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VIEWPOINT
INSIGHTS
7 | What are industry trends for VFDs and VSDs? 5 | How many hours should you work every week?
SOLUTIONS
10 | Developing a data-driven approach to mitigating risk
Companies looking to modernize or improve their technology often face many challenges
17 | Using data to improve fleet and asset management systems
Asset and fleet management systems aid in optimizing fleet operations
20 | How to assess transformer condition using liquids testing
By regularly testing a transformer’s liquid, condition information can be tracked and acted upon if needed
26 | The 10 key ways magnetic drive pumps maximize plant reliability
The innovative design of magnetic drive pumps provides 10 distinct advantages
SOLUTIONS
| NFPA 70B codification for industrial safety
THE COVER:
Understanding and evaluating a company’s installed base, including supporting inventoried assets, is key to mitigating risk when operating obsolete systems. Courtesy: Rockwell Automation
The new NFPA 70B standard will change electrical equipment maintenance
| How can plant personnel successfully maintain LVDTT?
Low-voltage dry type transformers are often forgotten pieces of necessary electrical equipment, however they need regular maintenance
42 | Six ways connected worker platforms benefit factory automation
Connected worker platforms can help make workers safer and more productive
46 | Finding the right process for achieving oil-free compressed air
Achieving quality oil-free air for these applications is vital to help ensure product quality and safety, but there are different methods to achieving this
50 | Test equipment upgrades balance art and science
Equipment upgrades are dependent on a welldeveloped plan
56 | What makes an engineering trailblazer? Read about the 2023 leaders here
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, President, Automation Plus
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 author an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Energy efficiency
• Expert Q&A: Maintenance
• Expert Q&A: Power and electrical systems
• Power systems
• Lubrication
• Mechanical systems, including liquid movement
• Pneumatic and hydraulic controls
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Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about — engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
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TM Technology and
How many hours should you work every week? In a nutshell, fewer
Research shows that fewer hours or a shorter workweek can improve productivity
and employee sentiment
The UAW strike has been interesting to watch. On the one hand, union leaders are bargaining for many things: higher pay, a different workweek structure and better retirement plans. On the flipside, the three U.S. automakers seem to have several challenges: profits are targeted for the transition to electric vehicles, the supply chain problems continue and the labor shortage remains a challenge for them. The icing on the cake for everyone: artificial intelligence looms large.
workweek significantly increased job satisfaction, improved work-life balance and reduced employee stress. The results also showed improved product quality and customer service, and a significant reduction in absences and sick days. Nine in 10 of the participating companies are continuing with the four-day workweek.
Amara Rozgus, Editor-in-Chief
There is no one solution and, like any negotiation, not everyone will walk away happy.
One of the most thoughtprovoking demands by the UAW is for employees to work a 32-hour workweek at 40 hours of pay. The UAW is calling for the introduction of a four-day, 32-hour workweek at the same rate of pay, and overtime pay for anything beyond that.
Is a four-day workweek even possible? The short answer is “yes.” But put an asterisk on that.
The world’s most extensive fourday workweek research study to date — in which 2,900 workers from 61 companies in the U.K. participated from June to December 2022 — shows various four-day-week models, with days “off” staggered, decentralized and annualized, were followed.
The trial found that the four-day
Some industries must always remain open, such as hospitals. Manufacturing and industrial plants rarely shut down entirely, unless it’s a planned outage or routine maintenance.
So what workweek scenario is possible? What is more productive? What will end the strike?
A study from 2014 shows that hourly production drops off quite a bit after 50 hours of work per week. That essentially means that a long workweek is less beneficial; the workweek with fewer days improved productivity.
So what is the perfect number for the manufacturing workforce? Union bargaining may help guide us in the coming years. PE
Insightsu
Insights on a changed workweek uUAW strikes and bargaining helped create what the U.S. now considers a “standard” 40-hour workweek.
uManufacturing and industrial plants frequently have multiple shifts, and are able to adjust an employee’s workweek to meet the needs of each shift.
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What are industry trends for variable frequency drives and variable speed drives?
Variable frequency drives (VFDs) and variable speed drives (VSDs) play a key role in manufacturing facilities and those are shifting and changing due to real-world and technology changes.
Plant Engineering: What are some of the current trends for variable frequency drives and variable speed drives (VFDs and VSDs) for industrial and manufacturing facilities?
Thomas Burke: Compact AI is driving advanced diagnostics in next-generation variable frequency drives (VFDs). We will see various Innovative use of Compact AI in quality control, waste reduction and production optimization. In VFD, compact AI will make it possible to analyze and determine the lifetime of critical components, such as capacitors, contact relays, cooling fans and inrush current limit resistors. Another use case could be to identify signs of inverter damage caused by hydrogen sulfide or other corrosive gases typically found in some VFD applications.
When the production environment needs to be improved to avoid equipment failure and unplanned downtime, the operator will receive a notification. Some VFDs will also have AI in the setup software to ease installation. The AI-based diagnostics can analyze downtime causes such as over-currents caused by acceleration bursts. Some inverters can detect deviation in load profiles, which may be an indication of mechanical failure such as a clogged filter or a broken belt.
Edward Polzin: VFDs are being used as a way to optimize energy usage and equipment audible noise emissions. Many drives now provide energy tracking data for use in carbon emission calculations and tracking. Smaller footprint and higher power density and better internet connectivity.
PE: What long-term trends do you see for VFDs and VSDs (looking ahead to the next 12 to 18 months)?
Thomas Burke: The long-term trend with respect to VFDs and VSDs is based on the need for companies adopting the digital technology and wanting to have connectivity for their manufacturing processes. It's all about the digital world and collecting and analyzing data to turn it into useful information to optimize performance and improve energy efficiency. There's also a movement with respect to the technology that includes artificial intelligence, machine learning and big data analytics — these technologies will further improve the performance and efficiencies of VFDs and VSDs. Efforts with respect to standardization where companies are driving for interoperability and integration with different systems and applications also will continue to evolve.
Edward Polzin: Fixed speed systems require mechanical adjustment when different speed profile is required. VFDs offer speed and acceleration control, flexible system design, and easier adaptation to changing requirements. The cost differential between the soft start unit and VFDs is becoming less significant for some sizes. VFDs can provide additional diagnostics data for easy troubleshooting as well as programmability.
PE: How do you select the appropriate size and rating of a VFD and VSD for a specific motor application? What are the key factors that need to be considered in this process?
FIGURE 1: VFDs can be used to control the spindle of a CNC machine. Depending on the material and tool, different speeds are desired. Courtesy: Bosch Rexroth
Thomas Burke: There are many factors to consider when you think about selecting the appropriate size and rating of a VFD and VSD for a specific motor application. Things to take a look at are the horsepower, the voltage, the current, the starting torque, the full load current, and the duty cycle for the motor. The respective VFD or VSD must be able to handle and deal with the requirements of the motor. Basically, it's all about looking at the motor and its application and then selecting the proper VFD or VSD that can meet the requirements of the motor. You want to make sure that the VFD or VSD can meet the upper limit of the specific motor.
Edward Polzin: The application requirements such as motor power, acceleration, maximum travel speed, and system stability are main concerns. Some applications may select a VFD device solely based on the power requirements. For precise positioning applications, it may be necessary to have a feedback device for velocity and position control.
PE: VFDs can produce harmonics that may affect the power system and other connected equipment. What are the most effective methods to mitigate harmonic distortion in VFD applications?
Thomas Burke: VFDs are electronic devices that control the speed of an electric motor by varying the frequency and voltage of the electrical current supplied to the motor. VFDs can also pro-
duce harmonics, which are unwanted frequencies that can affect the power system and other connected equipment.
When selecting a VFD, it is important to make sure you have a VFD that has features to reduce harmonics, such as harmonic filters and pulsewidth modulation (PWM) control. You need to balance the load on the power system to reduce the harmonics. We suggest using a power quality conditioner device, which can be installed to improve the quality of the power, including reducing harmonics. Surge protectors can help to protect equipment from damage caused by harmonics.
Edward Polzin: If necessary, a line filter circuit can minimize the effect of harmonic noise. VFDs with an active front end, such as IGBT rectifier circuit, can reduce the total harmonic disturbance (THD).
PE: What are the key differences between scalar control and vector control techniques in VFDs? In which scenarios is each method preferred?
Thomas Burke: Scalar control is simpler and less expensive control method than vector control. No feedback is required from the motor, consequently it is less accurate than vector control. Vector control is a more complex and expensive control method than scalar control. Vector control does require feedback from the motor, therefore it is far more accurate than scalar control. Vector control offers more adaptable and dynamic performance inclusive of faster acceleration and deceleration. The problem is vector control is more vulnerable to harmonics and noise.
Edward Polzin: Vector control offers much better speed control compared to VFD drive using V/Hz (scalar control). Dynamic systems can benefit from vector control whereas very low speed systems will benefit from scalar control.
PE: How do you assess the efficiency and energy-saving potential of a VFD installation in a motor-driven system? Are there any standard methodologies or tools for this evaluation?
Edward Polzin: Understanding the duty cycle of the equipment will best determine energy savings potential. For example, VFD driven hydraulic power units can offer up to 80% energy savings compared to a fixed speed motor system. PE
FIGURE 2: VFDs are often used to control the speed of conveyor belts. This example shows multiple conveyor belts that operate at different speeds. Courtesy: Bosch Rexroth
Modernization – extend the lifetime of your drives and avoid up to 55 percent of emissions
As variable speed drives get older, modernization offers a circular solution that extends the lifetime of the equipment, enhances performance and provides the latest technology and long-term support.
By Oswald Deuchar, Global Head of Modernization Services, ABB Motion
Often a business will wait until equipment comes to the end of its life, then fully replace it. But this might result in costly unplanned downtime and a lot of unnecessary waste and scrap material.
Even before a drive reaches the obsolete phase of its life cycle, and it no longer qualifies for service support, you can perform modernization services to bring the drive back into the active phase of its life cycle. This extends its lifetime by up to 15 years, avoids material waste from premature scrapping and can avoid up to 55 percent of CO2 emissions compared to a full replacement. It’s a costeffective, circular approach.
A modernization service is performed on-site and only replaces essential components, avoiding the need to rip out and fully replace old equipment, such as cabinets and cabling, as well as altering civil works. Modernization returns drive equipment back to its original reliability, potentially increasing its performance and providing greater flexibility with new features.
ACS880 technology, normally within an eight-hour maintenance break.
Modernization in use
Modernized drives offer all the benefits of brand-new ones –higher serviceability and uptime and lower harmonics – but with a lower carbon footprint and less waste. For example, Swedish utility, Jämtkraft, saved 10 tons of CO2 emissions with this circular approach – the equivalent of a gas car running for 5 years. “We completed retrofits on nine of our existing drives to bring them into the active phase of their life cycle,” said Anders Gjerstad, Automation Engineer from Jämtkraft. “Since we kept the existing cabinets were used for the retrofits, there were no substantial modifications to the current infrastructure. This reduced the overall expenditure, while also allowing us to execute the project more sustainably.”
Modernization also enables the availability of the latest digital solutions – like cloud-based condition monitoring that allows service engineers to spot failures before they even occur. This enables them to reduce costly downtime and optimize system performance.
The key to modernization is that it can be performed quickly at the same time as regular, scheduled maintenance – minimizing downtime. For example, installations with an ABB ACS800 drive can get a new lease of life by replacing the internal components with the latest
Closing the circularity loop
It is often said that around 80 percent of a product’s environmental impact is determined at the design stage. To address this, suppliers are investing R&D into “designing for circularity” - where equipment can be upgraded and retrofitted over its lifecycle, as opposed to being scrapped and replaced. This ensures that, as a society, we maximize the full use of resources.
With a growing need to act more sustainably, plant operators can improve resource efficiency by the way they source and use equipment, by extending the life of assets rather than buying new.
Click here for modernization options for ABB’s ACS800 drives - https://explore.abb.com/acs800/
ENGINEERING SOLUTIONS
James Henry, Rockwell Automation, Houston
Developing a data-driven approach to mitigating risk
Companies looking to modernize or improve their technology often face many challenges and need a risk mitigation strategy to get a better idea of what needs to be done.
For many organizations, keeping up with the ever-evolving industrial digitalization or smart manufacturing trends and technologies is not easy. Most manufacturing companies have a large monetary investment in long-running, stalwart legacy systems and there is some personal attachment to them. It’s
no wonder making the decision to move on and upgrade or migrate their systems can be difficult. Change can be hard.
The resistance to change is why some manufacturers still run their operations with old and obsolete equipment. Due to limited resources, they are hard-pressed to keep plant automation current and functioning at the highest level, which can lead to issues impacting reliability, including unplanned downtime, extended outages due to parts availability and lack of available replacements. Performance, safety, and network and cybersecurity also are impacted.
To address this situation, manufacturers must first understand what automation assets are installed in the plant and what exists in the storeroom to support those assets. This initial assessment will be the foundational piece that will serve as the basis from which data-driven strategies are derived and developed enterprise-wide.
Physical and digital data collection
Gathering the initial assessment data is easier than it may seem. Personnel can use existing methodologies to perform this data collection process physically or digitally.
• Physical data collection – A field engineer manually collects the data. The amount of data collected depends on the size of the plant and requires some scoping. This process also includes collecting information on spare parts from the storeroom, which are essential for supporting the existing installed base.
• Digital data collection – This approach involves running a data acquisition program across the network to identify and gather the data from the connected assets. In this scenario, the scope can be delivered on a turnkey basis as the size of the plant doesn't impact it. The storeroom spare parts information is manually collected.
FIGURE 1: Understanding and evaluating a company’s installed base, including supporting inventoried assets, is key to mitigating risk when operating obsolete systems. Courtesy: Rockwell Automation
FIGURE 2: Working with the plant’s third-party technology suppliers, manufacturers can negotiate inventory levels to ensure sufficient spares are available in the storeroom and off-site. Courtesy: Rockwell Automation
Once the data collection is completed, if lack of bandwidth is an issue, third-party reliability consultants can help personnel analyze the data and develop risk mitigation strategies, such as inventory management and repair and future modernization planning.
Using the right risk mitigation strategy
To gain greater visibility into the risks associated with operating obsolete and end-of-life automation assets, manufacturing personnel need a clear understanding of a plant’s installed base. Once they have insight into the lifecycle status of automation assets enterprise-wide, they can make strategic data-driven decisions to mitigate risk.
Inventory management and repair
Manufacturers trying to extend the life of their old and obsolete automation assets must rely on dependable resources for the repair of failed units. This is often done in a haphazard manner using multiple independent repair suppliers mixed in with original equipment manufacturer (OEM) services. The process is transactional and can leave companies who operate in this way dissatisfied with price, quality and turnaround time. Quality has a direct impact on unplanned downtime, and longer repair turnaround times can result in extended downtime as the plant waits for the critical part to be repaired.
Market leaders take a more in-depth look into this process, understanding the impact on the entire production process. Newer strategies tend to be contractual in nature, moving the process away from being strictly transactional. Two of these strategies are fixed-spend and all-inclusive models:
• Fixed-spend model – A manufacturer determines the annual repair spend and issues a purchase order in that amount. All repairs draw down against the purchase order until the spend is depleted. The funds can be used for all repairs. Funds can be added to the purchase order if it is depleted before the end of the term.
• All-inclusive model – A manufacturer and a third-party vendor agree on an annual amount based on a specified bill of materials (BOM). The amount covers all repairs for the BOM regardless of the volume. The manufacturer is protected against any unexpected costs for the period of the contract.
‘ The resistance to change is why some manufacturers still run their operations with old and obsolete equipment. ’
While a good repair policy can make a positive impact on risk mitigation, it should not be regarded as the only solution for implementing a comprehensive risk mitigation strategy. When combined with an inventory strategy, the repair strategy’s impact increases. Together, the two strategies can impact the plant in a positive way by helping to reduce downtime and the mean time to repair (MTTR) when failures occur.
Working with the plant’s third-party technology suppliers, manufacturers can negotiate inventory levels to ensure sufficient spares are available, either in the storeroom, an off-site location or both. Quantities are dictated by the installed base, criticality of the operations the automation supports, and availability of the specific part.
For example, if the plant has 100 units of a specific part number, then the storeroom would need approximately 10 units to support the installed base,
Continued on pg. 14
u
Objectives
• Learn about the benefits of developing a data-driven approach to reducing risk with obsolete systems.
• Understand data collection’s role in developing a risk mitigation strategy.
• Learn about the different types of risk mitigation strategies and how they can be successfully utilized.
Thank You
In 2023, Atlas Copco celebrates our 150th anniversary. From the United States compressed air and gas team, we want to say a heartfelt ‘thank you’ to all our employees, customers, and suppliers who have been part of our journey –we could not have achieved it without you! As we pass this milestone, our unwavering commitment is to continue to provide innovation which empowers our customers to grow and drive society forward.
ENGINEERING SOLUTIONS
Continued from pg. 11
or possibly 15 units for critical applications. Off-site stock can be protected for a specific company’s use only, thus ensuring availability when needed.
Companies also can supplement the execution of this with on-site resources to help manage the process and ensure the desired outcomes are achieved. Both repair and inventory strategies require a thorough understanding of automation installed in the plant to deliver the best outcomes.
‘ Modern technological advances will continue to evolve, and manufacturers need to evolve, as well. ’
them to manage this on a day-to-day basis, helping to extend the usable life of these obsolete technologies.
Delaying modernization cannot and should not be indefinite, though. End-of-life and discontinued automation systems and technologies lack the performance, safety and cybersecurity features of the current product offerings on the market.
Modern technological advances will continue to evolve, and manufacturers need to evolve as well. Companies need to start planning their modernization project and understand that in most cases, expenditures will include multiple projects over multiple years, requiring capital expenditure approval. A third-party technology and solutions partner can help companies prioritize and plan these projects based on budget, criticality, production risk and cybersecurity threats.
u
Insights
Asset management insights
u Companies are often financially tied to their legacy machinery and are loath to change, which can lead to companies becoming less efficient and more prone to breakdowns.
u Developing a risk mitigation strategy while moving toward modern control systems and technology can help ease some of the financial burden and make companies better positioned toward the future.
The combination of these strategies will allow the plant and/or the enterprise to extend the life of the installed base assets. Benefits of doing this well include reduced downtime, reduced MTTR and lower maintenance, repair and operations (MRO) costs by ensuring the right quantities of spares are available when needed based on criticality.
Once companies understand their risk profile from an end-of-life perspective and know about the obsolete automation technology being used in production, they can leverage cloud-based technology to view, analyze and consume the data. They also can apply this data insight to continue to manage their risk mitigation strategies such as inventory management and repair and modernization planning.
Modernization planning strategy
The combined inventory management and repair strategies allow manufacturers to delay modernizing their technology installed base for the short-term. A cloud-based portal allows
Benefits of developing a risk mitigation plan
As companies look to understand and take inventory of their plant-wide automation assets, they need a solid plan that includes risk mitigation strategies with an eye toward future modernization. Modern control systems contain valuable technologies and tools that can help manufacturers manage their assets and operations. When this infrastructure is combined with a strategic data-driven approach to asset management and optimization, companies can increase efficiency and productivity throughout the enterprise to achieve desired business outcomes and keep their competitive edge. PE
James Henry (james.henry@rockwellautomation. com) is a senior global product manager – equipment lifecycle services for the LifecycleIQ Services business at Rockwell Automation. He has been in the equipment reliability space for more than 30 years, working domestically and internationally, delivering technology and service programs to the industrial market.
FIGURE 3: Having the right quantities of spares on hand is critical to extending the life of installed base assets and keeping operations up and running. Courtesy: Rockwell Automation
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need, when you need inventory, and warehouse you with quality
business days (or less) within may apply; see Terms and http://go2adc.com/terms) your order.
You want to be confident in our products and our commitment to you. We stand behind our products and guarantee your satisfaction. We want you to be pleased with every order. That’s why we offer a 45-day money-back guarantee on almost every stock product we sell. (See Terms and Conditions online for exclusions.)
The best values in the world
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Rosenberger,
Using data to improve fleet and asset management systems
Asset and fleet management systems aid in optimizing fleet operations, assist in reducing maintenance costs and enhance equipment utilization through effective data utilization.
In today’s evolving industrial landscape, asset and fleet management systems provide an accessible entry point into data acquisition. By offering valuable performance data, these systems aid in optimizing fleet operations, assist in reducing maintenance costs and enhance equipment utilization, making them a critical tool for optimizing productivity, profitability and equipment and asset utilization across a range of industries.
For businesses seeking to improve operational efficiency and maximize returns on investments, the seamless acquisition and integration of telematics-based data into these systems allows for real-time insights into fleet performance and equipment utilization. Thanks to powerful reporting functionality, facility managers and operators now have the opportunity to harness real-time actionable data, extract valuable trends and make informed decisions for their businesses.
The difference between asset and fleet management systems
For organizations ready to take their first steps into data acquisition through telematics, the choices — and even the language — can seem overwhelming, starting with the terms themselves: fleet management and asset management. After all, isn’t an equipment fleet technically an asset?
Yes and no. While some operations and suppliers use the terms interchangeably, asset management applications often allow for maintenance tracking and history, maintenance cost analytics, remote service dispatch, automated work order generation and more.
Fleet management applications may collect usage data on individual vehicles and operators, helping managers identify opportunities for improving productivity. Fleet management systems also may include features such as vehicle access control, location tracking, impact reporting or compliance checklists.
Whether the terms themselves are used separately or interchangeably, data is the critical deliverable of fleet and asset management systems. Collection of real-time machine and operator performance data enables advanced reporting, allows detailed, customizable analysis and facilitates effective, data-driven decision-making.
Using the material handling vehicle as a data source
The material handling vehicle is no longer just a lift truck. It is now seen as the operator’s cockpit — and the manager’s data source. A multitude of advanced technology options can be layered onto traditional base lift truck offerings, including tools to assist operator productivity and security and to provide facility managers actionable, data-driven insight into vehicle and operator performance.
Through continuous tracking and analysis of maintenance, service and material costs, managers gain a comprehensive understanding of operational trends. The integration of battery data — such as charging times, intervals and transit durations to charging stations — gives managers the visibility and granularity necessary to optimize equipment usage, minimize downtime and enhance productivity. In total, a comprehensive fleet manage-
• Understand the difference between fleet and asset management systems.
• Learn how data plays a key role for both and how the optimize material handling operations and reduce maintenance costs.
ENGINEERING SOLUTIONS
‘ The material handling vehicle is no longer just a lift truck. It is now seen as the operator’s cockpit — and the manager’s data source.’
RAYMOND’S iWAREHOUSE technology collects and reports real-time truck and operator data, accessible through a unique, single-view web portal that gives users the information needed to help achieve timely productivity gains and lower operating costs while helping the operation run better and letting users manage smarter. Courtesy: Raymond Corporation
Insightsu
Fleet and asset management insights
uFleet and asset management systems have been around a long time and offer many benefits for their users, which can now be augmented with datadriven systems.
u A data-driven approach allows companies to simplify operations, reduce safety incidents and effectively manage and monitor their workers and other resources.
ment system can effectively monitor and optimize battery performance, decrease incidents, simplify asset maintenance management, optimize labor resources and deliver on key performance indicators (KPIs).
Making data the foundation for future functionality
In addition to helping managers identify opportunities for improvements in vehicle, operator and cost efficiency, the information gathered today will serve as the foundation for emerging and future technologies. Predictive analytics, for example, may require several years’ worth of performance data to function to its fullest potential.
The payoff, however, may easily justify the effort and cost by allowing facility operators to analyze different “If I optimize this, what happens to that?” scenarios. They also can determine whether a facility can take on additional workload with the existing fleet, labor and infrastructure; and to predict equipment maintenance or service requirements more accurately.
Three steps toward data acquisition effectiveness
The benefits of data acquisition may be clear, but the journey can be fraught; and while every
operation is different, general guidelines can help keep things moving in the right direction.
First, engage with the information technology (IT) group as early as possible in the process. Even simple variables like the locations of Wi-Fi repeaters within a plant or warehouse can have significant impact on the functionality of a telematics-based system. Second, take data security seriously. A compromised data source could easily undo years’ worth of information-gathering efforts. Third, engage a reputable equipment and telematics supplier that will take the time to understand the business and operation.
A comprehensive telematics system is a critical component of any data-gathering initiative and can enable the insights necessary to visualize improvements and to optimize the organization to meet increased productivity and profitability demands.
By collecting data, businesses can drive productivity and continuous improvement across operations by:
• Simplifying asset management and maintenance
• Reducing incidents
• Optimizing labor resources
• Effectively managing and monitoring components such as batteries
• Turning actionable data into results that reduce costs, improve efficiency and empower data-driven, future-proof decision-making. PE
John Rosenberger, director, iWAREHOUSE GATEWAY & global telematics at The Raymond Corporation
Join us at Automation Fair 2023, the world’s premier manufacturing technology event, and experience the hottest innovations, the smartest experts and the latest strategies for industrial automation and digital transformation.
This year’s event is bigger and better than ever before — more training, more technology, more inspiration, more ways to connect. It’s everything you love about Automation Fair plus the best of ROKLive, PowerPlex, and Process Solutions User Group — all in one extraordinary event. No matter your role or specialty, there’s something for everyone at Automation Fair.
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NOVEMBER 6-9, 2023 | Boston, Massachusetts, USA
Register now!
ENGINEERING SOLUTIONS
ELECTRICAL SAFETY
Simon Sutton, Ph.D, Lance Lewand and Andy Davies, Doble Engineering, Marlborough, Mass.
How to assess transformer condition using liquids testing
By regularly testing a transformer’s liquid,
condition information can be tracked and acted upon if needed
An insulating liquid sample can reveal a wide variety of information about the condition of an electrical asset; this includes evidence of overheating, partial discharge and arcing, paper degradation, water ingress, oxidation, presence of chemical and physical contaminants and more.
and enables asset managers to plan appropriate actions. This could involve offline electrical tests to determine the underlying cause, fitting online monitoring devices to monitor the condition of the asset more effectively or scheduling a repair or replacement.
Importance of a high-quality transformer sample
FIGURE 1: Duval triangles represented in InsideView Software, a Doble Engineering Software. Courtesy: Doble Engineering
Consequently, insulating liquid testing is a key method for assessing a transformer’s condition and identifying incipient faults before they become critical. A single measurement is valuable, and trending changes in the data over time enhances the diagnosis by revealing the severity of the situation
Ensuring good results for an electrical component assessment starts with delivering a good insulating liquid sample to the lab. Even perfectly performed lab tests are rendered meaningless if they are based on a poor sample. Failing to take the sample correctly will inevitably lead to poor results and the additional cost of having to retake the sample and perform the analysis yet again. A good sample needs to be truly representative of the bulk liquid circulating within the electri-
Courtesy: Doble Engineering
cal equipment. Getting to this representative insulating liquid requires several liters to be flushed through the sampling pipework and into an appropriate waste container before collecting the sample proper. In the process of waiting for the flushing to complete, this insulating liquid can be used to rinse the sample container and caps to ensure they are free from contamination.
When taking a sample, it is beneficial that the container is large enough to hold the amount of insulating liquid needed with some extra just in case the lab needs to repeat a test to verify unusual results; this typically means about 1 liter.
There are many suitable containers for taking an insulating liquid sample and each has its own benefits and pitfalls. Generally, glass or aluminum bottles or metal cans are the preferred options. The container should properly seal the sample, preventing ingress and egress of any liquids and gases. Because insulating liquids can degrade in sunlight (photodegradation) leading to the synthesis of hydrogen or an increase in acid number, the containers, sleeves and/or packaging should be lightproof to protect the sample from sunlight.
‘ There are many suitable containers for taking an insulating liquid sample and each has its own benefits and pitfalls.’
Plastic bottles should be avoided because water molecules can easily diffuse through the container walls, thus increasing the water content of the sample. Studies have revealed that tenths of parts per million, aka ppm, of water can enter the sample during transportation and storage before testing. Conversely, small molecules like hydrogen can diffuse out of the oil through the plastic container walls, which decreases the concentration ultimately measured in the sample.
Lastly, it’s important to pack the samples well to avoid damage during transportation to the testing laboratory. Make sure the bottoms of the bottles are protected as well.
Using dissolved gas analysis to assess transformer condition
Dissolved gas analysis, or DGA, is arguably the most powerful tool in the industry when it comes to assessing transformer condition. Commonly performed according to ASTM D3612C and known as
the headspace method (also detailed in IEC 60567), this diagnostic test measures the concentration of certain key gases dissolved in the insulating liquid. Additionally, if samples are taken at regular intervals, the rate of gas generation can also be determined. This information enables specialists to understand which faults are emerging and their severity.
While acetylene is the most important gas to measure for detecting severe faults, all gases are important from an incipient fault perspective. The types and quantities of gases that form within the insulating liquid will unveil the nature of the fault and determine whether it involves the solid insulation, is a thermal or electrical issue and whether there is a leak within the sealed system or premature degradation in an open system.
There are many recognized methods for interpreting DGA data — with insufficient time to review here — as well as suggested gas limits in guides such as IEEE C57.104-2019 and IEC 60599. Nevertheless, it’s important to remember that allowance must be made for factors such as the type of the dielectric liquid involved (silicone, mineral or
• Understand the basics of determining a transformer’s condition, and identifying the faults.
• Review the technical aspects of dissolved gas analysis to identify problems and what next steps may be taken.
• Learn about the recommended tests to identify oil aging or contamination
FIGURE 2: The foreground show special bottles used for corrosive sulfur testing. The background is graduated cylinders used in everyday lab activity.
ENGINEERING SOLUTIONS
ester liquids). However, a high-level summary of DGA interpretation (see Figure 1) would include:
• Acetylene usually indicates arcing or a high-temperature thermal condition.
• To check for partial discharge, look at hydrogen levels.
• For low-temperature faults, pay close attention to ethane and methane.
• Ethylene is an indicator of a high-temperature thermal issue.
• In temperate climates, high levels of carbon monoxide are a sign of paper degradation, whereas in hotter climates, high levels of carbon monoxide can persist without other indicators of paper degradation being present.
• High levels of carbon dioxide can indicate general overheating of the paper insulation.
A single set of DGA data fails to inform us whether the gas concentrations are stable, increasing or even subsiding or indeed how long they have been there or if they are associated with a known incident like a transient condition or if they occur when the transformer is stressed in a particular manner. All that is known is that gases are present and the concentration of each. This may indicate an issue, but it cannot indicate whether there is an active problem.
Therefore, a trend of several data points needs to be established, which will inform the asset manager if the gassing is stable, becoming more intense or is progressing from one fault type to another. Even after having established the DGA trend, as with all diagnostic tests, context is paramount. Know the normal behavior for an asset, its age and local conditions, such as ambient temperature, loading, transients, harmonics or other circumstances that would explain the gases in the
oil. Comparing gassing of an asset to sister units (if available) can provide additional information. Changes in the gassing levels may have been caused by a change in loading pattern or a through fault.
Also consider any maintenance activities that have been performed. Have any repairs been made? What electrical tests have been conducted? If results from several transformers have changed, has there been a change in the sampling procedure or the laboratory used?
Under some circumstances degassing of the transformer insulating liquid is undertaken — typically, when filling a new transformer or after maintenance that has exposed the core and windings. This inevitably changes DGA values and requires new benchmark tests to reestablish the trend in gas behavior over a period (at least three months). It is important to remember that degassing the oil will not fix the underlying cause of the problem; it erases the DGA trend and, as a procedure, is not risk free even when using competent contractors.
Understanding oil quality data
The diagnostic value of monitoring changes in the chemical, physical and dielectric properties of the insulating liquid cannot be understated, as these can also degrade over time and affect the performance of the transformer. Here, we consider some of the other tests that provide further valuable information about oil quality.
Water is the most damaging molecule in the transformer. When dissolved in the insulating liquid, it catalyzes reactions, weakens bonds, attracts other polar contamination to the paper and allows acids to be aggressive. Conversely, free water in oil will generally sink to the bottom of the transformer where it contributes to tank corrosion; if it precipitates onto a winding due to oversaturation, it can cause flashovers.
Water concentrations are generally much lower in the insulating liquid compared to the paper. Typically, water exists at parts per million levels in the insulating liquid compared to single-figure percentage levels in the paper. This is because paper itself has polar components (e.g., hydrogen bonding), which although giving the paper additional mechanical strength, also attracts water molecules.
FIGURE 3: Breakdown voltage cell dielectric strength testing for insulating liquids. Courtesy: Doble Engineering
The presence of water in the paper is important as it disrupts the hydrogen bonds reducing the physical strength of the paper.
Knowing how water partitions between the insulating liquid and paper means that by measuring the water content in the insulating liquid, the content in the paper can be calculated. Nevertheless, different insulating liquids have different levels of affinity for water. Thus, it is important to know which oil is being tested as the difference is particularly marked between mineral oils and ester liquids.
To further complicate the situation, the polarity of the insulating liquid can be affected by aging byproducts, especially in mineral oils. It is therefore better to examine the relative saturation of water in an insulating liquid rather than parts per million. It should remain below 50% to retain adequate dielectric breakdown voltage.
Under particular circumstances, the water in the paper can generate gas bubbles, for example, during transformer overloading events or during startup before adequate oil circulation is established. Under these conditions, the conductors can heat the paper above 100°C causing water to vaporize, thereby increasing the likelihood of bubble formation, which in turn can lead to partial discharge (PD) and risks localized physical PD damage. The probability of bubble formation is dependent on both the concentration of the water in the paper and temperature; for example, with 2% by dry weight of water in the paper, the risk of bubble formation is very low below 140°C.
Transformer insulating liquids are designed to provide electrical insulation under high-electrical fields. Any significant reduction in the dielectric strength may indicate that the insulating liquid is no longer capable of performing this vital function. Breakdown voltage is a measure of the electrical stress the insulating liquid can withstand without breaking down. The test is conducted by increasing the voltage between two electrodes within a test vessel containing the test insulating liquid until the insulating liquid breaks down. Sampling technique plays a significant role in obtaining meaningful breakdown voltage results, particles and fibers accidentally introduced during cleaning the test cell or sampling bottles (chamois leather, cotton rags, paper towels) can all drastically reduce the measured result.
Accelerated transformer aging
Transformers typically last at least 40 years even though the design life is usually around 25 years — but that is not by accident. Keeping the asset sealed and operating at or below nameplate will preserve this life expectancy. High temperatures, elevated levels of oxygen, water content, acidity and sludging — all in the presence of other catalytic factors like copper in the windings, silver contacts and iron — can speed up the aging of paper and insulating oil, as well as corrode the metal in the transformer.
Three recommended tests identify oil aging or contamination, thus enabling early intervention:
1. Power factor testing measures the dielectric losses of the insulating liquid. As the insulating liquid oxidizes or polymerizes with increasing time in service, the polar content increases, which can be detected through increased power factor. This test can also detect the presence of other contamination in the insulating liquid and while it cannot identify the actual molecules, highlights the need for further investigation.
2. Color tests are a simple rapid indicator of aging in the insulation system; the darker the oil sample, the more aged the oil.
3. Interfacial tension (IFT) is an indirect measure of the polar nature of the insulating liquid and provides powerful insight into early oil oxidation and polar contaminants, such as water or acids. The test measures the strength of the separation between water and the oil or natural ester
4: Setup for ASTM D1816 testing of a breakdown voltage cell. Courtesy: Doble Engineering
‘ Transformer insulating liquids are designed to provide electrical insulation under high-electrical fields.’
FIGURE
ENGINEERING SOLUTIONS
‘ Analysis of insulating liquid samples collected from transformers is the starting point for understanding the condition of the asset.’
sample. Oil/natural ester and water should form distinct layers when there is little contamination present, but as the oil/ natural ester becomes aged or wet, the tension between the liquids becomes less distinct and therefore weaker, such that a lower IFT result is worse than a higher one. It should be noted that IFT is also affected by the presence of detergents such that residual deposits from cleaning sampling equipment, sampling containers or the test vessel with such surfactants can have a dramatic effect on this test parameter. Other insulating liquid quality tests such as acidity and relative density can be performed in tandem for a more in-depth examination of the characteristics of the insulating liquid. It takes gross contamination, aging or overprocessing for these properties to change significantly, so if
either of these values fluctuates between tests, it could be cause for concern. If an issue with the insulating liquid does present itself, there are other investigative tests that can be employed. Analysis of insulating liquid samples collected from transformers is the starting point for understanding the condition of the asset. The applied tests can reveal a lot about incipient faults or developing problems; nevertheless, additional contextual information and further electrical testing may be required to build a complete picture of the underlying problem and diagnose the root cause. PE
Simon Sutton, Ph.D, is Director of Services for Altanova, a Doble company. Lance R. Lewand is the Technical Director for the Doble Insulating Materials Laboratory. Andy Davies is Transformer Oil Services Engineer for Doble. This article was provided by the InterNational Electrical Testing Association (NETA), and originally appeared in its publication. Doble Engineering Co. is a NETA member.
Time
Your Side
Idon’t know many people who worry about what to do with their spare time. In fact, the inverse is often true. Some days, it is hard to find just fifteen minutes to focus on a single issue. Because today, with high-speed and abundant communication, you must be extremely time-efficient just to keep your head above water. Think about it: Phone calls, voice messages, texts and emails combine into an information avalanche that needs to be processed at all hours.
It wasn’t long ago that apart from the telephone, most information was gleaned from a correspondence, a newspaper, or a news broadcast aired at a strategically designated hour. In other words, at the time of one’s choosing. Some might be quick to say that times were easier then, but I don’t necessarily think that is true. There is a convenience to the instantaneous exchange of information, which can save even more time when managed properly.
Study after study sets out to teach practitioners the best strategy for time management. It turns out that “learning to delegate or outsource” is often cited as one of the best ways to gain some much-needed time. This is where Motion excels. Since 1946, we have been a reliable source for our customers, maximizing their plant uptime by expertly applying MRO products and solutions. Unscheduled downtime can rob you of much-needed hours for other things, like building a
strategy, organizing a meeting, completing an analysis or just savoring a cup of coffee.
So, if you haven’t already, take a minute and reach out to us. You’ll see that “Mi Time means more quality time. With the broadest mix of industrial products and expertise at your fingertips, the only downtime you’ll need to worry about is yours.”
Joe Limbaugh is Executive Vice President & Chief Operations
O cer at Motion. Serving the Company since 1983, he is currently responsible for product procurement and inventory, distribution and ful llment centers, branch operations support, headquarters campus operations, marketing, productivity improvement, automation intelligence, conveyance, repairs/services, and company-wide lease management.
Visit Motion.com or our Onsite Solutions page at motionind.biz/3L0XpU1
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MEDIA SHOWCASE FOR ENGINEERS
BOILER TECH SUPPORT
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Electronic Control of Work:
The What, Why, and How of Streamlining your Permit to Work & Contractor Management Systems
VelocityEHS
The use of temporary workers and contractors is on the rise and this trend shows no signs of slowing. Yet, many employers are still relying on paper-based systems and basic spreadsheets to manage Control of Work functions like contractor prequalification, onboarding, permit-to-work processes, site access, and performance tracking. These outdated systems introduce unnecessary administrative burdens, bottlenecks that hold up productivity, and unacceptable safety risks to workers.
Download this complimentary eBook that breaks down the core elements of an effective Control of Work system— what it is, why you need it, and how it keeps people safe and processes running smoothly.
Register to download the paper here.
• www.ehs.com Contact VelocityEHS
ENGINEERING SOLUTIONS
PUMPING AND LIQUID MOVEMENT
Pete Scantlebury, Finish Thompson, Erie, Pennsylvania
The 10 key ways magnetic drive pumps maximize plant reliability
The innovative design of magnetic drive pumps provides 10 distinct advantages. Operations that employ these pumps benefit from enhanced reliability and productivity
Reliable operations are foundational to success. When processes run smoothly, production and profit can increase and costs and risks decrease. Magnetic drive pumps, commonly known as “mag drive” pumps, can play a key role in this process. These durable, efficient pumps are ideal to help maximize plant reliability.
What is a mag drive pump?
A mag drive pump features a magnetic connection between the drive and the motor. To create this type of design, a set of strong magnets is attached to the end of the motor shaft and anoth-
er set is contained within the impeller assembly. As the drive shaft rotates, the magnets create a balanced field to rotate the impeller. The magnets work in synchronization to create a sealless pump operation.
This operation differs from most other pumps. Traditional centrifugal pumps feature a direct connection between the motor and the impeller. A magnetic pump eliminates the need for this direct drive mechanism. Because magnets rotate the impeller, a magnetic field replaces the mechanical seal.
The mag drive design includes 10 main components:
FIGURE 1: Magnetic drive pumps feature leak-free technology that replaces mechanical seals. Courtesy: Finish Thompson
1. Housing: Also known as the casing, this component is located at the front of the pump. It contains the suction and discharge connections as well as a thrust ring.
2. Impeller: This component contains a thrust ring that partners with the thrust ring inside the housing. Together, the rings guide liquid into the eye of the impeller and absorb any forward thrust in the pump.
3. Impeller drive: Connected to the impeller, the impeller drive contains the magnets that drive the pump.
4. Bushing: This component is located inside the impeller drive. In conjunction with the shaft, the bushing keeps the impeller drive centered inside the pump.
5. Shaft: This part supports the rotating impeller/impeller drive assembly. The shaft prevents the impeller from being magnetically attracted to the drive magnet assembly that is located on the outside of the pump.
6. Barrier: Located at the rear of the pump near the motor, the barrier on a magnetic sealless pump is solid. This differs from a mechanically sealed pump, which would feature an opening in the barrier.
7. Housing O-ring: This component seals the pump to prevent leaks. It is situated between the impeller housing and the barrier.
8. Drive magnet assembly: Also known as the outer drive magnet, this assembly is connected to the motor shaft and contains the magnets that rotate the impeller drive inside the pump when the motor shaft rotates.
9. Magnets: The magnets that drive the pump can be constructed of a variety of materials, includ-
‘ A magnetic pump eliminates the need for this direct drive mechanism. Because magnets rotate the impeller, a magnetic field replaces the mechanical seal. ’
ing samarium cobalt, neodymium or a mixture of ceramic and neodymium.
10. Motor: There is a wide range of motor types that can potentially drive a magnetic sealless pump. The specific motor selected must be based on pump compatibility.
Mag drive pump advantages
The magnetically driven pump style offers 10 advantages that help improve plant reliability.
1. Leak-free technology
Other pump styles include a direct drive mechanism — the drive shaft is connected to the impeller. This requires the use of a seal on the shaft. However, because mag drive pumps replace this physical mechanism with a magnetic connection, the need for a seal is eliminated.
This sealless technology is a game-changer for many operations. No mechanical seal means no leaks. A mag drive pump maintains two separate contained areas for the motor and the impeller. The pumped liquid remains in a hermetically sealed housing. Even the most corrosive chemicals can be pumped without concern of leakage.
In contrast, pumps with mechanical seals inevitably leak, creating potential hazards to employ-
• Understand what a mag drive pump is, how it works and its main components.
• Realize the advantages of mag drive pumps and how they maximize plant reliability.
• Learn common applications for mag drive pumps.
FIGURE 2: The innovative design of mag drive pumps is streamlined and durable. These pumps are built from the ground up to provide long-term reliability. Courtesy: Finish Thompson
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.
Capability
ENGINEERING SOLUTIONS
ees and the environment. The mag drive pump design decreases maintenance costs and can dramatically improve system uptime.
2. Run-dry capability
Many pump designs cannot withstand a run-dry situation. Running dry can quickly damage or even destroy a pump. This may happen due to operator error or an issue in another part of the system. However, this is not a problem for a mag drive pump with a carbon bushing. The innovative carbon formulation provides the pump with a low coefficient of friction. Some mag drive pump models with this design can run dry for hours without issue. If a system malfunction or human error occurs that causes a run-dry scenario, these pumps have the robust construction to survive. In settings where pumps are not under constant supervision, this feature offers a significant advantage.
3.
Chemical resistance
Not all pumps can handle harsh substances. Because a mag drive pump has no mechanical seal that could be affected by strong chemicals, this pump style is ideal for handling tough chemical applications. A mag drive pump can safely and effectively transfer liquids that other pumps cannot. This resistance to chemicals also increases plant safety, particularly for system operators and technicians.
4. Durability
The design of a mag drive pump makes it long-lasting and reliable. Applications that would quickly cause wear and tear to other designs are not an issue for these pumps. Operations that involve the transfer of harsh chemicals, the potential of running dry and other challenges do not faze mag drive pumps. They can operate under extreme conditions while delivering long-lasting performance.
FIGURE 3: Magnetic drive pumps can handle the harshest chemicals including sulfuric acid. Courtesy: Finish Thompson
ENGINEERING SOLUTIONS
5. Reduced maintenance
A mag drive pump requires little to no maintenance to deliver long-term top performance, potentially for years at a time. It has no mechanical seal that must be replaced periodically and it is resistant to chemicals, so it is not susceptible to corrosion. Pump owners can enjoy years of maintenance-free operation from a mag drive pump. These durable pumps deliver optimal return on investment with little required maintenance and long lifespans.
6. Increased productivity
Any time maintenance is required on a component, productivity suffers. Operations can come to a standstill while technicians make the necessary repairs.
With sealed pump styles, maintenance staff must remove the pump from the piping, decontaminate the unit of toxic fluids, replace the mechanical seal, then reinstall the pump. In some cases, this process could shut down operations for a full shift or longer. If a component must be ordered, the downtime
could be extended even further. This downtime directly affects the company’s bottom line.
Mag drive pumps eliminate the time-consuming tasks of maintaining a mechanical seal. When this maintenance task is eliminated, productivity improves. When productivity is strong, so is the bottom line.
7. Smooth operations
Mag drive pumps offer smooth, accurate flow. This reduces the risk of system failure or production compromises that can be caused by pulsation. With these pumps in place, it is also likely that flow conditioners and pulsation dampeners will not be necessary, which reduces the cost and complexity of the systems involved.
This smooth operation is particularly crucial when transferring chemicals that require high safety measures and delicate handling. It is also key when systems must deliver precision fluid transfers. The smooth flow provided by mag drive pumps provides accurate, reliable transfer, without sacrificing speed and volume.
8. Enhanced safety
In any setting that involves harsh chemicals, safe handling is a primary concern. Mag drive pumps are designed from the ground up to handle the most corrosive and toxic chemicals —without the possibility of leakage. This leak-free design is made possible by eliminating the mechanical seal that would otherwise wear and eventually leak. With a sealless pump, operators and maintenance personnel will not be exposed to the hazards of leaking chemicals or emissions. This lack of exposure greatly enhances workplace safety. Improved safety leads to fewer accident incidents and medical claims, which consume company resources.
Safer surroundings also improve morale, as employees feel more comfortable in their work environment. A likely result of this improved morale is an additional increase in productivity.
9. Enhanced compliance
If pumps are unable to prevent fugitive emissions, an organization may fail to adhere to local and federal health and safety standards. This not only threatens employee and public safety, but
FIGURE 4: Magnetic drive pumps are a versatile solution that brings benefits to a wide range of industries.
Courtesy: Finish Thompson
lack of compliance can result in fines or shutdown orders. These situations can prove costly.
Fortunately, magnetic drive pumps make the entire compliance process easier. The lack of mechanical seals in magnetic drive pumps makes it easier to maintain an emission-free environment. This, in turn, makes it easier to comply with emissions standards.
The elimination of emissions creates safe surroundings that comply with health and safety regulations. Pump owners can enjoy full compliance as they remove this concern from their operations.
10. Energy conservation
As facility owners seek sustainable solutions, any components that can create energy-saving operations are a win. Mag drive pumps fall into this category. Mag drive pumps rank high in energy efficiency compared to other pumping technologies.
This energy conservation offers two key benefits. First, efficiency reduces operating costs. Second, the pumps are less demanding of the energy systems involved. This is particularly important when facility managers must run multiple pumps and other equipment simultaneously. The energy-efficient mag drive pumps reduce the strain that large operations can place on energy supplies.
Common applications for mag drive pumps
Yet another advantage of mag drive pumps is their versatility. The benefits noted above make mag drive pumps ideal for myriad applications. The pumps are available in various configurations to suit a full range of operations. Pump owners in each setting can rely on mag drive pumps to provide robust solutions for their liquid transfer needs.
Common mag drive applications include:
• Aquariums/aquafarming: Magnetic drive pumps provide the delicate care, diverse solutions and durability required to meet the needs of the aquarium industry. These pumps are used for focus tanks, water circulation and wastewater transfer.
• Chemical manufacturing: When manufacturers need to circulate chemicals, transfer chemicals or provide reliable flow through heat exchangers, a mag drive pump offers a reliable solution. Operators can expose these pumps to the harshest
‘ Across multiple industries, mag drive pumps offer robust technology that increases reliability and decreases costs. ’
chemicals with confidence in their robust, reliable construction.
• Diesel exhaust fluid (DEF): Built for heavyduty chemical transfers, mag drive pumps offer reliability that improves safety and reduces cost for DEF and diesel applications. Mag drive pumps are ideal for DEF dispensing systems, portable DEF transfer, container-to-container transfers, blending and pumping deionized water.
• Electroplating and anodizing: In this industry, it is essential to keep plating solutions clean and a mag drive pump is ideal to provide flow for filters. Mag drive pumps are often used to provide flow-through eductors and filters, transfer wastewater and transfer chemicals.
• Food and beverage: Mag drive pumps are ideal for transferring additives and pumping water for cleaning processes in food and beverage applications. Food and Drug Administration-compliant mag drive pumps are also used in the pumping of clean-in-place chemicals.
• Mining: Mining involves frequent transfers of chemicals, tank unloading and chemical treatment processes. For the harsh conditions often encountered in this industry, operators can turn to a mag drive pump to handle these applications.
• Steel processing: The steel industry must safely handle acids and acidic wastewater. Manufacturers also need heavy-duty solutions for wire processing, cleaning and steel pickling. A mag drive pump has the sealless, corrosion-resistant design that makes it a top choice for this industry.
• Wastewater treatment: Treatment plants can use a mag drive pump throughout their facilities. A mag drive pump is perfect for transferring chemicals from bulk storage to tanks, disinfecting treated wastewater and providing flow for ion exchange tanks.
Across multiple industries, mag drive pumps offer robust technology that increases reliability and decreases costs. PE
Pete Scantlebury is vice president of development at Finish Thompson.
Insightsu
Mag drive pump insights
uMagnetic drive pumps, also known as “mag drive” pumps, offer 10 benefits through their innovative design, resulting in enhanced reliability and productivity for various operations.
uUnderstanding the working principles, components and applications of these pumps can lead to improved plant performance and decreased risks.
Douglas Beck, Schneider Electric, Orlando, Florida
NFPA 70B codification is a much-needed development for industrial safety
The new NFPA 70B standard will change electrical equipment maintenance, and understanding the standard and how it fits with others will help facility managers achieve compliance and build a greater culture of safety
In January 2023 NFPA enacted a significant change, officially adopting NFPA 70B: Standard for Electrical Equipment Maintenance as a standard, making 70B compulsory. Issuance of 70B as a standard immediately empowers authorities having jurisdiction, whether Occupational Health and Safety Administration or otherwise, to enforce the newly created and/or updated provisions as overseers of compliance.
Changes to the standard will reinforce a culture of safety and preventive maintenance in facilities and reflect the growing importance of digitized electrical maintenance for industrial plant operators.
Safe operating regulations now include 70B mandate
NFPA 70B is the third piece of the safety puzzle. NFPA 70: National Electrical Code governs safe equipment installation. NFPA 70E: Standard for Electrical Safety in the Workplace outlines how facilities should safely operate electrical equipment, however 70E thresholds for worker safety are only valid if the equipment is working properly, which is where 70B comes in.
Electrical fires and other safety issues tend to happen during maintenance, which puts systems in abnormal configurations. Transitioning 70B from a recommendation to a standard should help mitigate some of the risks inherent to maintaining equipment by improving system documentation and working harmoniously with the facility’s electrical safe work policy. The change addresses current industry trends, including aging equipment, increasingly complex power systems and the loss of expertise from the industry.
FIGURE 1: Proper maintenance can increase employee safety, machine uptime and process efficiency. Courtesy: Schneider Electric
FIGURE 2: Partnering with outside experts can help optimize maintenance procedures and NFPA 70B: Standard for Electrical Equipment Maintenance compliance. Courtesy: Schneider Electric
Even properly installed equipment degrades once it is in place, especially if maintenance is irregular or done poorly. Equipment manufacturer maintenance guidelines have always taken precedence, however there are many power system assets that lack clear maintenance practices from the original equipment manufacturer or have been obsoleted and are no longer supported.
At the same time, power systems have become increasingly complex. More industrial organizations are installing microgrids, backup generation and multiple power sources, coupled with digital systems to control this equipment. Each new addition to the power system represents another potential point of failure.
Standards like 70B are emerging at a time when maintenance staff is retiring en masse. New hires do not always possess the requisite experience or skill level to replace departing knowledge. The result is that where facilities once had many specialized maintenance engineers, they may now have only one person responsible for everything from the loading dock to the microgrid.
Enacting 70B as mandatory introduces clear guidance for a robust documentation and maintenance plan that provides a backstop to industry talent loss and increasing system complexity.
Changes to NFPA 70B standardize assessments, tighten requirements
The new standard clarifies documentation requirements for electrical maintenance programs. Now organizations must have a written, documented plan and identify specially trained coordinators to manage said plan. Organizations must also audit their programs every five years to ensure the programs still apply and inspect and assess all equipment annually.
A crucial part of the mandated documentation is a system one-line diagram and power system protection and arc flash studies, which must be kept up to date. Having a well-documented system is a foundation for a safe, reliable system. It ensures workers planning maintenance actions and secur-
‘ NFPA 70: National Electrical Code governs safe equipment installation. NFPA 70E: Standard for Electrical Safety in the Workplace outlines how facilities should safely operate electrical equipment.’
ing equipment for maintenance are fully aware of the risks associated with their work and/or the potential impact to the system the activity poses.
Electrical maintenance intervals and procedures manufacturers’ recommendations take precedence. However, if the documentation no longer exists or procedures are unclear, operators must then assess their equipment per NFPA 70B, using three factors: physical condition, criticality of that equipment to the system and the environment that equipment is in. Each factor receives a score and maintenance schedules depend on the lowest score received in any individual category.
For example, if during an assessment a low-voltage circuit breaker scores a 1 (highest score) on every factor, then the plant operator can maintain the equipment in longer intervals potentially up to 60 months. If the breaker enclosure is found not properly sealed correctly or has signs of other damage or moisture, it may receive a score of 2 or lower, which could require maintenance every 12-36 months.
• Gain awareness around the new NFPA 70B: Recommended Practice for Electrical Equipment Maintenance standards.
• Learn how this NFPA 70B fits with other standards to enhance operational safety.
• Understand how these standards will impact electrical equipment maintenance protocols moving forward.
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‘ Converting single-line diagrams to living digital twins streamlines documentation updates, a commonly neglected part of maintenance programs. ’
Insightsu
NFPA 70B insights
uNFPA 70B: Standard for Electrical Equipment Maintenance is now a standard, making it required for facilities to use and follow.
uNFPA 70B will demand not only regular maintenance, but adherence to specialized preventive maintenance, such as arc flash mitigation techniques.
Digitization and partnerships can bolster NFPA 70B compliance
The NFPA’s decision to transform the 70B recommended practice into a standard enhances the need to create and maintain a culture of safety. Adhering to its requirements for standardized maintenance procedures should help prevent arc flash and other incidents in industrial settings. Facility operators can and likely should layer on additional safeguards, available through digitization and partnerships.
Digitizing maintenance programs will make life easier for operators. Tools, such as continu -
ous thermal monitoring platforms, provide near real-time view of asset health to help identify potential problem spots outside of scheduled maintenance. Converting single-line diagrams to living digital twins streamlines documentation updates, a commonly neglected part of maintenance programs.
Organizations may also want to consult an independent expert. Acting as a sort of wealth adviser for electrical power equipment, independent experts have deep knowledge of these systems, understand what they are looking at and how to assess each situation. Experts can apply the needs of different facilities to the recommendations, ensuring facilities are optimally deploying a maintenance plan that optimizes uptime, operational cost and safety. PE
Douglas Beck is Leader-Consulting & Digital Services at Schneider Electric.
Thermal Insulative Coatings Offer Multiple Safety Advantages for Manufacturing Facilities
Kristin Meyers | Market Segment Manager – EV Battery and Automotive Facilities, Sherwin-Williams Protective & Marine
Dangers lurk around many corners in manufacturing facilities. That includes anywhere high-temperature equipment is in close proximity to personnel, as workers can easily burn their skin on hot equipment if it’s not isolated or insulated. In addition, both hot and cold assets are susceptible to condensation forming on exterior surfaces and dripping onto walkways where it may cause slips and falls. Finally, facilities must contend with the hidden dangers of corrosion under insulation (CUI), which can lead to dangerous leaks.
Fortunately, a simple solution – applying a layer of thermal insulative coatings (TICs) – can help to mitigate dangers related to burns, condensation and CUI. Such TICs can keep exterior surfaces safe to the touch, protecting personnel without requiring exterior isolation structures or insulation. They reduce the likelihood of condensation forming on coated assets, minimizing the potential for moisture-related slipping hazards. In addition, TICs can effectively eliminate the concerning issue of CUI.
CLICK HERE to download the paper. swprotective@sherwin.com
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When
Frank Basciano,
ABB Inc., Cary, North Carolina
How can plant personnel successfully maintain low-voltage dry type transformers?
Low-voltage
dry type transformers (LVDTT) are often forgotten pieces of necessary electrical equipment, however they need regular maintenance
Low-voltage dry type transformers (LVDTT) are a low-voltage class of distribution transformers operating at voltages below 1.2 kilovolts (kV) with most operating at or below 600 volts alternating current. The U.S. Department of Energy and the Natural Resources Canada define LVDTTs as distribution transformers that consume energy.
Therefore, both the U.S. and Canada have regulated minimum efficiency levels for these trans-
formers and the testing and minimum efficiency levels are the same in both countries. Nevertheless, the reason for the regulation is that transformers consume energy and they give off this energy as heat. As a result, the heat byproduct of transformer energization is a factor that must be carefully observed. Over time, the accumulation of heat will degrade the transformer’s essential insulation system while also contributing to premature failure or end of life. There are three major contributors to heat accumulation — loading, connections and restricted airflow.
Loading the LVDTT
Transformers have maximum load ratings known as its capacity. This capacity is measured in apparent power in kilovolt amps (kVA). The capacity is stated on a typical transformer nameplate (see Figure 1).
This transformer shows a capacity of 75 kilovolt amperes (kVA). It is important to understand that this kVA rating is based upon the temperature rise also stated on the nameplate — in this example 302°F rise. At 75 kVA, a 208-volt secondary will provide 208 full-load amps (FLA) of current and this transformer will exhibit a ≤302°F temperature — this is almost hot enough to bake a cake.
As we mentioned earlier, heat is a critical factor in the longevity of a transformer. Applying more load to this transformer for even short periods of time (less than four hours) will increase the heat of this transformer exceeding its nameplate rating. Therefore, it is wise to periodically check the loading of the transformer, especially as different renovations may occur during the building’s life.
It is important to consider the loads operating during a 24-hour period. For example, to get a
• Learn why low-voltage dry-type transformers should not be neglected and the benefit of maintaining them.
• Understand what standards apply to maintaining lowvoltage dry-type transformers, along with further informative sources.
• Review some of the common tests and procedures that should be part of a preventive maintenance program for lowvoltage dry-type transformers.
higher load, measure the loads during peak usage, like summer for air conditioning or winter for heat. In fact, a 24-72 hour or more period of load study would reveal periods of peak load. To check for loading, the transformer must be energized; therefore, only a qualified electrician should do this testing and evaluation. The electrician should compare the overall results of the load study to the nameplate of the transformer to assess any overload periods and the duration of the overload.
Transformer connections
These are the electrical connections of the transformer. In a typical three-phase, delta-wye transformer, there will be at least seven connections and often 20 or more. Over time, these electrical connections degrade and must be maintained at a minimum to the manufacturer’s torque requirements. This connection degradation occurs over time due to changes in temperature and mechanical vibration.
All energized LVDTTs vibrate and this ongoing vibration, along with temperature changes, will cause the metallic connections to flex and become loose. Therefore, it is important to inspect and even test the connections periodically.
The ANSI/NETA MTS: Standard for Maintenance Testing Specifications for Electrical Power Equipment and Systems (Section 7.2.1.1) calls for a more thorough analysis of the LVDTT connections using at least one of these three methods:
• Thermography readings (energized test).
• Low-resistance (milliohm) meter (nonenergized test).
• Verify connection tightness using a calibrated torque wrench to the manufacturer’s specification (nonenergized service).
Thermography reading allows the measurement of the heat being generated at the connection points. This test is done while the transformer is energized and under load (normal operating conditions). If infrared (IR) windows are installed in the transformer covers, these readings can be done without removing the covers, providing a greater element of safety for the technician. This is a fast and easy way to provide preventive maintenance documentation of the transformer. If there are no IR windows installed, then the front cover needs to be removed to do thermography measurements — this will require qualified electrical technicians and the use of proper personal protective equipment (PPE).
The low resistance (milliohm) meter method requires the de-energization of the transformer. A skilled and qualified technician should perform this test to ensure accurate results in a safe environment. Typically, the desired reading should be in the very low milliohm or, even better, microohm ranges.
For example, a 75 kVA transformer can provide 208 FLA per phase. If the main connection termi-
FIGURE 3: Top cover no storage label. Courtesy: ABB
FIGURE 2: Damaged primary coil winding due to overheating. Courtesy: ABB
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FIGURE 4: Example of a troubling transformer installation with clutter, combustible materials and water nearby. Courtesy: ABB
nals to the secondary of the transformer are measured at 1 milliohm, the connection point will generate 43.3 watts of power (W)=I2R; 2082 x 0.001 = 43.3 W — just at the connection point.
Remember, heat accumulation can degrade and lead to the failure of the transformer. In Figure 2, this point of degradation and failure at a connection point is very clear. The heat accumulation at the connection point far exceeded the 428°F temperature rating of the insulation system, causing insulation burning and transformer failure. The burned connection points in Figure 2 are one of the three transformer primary winding taps. The position of the taps can be arranged during the installation to best match the incoming power supply voltage.
Considering the nameplate of Figure 1, the primary voltage of 480 volts will pull from the incoming power supply 90.2 FLA per phase, much less than the secondary windings. Nevertheless, considering the same terminal resistance of 0.001 ohms, the resulting power will be 8 watts, much lower than the secondary, but still consuming power and generating heat.
Given that Figure 2 shows the primary taps, this connection must have been much higher than 0.001 ohms, perhaps in the several ohm range. For example, if the connection point resistance was 0.2 ohms, the resulting power dissipation would have been 1,627 watts — much hotter, which may have caused this burning and the insulation system failure.
Additionally, the low-resistance (milliohm) test can reveal any connections that have oxidized over
time. The oxidation will increase the connection resistance (even if the connection torque is within range) resulting in higher temperatures at the connection points. Removing the oxidized connectors and removing/cleaning the oxidation before reinstalling the connectors will return the connection to its designed intent when reinstalled using the torque requirements of the manufacturer.
Because most transformers are wired using aluminum cables and connectors, when reinstalling the connectors, it is recommended to use an anti-oxidizing compound on the connection points and lugs. After cleaning and reinstalling the connectors, take a new resistance measurement of the connection point. The NASA-STD-4003A electrical bonding requirements standard recommends that electrical connection points should exhibit an electrical bond with a direct current resistance measurement of 0.0025 ohms (2.5 milliohms) or less.
Some transformer manufacturers provide a typical connection resistance and that should be followed as a guide. In practice, the lower the connection resistance point, the lower the wattage (and heat generation) of that connection point. At a minimum, the torque of the mechanical connections should be checked before reenergizing the transformers.
As a guide, both the NFPA 70B: Standard for Electrical Equipment Maintenance and NETA MTS mention that “as found” and “as left” tests should be recorded during the maintenance and cleaning.
Restricted airflow in LVDTTs
Restricted airflow is hazardous to LVDTTs and surrounding equipment. Two factors are most common to restricting airflow:
• Installation clutter.
• Dust and dirt.
Installation clutter is somewhat addressed in NFPA 70: National Electrical Code (NEC) in sections regarding working space or clearances. While transformers are not explicitly called out in the NEC working space definition, other electrical gear often located near transformers are included.
The common explanation of working clearances/spaces is that if the electrical gear needs to be accessible while energized for servicing, repair,
‘ Because most transformers are wired using aluminum cables and connectors, it is recommended to use an anti-oxidizing compound on the connection points and lugs. ’
testing or maintenance, then 36 inches of clearance is required from service entry doors or panels. Because we have already established that thermography and load testing require an energized transformer, it is prudent to install the transformer using the same working clearance requirements as other electrical gear.
In addition to working clearances, the NEC requires adequate space for heat ventilation of transformers. LVDTTs require space around the enclosure for airflow and preventing dangerous coupling of heat to combustible wall surfaces. Typically, transformer manufacturers require a 6-inch minimum spacing, with some as low as 3 inches from nearby noncombustible walls.
On the transformer nameplate seen in Figure 1, 6 inches is the required clearance from walls. Also, NEC Article 450.9 requires that transformers be marked as shown in Figure 3 with a label that states the top of the enclosure is not to be used as storage — remember these transformers can get as hot as a baking oven under full load.
It is, therefore, imperative that transformers be given the clearances for safe operation. Restricting the airflow of the transformer by not providing the necessary clearances, either due to clutter or inadequate clearances, will force the transformer to operate at or above design temperatures causing excessive heat accumulation and degradation of the transformer’s insulation system.
In addition, Figure 4 shows multiple violations of the NEC; although this is an older installation, it is risky at best and could lead to premature failure or worse.
The NFPA 70B Chapter 11 recommends that LVDTTs be cleaned once per year. The accumulation of dust and dirt within the transformer will inhibit airflow through the transformer. LVDTTs are air-cooled electrical products (Class AA — see Figure 1 nameplate) and the cooling works by what is known as the “chimney effect” where cooler
ambient air enters the bottom of the transformer and through convection, rises through the core and coil structure exiting through the top vents or openings.
Transformer core and coil design and construction adds planned ventilation by providing cooling ducts as shown in Figure 5. Over time, through the movement of air and temperature changes, these cooling ducts can get clogged with dust and dirt. To clean these ducts, the transformer must be de-energized and allowed to cool before lightly blowing in air and vacuuming out the accumulated dust and dirt. Depending on the installation environment, this service should be annually for environments known to have significant amounts of airborne dust and dirt or every few years in environments where the airborne particulates are known to be moderate or low.
Space for core
Preventive maintenance of LVDTTs
Remember to maintain dry-type transformers. Keep them clean, secure and clear. These simple rules will help give a transformer the best chance of providing 30-40 years of useful service life. Recommendations include: clean the transformer interior periodically, secure the connections at a minimum to the torque requirements of the transformer manufacturer and clear out the clutter around the transformer that may accumulate over time.
Adding the low-resistance connection measurements will help assure that connection points have not oxidized over time. It is best to refer to and follow the maintenance guidelines for LVDTTs in the ANSI/NETA MTS, NFPA 70B and the IEEE C57.94 standards. PE
Frank Basciano is Global Product Manager, LV Dry Type Transformers with ABB Inc.
FIGURE 5: Single coil construction showing cooling ducts. Courtesy: ABB
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INDUSTRY 4.0
Eric Whitley,
L2L, Salt Lake City
Six ways connected worker platforms benefit factory automation
Connected worker platforms can help make workers safer and more productive in the factory of the future by giving them better insights through real-time data.
Factories face numerous challenges from maintaining operational efficiency to ensuring worker safety. As technology advances, connected worker platforms emerge as a promising solution to these challenges.
Through real-time data access, enhanced safety measures and improved collaboration, connected worker platforms empower factory workers. They provide workers a clear, immediate view of the production process, the performance of machines and critical safety information.
By integrating data, connectivity and human skills, connected worker platforms not only address the challenges factories face today, but are helping shape manufacturing’s future.
The real-time data gives workers the insights needed to respond to any changes in the production process. In an environment where every minute counts, the capacity to make swift, informed decisions can enhance the overall productivity of factory operations.
Furthermore, the data derived from these platforms can be used for predictive analysis, making it possible to forecast production trends and detect potential issues before they escalate. This optimizes operational efficiency and reduces downtime, leading to improved output and cost-effectiveness.
Integrating connected worker platforms with other factory systems such as enterprise resource planning (ERP) and manufacturing execution systems (MES) promotes holistic factory management. The seamless flow of real-time data across these systems improves coordination and streamlines the decision-making process, further bolstering productivity.
2. Improving factory safety measures
Connected worker platforms improve factory safety with their comprehensive safety features, which include real-time alerts, detailed procedures and simplified incident reporting mechanisms.
• Understand how the factory floor has changed thanks to automation and how the connected worker benefits.
• Understand connected worker benefits such as improved productivity, safety and better collaboration and communication among workers.
1. Enhancing productivity with real-time data
Connected worker platforms are vital assets in modern manufacturing due to their ability to deliver real-time data to factory personnel. Instant access to data provides workers with a transparent, up-to-the-minute view of the production process, including machine performance, production rates, and potential anomalies or disruptions in the workflow.
Real-time alerts notify workers of potential hazards such as machinery malfunctions or unsafe conditions. Delivering real-time alerts to relevant personnel, from factory floor workers to management, ensures necessary safety measures can be implemented.
They also provide access to comprehensive safety procedures. These guidelines offer clear instructions for operating machinery, handling materials and responding to emergency situations. By making these procedures available to all workers, the
‘ As technology advances, connected worker platforms emerge as a promising solution to to these challenges.’
platforms foster adherence to safety protocols and minimize the risk of human error.
Connected worker safety features also extend to post-incident processes. Streamlined incident reporting allows for swift accident response, facilitating immediate medical attention for injured workers and rapid hazard mitigation. The collected data can be used to identify patterns and trends in factory accidents, providing valuable insights for formulating preventative measures.
3. Boosting collaboration and knowledge sharing
Connected worker platforms have revolutionized the way factory workers interact, collaborate and share knowledge. These platforms serve as centralized hubs for information exchange, breaking down barriers between roles and departments, and fostering unity within the workforce.
Through these platforms, workers can share information about machine performance, operational issues and process improvements. An open line of communication enables rapid problem-solving, leveraging the collective knowledge and experience of the workforce to find innovative solutions. As a result, this reduces downtime and improves operational efficiency.
Connected worker platforms also enable the documentation and preservation of critical knowledge.
As experienced workers leave, their expertise and understanding of specific factory processes can be lost. These platforms help mitigate this issue by allowing workers to document their knowledge and experiences, making it accessible to new or less experienced workers.
The ongoing process of knowledge sharing fosters a culture of continuous learning, equipping workers with the skills and understanding they need to adapt to new technologies and processes. As such, factories become more agile and responsive, capable of meeting the evolving demands of the modern industrial landscape.
4. Facilitating data-driven decision making
Data is the new oil in the Industry 4.0 era. Connected worker platforms play a pivotal role in this data-centric approach by collecting, organizing, and analyzing a vast array of data from the factory floor.
They gather data from diverse sources such as machine performance metrics, production rates, quality checks and worker feedback. The ability to compile such a comprehensive dataset offers a holistic view of factory operations and helps companies make informed decisions.
However, the value of data lies in its analysis: connected worker platforms transform raw data into actionable insights. Data analysis can high-
WORKERS in an air bag factory using a connected worker platform. Courtesy: L2L
Insightsu
Connected worker insights
uConnected worker platforms enhance factory productivity by providing real-time data, enabling rapid decision-making, predictive analysis and seamless integration with other factory systems.
uThese platforms significantly improve factory safety by delivering real-time alerts and safety procedures, fostering adherence to safety protocols, minimizing error and providing valuable insights.
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light patterns and trends, identify inefficiencies and forecast future scenarios, equipping decision makers with the knowledge needed to strategically steer their operations.
By harnessing the power of data, factories optimize various aspects of their operations, from production scheduling to inventory management and quality control. A data-driven approach also enables proactive risk management because potential issues can be identified and addressed before they become more serious.
‘ The real-time data gives workers the insights needed to respond to any changes in the production process. ’
5. Increased worker satisfaction and engagement
Satisfaction and engagement among the workforce are vital to the success of any organization. Connected worker platforms improve workplace morale by incorporating features designed to enhance the user experience and promote active engagement.
One such feature is the user-friendly interface, which are intuitive and easy to navigate, reducing the learning curve and making it simpler for workers to access the information they need. This ease of use can improve workers’ experience, thereby increasing their satisfaction and willingness to engage with the platform.
Connected worker platforms also provide realtime feedback, giving workers immediate insights into their performance. Feedback allows workers to understand how their actions contribute to the overall process, helping them feel valued and part of the larger team. It also identifies areas for improvement, fostering a culture of continuous learning and personal growth.
6. Enhancing human workforce capabilities with advanced technology
Connected worker platforms, with their integration of advanced technologies, are at the fore-
front of a new era of factory automation. This revolution is characterized by a balance between operational efficiency, technological innovation and the well-being of the workforce.
They harness advanced technologies such as AI and machine learning, IoT and cloud computing:
• Artificial intelligence (AI) and machine learning (ML) can analyze vast amounts of data to predict machine failures, optimize production processes and identify safety risks.
• IoT sensors collect real-time data from the factory floor, providing insights into every aspect of the operation.
• Cloud computing allows for the storage and analysis of this data, making it accessible anytime, anywhere.
What sets these platforms apart is how they integrate these technologies to create a unified system that improves operational efficiency and supports the human element of factory operations.
For instance, they can provide workers with personalized, real-time training or guide them through complex tasks using augmented reality. They also can monitor worker health and safety in real time, using wearable sensors to detect signs of fatigue or stress.
Connected worker platforms are the future
Connected worker platforms are not only addressing the challenges of today's factories, but also are leading toward a future where technological advancement does not overshadow the human element.
Instead, connected worker platforms are creating a synergistic environment where technology is used to amplify human skills and fostering a seamless coexistence of technology and human ingenuity in the factory of the future. PE
Eric Whitley is the director of smart manufacturing at L2L, a CFE Media and Technology content partner.
Bob Lord, Hitachi Global Air Power, Indianapolis
Finding the right process for achieving oil-free compressed air
Achieving quality oil-free air for these applications is vital to help ensure product quality and safety, but there are different methods to achieving this.
Compressed air purity is critical for many operations — particularly sensitive applications such as food and beverage, pharmaceutical, semiconductor manufacturing and more. Delivering quality, oil-free air for these applications is vital to help ensure product quality and safety in some cases.
There are many ways an operation can attain oilfree air, but the process is not as straightforward as it seems. In a typical rotary screw compressed air system, oil is present in the air leaving the compressor, and will come in contact with the end product unless steps are taken to treat the air; or an oilfree rotary screw compressor is used. The type of air compressor, the filters used and even the ambient air the compressor is pulling from impacts the quality of compressed air produced.
Air quality standards, ISO 8573-1 Classes
To complicate matters, air quality is classified according to the level of contaminants in the air; from Class 0 to Class 1-2-1 to Class 1-3-2, etc. There is a lot to unpack when it comes to air and air quality; the following will break down the different air classes as well as examine the important differences between oil-flooded and oil-free rotary screw air compressors. We will also examine the types of air treatment — and their role in air purity.
Air quality classes
Air quality is broken down into seven primary classes of three contaminant types: solids, humidity and liquid water and oil. Solid particulates (like dust or pipe scale) can be removed by filters. Humidity and liquid water can be removed by compressed air dryers. Oil (liquid and vapor) can be removed by coalescing oil removal filters and activated carbon (charcoal) oil vapor adsorbing filters.
The International Organization for Standardization (ISO) 8573-1:2010 Air Quality Classes outlines the contaminants allowed by class. Depending on the application, Class 1 air – sometimes called “technically oil-free” may be appropriate, but also may require additional downstream filtration. For applications where air purity is essential, Class 0 air has the most stringent requirements for
FIGURE 1: ISO Air Quality Standards define oil vapor and solid contaminant class levels in compressed air. Courtesy: Hitachi Global Air Power
each type of contaminant – solid particles; water/ moisture; and oil and oil vapor.
ISO8573-1:2010 measures contaminants in three categories:
• Solid particles: Measures the solid particles contained in the compressed air stream. Within this column are three sub-columns indicating the quantity of allowable particles by micron size. The bigger the particle, the fewer parts per million allowed.
• Pressure dew point: Measures the maximum allowable water content in the compressed air stream.
• Oil (including vapor): Measures the maximum allowable oil content in the compressed air stream.
Class 0 air is more stringent than Class 1 and essentially, the lower the class, the lower the concentration of compressed air contaminants. For applications requiring oil-free air, Class 0 air is a less risky solution than Class 1 because it doesn’t require inline filtration — which may fail and requires regular monitoring — to remove oil contamination which may be coming from the compressor.
Class 0 air is commonly produced utilizing an oil-free compressor which does not introduce any lubricant into the compression chamber that can then enter the compressed air stream.
The difference between oil-free and oil-flooded air compressors
The simple difference between oil-free and oil-flooded rotary screw air compressors is the introduction and use of oil in the air compression chamber. In an oil-flooded rotary screw compressor, lubricant is used to coat and seal the rotors to help with temperature and lubrication. As the input air moves through the compressor, it mixes with the oil in the chamber. While most of the injected lubricant is separated from the airstream after compression, residual oil is still present. Removing additional oil requires a downstream filter.
However, oil-free rotary screw air compressors do not utilize oil in the compression chamber thanks to a special coating on the rotors and there-
fore no oil comes in contact with the air as it is compressed. Further air purity may be obtained by downstream filtration to remove any contaminants in the intake ambient air.
Recognize just because an oil-free compressor doesn’t introduce lubricant into the compressor chamber doesn’t mean oil can’t be introduced from the outside air. If the ambient air feeding the compressor contains oil vapor from other machinery, etc., the air leaving the compressor may be contaminated. Think, garbage in, garbage out. To help maintain air purity when using an oil-free compressor, particular attention should be paid to the intake air. The cleaner the intake air, the less chance of contaminants downstream which can affect production. To meet even more stringent air quality needs, air treatment (filtration; mist elimination) may still be necessary to eliminate other contaminants.
Why doesn’t everyone choose an oil-free compressor? For some applications, air purity is not a priority and oil-free compressors often come with a higher upfront cost. It all comes down to the application and the quality of air needed. The peace of mind of knowing downstream applications are less likely to be contaminated is often worth the added up front expense.
Air treatment in oil-free compressors
Once the compressed air leaves the compressor, there are more opportunities for it to be treat-
‘ Air quality is broken down into seven primary classes of three contaminant types: solids, humidity and liquid water and oil.’
Objectives Learningu
• Explore the air quality classes and what the different levels and classifications mean
• The differences between oil flooded and oil free rotary screw air compressors including the benefits of each
• The types of air treatment and the role each plays in air purity
FIGURE 2: Inlet air filters help to reduce contamination from ambient air as it enters the compressed air system. Courtesy: Hitachi Global Air Power
ENGINEERING SOLUTIONS
FIGURE 3: Removing excess moisture from compressed air with a refrigerated or desiccant dryer helps maintain air quality and is an important step in preventing rust and corrosion in your compressed air system. Courtesy: Hitachi Global Air Power
Insightsu
Compressed air insights
u An oil-free compressor can help improve a company’s operation and is a valuable tool if air purity is important for the manufacturing process.
uThere are several different types of compressors and some work better than others, depending on the operation and the importance of air quality.
ed before leaving the compressed air system and entering the greater manufacturing process. The major categories of air treatment in a compressed air system are 1) dryers — most commonly refrigerated and desiccant — more on those below — and 2) downstream filtration and mist eliminators. There are dozens of different options and assortments to help remove contaminants from compressed air.
For an industrial compressed air system, removal of moisture from the compressed air stream is a vital task. Dry compressed air* helps keep air-powered tools, equipment, and instruments running well. It can also help prolong the life of both tools and piping by reducing the rate of corrosion caused by excess moisture. In sensitive applications, where the air contacts the final product, or in some cases even its packaging, it is critical the compressed air be the proper quality, including the dew point of the air.
Refrigerated air dryers as their name implies, remove moisture from the compressed air stream mechanically by cooling it. Cool air can’t hold as much water vapor as warm air, so as the air cools excess water vapor condenses out as liquid water which is then removed from the system.
Desiccant dryers remove moisture from the compressed air stream chemically by passing the air over a bed of desiccant. The desiccant adsorbs the water vapor, meaning the water vapor clings
to thousands of tiny pores in each bead of the desiccant. Once the desiccant bed becomes saturated, either very low dew point compressed air or heated purge air is used to dry the desiccant. Desiccant dryers often have drying beds arranged in pairs. So while one desiccant bed is drying the air, the other desiccant bed is being dried, allowing for continuous drying of the compressed air stream.
Air purity benefits in manufacturing
If air purity is important for the manufacturing process, an oil-free compressor can help improve a company’s operation, profitability and peace of mind by reducing risks. However, users shouldn’t forget to maintain air treatment and ensure the oilfree compressor is pulling quality ambient air.
*The term “dry” when associated with compressed air is relative to the needs of the process. Compressed air considered clean and dry enough to operate machine tooling is not considered dry enough for a powder coating process. PE
Bob Lord is senior product manager of stationary oil-free compressors at Hitachi Global Air Power. Bob joined the company in 2021 and brings more than 15 years of product management and launch experience to his role. Bob holds a Bachelor of Science degree in Mechanical Engineering from the Illinois Institute of Technology and an MBA from the University of Chicago.
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ENGINEERING SOLUTIONS
MAINTENANCE STRATEGY
Daryl Rothamer, ACS
Test equipment upgrades balance art and science
Equipment upgrades are dependent on a well-developed plan that can help companies make informed
data-driven decisions
Upgrading test equipment and systems for research and development (R&D) testing or end-of-line production quality testing is an art and a science.
Managers of development and testing labs, as well as manufacturing facilities, face ever-expanding markets, pressure from competition, emerging technology and regulatory requirements, which can lead to companies needing upgrades.
Add budgetary constraints, time and resource demands, and the expertise to integrate enhancements while keeping normal operations running smoothly and the job can be overwhelming.
The solution is twofold: Create a well-developed plan for equipment upgrades to provide the framework required to make data-driven decisions that contribute to the overall business goals of the organization and encourage an innovative mindset to drive cutting-edge solutions.
Upgrades are a constant
When businesses only upgrade equipment that fails or shows wear, they miss opportunities to improve testing capabilities. R&D and production testing equip-
ment are a central consideration when developing new products, increasing throughput, improving efficiency or automating processes.
Effective R&D and production testing means gathering the right data to make informed design and business decisions. The need to upgrade stems from business growth objectives to boost productivity. It can make testing environments safer, improve facility layout or increase market share in a particular sector.
These broader business goals are often reflected in changes to regulatory requirements that mirror shared industry objectives. For example, California voted yes on the Advanced Clean Cars II proposal in August 2022 to augment the state’s already growing zero-emission vehicle market and robust motor vehicle emission control rules to meet increased emissions standards.
By 2035, California aims for all new passenger cars, trucks, and SUVs sold in the state to be zero emissions. While some experts are critical of the state’s ability to address these goals, its approval paves the way for net-zero commitments across all industries to turn these goals into real action.
FIGURE 1: Electric transmission assemblies test stand includes real-time control, data acquisition, and recording of all functionalities. Courtesy: ACS
Naturally, “real action” requires new testing capabilities for the automotive industry, battery, and power markets, and connected industries. California’s mandate accelerates a mass shift into the electric vehicle age, making it clear how integral equipment upgrades can meet new R&D equipment requirements while keeping steady production going. It’s no surprise electric vehicle sales are on course to hit an all-time high this year and automotive manufacturers are in a race to keep up.
In most cases, business objectives and regulatory requirements are only one part of a bigger picture when it comes to equipment upgrades. The effectiveness of R&D and production testing equipment is also impacted by outside forces, including geopolitical unrest, a globally disrupted supply chain,
Continued on pg. 52
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ENGINEERING SOLUTIONS
Continued from pg. 50
labor shortages, evolving technology, sustainability initiatives and changing regulations. These factors shape the growing need for R&D testing and production equipment and systems upgrades.
Accelerated by the pandemic, supply and labor crises have instigated further development and investment in automation technologies. For example, robot orders, a leading indicator for all automation equipment, increased 40% in the first quarter of 2022, and were up 21% overall in 2021, according to the Association for Advancing Automation, driving the industry to an estimated value of $1.6 billion.
The shift to automated or automation-augmented equipment is necessary for many companies to meet high demand in a disrupted marketplace, but still requires ongoing engineering resources for maintenance and improvement. These drivers push vast and rapid equipment upgrade needs across many industries, making a strategic upgrade planning process essential to stay ahead of the competition.
Planning for equipment upgrades
Insightsu
Test equipment insights
uWhen businesses only upgrade equipment that fails or shows wear, they miss opportunities to improve testing capabilities.
uThere is an increased need for better and more automated equipment as manufacturers are dealing with supply chain and labor challenges.
It’s a delicate balance to integrate new technologies and equipment upgrades in a way that addresses external pressures, scalable business growth goals, and customer needs. R&D testing equipment is expensive, so longevity matters when making initial investments. Companies want to ensure they get the most out of what they paid for. But simply waiting for a piece of equipment to break down can result in even greater costs for businesses if production or testing comes to a complete halt.
Planning for upgrades should be a calculated, fundamental and continuous part of the maintenance process. Companies can’t react to outside forces and compliance standards and expect to maintain market share. Consistent planning for equipment upgrades ensures businesses can implement improvements that address internal operational needs and customer needs, extending the facility’s overall lifespan. Strategic planning starts with acknowledging when an upgrade is necessary. It demands deliberate alignment from business leaders, engineers, facility managers,
operators, and stakeholders informed with their roles and expertise in mind.
It’s part and parcel that equipment upgrade planning will require an adaptive, solutions-oriented mindset to effectively react to inevitable changes, supply or construction challenges, and reoriented goals. This is where a balance of art and science is necessary for equipment upgrade planning. It demands the structural and scientific knowledge to develop realistic upgrade plans alongside the innovative and adaptable thinking that makes upgrade planning an art.
The science of equipment upgrades
Identification of the key business and technical drivers is the first step in making a strategic plan. This might include increased market share in a particular industry, improved throughput to meet high demand, or competitive advantages through new technology. These high-level, data-driven objectives are central to establish a clear vision providing value to the business. Industry metrics, technology assessment, evaluation of suppliers, budget development, age of the facility, and even company culture all play a role in the decision-making process.
Close and early collaboration between test and design functions drive product quality. When planning for equipment upgrades in a testing facility, it’s vital to start with a thorough understanding of the product being tested, whether an engine, appliance, or component.
From there, articulate how the item is tested, how it will be tested and the data desired from the test. The designer can assess the necessary steps to upgrade equipment for the system to effectively test and collect the desired data. It’s also important for designers to evaluate and articulate the mechanical systems the equipment will need and ensure it can accommodate them.
The equipment may have special requirements to operate, such as electrical power, steam, or chilled water. Plans will look different whether adding upgrades to an existing space or developing a draft for a new construction. From there, design demands the precision to make concepts into realistic outcomes. PE
Daryl Rothamer is the Director, Systems and Equipment at ACS.
FIGURE 2: End of line production quality verification test stand.
Courtesy: ACS
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CWhat makes an engineering trailblazer?
The 2023 Engineering Leaders Under 40 include 32 rising stars of innovation.
Amanda McLeman, Research Director
FE Media and Technology proudly presents the Engineering Leaders Under 40, Class of 2023 — a cohort of 32 exceptional minds, all hailing from the industrial manufacturing, controls, automation and systems integration professions. These pioneers are reshaping the industries of technology and engineering.
These remarkable individuals have surpassed boundaries and expanding the boundaries of what’s possible. From optimizing industrial processes to engineering seamless automation solutions, their collective achievements have streamlined operations and laid the groundwork for a more sustainable and efficient future. Their varied interests make them talented, quirky and downright fun.
Delve into the stories behind these engineering leaders — their aspirations, breakthroughs and the journeys that have led them to their various careers.
Learn about clever problem-solving skills of these young leaders, each a driving force behind the transformative advancements that are shaping the course of engineering, applied creatively across many industries.
ChatGPT was allowed to “read” select entries and suggested some of the introductory wording, which was reviewed and edited by Control Engineering and Plant Engineering editors. Learn more about the program and how to nominate a colleague for 2024 at www.plantengineering.com/EngineeringLeaders. Nominations open April 1, 2024. (No fooling!) ce
Andres Aguilar, 39
Lean Six Sigma Black Belt
John Crane
Morton Grove, Illinois
—Andres started at John Crane eight years ago as a reliability service engineer in Colombia and later relocated to Baton Rouge, Louisiana, supporting customers in the Gulf region. He was promoted to a regional service manager for North and Central America to deliver asset management contracts. Adding responsibilities, he led the project management team for major customers in the oil and gas industry, including the company's first methane detection projects that added value to the energy transition journey and enabled agile methodologies for mechanical seal contracts implementation.
Richard Ahlfeld, 33
CEO & Founder Monolith
London
Fun fact: To encourage camaraderie, Andres organized and leads a soccer tournament pool at John Crane.
Matthew Bailey, 38
Controls Engineer
Hargrove Controls & Automation
Mobile, Alabama
—As a talented and well-respected engineer, Matthew can take small to highly complex projects and ensure successful completion. He is motivated, driven and has diverse engineering experience in system integration of multiple control system platforms. He works hard, guiding teammates to successful outcomes. For clients, he identifies cost and time savings. He maintains the highest ethical standards and understands and meets client needs. He is viewed as a leader by peers and mentors junior teammates.
—Richard has developed artificial intelligence (AI) technology that allows engineers to solve tough challenges and has contributed to the acceleration of electric car adoption and hydrogen fuel cell development. The software has helped make cars safer, gas bills cheaper, reduced the costs of petrol cars and reduced noise pollution. Richard is committed to empowering 100,000 engineers to cut their product development cycle in half by 2026. The scope of applications for AI in the automotive industry is enormous, and it is Richard's mission to invoke greater change and facilitate innovative product development for more engineering teams.
Fun fact: Matthew comes from nine generations of ship captains and collects antique seafaring equipment.
Ioannis Bonis, 39
Senior Engineer in Industrial ControlSystems Dept.
Helleniq Energy
Aspropyrgos, Greece
—Ioannis is a charismatic engineer with a strong technical background and a clear inclination for innovation. He is self-motivated and has the capacity to coordinate the teams he participates in. He has high emotional intelligence and is a team player, which helps produce outstanding results. Ioannis has worked on all major control engineering projects during the past 10 years in Aspropyrgos and Elefsina refineries and is an integral part of the digital transformation program.
Fun fact: Ioannis has served as an expert for the European Climate, Infrastructure and Environment Executive Agency.
Fun fact: Richard plays the piano daily to relax and think.
Chase Beard, 30
Controls & Automation Engineer
Hargrove Controls & Automation
Johns Creek, Georgia
—Chase started at Hargrove as a Controls & Automation Co-Op in summer 2014. He worked at Hargrove while finishing his Chemical Engineering degree at Auburn University.
After graduating in 2017, Chase joined Hargrove full-time as a Controls & Automation Engineer. He mentors multiple engineers in Hargrove's Co-Op program. In 2021, Chase joined Hargrove's Purview talent development program and passed the professional engineer (PE) exam. He works on a variety of controls and automation projects.
Fun fact: Chase enjoys hiking, biking, fishing and other outdoor activities.
Iain Brearton, 30
Senior Controls Engineer
Concept Systems Inc.
Kent, Washington
—Iain is a talented, dedicated engineer who inspires others. He has displayed adaptability by successfully overcoming an ABB robot challenge during 2022 project. He seamlessly integrated it with a third-party press, tackling intricate programming obstacles. Iain played a crucial role in the Fanuc CRX robot demo for the Rockwell Automation Fair. He wrote a comprehensible and accessible operations manual for the engineering and sales teams.
Fun fact: Iain has his own “fan club” at a nearby restaurant who loves listening to fun stories and love for the Wizarding World of Harry Potter.
Control Engineering and Plant Engineering Awards programs
In addition to Engineering Leaders Under 40, CFE Media and Technology publications have awards programs related to new products and system integrators. These include:
• Product of the Year
• System Integrator Giants
• System Integrator of the Year
LEARN MORE AT: www.controleng.com/events-and-awards www.plantengineering.com/events-and-awards.
Andrew Edmondson, 38
Project Engineer
Applied Control Engineering Inc.
Newark, Delaware
—Andrew is a technical expert specializing in distributed control systems (DCS), notably Honeywell TDC, Honeywell Experion and Rockwell PlantPAx. He is the technical lead on DCS projects and has an affinity for modernization efforts. Andrew is leading a customer through the process of replacing an aged DCS with a modern control system, educating the customer on the process and teaching new engineers at ACE skills in the new DCS. Mentoring new engineers is something Andrew has a passion for.
Fun fact: Andrew is learning the guitar, especially the blues. He enjoys the challenge and combining expression with a love for music.
Ashish Garg, 37
Assistant General Manager
Jindal Saw Ltd.
Anantapur Andhra Pradesh, India
—Ashish Garg is a member of the International Society of Automation, a certified Chartered Engineer from The Institution of Engineers India and inspires many industrial automation professionals. Many initiatives include process safety and plant reliability. Under his leadership, more than 90 people were trained for blast furnace operations and maintenance. He wrote a book on instrumentation and represented Jindal Saw at international forums and conferences. With 14 years in automation and instrumentation, he has successfully completed multiple greenfield and brownfield projects.
Fun fact: Ashish is proficient at social and interpersonal skills.
Joseph Dolivo, 35
Chief Technology Officer 4IR
Solutions Corp.
Bethlehem, Pennsylvania
—Joseph is recognized as a thought leader among peers and maintains a strong technical competency to augment his broad industry knowledge. Joseph envisioned and leads the development of flagship products FactoryStack and PharmaStack, which provide managed operational technology infrastructure. He is wellknown in Inductive Automation's Ignition ecosystem, serving as a Solution Partner and subject matter expert for SAP connectivity, 21 CFR Part 11, Docker containers and the cloud. He helped create and supports an SAP-certified connector module suite.
Fun fact: While in university, Joseph co-founded a game development startup called Stencyl to make programming accessible and fun.
Mercedes Elizalde, 26
Senior Product Owner, Hardware
Rockwell Automation
Mayfield Heights, Ohio
—Mercedes is a dedicated, passionate technical leader within her team and a fast riser within the Rockwell Automation hardware design and development organization. In five years of professional experience, she assumed the role of Product Owner within one of the most complex product design programs in the company, leading a team of 14 engineers with levels of experience from less than one year to more than 25. Her role is to define the technical roadmap for the next two years and remove barriers for peers.
Fun fact: Mercedes recently took up quilting and has fallen in love with the meditative process.
Nick Gigliotti, 30
Group Manager, Customer Success Management (EMEA)
Seeq
Seattle
—Nick has technical expertise and domain knowledge of the chemicals industry and interpersonal communication and relationship-building skills. He helped Seeq land new and grow existing business. He plays a key role in company culture, fostering a collaborative environment by providing best practices across the customer success department and leading his team as a group manager. He engages with key stakeholders, presents and writes content.
Fun fact: Nick is improving his chess skills by attending chess classes and joining a weekly over-the-board chess club.
Pankaj Goel, 36
Instrumentation, Measurement & Control Systems Engineer
ExxonMobil Spring, Texas
—Pankaj is a conscientious engineer eager to use his knowledge and expertise to design a better and safer world. He has contributed to the advancement of technologies and solutions through his research and engineering leadership at a global level. Pankaj published five peer-reviewed manuscripts, presented at conferences, contributed to standard committees as a subject matter expert and worked with key automation vendors to define and develop technology roadmaps.
John Grounds, 34
Plant Engineer
PAC Worldwide
Phoenix
Fun fact: Pankaj previously worked on a team to develop the nextgeneration ocean research vessel, equipped with artificial intelligence and other innovative technology.
Zachary Jones, 29 Director of Engineering
Pigler Automation
Longmont, Colorado
—As a recent college graduate, Zach began working for Pigler Automation in 2017 as a Process Controls Engineer. He was promoted to Lead Controls Engineer and then Technology Manager before becoming Director of Engineering in 2022, where he demonstrates his leadership qualities. Zach is certified in Siemens PA and FA control systems, process safety and Inductive Automation Ignition, with other control system credentials. He has lead projects in industrial gas, food and beverage, automotive, renewables and others.
—Upon his arrival at PAC Worldwide, John began setting the tone within operations by spearheading major scrap reduction projects within operations. Outside of his expertise, John was willing to dig in and learn new processes and equipment while learning the inner facets of the organization. Within six months, PAC began to experience the benefits of John's talent. He oversees an expansion and HVAC project in excess of $5 million, leading efforts to ensure timely projection completion. John is spearheading the next phase of the expansion from facility layout to equipment installation.
Fun fact: John has a passion for off-road racing and flying remotepiloted vehicles.
Justin Katz, 37
Manager of Product Management, Inside Sales & Tech Support
Schmalz
Raleigh, North Carolina
—Justin has much to be proud of during his time at Schmalz, a material handling equipment supplier. He assisted companies with process improvements and helped decrease repetitive stress injuries. He has become an expert on vacuums and materials handling and helped Schmalz grow from a $2.5 million company to a $50 million company. A direct report says Justin is “by far" the best manager to work with, by ensuring employees are well taken care of and able to complete tasks.
Fun fact: Zach and his wife, McKenzie, were high school sweethearts and nominated for Prom King and Queen their senior year.
David King, 29
Lead Analytics Developer
Interstates Inc.
Sioux Center, Iowa
—Through on-site immersion and tackling complex roadblocks, David paves the way for robust solutions. Constantly seeking new use cases, he stimulates innovation and ensures client success. David's team engagement nurtures a collaborative learning environment, fostering skill growth and strong project delivery. His volunteering spirit underlines his commitment to progress. David champions advanced projects, like vision analysis, edge data collection and global software deployment.
Fun fact: He is a hopeful fan of Cleveland's sports teams, cheering for the Cleveland Browns, Guardians and Cavaliers
Fun fact: Justin enjoys vacationing with his loving wife and daughter.
Kristen Kosatka, 32
Product Manager
Rockwell Automation
Mayfield Heights, Ohio
—Kristen helps craft a seamless user experience across all Rockwell Automation products. She is a fierce advocate for customers and users. As an early career manager for Rockwell’s training program, Kristen coached and managed nearly 200 early-career employees, using real-world examples to guide development. Kristen helped employees grasp nuances of customer communication and reshaped soft-skills training. Yellow belt training and certification streamlined workflows, eliminated duplication and minimized waste.
Fun fact: Kristen is dedicated to inclusivity and creating a supporting environment.
Ankur Kumar, 34
Operations Technology Development Lead Linde
Tonawanda, New York
—Ankur made substantial contributions to Linde’s technology stack through award-winning machine learning-based solutions for hydrogen and air separation units. His tool, PlantWatch (for plantwide monitoring), received the 2021 Industry 4.0 Award from the Confederation of Industry of the Czech Republic. Ankur is a passionate digitalization evangelist. He engineered an advanced monitoring solution for cyclic processes and helped with adoption of ML-based MPC. He received 2022 awards for digitalization innovation and for product impact.
Kaleigh Linton, 23
Industrial Engineer, Simon & Schuster
Riverside, New Jersey
—Kaleigh’s first project at Simon & Schuster was to analyze the usage of the automated sortation technology being used in the warehouse and figure out how to improve its output. Through studies, observation and research, she has nearly doubled output with the automated sortation device. Before starting the project, the company’s output was around 13,000 to 15,000 units per day across three shifts and now the average is between 20,000 and 23,000 units daily. Kaleigh has played a role in reestablishing labor standards at the company, with increases in productivity and efficiency.
Fun fact: Ankur joined Vibha, a USA-based nongovernment organization that raises funds to educate underprivileged children.
Derrick Marlow, 28
SCADA Engineering Manager
Tesco Controls
Sacramento, California
—Derrick is a self-taught automation professional and a mentor of high-performing teams. He turned his passion for automobiles and electronics into a career in industrial automation. He devotes his talents and energy to preserving precious water resources. He rapidly advanced from SCADA Engineer to Supervising SCADA Engineer, and, in June 2023, to leading the SCADA department of more than 30 engineers. Derrick has a positive outlook, unrelenting work ethic, outstanding leadership and can solve complex challenges.
Fun fact: Kaleigh is an avid skier and has been social chair of Penn State’s Ski Club, allowing her the opportunity to travel for her winter hobby.
Chad McDowell, 34
Technical Resource Director
Concept Systems Inc.
Albany, Oregon
—Chad leads challenging automation system integration projects. When Concept established a mechanical engineering team and entered the robotic work cell market, Chad was promoted into management. He helped develop most mechanical work cells deployed by the company. As the automation team manager, he led the company's largest single project, a multirobot, multimillion-dollar custom palletizing system. As Technical Resource Director, he leads company strategy on technology portfolio and resource skill development.
Fun fact: Derrick is an active home brewer who has used his skills to invent a sensor retrofit lid with apps to monitor keg levels.
Megan McIntosh, 29
Controls Engineer
Hargrove Controls & Automation
Mobile, Alabama
—Megan has led several small projects at Hargrove Controls & Automation and has played a highly technical role in larger projects. She is versed in Rockwell and Emerson DeltaV in continuous and batch control applications. Clients praise Megan's attitude and knowledge, requesting her by name on projects. She takes part in extracurricular activities in her community and the organization, and she’s an active leader as a mentor to high school students and co-ops. She has twice been awarded Teammate of the Quarter at Hargrove.
Fun fact: After earning his private pilot’s license, Chad purchased a kit airframe, to build a plane himself.
Bradley Meissner, 35
Engineering Manager
Neomatrix Inc.
Andover, Massachusetts
—Bradley possesses a deep understanding of engineering principles and concepts. He exhibits exceptional leadership qualities, such as the ability to inspire and motivate a team of engineers, provide guidance and effectively manage resources. Bradley has experience in coordinating and organizing engineering projects, setting goals and ensuring successful project execution. By leveraging expertise in automation technologies, Bradley has played a pivotal role in helping various industries by enhancing productivity, efficiency and reliability.
Fun fact: Megan loves to spend free time fishing in Mobile Bay and Baldwin County and has recently learned to clean and cook the fish.
Fun fact: Bradley is an adventure seeker and avid skier who plans annual ski trips with friends.
Elliott Miller, 35
Controls & Automation
Technical Consultant
Hargrove Controls & Automation
Johns Creek, Georgia
—Elliott provides strong leadership and guidance to his peers at Hargrove Controls & Automation. As a collaborative colleague, he is willing to share knowledge and experience, such as multiplatform expertise in DCS and programmable logic controllers, to uplift and educate teammates. Elliott provides practical solutions to clients. He acquired his professional engineer license. He is learning more about information technology, OT and cybersecurity.
Seth Purk, 30
Quality Engineer/Supervisor
Rittal North America LLC
Urbana, Ohio
Fun fact: Elliott recently picked up sailing and got his bareboat charter license this past year.
Jackson Redline, 29
Engineered System Solutions
Project Manager
Rogers Machinery Co.
Portland, Oregon
—Jackson started as an Inside Sales Engineer with Rogers and quickly moved from Outside Sales to Project Manager and sales leader with product sales responsibilities for the electronics industry. He is the primary resource among peers to help solve problems. Diligent and cheerful, he provides leadership to many colleagues and contributes a keen understanding of control logic to complex engineered solutions.
Fun fact: Jackson participated in a research project for studying ceramic coatings for an artificial ACL replacement in college and tore his ACL during the project. Coincidence?
Zach Sample, 33
Global Digital Enterprise Consultant
Emerson
Round Rock, Texas
—Zach has been engaged in the larger industry, serving the local chemical engineering community in the St. Louis chapter of AIChE, holding positions as Secretary, Treasurer and YP Chair. He presents at conferences about the value of a well-thought-through enterprisewide software deployment and use plan. Zach has been a lead engineer, managed projects, lead sales teams and consulted with customers on enterprisewide digitalization solutions to ensure success.
Fun fact: With an Emerson-donated simulation system at Missouri University of Science & Technology, Zach helped to enhance unit operation and controls lab for the chemical engineering department.
—During his first year at Rittal, he was promoted to the Quality Supervisor for the department and continued as the Quality Engineer in the fabrication department. He took leadership and management courses through a local college, and he is progressing into a management position. He is working to achieve his ASQ certification as a Quality Engineer and taking several quality-related courses. A big achievements includes implementing Rittal’s first automated robotic weld cell to improve the product quality and productivity.
Fun fact: Seth has coached high school football, basketball and baseball for more than 10 years.
Carlos Rodriguez, 32
Engineering Manager
MartinCSI
Plain City, Ohio
—Carlos has become the go-to engineer for technical questions from other engineers. This led to Carlos taking over the training program for new hires. He makes it easy for younger engineers to understand, makes everyone comfortable and unafraid to ask questions and connects on a personal level. He took an outline for a formal engineer training program and put it into useful practice. Carlos mentors younger engineers and assists them in developing career paths.
Fun fact: Carlos loves to cook. He and his friends gather monthly for themed cooking parties where they create new dishes and enjoy being together.
Darren Schlemm, 24
Associate Process Engineer
Dart Container Corp.
Leola, Pennsylvania
—Darren is known for dedication and contributions to the ongoing success of the corporate utilities engineering team, which is critical to the manufacturing processes at Dart Container. He designed and managed various installation projects at different facilities and is responsible for creating, updating and monitoring utility process control plans at many plants, assuring the equipment critical to production is running optimally, allowing for greater longevity and less downtime. Darren completed trainings including boiler room training.
Fun fact: Darren's diverse interests include fitness and weightlifting, engineering and leadership.
Chris Shomin, 39
Manager - Site Automation
Merck Animal Health
De Soto, Kansas
—Chris with almost a decade in process controls in diverse industries, rose from team member to manager, leading an expanding team of engineers and technicians. Chris prioritized cybersecurity, obtaining certifications and devising a more than $6 million modernization plan for production networks, SCADA and more. Connecting with management and shop floor personnel enhances contributions to vision and troubleshooting efforts. Chris’ efforts in barcoding for SAP and manufacturing execution system integration are being considered globally.
Fun fact: Chris has crafted furniture, including a walnut kitchen table. He is restoring a classic Ford pickup with his three sons.
Gayland Waindim, 33
Staff Systems Integration Engineer
Twist Bioscience
Wilsonville, Oregon
—As a staff software integration engineer at Twist Bioscience, Gayland demonstrates expertise and dedication and consistently elevates operations and advancements in DNA manufacturing. His adeptness in seamlessly integrating software systems has led to heightened efficiency and streamlined processes. Gayland facilitated the installation of multimillion-dollar photolithography machines worldwide, improved safety protocols and played a key role in DNA synthesis machine implementation. Sustained efforts in plant instrument software and hardware maintenance underscore his lasting impact on engineering.
Fun fact: Gayland recently learned how to weld and is taking courses in systems science and computer science.
Justin Wengatz, 35
Lead Product Manager
Rockwell Automation
Mayfield Heights, Ohio
—Justin's forward-focused approach consistently seeks long-term solutions by addressing root causes. His receptivity to customers' unique problems and ideas drives innovation at Rockwell Automation. Beginning as an Engineer-in-Training in 2013, he progressed to Project Controls Engineer, integrating PlantPAx solutions. Leading major releases for Studio 5000 Logix Designer, Justin’s expertise has propelled him to Lead Product Manager, guiding a team and shaping the strategic direction of Rockwell Automation’s control software.
Fun fact: Justin’s profession began in pharmacy. He transitioned to engineering due to its alignment with his problem-solving mindset.
Chris Thompson, 39
Project Engineer
Applied Control Engineering
Newark, Delaware
—Chris is a skilled and fun-loving control engineer at Applied Control Engineering. His troubleshooting prowess, coupled with a positive and curious demeanor, makes him a valued team member and customer favorite. Chris has contributed many projects, including chemical processing and NI LabView systems for semiconductor research. Background includes optoelectronic research, utility-scale solar and semiconductor degradation studies, with published works. Expertise extends to complex electrical systems. Eagerness to learn and teach new technologies defines his control engineering career.
Fun fact: Chris finds joy in sailing sailboats on the upper Chesapeake Bay, embracing the excitement of competition and camaraderie.
Engineering Leaders Under 40
Know someone who qualifies as an Engineering Leader Under 40? Help give them the recognition they deserve.
The Engineering Leaders Under 40 program recognizes manufacturing professionals under the age of 40 who are making a significant contribution to their plant’s success, and to the control engineering and/or plant engineering professions. Our research shows that finding, training and retaining workers is the biggest issue facing manufacturing today. The goal of the Engineering Leaders Under 40 program is to call attention to these successful young engineers in manufacturing and to show how manufacturers are recruiting and developing the next generation of manufacturing professionals.
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