates that workers involved in electrical tasks be not only adequately trained but also fully competent in the specific safety procedures relevant to their tasks. This includes a thorough understanding of the use and benefits of PESDs, the application of LOTO procedures and the ability to recognize and mitigate electrical hazards effectively.
Incorporating PESDs into the hierarchy of risk controls presents an opportunity to significantly reduce electrical hazards. These devices serve as a critical barrier between electrical workers and potential sources of electrical energy, ensuring that safety measures are not just reactive but inherently built into the system. Their use, combined with stringent LOTO practices, forms a robust defense
ENGINEERING SOLUTIONS
against electrical accidents, aligning with the NFPA 70E's goal of creating safer work environments.
Practical implementation of NFPA 70E
Implementing NFPA 70E-2024 updates begins with a thorough assessment of current electrical safety programs against the new standards. For PESDs, this involves identifying key areas where these devices can be integrated to ensure voltage verification processes are both efficient and comprehensive. Training sessions tailored to these updates can empower workers with the knowledge to apply “point of work” safety principles effectively.
A comprehensive overhaul of LOTO procedures, aligned with the latest NFPA 70E guidelines, has helped organizations strengthen their safety culture, demonstrating the tangible benefits of adherence to updated safety practices.
Training and competency development
Developing a robust training program is essential for ensuring that workers are not only aware of the NFPA 70E-2024 changes but are also competent in applying these standards in their daily tasks. This includes practical training on the correct use of PESDs and an understanding of enhanced LOTO procedures. Competency checks and refresher courses can help maintain a high level of safety awareness and compliance.
In 2023, the Occupational Health and Safety Administration (OSHA) reported significant violations related to the control of hazardous energy, underlining a critical need for improved safety practices in workplaces. Here is a summary for the key areas of concern and the solutions to address these OSHA violations:
Energy control procedure (730 violations): Difficulty in creating or updating detailed, equipment-specific energy control procedures and ensuring their consistent application and communication.
Solution: Develop and maintain precise procedures, train relevant employees thoroughly,
Insightsu
NFPA 70E insights
u Explore the critical updates in NFPA 70E2024, emphasizing the “point of work” concept and understand the integral role of permanent electrical safety devices (PESDs) within the hierarchy of risk controls.
uThis article delves into how these elements, alongside robust lockout/tagout (LOTO) procedures, can significantly uplift electrical safety standards in the workplace.
FIGURE 4: High impedance protected test point and multimeter. Courtesy: Grace Technologies Inc.
ENGINEERING SOLUTIONS
FIGURE 3: Portable test instrument taking a reading through a UL 61010 test point permanent electrical safety device (PESD). Courtesy: Grace Technologies Inc.
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The continuous evolution of electrical safety standards and technologies promises further advancements in protecting workers from electrical hazards.
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perform regular audits and updates and keep documentation clear and accessible. Incorporating PESDs can simplify adherence and enhance the effectiveness of these procedures.
Training and communication (491 violations): Insufficient training and updates on safety procedures.
Solution: Enhance and tailor training to specific roles/equipment, regularly communicate procedural/equipment changes and adopt engaging training methods for better retention.
Periodic inspection (362 violations): Failures in conducting regular inspections of LOTO procedures.
Solution: Set up a structured schedule for inspections, allocate necessary resources and integrate these inspections into safety practices for continuous compliance.
Energy control program (265 violations): Absence of a comprehensive energy control program.
Solution: Establish a detailed program with clear procedures, ensure regular training/communication and conduct routine audits, keeping documentation up to date.
Application of control (231 violations): Incorrect application of energy control procedures.
Solution: Enhance documentation and training on LOTO procedures, perform regular drills and monitor real-world application to rectify any discrepancies.
These violations highlight the paramount importance of comprehensive training and rigorous adherence to safety standards. Ensuring that employees are well-versed in energy control procedures is not just a regulatory requirement but a fundamental aspect of maintaining a safe working environment.
Embracing technology for electrical safety
The future of electrical safety also lies in leveraging technology beyond PESDs. From advanced software that helps manage LOTO procedures to mobile apps designed for safety audits, technology can provide additional layers of safety and efficiency. Adoption of such tools can complement the physical safety measures provided by PESDs, offering a more holistic approach to electrical safety management.
While the implementation of NFPA 70E-2024 standards, PESDs and enhanced LOTO procedures poses challenges, such as budget constraints and resistance to change, the benefits far outweigh the hurdles. Proactive engagement, clear communication and demonstrating the value of these safety investments can help overcome obstacles. The continuous evolution of electrical safety standards and technologies promises further advancements in protecting workers from electrical hazards.
The integration of NFPA 70E 2024 updates, PESDs and robust LOTO procedures represents a comprehensive approach to mitigating electrical risks. By embracing these standards and technologies organizations can significantly enhance their safety protocols, protecting a valuable asset — their workforce. As we look to the future, staying informed and adaptable to emerging safety trends and innovations will be key to maintaining a safe and productive workplace. PE
Nick Schiltz is a Content Specialist for Grace Technologies.
William McGugan, PE; and Tyler Roschen, PE, CDM Smith, Raleigh, North Carolina
Know how to identify, recognize electrical and unapparent hazards
The purpose of this article is to help identify a variety of workplace hazards and provide basic electrical safety
Electrical safety topics include shock hazards, arc hazards and safe working conditions. Other hazards persist for those working with electrical systems, some of which are so obvious as to become forgotten.
The authors of this article strongly encourage all involved in electrical work, even tangentially, to familiarize themselves with the requirements of Occupational Health and Safety Administration
(OSHA), NFPA 70E: Standard for Electrical Safety in the Workplace, NFPA 70: National Electrical Code, the National Electrical Safety Code (NESC), other industry consensus standards on safety and their company’s safety materials.
Electrical hazards
Objectives
• Identify electrical, weather-related and environmental-related hazards.
• Recognize protection boundaries and a basic overview of electrically safe work conditions.
• Understand basic electrical safety codes and resources for identifying other hazards.
An electrical hazard is defined as a condition where there is the potential for injury from electric shock, arc flash burn, thermal burn or arc blast energy due to making direct or indirect contact with energized equipment or conductors. These hazards can expose workers to serious potential injuries and they should be aware and identify these hazards when near these types of equipment. There are three major categories associated with electrical hazards in accordance with Annex K in NFPA 70E:
• Electric shock.
• Arc flash.
• Arc blast.
Electric shock: Electric shock is associated with current passing through the body caused by contact or close approach to energized electrical conductors or circuit parts. Shock hazards exist when in contact with equipment or sources 50 Volts (V) or greater. An electric shock risk assessment is conducted to identify the voltage, limited approach and restricted approach boundaries and personal protective equipment (PPE) required to protect against electric shock hazards.
FIGURE 1: An example of a motor control center with lockout/tagout devices. Courtesy: CDM Smith
There are two electric shock protection boundaries that should be identified for each given piece of equipment: limited approach and restricted approach. These boundaries identify the distance, determined based on the voltage potential between the source and ground, from where qualified and unqualified persons, as defined by OSHA 29 and NFPA 70E, may interact with equipment where shock hazards are present.
• Limited approach boundary: An unqualified person may enter this boundary under supervision of qualified persons.
• Restricted approach boundary: Only qualified persons may enter this boundary with proper PPE as listed in NFPA 70E.
Arc flash: Arc flash is a release of thermal energy from an electric arc between electrical conductors or to ground. The amount of energy, or arc flash, is dependent on the fault current and clearing time. The fault current value is dependent on the utility and its equipment supply. The clearing time is the amount of time the overcurrent protective device takes to trip (open) during a fault situation. An arc flash risk assessment is conducted to identify the incident energy at the work distance (or arc flash PPE category), arc flash boundary and PPE required to protect against arc flash hazards.
Like the electric shock boundaries, although completely independent from one another, there is a single arc flash boundary required to be identified to determine the distance at which the incident energy equals 1.2 cal/cm2
This value was determined based on the Stoll skin burn injury model, where the onset of a second-degree burn on unprotected skin is likely to occur at an exposure of 1.2 cal/cm2 for one second. This value is deemed to be a curable burn.
When working within the arc flash boundary, proper clothing and PPE should be selected and worn for protection from arc flash hazards. Selection of proper PPE is determined based on either the incident energy method or the arc flash PPE category method as defined in NFPA 70E.
For example, when using the incident energy level method, NFPA 70E Table 130.5(G) should be used to select proper PPE based on amount of incident energy calculated for each individual equipment. When using the arc flash PPE cat-
egory method, NFPA 70E Table 130.7(C)(15)(c) would be used for selecting proper PPE. Outside of this boundary, PPE is not required. However, caution should still be considered as injury can still occur even when working outside of the arc flash boundary.
Arc blast: Arc blast is simultaneous with an arc flash and is the pressure wave released during an arc flash event. An arc blast, traditionally associated with an incident energy level of 40 cal/cm2, can throw people and objects due to this pressure wave. However, NFPA 70E no longer defines this 40 cal/ cm2 limit. PPE can be rated above 40 cal/cm2, but at these levels the actual blast will be more potentially lethal. There is currently no assessment or method per NFPA 70E to help identify proper PPE to prevent injuries due to an arc blast.
There are other important aspects to electrical safety regarding these electrical hazards, including establishing electrically safe work conditions. An electrically safe work condition as defined by NFPA 70E is “a state in which an electrical conductor or circuit part has been disconnected from energized parts, locked/tagged in accordance with established standards, tested for the absence of voltage and, if necessary, temporarily grounded for personnel protection.” Establishing this electrically safe work condition is employed to prevent injury from either direct or indirect electrical contact.
The process for establishing and verifying an electrically safe condition is based on NFPA 70E and includes eight items:
FIGURE 2: This photo displays cold-related hazards due to ice forming in the working space of the cabinets. Courtesy: CDM Smith
Insightsu
Electrical safety insights
uThis article will briefly discuss some of the major electrical safety topics and will also cover other — sometimes so obvious as to become forgotten — hazards that workers may find themselves exposed to in the course of their work.
uReferences and tools to help assist with electrical safety best practices include codes, standards, U.S. government websites and a variety of other resources.
ENGINEERING SOLUTIONS
• Determine all possible electrical sources.
• Open disconnecting devices(s) for each source.
• Visually verify that all blades of disconnecting devices are withdrawn to the test or full disconnected position.
• Release stored electrical energy.
• Block or relieve stored nonelectrical energy in devices.
• Apply lockout/tagout devices.
• Use adequately rated portable test instrument to test conductors for absence of voltage.
• Where the possibility of induced voltages or stored electrical energy exists, ground all circuit conductors and circuit parts before touching them.
Overall, it is vital for worker’s safety to be aware of electrical hazards and how to properly prepare to work on or near energized or unenergized equipment. Other important subjects, such as equipment
maintenance and proper training, also exist to help prevent electrical hazards but are not discussed in this article.
Whether working on energized or unenergized equipment, it is important to maintain an electrically safe work condition, identify and wear proper PPE to help prevent against injury to electrical hazards. Other unapparent hazards that workers may encounter are as important as the electrical hazards already discussed.
Weather-related hazards
Weather-related hazards for people working on or around electrical equipment are most common at temperature extremes, such as when it is hot, humid, cold or windy. During hot and/or humid conditions, major risks include dehydration, heat exhaustion, heat stroke and somewhat ironically, overhydration. During cold conditions, major risks include hypothermia and frostbite. As weather-related hazards can dull mental and physical acuity, they can be especially concerning when working around electrical equipment.
Heat-related hazards: Heat exhaustion occurs when a person’s body loses excessive amounts of water and salt. Symptoms include headache, nausea, dizziness, thirst and heavy sweating. Heat stroke occurs when a person’s body can no longer control its temperature and can cause permanent damage or death. Symptoms include confusion, loss of consciousness, profuse sweating, seizures and very high body temperatures.
First aid includes getting medical treatment, removing the person from the heat, ensuring the person drinks liquids, removing unnecessary clothing and applying cold compresses. For heat stroke, immediate emergency medical attention is necessary and more drastic methods to cool the affected person are encouraged, including ice baths.
Dehydration and overhydration (or water intoxication) can have similar symptoms — both commonly presenting with nausea, fatigue and headaches — making communication key in understanding what first aid efforts should be undertaken. While the treatment for dehydration is relatively straightforward, cool down and hydrate, overhydration may require medical attention.
Cold-related hazards: Hypothermia occurs when a person’s body loses heat faster than it can make
FIGURE 3: An example of a natural hazard where a snake was hiding in an electrical enclosure. Courtesy: CDM Smith
it, leading to low body temperatures, which can in turn affect a person’s decision making and physical movement. Shivering, fatigue, loss of coordination and confusion indicate early stages of hypothermia. A lack of shivering can indicate late stages of hypothermia, along with blue skin, dilated pupils, slow breathing and loss of consciousness. First aid includes moving the person to a warm area, removing wet clothing, warming their body — torso and head first and providing warm nonalcoholic drinks.
Environmental hazards: Chemicals, toxins and other exposures
Many other health hazards that may be encountered by electrical personnel are from chemicals or other compounds that have served or continue to serve an important purpose in the electrical industry but are also now known to cause cancer or other serious diseases. Examples include polychlorinated biphenyls (PCBs), asbestos and sulfur hexafluoride (SF6) byproducts. Workers should also be cognizant of other chemicals and exposure hazards in the areas they are working, for instance, caustic chemicals in an industrial plant, microorganisms in a wastewater treatment facility, or other natural hazards such as snakes or poison ivy.
Polychlorinated biphenyls: PCBs are synthetic chemicals which were used in transformers, fluorescent lighting and other electrical equipment in the United States until 1977. PCBs were excellent electrical insulators but can cause severe skin and eye irritation in workers that breathe contaminated air or touch contaminated surfaces.
While most of this equipment is at or beyond its expected service life, PCB-contaminated equipment or areas may still be encountered. Given such equipment’s age and likely need for maintenance, it is more likely to leak contaminated oil. Federal law requires PCB-contaminated equipment to be marked with an appropriate hazard label. Labels are required to indicate insulating fluids are non-PCB. Assume equipment contains PCBs unless labeled otherwise.
Asbestos: For similar reasons to PCBs, asbestos was used for decades in the electrical industry (and industry at large) due to its excellent heat and electrical insulation characteristics. Banned in 1989 due to its association with mesothelioma and other cancers, asbestos may still be found in many electrical installations, especially in circuit breaker arc
Electrical safety references and tools
CODES, STANDARDS, government organizations and websites should all be referenced when working with electrical systems
Organizations and standards for those exposed to an electrical hazard:
• Centers for Disease Control and Prevention (CDC).
• National Institute for Occupational Safety and Health (NIOSH).
• National Fire Protection Association.
• Occupational Health and Safety Administration (OSHA).
• National Electrical Safety Code (NESC).
• NFPA 70E: Standard for Electrical Safety in the Workplace.
• NFPA 70: National Electrical Code (NEC).
• OSHA 29 CFR 1910 Subpart S — Electrical.
Resources and information
Per OSHA, workers must be provided a safe workplace clear from recognized hazards. While in the electrical industry, we understandably often focus on electrical hazards such as shock and arc flash events. We must also be cognizant of other hazards, such as those presented from extreme weather, animals, plants and chemicals.
The following is only a short list of resources that may be helpful in identifying and protecting personnel from hazards.
• Cold-related illnesses.
• Heat-related illnesses.
• Snake bites.
• Spider bites.
• Tick bites.
chutes. Asbestos may also be found in wire insulation or asbestos-cement conduits. In general, asbestos is only a health threat to humans if its fibers are inhaled.
Sulfur hexafluoride byproducts: SF6 gas is used as an electrical and mechanical insulating material in medium- and high-voltage electrical equipment. SF6 gas itself is not a significant direct health risk to humans, though it is the most potent greenhouse gas according to the Environmental Protection Agency and can greatly impact global climate change.
Byproducts of SF6 gas — which are created when high fault currents or other electrical discharges pass through the gas — can be toxic to humans, often causing irritation or even severe burns to the eyes and the respiratory system. While many SF6 byproducts appear as light-colored powder with strong sulfur smells, the most potently toxic byproduct is odorless.
ENGINEERING SOLUTIONS
FIGURE 4: A diagram displaying the restricted, limited and arc flash boundaries. Courtesy: CDM Smith
Natural hazards: Electrical workers are likely to be exposed to smaller creatures such as snakes, spiders, bees, ants and ticks. While most such creatures are harmless to humans, there are varieties that are venomous or otherwise potentially dangerous. Electrical equipment offers spiders, bees and other flying biting/stinging insects, ants and even snakes warm, sheltered locations in which to rest or build a home. Snakes, spiders or ticks may be encountered when accessing outdoor equipment in areas that have not been well maintained in places like overgrown grass or shrubbery. In general, such animals are unlikely to bother workers unless disturbed or directly confronted, so a worker may reduce their exposure simply by being aware of their surroundings and avoiding interactions.
When bitten by a spider or snake, common incorrect actions include trying to catch or handle the creature, even when dead (instead: take a picture), attempting to suck out the poison, applying tourniquets, etc. First aid for most incidents includes washing the bite with soap and water, removing rings and watches before swelling occurs and seeking immediate medical attention.
Ticks should be removed within 24 to 48 hours using clean, precision tweezers to carefully grip the tick as near to the skin's surface as feasible. Pull upward with steady, even pressure, being sure that no parts of the head remain, per the CDC.
By adhering to these many guidelines, electrical safety practices in the workplace can be improved. PE
William McGugan, PE, is an electrical engineer with CDM Smith with a focus on the design and analysis of electrical power systems.
Tyler Roschen, PE, is an electrical engineer at CDM Smith with expertise in electrical design with a focus on power concepts.
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Effective Air Preparation
By: IMI Norgren
The efficient and long-term performance of pneumatic equipment and systems fundamentally depends on the availability of clean and dry compressed air. Supplying air of the highest quality to pneumatic devices ensures that these machines operate at their peak efficiency for the longest possible duration, ultimately minimizing life cycle costs. When pneumatic systems receive uncontaminated air, free of particles, moisture, and oil, they function more reliably and require less maintenance. Contaminants can cause significant wear and tear on internal components, leading to premature failure and increased downtime. By using clean and dry air, you reduce the risk of these issues, ensuring consistent and optimal performance over time.
Additionally, providing high-quality air is crucial for maintaining precision and consistency in pneumatic operations. This level of performance is essential in industries where accuracy and reliability are critical. Efficient air supply not only enhances operational efficiency but also reduces energy consumption, resulting in lower operational costs and better overall return on investment.
Compliance with manufacturers’ warranties often hinges on the quality of the compressed air used. Many warranties specify air quality standards that must be met to maintain coverage. If these standards are not adhered to, warranties can become void, leaving you liable for repair and replacement expenses.
Download this white paper and learn the top tips in air preparation to set you up for success in air treatment solutions that deliver clean, dry compressed air is vital for the efficient and cost-effective operation of pneumatic systems. The goal is to help improve performance, reduce maintenance needs, extend equipment lifespan, and provide compliance with warranty requirements, protecting your investment and enhancing productivity.
CLICK HERE to download the paper, or scan the QR code at right. www.norgren.com
Lucas Hall, EIT, Hedgehog Technologies, Burnaby, British Columbia
Back to basics: How to reduce electrical hazards in industrial workplaces
Electrical safety in industrial workplaces begins with awareness of potential electrical hazards and the strategies that are available to mitigate them
Industrial workplaces can present a variety of electrical hazards. Electric shock can result in internal and external burns, cardiac problems, seizures, muscle contractions and difficulty breathing. Additionally, there is the risk of arc flash, leading to severe burns, eye injuries and hearing loss and arc blast, which can cause acute internal and external trauma.
Electrical incidents can also lead to other modes of injury, including falls, especially if an incident occurs while working at heights. Given the severity of the injuries that can be sustained during electrical incidents, it is critical for firms to implement risk mitigations and for workers to practice safe work procedures to reduce the likelihood and severity of harm.
The hierarchy of electrical hazard controls
• Learn about the hierarchy of electrical hazard management controls.
• Understand the requirements of workplace electrical safety standards.
• Gain insights into practical examples of safe work practices.
This article delves into the hierarchy of controls model used in CSA Standard Z462:21: Workplace Electrical Safety and NFPA 70E: Standard for Electrical Safety in the Workplace. This model recognizes six categories of hazard mitigation strategies, which are ranked according to effectiveness.
• Elimination: The most effective measure is elimination, which removes the existence of a hazard in the workplace.
• Substitution: Substitution replaces the hazard with a less severe or more manageable condition.
• Engineering controls: Engineering controls aim to isolate the worker from hazards through the design of the plant, equipment or process they interact with.
• Warnings: Warnings are designed to indicate the presence of hazards that remain after the first three mitigation approaches are applied.
Administrative controls: Administrative controls are procedures designed to encourage safe work practices.
• Personal protective equipment (PPE): The last line of defense is PPE, which refers to items worn by personnel to protect them from workplace hazards.
A well-designed safety program will address hazards with the highest practical control level in the hierarchy and may use a combination of controls to address a single hazard.
1. Elimination
Elimination represents the highest tier of the hierarchy of controls. This strategy involves removing
FIGURE 1: Example of a lockout procedure in a test lab for safety controls. Courtesy: Hedgehog Technologies
the hazardous condition from the workplace entirely, thereby preventing any possibility of an electrical incident. Elimination is an entirely effective mitigation method, resulting in no residual risk. It stands as the gold standard in the hierarchy of controls.
However, given the nature of modern industrial facilities, it is rarely a feasible strategy for addressing electrical hazards.
2. Substitution
Substitution is the second tier in the hierarchy of controls. This strategy involves replacing a hazardous condition with something that is less hazardous or more easily mitigated using other controls.
For example, a plant designer might choose to replace conventional switchgear with arc-resistant designs, which divert the energy of an electric arc away from personnel and decrease the risk of injury in an electrical incident. Other common substitutions include replacing line voltage control systems with power-limited or low-voltage designs to reduce the severity of electric shocks and substituting power tools with battery-operated models to eliminate the risk of shock from damaged extension cords.
3. Engineering controls
Engineering controls constitute the third tier in the hierarchy of risk management strategies. Although they do not remove or directly reduce the unsafe condition, engineering controls isolate workers from hazards through the design of the plant, equipment or processes with which they interact. A prevalent engineering control in electrical systems involves the insulation and guarding of energized components, which may include mechanical barriers and interlocks. Other common engineering controls encompass the use of finger-safe components, circuit protection devices (including ground fault detection) and equipment bonding systems.
CSA Z462:21 recognizes the importance of inspecting and maintaining engineering controls to uphold their effectiveness. Some controls, such as equipment doors, may require removal during plant operations and must be replaced to restore the effectiveness of this mitigation scheme. Others, such as ground fault detection devices, may fail unexpectedly and should be regularly tested by plant personnel. An electrical safety program should include procedures for inspecting and maintaining electrical equipment.
FIGURE 2:
Diagram representing the hierarchy of controls. Courtesy: Hedgehog Technologies
4. Warnings
While warnings do not remove hazards from the workplace, they alert personnel of the existence of dangerous conditions and prompt the application of administrative controls and/or personal protective equipment. Typical warnings include labels, signage, lights and audible alert systems.
5. Administrative controls
Administrative controls are procedures designed to promote safe work practices. Common examples include procedures for working on energized equipment, prohibitions from working while fatigued, distracted or under the influence of drugs or alcohol, limitations on working alone, restrictions on unqualified workers and the implementation of emergency plans and first aid procedures.
FIGURE 3: Engineer in front of a lockout/ tag out wall. Courtesy: Hedgehog Technologies
ENGINEERING SOLUTIONS
Two key administrative controls are the plant’s live work and lockout policies. CSA Z462 requires that electrical equipment is de-energized before a worker enters the limited approach boundary unless de-energization is infeasible or would introduce additional hazards. The standard also mandates firms to create a lockout policy and provide lockout training to their employees at three-year intervals.
The objective of a lockout is to securely isolate a piece of equipment from sources of energy while work is being performed. An energy-isolating device, such as a circuit breaker or disconnect switch (in the case of electrical energy), is operated and an individually-keyed lock is applied to prevent the reenergization of the equipment until it is safe to do so. The equipment is then tested to ensure that the isolation is effective - switching mechanisms can fail and equipment may be energized even when a disconnect is in the “off” position. Additionally, testing may reveal that the equipment is fed from different (or multiple) sources that were not anticipated by the worker. Workers should also be aware of the hazards of stored energy, including energy stored in capacitors, the insulation of high voltage cables, hydraulics, pneumatics, suspended parts, springs and other sources.
An important but often neglected component of an administrative control is the documentation of a plant’s electrical systems. Accurate documentation will help workers identify sources of energy and
devices that can be used to isolate equipment. However, workers should not assume that the plant’s documentation is accurate. Industrial plants are dynamic workplaces and documentation becomes outdated quickly if not maintained.
6. Personal protective equipment
PPE refers to items worn by personnel to protect them from workplace hazards. As the least effective control method, PPE should be considered a last line of defense when other controls are infeasible or inadequate.
However, PPE is often used in conjunction with other controls as part of an effective hazard mitigation program. PPE must be chosen based on an analysis of the hazards involved. Typical PPE for an electrical worker may include safety goggles, hard hats, hearing protection, insulating gloves and arc flash-rated clothing.
Six categories of hazard control strategies can be implemented in a firm’s electrical safety plan. Priority should be given to removing, reducing and guarding workers from a hazard, but warnings, safe work procedures and PPE are often needed to manage residual risk. Standards like CSA Z462:21 and NFPA 70E are based on this hierarchy and provide guidance for developing a robust electrical safety program. PE
Lucas Hall, EIT, is an Electrical Engineer at Hedgehog Technologies.
FIGURE 4: Close-up of lockout/tag out display. Courtesy: Hedgehog Technologies
FIGURE 5: View of an emergency stop button in a testing lab. Courtesy: Hedgehog Technologies
Arc Flash Prevention: What You Need to Know
By: Rittal North America
Arc flash risk is a concern where energized equipment over 50V is involved. Not following proper safety protocols or having the right equipment for the job can lead to potentially fatal injuries. In this paper, details from each of the three regulatory agencies will be discussed to help build a solid foundational understanding of arc flash, potential risks and hazards, and best practices for minimizing arc flash related risks and exposure, including proper personal protective equipment (PPE), lockout tagout, and energy isolating devices.
Understanding these concepts will make it easier to identify the best solution for unique applications, which will be discussed at the end of the paper. Lastly, we’ll explore how engineers can build a custom solution to help prevent arc flash exposure and how this helps to keep employees safe.
Download the paper at: https://tinyurl.com/3wh6h6v7
Maximizing Cleanroom Performance Through Advanced Coating Systems
As cleanrooms are becoming increasingly adopted across a spectrum of industry sectors, it is critical to ensure the materials used in their construction help to maintain the pristine controlled environments required inside these areas. Coating systems are one such fundamental material. They serve as barriers against contamination while withstanding the demanding conditions inherent to such controlled spaces. Key among coatings system requirements are properties like non-particle shedding and non-outgassing – essential for stopping the entry of particulate matter and volatile organic compounds (VOCs).
A range of coating solutions – for walls, floors, ceilings and fireproofing – exists that can maximize the effectiveness of cleanrooms while helping companies meet strict requirements and avoid costly fines or product recalls. This paper will help readers understand how to work with experienced coatings professionals to select the most suitable coatings systems for specific cleanroom requirements, taking into account factors such as cleanliness standards, environmental conditions and regulatory compliance.
Download the paper here: https://tinyurl.com/mr3d527f
rittal@rittal.us rittal.com
swprotective@sherwin.com
ENGINEERING SOLUTIONS
SAFETY STANDARDS
Aaron Beatty, Salas O'Brien, Evansville, Indiana
How to create a culture of electrical safety at a manufacturing facility
More awareness and education are needed to create a culture of electrical safety
Over the past 50 years, the landscape of electrical safety has undergone a substantial transformation. Journeyman electricians, who might have once relied on the rudimentary method of wetting a finger to test a light socket for electricity, now adhere to stringent lockout/tagout (LOTO) procedures and use specialized test equipment to create a safe work environment.
The practice of placing a test probe on energized equipment with 480 volts (V) alternating current (ac) or 600 V direct current (dc) has given way to the use of software diagnostics and remote testing points for monitoring. Much of the disparity can be attributed to management’s lack of understanding or incentive to learn about electricity, exacerbated by trade-specific jargon.
In the 1940s, voluntary standards focused on the physical aspects of electrical installations, rather than the safe handling of energized equipment.
The creation of the Occupational Health and Safety Administration (OSHA) in 1970 marked a shift toward a greater emphasis on safety.
However, there was a noticeable gap in the guidelines that companies and OSHA could follow to ensure safety in electrical work.
To address this, the National Fire Protection Association (NFPA) introduced NFPA 70E: Standard for Electrical Safety in the Workplace in 1979, providing a comprehensive guide for the safe installation and management of electrical systems. It is continuously evolving to reflect the
latest research, technology and best practices in the industry. As of 2024, NFPA 70E is in its 13th edition.
Arc flash and LOTO protection
Arc flash protection is a term that refers to the methods and equipment used to reduce the risk of an arc flash — an electrical explosion that can cause severe burns, fires and and deafening noises. Arc flash protection includes correct installation and maintenance of electrical equipment, but also protection for people using the equipment through use of personal protective equipment (PPE) and application of warning labels and signs on potential arc flash sources.
LOTO is a safety procedure that prevents hazardous energy from being released during maintenance or servicing of machinery. It involves locking and tagging switches, valves or or breakers so that the equipment can’t be operated until the work is completed. LOTO protects workers from injuries caused by unexpected startup or release of stored energy.
When referencing electrical safety in manufacturing today, NFPA 70E and and more specifically, arc flash and LOTO, are the first things that are referenced. However, not all manufacturing employees are familiar with NFPA 70E or its requirements. Even after OSHA adopted the standard, many facilities did not implement LOTO or arc flash protection until recently.
Therefore, there is still a need for more awareness and education on NFPA 70E and its benefits.
FIGURE 1: Plant personnel can provide necessary maintenance if they are wearing personal protective equipment (PPE). Courtesy: Salas O'Brien
Solutions for arc flash compliance
Companies now face a variety of solutions compliance with arc flash requirements. The first hurdle is the technical classification of installed equipment and which rating to put on the gear. One choice is evaluating all the electrical gear in the facility and what energy level each piece of electrical equipment is capable of, then setting the classification. This method allows for further remediation of components to reduce the classification and make access easier for support personnel. The downside of this approach is the time and expense involved in performing the studies (short circuit, protective device coordination and arc flash hazard) and any follow-up remediation.
An alternative method employed by numerous facilities involves conducting a preliminary assessment, assigning a “Category 2” classification to the production equipment and a “Category 4” to the switchgear/large electrical distribution equipment, effectively marking the task as complete. This approach can be executed swiftly and at a considerably lower cost, as extra precautions needed in some equipment that can take longer to work on during an unplanned maintenance event. This methodology also takes on some additional risks as the detailed engineering calculations are not fully performed and the preliminary assessment is based on the user identifying and making assumptions about the electrical system and the components involved.
The need for electrical safety training
All personnel exposed to production equipment must receive training, not only the technical staff. The training begins with identifying the “qualified persons” who will be trained on arc flash safety in detail. Then, decide who else will be near the
‘ All personnel exposed to production equipment must receive training, not only the technical staff. ’
equipment and who will be the “unqualified persons” who will receive more generalized training. Anyone who is a qualified person must be confident around electrical equipment. A key consideration is if someone isn’t comfortable, do not force them into the role. This training should be repeated every three years at a minimum.
The target audience for LOTO training is often overlooked. Many facilities have LOTO procedures for their technical staff who work on the equipment, but not for their production staff. However, as production staff are increasingly involved in clean/inspect/lubricate (CIL) activities, they also need to know how to apply LOTO safely and correctly. The facilities that have implemented CIL have good LOTO practices, but the staff may not understand the rationale behind them.
Focusing beyond PPE
To ensure electrical safety, focus not only on the environment, but also on the sources of hazards. This means identifying and eliminating the risks that can be avoided, before considering the identification, labeling, PPE and and training needed. This approach requires a thorough safety assessment and risk analysis.
The first safety remediation level is mitigating and/or removing the safety hazards that exist. By changing to lower energy circuit protection, many
Learningu
Objectives
• Learn about the shift in safety standards led by the introduction of OSHA and NFPA 70E, illustrating the progression from voluntary standards to comprehensive guidelines that prioritize worker safety and risk management.
• Gain insights into essential electrical safety procedures such as arc flash protection and the lockout/tagout (LOTO) process.
• Get inspired to create a safety culture within manufacturing facilities that extends beyond personal protective equipment (PPE) and technical measures.
ENGINEERING SOLUTIONS
‘ After the elimination, substitution and isolation of the safety hazards, rules can be created and the PPE selected for the tasks to be handled. ’
Insightsu
Electrical safety insights
uThe article highlights the significant evolution of electrical safety in manufacturing facilities over the past 50 years, emphasizing the shift from rudimentary testing methods to stringent standards and specialized equipment.
u By creating a culture of electrical safety, manufacturing plants can eliminate many electrical hazards.
panels can be derated to a Category 1 levelthrough the use of engineering software analysis, making them more convenient for qualified persons to work on. Reengineering the panels to separate the controls into separate 24 Vdc-only panels will remove them from arc flash rating and allow access to faster diagnostics without having to “gear up with added PPE” or even power down the equipment.
Placing barriers around higher energy containing components to isolate them provides another layer of protection that identifies the threat and physically separates unqualified persons from the hazard. Care must be taken to prevent an unsafe environment for qualified persons to access the equipment. Integrating removable barriers can
make safety more convenient and less prone to being ignored.
After the elimination, substitution and isolation of the safety hazards, rules can be created and the PPE selected for the tasks to be handled. Training can be developed based on the remaining dangers and the safety areas can be clearly defined for the unqualified persons.
Creating a culture of electrical safety
Creating a culture of safety for electrical hazards in manufacturing facilities is essential to prevent accidents and injuries and the best way to do that is by making it easy. The more personnel need to modify their behavior or go out of their way, the greater the challenge to maintain a safe environment. Management, especially technical personnel, must maintain focus on the actions and continuous improvements. PE
Aaron Beatty is a Principal at Salas O'Brien where oversees a team specializing in project management and design solutions for electrical power projects.
Tom Francisco, Emerson, Byline
Building a world-class predictive maintenance foundation
E. & J. Gallo’s World Class Maintenance initiative builds a predictive maintenance foundation to help process manufacturers drive improved performance.
As globalization continues to connect companies with new customers around the world, process manufacturing organizations face ever-increasing competition. The resulting corporate pressure trickles down to the plant level, where new goals continuously update the speed, quality, and quantity manufacturing facilities are expected to safely maintain. To meet these goals, plants often must operate at peak production 100% of the time.
One area where many organizations are finding the key to achieving peak performance is in improved automation of maintenance and reliability strategies. Reactive maintenance is the antithesis of optimized production. When a plant cannot predict how well — or even if — its assets will run, the organization faces increased costs, delivery delays, and quality degradation. Maintenance, reliability and analytics personnel forced to perform repetitive, low-value tasks risk oversights due to human error and limitations, and they miss opportunities to perform the high-value tasks that lead directly to increased plant performance.
Today’s most successful maintenance and reliability teams are pursuing increased automation to drive their predictive maintenance strategy. Top performers like E. & J. Gallo Winery are building a strong example for others to follow. Gallo, as part of its World Class Maintenance initiative, is embracing a Boundless Automation vision for connected maintenance and reliability solutions and following up on that vision by creating a roadmap for success.
Then, they implement modern automation solutions and follow through by sharing their wins to demonstrate return on investment (ROI) to build
popular support across the organization. It is a strategy any maintenance and reliability group can follow to make their team a jewel in the organization’s crown.
Building a boundless automation vision
At the heart of effective predictive maintenance is quality data. But just having data is not enough. Everyone often has more data than they can handle. To make an organization’s data work for predictive maintenance, it must be collected regularly, contextualized and made accessible by the people and systems that need it. To accomplish this, top performing maintenance and reliability teams are implementing their new technologies using a Boundless Automation vision — leveraging inherently integrated systems to move data seamlessly from the field to the edge and into the cloud.
FIGURE 1: Gallo's stemming and crushing machines are critical to operation. Continuous monitoring helps the team keep an eye on their health at all times so they can begin the busy season with confidence. Courtesy: Emerson
Affiliation
ENGINEERING SOLUTIONS
‘ Building a successful predictive maintenance program is about more than catching poor asset health before it becomes a problem. ’
When maintenance teams have mobility of data, they eliminate the need to spend long hours walking around plants collecting data on handheld devices, returning to the main office, uploading the data, filtering and analyzing it and manually entering it and monitoring work orders for repair.
A seamlessly connected system automatically collects data at the source, where it then automatically performs analytics at the edge or transfers critical data to more robust analytics software for analysis. When problems are identified, the software notifies the correct personnel in real time — wherever they may be.
Seamless connectivity in action
Gallo Winery delivers millions of cases of wine annually, so the company needed to find a way to streamline its maintenance and reliability practices. The organization has multiple massive facilities more than 30 miles apart. Because the facilities are so large, it was taking a very long time to complete walkarounds to perform manual rounds with handheld analyzers — a task that was performed weekly or monthly depending on the facility and equipment.
ty. Edge analytics devices are installed on essential assets in the plant to provide actionable information right at the source. Balance-of-plant assets are candidates for the wireless vibration monitors.
All the plant sensors transmit their data to a centralized data lake managed by an enterprise-level asset performance platform that also provides data management, automated workflows, and decision support. The asset performance platform is connected to Gallo’s business system so they can automatically generate work orders and quickly complete any repairs. All work orders and parts are automatically billed to the right cost center, empowering the maintenance team to work quickly, knowing all the costs will hit the appropriate finance line.
Create the right maintenance roadmap
Objectives Learningu
• Recognize the impact of predictive maintenance on manufacturing efficiency and competitiveness.
• Evaluate the role of data collection, analysis and automation in predictive maintenance strategies.
• Learn how companies like E. & J. Gallo Winery employ automation for predictive maintenance success.
Gallo’s maintenance team found that it could not capture data as frequently as needed to properly track and trend asset health for a successful predictive maintenance program. In addition, many of the assets were very large, requiring personnel to access them from above using catwalks, and to get in tight areas below some assets to perform full assessments. As a result, some checks were missed, and the team had gaps in its data. Maintenance was further complicated by the need for the limited staff to travel among sites to ensure all assets were accounted for.
As part of an initiative to bring their organization into the top 25% of performers in their industry, Gallo’s maintenance and reliability team spearheaded an initiative to better automate their procedures to transition fully to predictive maintenance within 10 years.
The team is reducing its dependence on walkarounds and handheld monitors by installing edge analytics devices and wireless vibration monitors on rotating equipment throughout the facili-
Few maintenance and reliability teams find success by sticking sensors on everything in the plant and hoping for the best. Successful programs are jumpstarted by thorough planning. The most successful projects often start with a pilot program, where teams identify key areas in need of improvement, and target those areas with modern automation solutions. As those pilot projects gather runtime, the team can better evaluate what works and what does not, and then adjust their larger roadmap.
Another key strategy to developing a good roadmap is to start with a criticality and problem asset assessment. Identifying the plant’s most problematic assets — even when they may not be the most critical — is often a good way to identify the ROI the organization is likely to gain by implementing a new predictive maintenance strategy. Those assets are ones the team knows will fail, so they can more quickly and clearly see the impact of catching problems early. And by following up with a criticality assessment of all the organization’s assets, the team can know where to best start allocating resources for a multi-year plan to drive the most benefit right away as they move out of the pilot stage.
Successful implementation in action
Because of Gallo’s size and the wide area where the plants are sited, the maintenance and reliability team knew they needed a well-defined plan before they started their World Class Maintenance initiative. Before the team could justify rolling out new
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technologies across their enterprise, they needed some reliability wins to help prove that their project would be effective.
The team started with criticality. The crushing area of operations was critical to Gallo’s busy season, and historically, the maintenance and reliability team had overhauled all the stemming machines in that area before the season began each year. Whether machines needed maintenance or not, they would be stripped down and overhauled. The process was expensive and time consuming. Moreover, opening equipment that was operating optimally also risked introducing problems where there originally were none. This area of production was the perfect candidate for a pilot program (Figure 1).
In addition, the team added asset monitoring to a turret bearing that had been a problem asset for some time. The bearing was not only prone to failure, but also in an area that was hard to reach while equipment was running, and thus regularly overlooked. Putting an edge analytics device on the bearing provided the team not only with continuous data on the asset, but also with an up-to-themoment health report so they could know when it was time to schedule an opportunity to shut down the equipment and intervene.
Build momentum with popular support
Building a successful predictive maintenance program is about more than catching poor asset health before it becomes a problem. The best programs thrive on popular support — from senior management and the technicians who use and maintain plant equipment every day. Documents wins is critical to the program’s success. Teams must be able to show senior management how newly installed solutions bring fast ROI, in money saved and freeing personnel for more valuable tasks.
Building momentum with technicians is often accomplished by showing them the time they can save in their walkarounds and inspections, as well as how much stress can be avoided when every repair is not a firefighting operation. While the most experienced technicians can quickly identify unusual sounds or temperatures to know something is wrong with an asset, by the time those signs are noticeable, failure has already begun. In such an event, the timeline to repair is shortened, and teams cannot schedule as easily, and repairs are
more expensive — especially when a small number of specialists are centrally located and must travel to site to perform repairs.
Teams can be much more effective when predictive maintenance notifies them early. Even improvements in safety can demonstrate value to the technicians who must interact with equipment daily as part of their jobs, but they likely will not know the value unless the project team is reporting it.
Building momentum in action
At Gallo, the team scored a big win right away on their predictive maintenance project. The turret bearing—selected because it was a problem asset— presented a problem shortly after installation of the edge analytics device.
When the team had the opportunity to stop the equipment and inspect the asset, they identified significant damage on the bearing and were able to replace it before it failed and impacted production. Upon completion of the repair, the team immediately created a report and showed the value of the save to senior management, who saw the benefit of the program and have become among its most ardent supporters.
Gallo’s maintenance team continues to report its wins, including ones that are not as obvious, such as a more right-sized parts inventory and more accurate kitting, the latter helping crews better prepare for repairs and turnarounds.
Predictive maintenance is possible in any facility
Gallo’s World Class Maintenance initiative has delivered impressive results because, for the Gallo team, maintenance and reliability are not an afterthought. Developing highly connected automation systems helps teams at Gallo and other successful organizations better navigate their predictive maintenance efforts, ensuring that they have a constant finger on the pulse of plant health. These teams have better insight into what is wrong with each asset and can manage their resources and schedule more effectively to reduce or eliminate the reactive maintenance strategies that lead to expensive outages. PE
Tom Francisco is a reliability subject matter expert at Emerson.
Insightsu
Predictive maintenance insights
uAutomation in maintenance strategies is key for optimized production. Effective data collection, contextualization and accessibility drive predictive maintenance success.
uSeamlessly connected systems streamline data collection, analysis, and personnel notification, minimizing manual efforts and maximizing timely, accurate maintenance actions.
uSuccessful predictive maintenance isn't about indiscriminate sensor placement. It begins with critical asset assessments, pilot programs and strategic planning for effective, highROI implementation.
ENGINEERING SOLUTIONS
Andrea R. Aikin, STLE, Denver
Evolution of copper corrosion testing for electric vehicle lubricants
New copper corrosion test methods are being developed to make electric vehicle (EV) lubricants better.
JObjectives
• Goals for new electric vehicles (EVs) will drive the need for lubricant improvements.
• Current copper corrosion inhibitors are very technical to select and use, expensive and toxic, all of which complicate enabling EV copper corrosion solutions.
• While current copper corrosion testing is mainly qualitative and generally not applicable to the actual application environment, new and better test methods are being developed.
ust like internal combustion engines (ICEs), electric vehicles (EVs) still need lubricants; however, the key characteristics of those EV lubricants are different from the lubricants used in ICEs. Additionally, EV lubricant chemistries are evolving to enable more advanced EVs. When the lubricant comes into contact with the EVs’ electrical components (e.g., motor, electrical connections, circuits), it needs to provide corrosion protection for copper and other metals, good heat transfer and electrical insulating properties, resistance to oxidation as well as the usual characteristics needed by any lubricant (e.g., wide temperature range, antiwear protection). Equipment specific tests may need to be developed, as well as industrystandard tests.
Copper corrosion is a concern for a number of industries, including seawater desalination, power stations, heat exchangers, sheets and pipelines, shipbuilding and electronics.2 However, copper corrosion is especially problematic for EVs as a short within the electronics or electric motor could disable the engine.
While not a necessary part of antioxidant systems, copper corrosion inhibitors can aid in oxidative stability by pacifying copper that would otherwise catalyze oxidation. Despite benefits, copper corrosion inhibitor treat rates are limited due to toxicity.
STLE member Greg Miiller is the vice president of engineering and new business develop-
ment with the Savant Group in Midland, Mich. He noted the corrosion and proximity of copper will be a multi-faceted challenge for next generation EV lubricants. Miiller said, “If coatings and the application process were all perfectly reliable, we would not be having this conversation.” However, knowing “that coatings can fail both in the initial application and also over time (potentially also related to the fluid), it becomes a true test of the fluid. Assumptions were originally made as to the overall cause of the failures; however, it appears as though the varying chemistries impact both the coating and copper alike.”
He noted that as EVs and lubricating fluids continue to evolve, improvements will continue to be developed.
EV test requirements
ASTM D130 (Standard Test Method for Corrosiveness to Copper from Petroleum Products by Copper Strip Test) is the standard method for testing copper corrosion; however, the method relies on operator judgment, which adds uncertainty, and there are known variations between labs as different testers may interpret the same strip as different colors. In addition, ASTM D130 has limitations for determining copper corrosion as the temperature and exposure times of the test do not necessarily match EV application parameters.
Juan J. Ayala, managing director at Ayalytical Instruments, Inc. in Chicago, said the ASTM D130 copper strip corrosion test is “performed manually and requires a visual determination of not only colors but combinations of various colors to determine a rating.” This process makes the test results subjective and possibly subject to bias. The test requires that a copper specimen be prepared, tempered in a fuel or lubricant and then rated using the ASTM color guide. Ayala noted that 7 to 8% of the population has some level of color vision deficiency, mak-
ing relying on manual interpretations of the D130 results subjective and lacking in reproducibility between different experimenters.
Better lubricants and test methods are being developed to meet anticipated new EV test requirements.
Copper inhibitors
STLE member Daniel Vargo is a senior research chemist with Functional Products Inc. in Macedonia, Ohio. He said, “Copper corrosion occurs when a copper surface reacts with chemically reactive components such as acids or sulfur compounds.”
These reactions can result in the formation of “ionic copper compounds, which being no longer part of the metal surface, can be removed.” This translates into corrosion of the copper surface, which can lead to equipment failure. EV lubricant chemistries are evolving to enable more advanced EVs.
Vargo said, “These copper parts can be eroded by the action of water, oxygen and active sulfur compounds, among other components that can be present in a lubricant.” Another factor that can promote corrosion is the temperature of the metal part when the engine is running.
Vargo said, “Copper passivators are film-forming agents in that they react chemically with the surface.” The resulting films are “unreactive to the effects of corrosive oxygen, nitrogen, active sulfur or acids in the lubricants, thus protecting the copper from corrosion.”
When copper is used in the fabrication of metal parts (e.g., gears, bearings), then the lubricant used in that engine needs a copper corrosion inhibitor. Vargo said, “A very low treat level of <0.1% is usually sufficient to inhibit copper corrosion” when there are low levels of exposed copper.
Vargo noted other components in a formulation can affect the performance of copper corrosion inhibitors. He said, “All performance additives have a certain degree of affinity for the metal surface.”
These different performance additives (e.g., antiwear, extreme pressure, friction modifiers) can compete with the copper passivator for the metal surface. The formulator must judiciously select the optimum treat level for each additive.
STLE member Brian Casey, R&D senior manager at Vanderbilt Chemicals, LLC in Norwalk, Conn., noted identifying the molecules that are the most effective copper corrosion inhibitors depends on the application. He agrees with Vargo
‘ While not a necessary part of antioxidant systems, copper corrosion inhibitors can aid in oxidative stability by pacifying copper that would otherwise catalyze oxidation.’
that “nitrogen-containing heterocycles such as triazoles can be very effective.” He also has found that “despite having sulfur, dimercaptothiadiazole (DMTD) copper corrosion inhibitors can be potent as well by actually forming a protective film or varnish.”
Casey noted non-aromatic copper corrosion inhibitors are most common in aqueous systems. He observed a judicious pairing of copper corrosion inhibitor additives “in specific formulations can provide benefits by filling gaps in the performance profile, including wear, friction, corrosion, etc.”
Some chemistries such as tolytriazole carry aquatic toxicity hazards. Casey said, “Flat, aromatic small molecule rings present a toxicity concern because they are able to intercalate between the base pairs of DNA.”
One way to mitigate the risks of small molecules like tolytriazole is to react them with other components. Casey said, “These reaction products can be engineered to provide the same performance but benefit from improved oil solubility, lower water solubility/bioavailability and aqueous stability.”
ENGINEERING SOLUTIONS
‘ Two tests that can be used to assess copper corrosion are the wire corrosion test (WCT) and the conductive deposit test (CDT).’
Role of the EU ecolabel program EU Ecolabel program
The EU Ecolabel system is a voluntary scheme for goods and services that demonstrate environmental excellence based on standardized processes and scientific evidence that tackles the main environmental impacts of products through their entire lifecycle. The EU Ecolabel program is managed by the European Commission and Member States following the Strategic Working Plan for the EU Ecolabel.
Vargo said, “There are few copper passivators on the market for Ecolabel applications. Typically, copper passivators are triazole derivatives, benzo and tolytriazoles and thiadiazoles.”
An example of a well-known thiazole is DMTD. For Ecolabel, Vargo said the published EU Lubricant Substance Classification list (LuSClist) shows the maximum treat level that can be used when formulating environmentally acceptable lubricant (EAL) products using approved copper passivators. These maximum treat levels are based on triazoles or their derivatives.
Vargo said, “The performance of a corrosion inhibitor can change with different base fluids as they are a major component in a formulation.” The base fluid is especially important for EAL or Ecolabel applications. He said, “The common base fluids are triglyceride oils, synthetic esters, polyalkylene glycols (PAGs) or, to a lesser extent, certain low viscosity polyalpholefins (PAOs).”
He noted each of these fluids have their own advantages and drawbacks (e.g., oxidative stability, hydrolytic stability, polarity, additive solubility) depending on the application. It is important to test a particular corrosion inhibitor “in a suitable matrix with the other additives present to determine the optimum level of each component.”
Current copper corrosion test methods
The SAE J3200 is an SAE International information report, titled “Fluid for Automotive Electrified Drivetrains,” that describes new performance properties and possible test methods for lubricants that are intended for use in EV drivetrain components.4 The relevant lubricants are appropriate for use in electrified drivetrains (e.g., e-transmissions and e-axles). The report covers only geared systems where an electric
motor is either immersed in powertrain lubricant or comes in contact with the lubricant.
The SAE J3200 report is continuing to be refined for EV drivetrains, and Miiller said it “is a guide to those testing the capabilities of the EV fluids and lubricants.” He noted the hope that the report will be modified to keep up with the continuing developments in the EV field. He said the document can be improved by “adding new tests, modifying some existing tests and potentially evaluating values reported.”
Two tests that can be used to assess copper corrosion are the wire corrosion test (WCT) and the conductive deposit test (CDT). The CDT and WCT are currently in the process of completing an ASTM test method.
Role of a wire corrosion test
The WCT involves placing thin copper wires of known length and hence resistance in the liquid and vapor phases of a lubricant and monitoring the change in resistance while maintaining a specific temperature for 72 hours. The test is very sensitive and can investigate the corrosion rate for lubricants under the actual EV temperature range. As would be expected, most often the corrosion rate increases with temperature, but surprisingly this is not always the case. This measures realtime change in resistance/voltage of wire rather than relying on subjective evaluations.
Miiller noted the WCT and the ASTM D130 are similar tests, but they can provide “distinctly different results.” He said, “The WCT provides excellent real-time information on the corrosion event as it takes place so the rate of the corrosion can be monitored at different temperatures.”
In contrast, “The ASTM D130 copper corrosion test does not apply a voltage and only looks at a rating of the copper in the end, which is very subjective.” Miiller has found “that the WCT detects corrosion and failures when the D130 test does not.” In addition, “even adding an elemental test as an extended D130 only values soluble copper and does not address the corrosion remaining on the wire.”
Role of a conductive deposit test
The CDT is used to assess risk to electronics and motors in contact with the EV lubricants.
The purpose of the CDT is to identify if conductive deposits will form when copper is exposed to lubricant or vapor. Copper that is corroded from the surface can deposit as copper sulfide onto the exposed copper when exposed to components of the liquid or vapor phase. These deposits can potentially bridge the gap between conductors at different electrical potentials, creating a catastrophic short in the circuits or electric motors.
The CDT involves placing a test printed circuit board in a sample of the test fluid, which is then heated for a period of time ranging from hundreds of hours to thousands of hours while the circuit is monitored in real time. If the resistance drops below a specific value, the fluid has failed by showing conductive-deposit-forming tendencies in either the vapor phase or the liquid phase or both. Photographs of the end-of-test board are evaluated for deposit accumulation and dendrite formation.
The extended D130 and vapor phase copper test extends the time the copper strip is exposed to the heated fluid. A visual rating is performed at the end of the test, where the amount of soluble copper seen in the solution is an indication of the copper that has leached out of the copper strip.
Miiller also found: “The CDT will capture conductive deposit failures that neither of the other two tests (i.e., D130 or WCT) are able to directly assess, and this is important to avoid real field failures.” He finds that the CDT “is looking at corrosion, but with a focus on conductive deposits which can damage a system with an arcing event.” The CDT is a test where voltage is applied to the copper traces but also goes beyond just corrosion.
Miiller said the CDT and WCT provided quantitative results, with both tests providing “A rate of corrosion or a measure of the propensity to form conductive deposits over time.” He observed: “The CDT offers an index value over time that can be utilized by the OEMs or specification setting organizations to determine critical limits.”
Miiller said, “Because of the history of the ASTM D130 test, it may be useful for comparative results.” In contrast: “The CDT and WCT offer superior testing applications and information that show correlation to the field, which will prove to be critical tests for the EV industry for many years to come.”
Developing new methods
Ayala said, “While copper strip testing continues to be a critical indicator of sulfur compounds present after the refining process, measuring copper corrosivity continues to be a challenge.”
The reliance of current test methods on manual and visual assessments introduces human bias and error into the testing process, leading to the potential for inaccurate or poorly reproducible results.
Ayala described copper digital detection imaging (CuDDI), a method that is in development, that “uses a highly stable and electronically controlled LED light source, which is stabilized at approximately 4,500 K and diffused at a 45-degree angle to simulate the ‘daylight’ effect referenced in current methods.” Using this light source method creates a more consistent environment via standardized simulation.
Ayala said the optical corrosion measurement employed in the method uses “the proposed charge-coupled device (CCD) camera-based solution that is trained using the ASTM color standards and logic defined in Table 1 of ASTM D130.” This means “the algorithm is fixed and not subject to variations in color perception or color blindness.” The measurements also are performed under tightly controlled lighting conditions, meaning under reproducible ambient lighting conditions. Currently, the D130 manual method lacks control parameters for ambient conditions, which matters when looking at reflective color.
Ayala identified CuDDI’s potential improvements over current test procedures and their end results as including:
• The elimination of inherent bias with the manual rating
• A voltage and current-controlled light box to create a consistent ambient light environment
• The automatic detection of the copper strip size
• A long-lasting LED light source
• Autorotation of the copper strip for recording results for both sides.
Insightsu
Electrical vehicle insights
uElectric vehicles (EVs) demand lubricants with unique characteristics, focusing on corrosion protection for electrical components, heat transfer and electrical insulation, distinct from traditional internal combustion engine lubricants.
uCurrent test methods like ASTM D130 for copper corrosion face limitations in replicating real-world EV conditions. Emerging tests like wire corrosion test (WCT) and conductive deposit test (CDT) offer quantitative insights, crucial for EV industry advancements.
uNovel approaches like copper digital detection imaging (CuDDI) promise enhanced accuracy and reproducibility in assessing copper corrosion. These advancements are vital for ensuring the reliability and longevity of EV components and lubricants.
ENGINEERING SOLUTIONS
The draft optical CuDDI method has not yet been established as an ASTM test method.
Conclusions
Vargo said, “The details of electric motor design will have a large impact on the lubricant system that will be needed.” In addition, “with the mandated development and increased interest in EVs, new copper corrosion inhibitors may need to be developed for the lubricant system.”
‘ Copper, with its high electrical conductivity, will be used extensively in EV motors.’
Copper, with its high electrical conductivity, will be used extensively in EV motors. The needed lubricants must provide protection from copper corrosion, effective cooling, the necessary dielectric properties and must not degrade or need to be changed over the EV’s lifespan.
With the growing EV fluid market, Casey said, “The additive manufacturing business is eager to get feedback on how existing additives can help solve the needs of emerging markets like EV and to develop new offerings to address the specific demands for EVs going forward.”
Along with refining and developing effective lubricants and additives, the testing process of predicting copper corrosion will continue to be a necessary field for research. PE
Andrea R. Aikin is a freelance science writer and editor based in the Denver area. You can contact her at pivoaiki@sprynet.com.
Reprinted with permission from the January 2024 issue of TLT, the official monthly magazine of the Society of Tribologists and Lubrication Engineers, an international not-for-profit professional society headquartered in Park Ridge, Ill., www.stle.org. Available at https://www.stle.org/files/TLTArchives/2024/01_ January/Feature.aspx.
Chain lubrication considerations for extreme conditions
Chain lubrication is useful for extreme applications for equipment or situations that are dangerous for humans to enter while in production and where speed, flexibility and friction reduction is needed.
Rope is one of our earliest tools and may be the oldest method in the history of transferring powering. Today, in industrial applications, ropes and chains are often made of metal and the lubricants for chains and cables are often grouped together, as their power transfer or conveyance functions are similar.
However, in extreme service realms, wire rope is found in fewer places because modern chain is designed to reduce friction and wear with engineered bushings and rollers. Metallurgy and manufacturing technique advances have resulted in modern chains being ubiquitous in today’s industrial equipment. Wire rope may carry very high loads, but in extreme applications where speed, flexibility and friction reduction are required chain carries the day.
What is considered an extreme condition for chain or conveyor operation? Under ambient atmospheres and temperatures properly specified and formulated, lubricants and lubricant carriers, which may be mineral oil or solvent-based, can do an excellent job. The extreme realm occurs when temperatures of the chain or conveyor range above 300 ⁰F or low temperatures below -40 ⁰F when exposure to chemical or corrosive environments can cause failures in manners different than those by normal wear and tear.
Additional scenarios are considered extreme because the lubricant itself, if not specifically formulated, can harm the actual process in which the chain or conveyor is operating. All of these extreme scenarios call for products which fall under the specialty lubricants umbrella. This is an area where typical mineral base oils and additives will cease to function adequately.
It’s also a domain where hand lubrication is now mostly impossible because of the environments and conditions these chains and conveyors are subjected to.
In extreme realms, fully automated lubrication systems are routinely utilized because lubricant dissipation and degradation can be rapid. For safety reasons, automated lube systems also can provide precise and timely application of the lubricant on equipment that is inaccessible or dangerous while in production.
Extremely high temperature chain and conveyor applications
When operating temperatures of chains exceed 300 ⁰F, new considerations must be made to protect from wear and failure and to mitigate issues with thermal degradation of the lubricants. This high temperature realm could be further subdivided into increasing increments of 100 ⁰F intervals each step making even more rigorous demands upon lubricant formulations.
FIGURE 1: Typical best temperature ranges for base fluids in fully additized finished formulations for extreme environments. Note: Silicone and PFPE fluids are not soluble with most additives and may exhibit unacceptable levels of wear.
Courtesy: JAX Inc.
Eric J. Peter, JAX
ENGINEERING SOLUTIONS
The first order of business is determining the exposure to the high temperature environment. For example, if the chain or conveyor is intermittently at high temperature, it may never get as hot as the actual process before returning to ambient conditions. This is important in terms of the price of the lubricant necessary to do an adequate job. Situations above 300 ⁰F likely require synthetic or solid film lubricants.
Learningu
Objectives
• Understand the challenges associated with lubricating chains and conveyors in extreme conditions such as high temperatures exceeding 300 0F or low temperatures below -40 0F.
• Identify suitable lubricant formulations and application methods tailored to specific environmental factors, including temperature variations, chemical exposures and operational demands.
• Explore the role of specialty lubricants in enhancing equipment reliability, mitigating wear and corrosion and optimizing production efficiency in industrial settings.
Under extreme temperatures, engineers will find suitable chemistries of the lubricant, carrier and solids will grow much more expensive as temperatures rise to 400, 500 and 600 ⁰F and maybe beyond that.
The plant engineer also should be diligent in measuring temperatures of the lubricated chain all along the process and determine the highest temperature encountered and the amount of time in the cycle it will be at its highest. Most often, the chain will not achieve the level of the high temperature process point. Ensuring lube reservoirs are at ambient or near ambient temperatures will protect the lubricant from thermal degradation before application. This data will be a necessary guide to optimal lubricant selection and is also instrumental in determining the lubrication method and lube intervals.
Since this is above temperatures at which most surface-active chemical additives will start losing effectiveness, more of the lubrication responsibility will be on the base fluid chemistry and possibly any solid film additives or components.
Polyalphaolefin- (PAO) based synthetic lubricants have found broad acceptance in transportation applications due to their high and low
temperature abilities, but by looking at the chart, it is clear it will no longer be the base fluid of choice above 300 ⁰F. One of the major culprits hindering proper high temperature chain lubrication is residue created as the lubricating fluid thermally degrades under the oxidative stress of the hot environment. Not only will PAOs start to degrade as temperatures rise, but the hard carbonaceous residue left behind will block lubricant passageways and can itself cause wear. Due to PAO’s non-polar nature, it also lacks the self-solubilizing attribute of some of the more polar molecules found in base fluids for higher temperature applications.
As temperatures rise above 400 ⁰F, engineers will find greater use of synthetic fluids with more polar molecules such as polyalkylene glycols (PAGs) and polyol esters (POEs). These fluids provide cleaner performance and withstand higher temperatures for longer times before thermally degrading. PAGs leave little or no residue but can generate some undesirable smoke as temperatures rise near 500 ⁰F. The other synthetic fluids listed have niche applications, but may show weaknesses in either wear protection or deposit control.
Extremely low temperature chain and conveyor applications
Most low temperature industrial chains and conveyors are found in food processing environments. These applications are often far below the -40 ⁰F range where conventional mineral based lubricants will function. Freezing methods in food produc-
FIGURE 2: Extreme low temperature spiral freezer. Courtesy: JBT-FrigoScandia Division
tion are continuous processes. Production lines for small pieces like cut fruit and vegetables, or small bits of protein are air driven freezing tunnels having no need for conveyor systems. The fan driven cryogenic air moves the product. As product size and weight increase this is not possible. Straight line conveyors may be used, but the typical freezing method is the cryogenic spiral freezer.
In this machinery, the chain is not driving the rotation. While it is performed by a gear box, but the chain is supporting the product conveying medium. Here is where PAOs outshine most other synthetic base fluids because they are suitable for H1 food grade applications and also are one of the best-performing synthetic fluids at extremely low temperatures in terms of flow. In extreme low temperature applications, a balance must be struck between viscosity and antiwear performance.
In the range of -70 to -90 ⁰F, lubricant flow becomes a critical factor. Freezing equipment original equipment manufacturers (OEMs) and processors are seeking to push the envelope to lower process temperatures. Product freezing can be nearly doubled with every 15 ⁰F drop in process temperature. Adding to the lubrication complications, these units also will undergo a clean-in-place (CIP) sanitization process. This involves chemical cleaning at ambient temperatures or above, which means the lubricant also must provide adequate wear and corrosion protection for the equipment before, during and after the CIP process.
Seven extreme chain and conveyor applications
In more specialized chains and conveyors, the processes may require lubricant formulations specifically engineered to provide compatibility with their particular environments. While many more exist, these seven are among the most common.
1. E-Coat (Electrostatic paint lines, coating compatibility and lubricity)
This application requires lubricants that satisfy wear protection, however the presence of lubricant in the process may cause paint issues such as fisheyes or poor surface adherence. These coatings are often water-based, which means the lubricant must be water and coating soluble and not cause deleterious effects should it migrate to the coating baths or painted surfaces. This application is often
lubricated with custom formulated water soluble PAG base lubricants, which will likely have to pass paint compatibility testing with the coating supplier in each production facility.
2. Lithograph ovens (Temperature, contamination)
The primary application is high speed beverage can production where the pin chains conveying the cans through the decorating process will encounter the same temperatures and coating residues as the cans themselves. Being lubricated with POE based lubricants for high temperature capabilities often provides better cleanliness factors on the conveying chain.
3. Fiberglass forming and drying chains (Chemicals, extreme temperatures)
Fiberglass insulation production is very aggressive on the conveying chains in the process. In the forming process the weight of the product means the lubricant will have to provide substantial load carrying benefits in addition to protecting against a potentially very corrosive chemical environment. This can be accomplished with a specialty additive formulation in a mineral base oil. When the glass mat proceeds to the drying oven the process is now a very high temperature environment requiring a low volatility, high flash point, clean running POE chemistry. Similar conditions apply to the gypsum and wallboard production processes with slightly less aggressive chemicals and slightly lower oven temps.
‘
3: Comparison of a bakery proofer line chain prior to using a properly additized lubricant for its environment (left) and its condition after using a properly additized lubricant (right). Courtesy: JAX Inc.
In extreme realms, fully automated lubrication systems are routinely utilized because lubricant dissipation and degradation can be rapid.’
FIGURE
ENGINEERING SOLUTIONS
4. Fish pack (Salt, water washout)
Pictured in dry form, but typically applied as a dispersion in a fluid carrier. Courtesy: JAX Inc.
‘ Most
Saltwater seafood packaging conveyors are subject to a corrosive environment due to the salt and sanitization chemicals. Although not extreme in terms of temperature, mineral-based lubricants used in these applications must usually be of H1 food grade integrity and also ensure an extra high level of wear and corrosion protection under a very severe environment.
5. Proofer ovens (Humidity, abrasives)
Bakery proofer chains see a very high humidity environment for extended periods. Temperatures are not the aggressive factor, but the environment and presence of particulates present challenges for the lubricant to protect against rust and abrasive wear.
dry lubricants also optimally function in an air-free vacuum environment.
’
6. Protein rendering plants (Corrosive, high loads)
The circumstances of equipment used poultry, beef and pork rendering subject it to corrosive chemicals as byproducts of the process. Chains employed in these plants must be lubricated with fluids possessing extra measures of protection against environmental and production induced corrosion.
7. Engineered wood presses (Extreme temperatures and contamination)
OSB, particle board and some plywood manufacturing present all of the high temperature issues in an extremely severe environment. The chains and conveyor systems on continuous presses are
subject to temperatures approaching 600 ⁰F in an oven system which has chemicals and particulates present. Lubricants that perform inadequately can cause issues with excessive carbon residue in conveyor rod cavities and on chain pins and rollers. These issues cannot be completely avoided due to the process. That means the lubricant also must have a good degree of self-solubility to help keep the conveying system running.
Dry
film lubrication in extreme environments
In areas so hot that rapid degradation or fire risk makes fluid lubrication impossible, the lubrication of chain systems can sometimes fall to solid lubricants. The solid lubricant is typically applied as a suspension or mixture in a sacrificial liquid carrier. The carrier’s job is enabling the solids to flow and penetrate into the wear points and then, as cleanly as possible, disappear. Mineral spirits, alcohols, or PAGs are often favorite carrier fluids due to their relatively clean evaporation or quick flash off characteristics.
Although dry film lubricants can exhibit some exceptional friction reduction and high temperature capabilities, like fluid lubricants they will need to be reapplied on a regular interval. One consideration is solids may not dissipate. They can accumulate, causing lube passageways to clog and chain surfaces to become caked. In the instance of bakery chains lubricated with water or solvent based graphite, the chains will have to be beaten with hammers each week or blasted with dry ice to remove excess graphite accumulation. Most dry lubricants also optimally function in an air-free vacuum environment. Even though
FIGURE 4: Common solid film lubricants used in extreme condition chain and conveyor lubricants.
they can be efficient in reducing friction in many industrial applications, their effectiveness can be adversely affected by humidity, air, water and impurity levels in the environment.
Their relative performance also can be altered by the particle size and purity of the solid film lubricant itself. Different solid film lubricants also will function at varying performance levels depending on their level of affinity for the lubricated substrate material.
The role of greased chains
In submerged conditions chains can be subject to such aggressive washout tendencies that fluid lubrication will not be adequate. Under these circumstances, chains are often engineered to accommodate grease lubrication through grease zerks leading directly to links and pins or to antifriction roller bearings. These chains require a specialty grease to remain lubricated. The grease also must be formulated to resist the extreme washout and any corrosion conditions associated with these applications. Considerations such as oil
bleed, lubricant recovery and environmental concerns also will guide the proper grease selection.
The tribology of chain and conveyor lubrication is not as simple as it would appear. The myriad of machinery, applications, environments and materials the chains and products they convey result in many factors that need to be considered.
Discussions with OEMs, consultation with lubrication engineers and even field testing may be necessary to find the best performing solutions for a particular application or situation.
Factors such as extending chain life, conserving energy and enhancing production speeds must be evaluated and balanced. There also may be more than one solution, but all extreme chain and conveyor conditions will demand some type of specialty lubricant and some form of automated application system. PE
Eric J. Peter is a company director at JAX Inc. and is widely recognized as an expert in the development, manufacture, and application of advanced industrial lubricants.
Insightsu
Chain lubrication insights u In extreme industrial conditions, specialized lubricants are crucial for maintaining efficiency and preventing failures, necessitating thorough understanding and tailored solutions for diverse applications and environments.
uExtreme temperatures, whether high or low, pose significant challenges for chain and conveyor lubrication, requiring meticulous selection of lubricant types and formulations to ensure optimal performance and equipment longevity.
u In hazardous or inaccessible environments, automated lubrication systems offer precise and timely application, mitigating risks of rapid lubricant degradation and ensuring equipment safety and efficiency in industrial operations.
ONE SOURCE
Lubriplate’s ultra-high-performance, 100% synthetic lubricants have been engineered to provide unsurpassed performance in the most demanding plant environments. They provide a wide range of benefits designed to make your plant run better. Benefits include: extended lubrication intervals, lubrication consolidation through multiple application capability, reduced friction, extended machinery life and reduced downtime. Products include...
HIGH-PERFORMANCE SYNTHETIC GEAR OILS
SYNTHETIC AIR COMPRESSOR FLUIDS
SYNTHETIC HYDRAULIC FLUIDS
HIGH-PERFORMANCE SYNTHETIC GREASES
NSF H1 REGISTERED FOOD GRADE LUBRICANTS
ECO-FRIENDLY SYNTHETIC LUBRICANTS
SPECIALTY LUBRICANTS
Worm Gear Oil
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.
LUBRICATION GUIDE
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The Energy-Efficient Solution Bridging Fixed
and Variable-Speed
Technologies
In the world of compressed air systems, choosing the right compressor type can significantly impact energy efficiency and operational costs. Traditionally, operators have had to decide between fixed-speed and variable-speed drive (VSD) compressors, each with its own set of pros and cons. However, a new player has entered the scene—the dual-speed compressor— offering a compelling middle ground between the two established options.
Introducing Dual Speed Compressors: A Middle Ground Solution
Fixed-speed compressors are the familiar workhorses of many operations. They’re simple and inexpensive upfront, but their constant full-speed operation leads to significant energy wastage when demand fluctuates. On the other hand, VSD compressors adapt their motor speed to match air demand, resulting in superior energy efficiency, albeit with a higher initial investment cost.
Dual-speed compressors bridge the gap between fixed-speed and VSD models, offering a unique blend of benefits. As the name suggests, these compressors operate at two speeds: full speed for maximum output when needed and a lower speed during periods of reduced demand. This dual-speed functionality significantly reduces energy wastage inherent in fixed-speed compressors.
Minimizing Transient Losses: A Key Advantage of Dual-Speed Compressors
One key advantage of dual-speed compressors is their ability to mitigate transient losses, a downside with traditional fixedspeed models. Transient losses occur during the startup and unload phases, where energy is wasted due to pressure differentials and venting processes. Dual-speed compressors can start under pressure, minimizing energy consumption during startup and experiencing lower blow-off losses during the unloading phases.
The overall result is up to 20% energy savings compared to fixed-speed compressors, making dual-speed models an attractive option for energy-conscious operations. Additionally, dual-speed compressors offer flexibility in pressure settings without sacrificing airflow or Free Air Delivery (FAD), allowing for smaller-sized units and further cost savings.
Optimal Choice for EnergyConscious Businesses
Dual-speed compressors represent a compelling alternative to traditional fixed-speed models, offering improved energy efficiency and operational flexibility without the higher investment cost of VSD compressors. For businesses seeking to optimize their compressed air systems, dual-speed compressors provide a promising solution that combines the best of both worlds.
AutomationDirect
A well-recognized name in the industrial automation market, AutomationDirect provides quality products with FREE award-winning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 45-day money-back guarantee is offered on nearly all items.
With more than 40,000-part listings, new products include Endress+Hauser pressure transmitters, Metal Work valves, WEG Rolled Steel Motors, and ifm efector barcode scanners, cameras and vision sensors. The company also offers the CLICK PLUS PLCs, DURApulse drives, enclosures, circuit protection, cut-to-length cable, pneumatic supplies and more.
The state-of-the-art headquarters facility near Atlanta is designed throughout for maximum performance. The majority of items are in-stock and ready for fast shipping; orders over $49 ship for FREE. Some exclusions apply.
The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. They also provide FREE online PLC training to anyone interested in learning about industrial controls. A Customer Forum utilized by tens of thousands of automation professionals provides peer support on technical and application questions.
AutomationDirect’s customer support team has been rated top-notch by its customers and has received numerous industry accolades/awards for providing the best service and support on various products. To ensure their service and support remains superior, they continuously survey customers and have consistently outranked other suppliers.
For an in-depth look at products offered, scan the QR code below or visit: www.automationdirect.com.
Company headquarters located just north of Atlanta, GA
Orders ship quickly from our state-of-the-art warehouse
Achieve sustainability goals and lower total cost of ownership with a holistic flow control approach.
To help businesses rise to the challenges of decarbonization and energy reduction targets, Flowserve has developed the Energy Advantage Program (EAP). The program incorporates proven engineering expertise, an innovative datadriven optimization of flow loop operations and defines a mutually-agreed-upon set of commitments to reduce efficiency costs and/or achieve carbon and efficiency goals.
Within the EAP, Flowserve performs engineering analysis, project management, and execution of aftermarket upgrades, tailored to the industry, application, and other site variables. The plant operator’s commitment is the collaboration on data, process information, and implementation.
Quantified Sustainability Impact
Implementing the Energy Advantage Program allowed the petrochemical operator to achieve:
• Combined power consumption reduction by approximately 3810 MWh per annum.
• Estimated annual savings from reduced energy consumption of $230,000.
As an example, Flowserve partnered with a petrochemicals plant operator to optimize energy usage of a cooling water system with five parallel VS3 pumps (rated 600 kW each) connected to a cooling tower in an open system. Flowserve was tasked with minimizing energy consumption across all operating scenarios — from reducing operational risks of having to operate all installed pumps to meeting the duty requirements and maintaining the existing electric motor and drive train, discharge head and motor frame.
• Approximate CO2 savings of 2285 metric ton per annum.
• Increased redundancy (5oo5 to 4oo5 operation).
• Increased reliability through higher NPSH3% margin
Flowserve’s EAP team implemented validation testing for open channel flow measurements to benchmark a dynamic system model for the different operating scenarios. This allowed new duty conditions to be defined for the pumps to achieve optimal energy efficiency at a system level. Following a data-driven analysis on the complete flow loop, Flowserve determined the most cost-effective, impactful upgrade was to retrofit the CW pumps with a custom hydraulic end. The improvements were validated through CFD analysis and factory tests prior to final on-site validation of the savings.
In addition to the petrochemical industry, Flowserve’s EAP is already helping companies realize measurable results in a wide variety of industries and applications — coal-fired power plants, pipeline, steelworks, and nuclear, just to name a few.
CLICK HERE or scan the QR Code to get in touch with Flowserve’s EAP engineering team to find out how we can help you achieve sustainability goals and lower TCO with an enhanced holistic flow control approach.
Delivering Trusted & Dependable Compressed Air Solutions
With over 170 years of industry experience, FS-Curtis has earned its reputation as the go-to provider of trusted and dependable compressed air solutions. FS-Curtis continues to lead with state-of-the-art technologies designed to optimize efficiency, enhance performance, and ensure exceptional durability.
Introducing the FS-Curtis NxD110: Excellence in Single-Stage Air Compression
Recipient of the 2024 Plant Engineering’s Product of the Year Gold Award, the FS-Curtis NxD110 is a testament to its reliability and performance excellence. Boasting advanced features like eCOOL ® Technology for superior component protection and dBA Shield Noise Reduction for whisper-quiet operation, the NxD110 delivers uninterrupted performance with a 100% continuous duty cycle. With easily accessible components and intelligent alerts, maintenance is a breeze, making it the top choice for industries that value longevity and reliability.
iCommand-Touch+ Premium: Enhancing Control & Efficiency
The iCommand-Touch+ Premium compressor controller represents one of the latest advancements from FS-Curtis. Engineered for enhanced performance and efficiency, it features a touchscreen interface and integrated Variable Frequency Drive (VFD) data for streamlined issue resolution. Users can optimize system performance through features like automatic restart, versatile operating modes, and comprehensive monitoring capabilities for up to six compressors.
FS-SmartConnect: Enhancing Compressor Performance Through IoT Monitoring
FS-SmartConnect is a game-changer in compressor monitoring. By continuously collecting and analyzing live data in the cloud it revolutionizes the way you manage your compressors. This real-time monitoring, accessible via an intuitive online dashboard, empowers you with proactive maintenance capabilities, maximizing uptime and reliability. Early issue detection and detailed performance reports ensure that your compressor always performs at its best, giving you peace of mind.
Continuously Supporting Our Valued Customers
FS-Curtis’s unwavering dedication to innovation and quality is evident in our comprehensive range of reliable compressed air solutions. As industries evolve, we remain dedicated to providing steadfast support, delivering tailored solutions that seamlessly adapt to our customers’ ever-changing requirements. With FS-Curtis, rest assured that your compressed air needs are in trusted hands.
Pioneering Innovation, Crafted in America
For over six decades, FS-Elliott has been an innovator in centrifugal compressor design and manufacturing. Our commitment to quality, efficient performance, and durability has been recognized globally for demanding industrial environments and applications requiring precise, custom-engineered solutions that deliver oil-free compressor air. Proudly headquartered in Export, Pennsylvania, USA, we honor our American heritage by being dedicated to manufacturing excellence. We ensure that the highest standards of quality, performance, and durability are upheld at every stage of the production process.
Introducing the P400HPR Compressor
Our latest innovation, the P400HPR, stands out in our acclaimed Polaris series. Recognized with the 2024 Plant Engineering’s Product of the Year Silver Award, the P400HPR boasts an industry-leading aerodynamic design that delivers peak performance and offers substantial energy savings compared to traditional compressors.
With its exceptional high discharge temperature capabilities, the P400HPR is ideally suited for Heat of Compression (HOC) drying applications, ensuring maximum efficiency and energy. Equipped with three stages of compression and capable of delivering up to 250 PSIG, the P400HPR provides operators with unparalleled power without compromising efficiency.
Regulus Control System Featuring FS-Connect
Our Regulus control system line, featuring FS-Connect, sets the standard for remote monitoring and control. Designed to efficiently manage plant load while maximizing energy savings, the Regulus system offers advanced control modes that enable operators to reduce waste and energy consumption.
FS-Connect, which provides remote access to Regulus panels, offers a comprehensive insight into compressor operation. It enables remote troubleshooting and real-time pressure, vibration, and temperature monitoring. Operational and maintenance notifications and monthly summaries inform operators about maintenance schedules and provide energy-saving recommendations.
A Legacy of Innovation
As we pave the way forward, FS-Elliott remains committed to advancing compressor technology, ensuring enhanced efficiency, reliability, and performance for our valued customers. At FS-Elliott, innovation isn’t just a goal—it’s our enduring legacy.
Kaishan USA Launches New Oil-Free Rotary Screw Compressor
Kaishan USA has introduced a new series of industrial, oil-free rotary screw air compressors, the KROF.
Plant managers and operators seeking to stay ahead of the everchanging innovation will find unrivaled value in the technical depth of the KROF. The KROF is a two-stage oil-free rotary screw air compressor that provides high-quality, ISO 8573-1 Class 0 oil-free, compressed air. By utilizing two sequential compression stages, intercooling and aftercooling, users will receive high-quality air that is suitable for sensitive applications where purity is paramount.
It’s the only oil-free compressor that’s 100% designed, engineered and manufactured in the United States.
Kaishan USA Launches New Industrial Vacuum Pump
Kaishan USA has introduced the KRSV, a new series of industrial vacuum pumps.
The new Kaishan KRSV oil-flooded rotary screw vacuum pumps are fully packaged, out-of-the-box ready to be plugged into any system or operate independently. Featuring a combination variable speed drive and variable discharge port airend, the vacuum pumps are universally applicable and an industry leader in energy efficiency.
Whereas most vacuum manufacturers utilize a fixed port, which means these systems operate at a static volume ratio, a variable discharge port enables Kaishan KRSV vacuum pumps to ensure the proper volume ratio at all ranges and demands, delivering stable, optimal control for the most energy savings.
Groundbreaking for Expansion
Kaishan USA, a leading manufacturer of
industrial rotary screw air compressors, is expanding its Loxley, Alabama-based facility to meet growing demand and industry needs. With over 65 years of heritage, the company has outgrown its current facilities due to high product demand, leading to a workforce increase of over 55%.
The 65,000-square-foot expansion aims to create 50 new jobs within five years, focusing on enhancing manufacturing capabilities and employee training.
257-0586
Kaishan’s latest industrial vacuum pump, the KRSV.
Kaishan’s newest oil-free rotary screw compressor, the KROF.
The $11 million expansion is targeted for completion by spring 2025.
Complimentary Value Added Services Include.. .
A Toll Free Technical Support Hotline and E-mail
We offer training programs tailored to fit your needs. These educational training sessions focus on all facets of machinery lubrication and are not a sales presentation. Seminars are graphically presented with PowerPoints and other support material. Available on-site at your facility or in a local conference room. Contact us at 800-733-4755 for more information. Lubriplate’s Complimentary ESP
You can call Lubriplate’s technical service center toll free at 800-347-5343 for quick answers to tough lubrication questions by phone, or you can e-mail questions to LubeXpert@lubriplate.com seven days a week.
Complete Plant Surveys and Lubricant Inventory Consolidation
Complete plant surveys by Lubriplate’s professional staff of lubrication engineers are also available to determine your exact lubricant requirements and identify opportunities for lubricant inventory consolidation.
Customized, Color Coded, Lubrication Charts and Machinery Tags
Lubriplate offers color coded lubrication charts and machinery tags to help prevent lubricant misapplication and ensure proper lubricant usage when servicing a particular piece of equipment. Based on a complete plant survey, tags can be provided for each piece of equipment in your plant.
Lubrication Maintenance Software
Lubriplate offers a PC based computer software program that puts your entire lubrication and maintenance schedules at your fingertips. This service is based on a complete survey of your entire plant. Contact Dan Moroses (Newark office) for details at 973-589-9150.
No-Charge Follow-up Oil / Fluid and Grease Analysis
Lubriplate’s Oil/Fluid and Grease Analysis Program is offered at no-charge on all Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO Cleanliness (optional). An interpretation of the results is included along with suggested actions to take.
In Plant User Lubrication Training Programs
Lubriplate Lubricants Company Newark, NJ 07105 / Toledo, OH 43605
Hitachi Global Air Power – Pushing the Boundaries of Compressor Efficiency
For more than 50 years, Hitachi Global Air Power and the Sullair brand have focused on customer needs to drive compressed air innovation.
The latest innovation – Sullair TS Series Two-Stage rotary screw air compressors offering best-in-class efficiency*. While Sullair two-stage compressors have been known for their reliability and durability, the new TS Series offers a quantum leap in efficiency.
“The Sullair TS Series is changing the game in the industrial compressed air market,” said John Randall, President and CEO of Hitachi Global Air Power. “Our goal is to design machines that answer customer needs – particularly the need for higher efficiency – and our engineers delivered. The redesigned two-stage air end sets a higher standard for efficiency and is another step forward in our new era of customercentric, environment-forward innovation...”
The Sullair TS Series addresses the needs of customers with big air requirements. The completely redesigned air end can reduce energy needed for compressed air production which translates into direct cost savings for a company. While two-stage compression typically saves energy when compared to single-stage compression, the TS Series’ patent-pending interstage cooling helps drive even more efficiency.
The TS Series innovations continue with the inclusion of several features from the Sullair LS Series of compressors. Lift-off panels simplify access to service and maintenance components. The enhanced Sullair Touch Screen Controller provides intuitive compressor operations.
Driving further efficiency, the TS Series incorporates Sullair-exclusive Electronic Spiral Valve Technology. This proven capacity control option helps match the compressed air produced to demand–and operates flawlessly in all operating conditions including high altitudes and dirty environments.
Hitachi Global Air Power is part of Hitachi Industrial Equipment Systems Co., Ltd. whose purpose is to realize a sustainable society through green products and innovation.
Hitachi Global Air Power in Michigan City, Indiana
John Randall President & CEO
Unlocking Reliability: ABB Motion Services Leads the Industry
Unlock the power of reliability with ABB Motion Services. In an era where downtime is simply not an option, we understand the critical importance of keeping your operations running smoothly. Our commitment to excellence is reinforced by the findings of the comprehensive survey conducted by ABB, shedding light on the pivotal role of reliability in today’s industrial landscape.
Our recent survey underscores the pressing need for dependable solutions, revealing that a staggering 87% of respondents cite reliability as the foremost concern in their operations. At ABB Motion Services, we take these insights to heart, pioneering innovative approaches to enhance reliability and minimize disruptions.
With our state-of-the-art technologies and unrivaled expertise, we empower businesses to achieve unparalleled levels of operational continuity. From predictive maintenance strategies to proactive monitoring systems, we tailor our solutions to meet your unique requirements,
Reliability means results | ABB
Decarbonize with Confidence
Let Air Products be your decarbonization partner through the transition to sustainable energy. We can help you utilize oxygen to improve your natural gas efficiency, find a potential carbon capture and sequestration solution, or introduce hydrogen to your process to reduce emissions.
Replacing or blending natural gas with low carbon intensity hydrogen like green or blue, can help energy-intensive industries lower their carbon emissions and meet sustainability goals. Whereas oxy-fuel combustion technologies offer unique possibilities for cost reduction, productivity, and sustainability. For operations that are in a suitable geography, carbon capture and sequestration (CCS) may be a viable option, as it can be one of the most cost-effective paths to decarbonization for hard-toabate industries. Whatever your need is, Air Products will work with you to find the most suitable decarbonization method for your operations. Visit our website and take the first step on your decarbonization journey.
Heat Activated Shut Off Valves
When a fire occurs process valves need to be shut down fast. Assured Automation’s FireChek valve does just that, and without the need for any external signal or power. This pneumatic valve uses shape memory alloy to quickly shift process valve actuators to their fail-safe condition in the event of high heat or fire.
When mounted in the pneumatic supply line, the FM approved FireChek valve quickly responds to heat in the event of a fire. It automatically exhausts the air in the actuator, closing the automated ball or butterfly valve. At the same time is seals the pneumatic supply line, so the fire is not fed oxygen.
An element made of shape-memory alloy inside the FireChek undergoes a phase transformation when it is heated above the alloy’s actuation temperature. This change releases stored energy to produce the necessary force to shift the valve; no other power source is involved. The element is 100% reliable because the shape memory effect is intrinsic to the alloy.
FireChek can be tested and reset which is an advantage over emergency isolation valves that rely on fusible links or plastic burn-through tubing.
Get Help with Your Journey to Lubrication Excellence
Benchmark Audit Shows Where You Are & What Comes Next
Lubrication Engineers developed its new Xpert Lubrication Benchmark Audit to help your organization know where it is and what comes next to achieve or maintain Lubrication Excellence. The audit can be done anytime, whether you are just getting started or well on your way. It can be repeated as needed to track progress, make adjustments, and determine next steps.
Audit Benefits
• Determines where you are on your journey using a nine-category scoring system
• Provides accurate benchmark by acknowledging both the good and the bad
• Includes detailed report with scores, photos, notes, and next steps
• Can be repeated whenever needed
• Is performed locally, ensuring familiarity and continued support
Achieving Lubrication Excellence is different for every company, but often starts with benchmarking. LE’s Xpert Lubrication Benchmark Audit is a simple, efficient way to evaluate your facility. After delivering the audit report, your LE representative can advise your next steps.
Audit Categories: Lubrication Best Practices • Asset & Lubricant Identification Storage & Handling • Oil Analysis & Sampling • Training, Skill Development & Certifications Contamination Control • Filtration • Software, CMMS & EAM • Safety & Accessibility
Contact us today to get started! info@le-inc.com | (800) 537-7683 | www.lelubricants.com
AIR PRODUCTS .22 .www .airproducts .com/decarbonize
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