With sizes as small as 55mm wide, these drives provide the needed motor speed control without taking up large amounts of panel space.
General Purpose VFDs
Starting at $147.00
General purpose drives offer great value for a wide variety of applications including conveyors, pumps, fans, HVAC systems, and elevators.
AutomationDirect carries a full line of AC drives, from basic micro drives to full-featured high-performance drives boasting flux vector control and built-in PLCs. So no matter the application or environment, AutomationDirect has an affordable drive solution for you!
High Performance VFDs
Starting at $232.00
High-performance AC drives are top-of-the-line drives that are usually specified when a high degree of precision in speed control is required or when full torque is needed at very low or zero speeds.
Washdown VFDs
Starting at $242.00
These NEMA 4X, washdown-duty drives are built to withstand harsh environments including food and beverage processing and water treatment facilities.
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• Available in 18 AWG to 6 AWG sizes
• 2, 3, 4, or 5 conductors
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Bulk Electrical Hook-up/Building Wire
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AutomationDirect has a large selection of quality electrical MTW, THHN, DLO, TFFN, AWM, and HAR wire in pre-spooled lengths that meets all NFPA and NEC requirements at great prices.
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MADE TO MAKE IT LAST.
VIEWPOINT
7 | The best way for professionals to advance their careers
Continuing education via B2B resources is the fastest way to gain knowledge.
INSIGHTS
8 | Is your facility watching these powerful electrical system trends?
These powerful electrical trends could reshape the way plants are designed.
SOLUTIONS
Manufacturers face a dilemma: boost production while minimizing energy consumption. 18 | Energy-efficient manufacturing with smart technology
Smart manufacturing can cut energy consumption, pollution and improve efficiency.
22 | How to ensure reliable motor operation with VFD
JANUARY/FEBRUARY
ciency compressors with intelligent control systems, optimizing energy use and reducing operational costs for large industrial facilities. Courtesy: Atlas Copco Compressors
SOLUTIONS
30 | How to use energy-efficient motors and drives to save money
Variable frequency drives (VFDs) and switched reluctance (SR) can offer manufacturers energy savings and environmental benefits.
34 | How to select PPE to protect against airborne hazards
Airborne hazards in your workplace may make specialized personal protective equipment necessary.
37 | Fall protection focus: What to know about body harnesses
When it comes to fall protection, fit and personalization are critical to harness selection.
Expansion joints require a reliable maintenance program given the vital role they play in accommodating thermal expansion and other piping system movements. 12 | Balance in high-output manufacturing with low energy
There are some best practices when it comes to variable frequency drives (VFDs), which ensure reliable motor operations.
41 | Here are the facts and myths about appropriate PPE
Choosing the right personal protective equipment (PPE) means seeking out the proper fit and making sure it meets regulatory standards.
45 | How to build a maintenance program for expansion joints
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AMANDA PELLICCIONE, Marketing Research Manager A Pelliccione@WTWHMedia.com
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What's the best way for manufacturing professionals to advance their career?
Continuing education via B2B resources is the fastest way to gain knowledge.
In manufacturing and industrial operations, staying ahead often comes down to one thing: knowledge. With advancements in technology, shifts in regulations and the growing emphasis on sustainability and efficiency, professionals at every level must continuously learn to remain effective.
Here’s the good news: continuing education has never been more accessible, thanks to business-to-business (B2B) media. Yes, this is a shameless plug.
safety updates, these resources deliver targeted knowledge directly to your inbox or desk.
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Amara Rozgus, Editor-in-Chief
Think about the challenges you face daily — streamlining processes, reducing downtime, improving safety protocols and meeting customer demands. How do you stay on top of it all? The answer lies in leveraging the wealth of resources. From newsletters and articles to webinars and in-depth training sessions, B2B media offers tailored, actionable insights that can help you navigate these challenges.
Here are some of the key ways to get continuing education:
Publications and newsletters
Magazines and enewsletters remain go-to resources for many in the field. Why? Because they’re curated with industry-specific information you can trust. Whether it’s a technical deep dive into predictive maintenance or a roundup of the latest
Webcasts have become a powerhouse for learning. These online sessions bring experts right to your office or plant, offering in-depth presentations on everything from motor troubleshooting to energy efficiency strategies. The best part? They’re often interactive, allowing you to ask questions and engage with peers facing similar challenges.
Technical articles and case studies
B2B websites are treasure troves of information. Articles and case studies give you quick, digestible insights into real-world applications. For instance, learning how another facility reduced downtime by upgrading its compressed air system could spark ideas for your own operations.
Investing in your education
Continuing education isn’t just about staying current — it’s about improving your performance, advancing your career and driving innovation in your facility. Take the first step today: sign up for a newsletter, register for a webcast or explore a trusted B2B website. The tools you need are out there. PE
Is your facility watching these powerful electrical system trends?
New trends in power systems will change the ways in which plants are designed. Our panel of experts weighs in on the electrical trends you need to know about.
General electrical and power systems
Question: What’s the current trend in electrical and power systems for industrial and manufacturing facilities?
Lee Ward: There are generally two schools of thought: Investment in renewable power generation sources or expansion in the cleaner fossil fuel generation sources. There is ongoing risk discussion around grid reliability vs. investment in self-sufficiency as a risk mitigation strategy. In addition to those topics, the over-arching specter of the cybersecurity challenge and how, if not given the true deference it deserves, cybersecurity risk can have a major impact on the business.
Lanny Floyd: Higher energy density.
Objectives Learningu
• Understand how current trends in electrical and power systems will impact manufacturers in the year ahead.
• Determine how future key trends will shape the ways in which manufacturers design their plants.
• Learn about the factors impacting electrical system efficiency.
Question: What future trends should engineers, plant managers and designers expect for such projects? (Looking ahead one to two years.)
Ward: Regardless of the generation genre, it is essential for them to harden their cybersecurity to reduce system vulnerabilities at the grassroots level, making the facility not only serviceable but also well-defended. My main concern is that when it comes to plant investment, expansion, or greenfield projects, a greater emphasis is often placed on capacity and the overall outcome of the project
rather than prioritizing the core control infrastructure, which poses the highest risk.
Floyd: Equipment with reduced exposure to hazardous electrical energy, increased capability for condition monitoring to enhances safety and reliability.
Question: What are the most critical power system maintenance practices that facility managers should prioritize to minimize unplanned downtime and maintain system reliability?
Ward: Asset visibility is the most overlooked practice. Other than routine mechanical operations, the digital information provided by equipment is often overlooked. Condition monitoring typically only occurs when a failure is imminent, but your equipment can be telling a story long before a catastrophic failure occurs. Runtime hours, duty cycles, incremental sensor readings all contribute to this valuable insight. Prioritize new analytics and predictive models to prevent unplanned downtime and avoid catastrophic capital equipment failures.
Question: Are you incorporating electric vehicle charging stations and if so, what power pros and cons have you come across?
B.J. Hanson: Yes, we are incorporating EV charging stations but are not seeing large-scale adoption yet, at least on larger installations. However, we do expect the NEVI initiative to help increase that adoption. Electric vehicle (EV) charging stations and EV's in general, certainly offer several benefits, including reducing greenhouse gas emissions, supporting the adoption of clean energy and improving air quality. They provide convenience for EV owners and can integrate
with renewable energy sources for a sustainable charging option. However, challenges include high installation costs, particularly for fast-charging stations and the need for significant infrastructure upgrades to handle increased demand. In certain locations charging stations can also strain the power grid, especially during peak hours, requiring smart grid solutions. Additionally, the environmental impact of local electricity generation and battery disposal must be considered to ensure overall sustainability.
Question: Is your facility implementing microgrid or renewable power systems? Describe the project.
Ward: Rockwell Automation has a microgrid controller application that is based on its PlantPAx® process controls platform. It is designed to monitor, manage and dispatch generating assets, as well as curtail loads when necessary. In addition, it provides visibility into asset operations and maintenance, equipment availability and performance insights. Notably, PlantPAx® is designed with security as a top priority and offers flexible configuration options along with extensive scaleability.
Question: What techniques have you used to mitigate harmonics in a facility?
Hanson: We have helped customers install lineside power quality products, such as line reactors, passive and active harmonic filters, dc link chokes. In doing so, we aim to help customers meet Institute of Electrical and Electronics Engineers Standard 519 (IEEE-519) for total harmonic distortion within their facility.
Ward: Equipment that tends to create harmonics typically includes devices that modify the regular sine wave, such as inverters or variable frequency drives (VFDs). If such devices are already in use or if we are supplying new equipment, then using active front-end VFDs or 18-pulse VFDs with line reactors and filters can help mitigate these disturbances. For existing equipment, either active or passive line filtering can be used to address the issue.
Question: What are some key trends in power distribution and automation that facility managers should be aware of and how might these trends impact future investments in electrical systems?
Floyd: Equipment with reduced exposure to arc flash and electric shock hazards, enhanced capability of condition-based monitoring.
Ward: The biggest trend in power distribution is twofold: enhancing asset visibility regarding power quality data and critical measurands and protecting the power system from malicious intrusion.
Electrical and power systems (efficiency)
Question: What are the key factors influencing electrical system efficiency?
Ward: Key factors influencing electrical system efficiency include understanding how to manage loads in relation to operating conditions and selecting the appropriate generation source at any given time.
Modern technologies, such as artificial intelligence, can help in the decision-making process, as there are multiple dynamic factors at play.
Floyd: Managing power quality, which includes harmonics and voltage balance.
Question: How does power factor correction impact overall system efficiency?
Hanson: Power factor (PF) correction improves system efficiency by reducing the reactive power, which does not contribute to useful work. Power factors closer to 1.0, lowers the total current flowing through electrical systems, thus reducing energy losses in transmission lines, transformers and equipment. By improving the PF, there is less heat generation from the equipment, as well as less stress and wear. It also helps optimize capacity, allowing for better use of existing infrastructure without overloading. Additionally, some utilities impose penalties or charges when PF drops below 0.90, therefore, correction of PF may reduce demand charges or penalties from utilities leading to cost savings. Overall, PF correction enhances voltage stability, improves power quality and ensures more effective use of electrical resources, increasing overall system efficiency.
Floyd: It improves efficiency by reducing nonproductive losses in power distribution equipment.
Question: Can you explain the concept of demand-side management and its role in improving system efficiency?
B.J. Hanson Energy Solutions Business Development Lead Werner Electric Supply Appleton, Wisconsin
Lanny Floyd Owner and Principal Consultant Electrical Safety Group Inc. Elkton, Maryland
Lee Ward Industry Sales ManagerProcess, Mining, Cement and Power Generation Rockwell Automation Marlborough, Massachusetts
ENGINEERING SOLUTIONS
‘Using artificial intelligence in decision-making processes provides owners and operators with valuable insights into plant and equipment operation.
Hanson: Demand-side management (DSM) refers to strategies that encourage consumers to adjust their energy usage to improve system efficiency. This can include reducing overall consumption, shifting energy use to off-peak times, or using more efficient equipment. DSM helps balance demand with supply, reducing the need for additional generation capacity and lowering peak demand. By optimizing energy use, it also minimizes system losses, reduces strain on infrastructure and lowers operational costs. DSM improves grid stability, reduces emissions and lowers consumer energy costs, playing a crucial role in enhancing the overall efficiency and sustainability of the energy system.
Question: How can we optimize the efficiency of electrical motors in industrial applications?
Hanson: The first and easiest way to optimize the efficiency of electrical motors in industrial applications is to ensure they only run when needed. Additional controls can monitor motors and shut them down motors when they're not needed. Utilizing variable frequency drives (VFDs) can adjust motor speed based on demand, reducing energy consumption.
Regular maintenance, such as cleaning and lubrication, ensures smooth operation and reduces friction losses. Use high-efficiency motors with better insulation and cooling designs to minimize energy waste.
Hanson: Advanced monitoring systems, like steam trap and compressed air leak monitoring, enhance power system efficiency by detecting inefficiencies and enabling timely maintenance. Steam trap monitoring identifies failed traps, preventing steam loss and optimizing heat recovery. Compressed air leak monitoring detects leaks that waste energy, ensuring the system operates at peak efficiency. These systems provide real-time data, allowing for proactive repairs and minimizing energy waste. By improving system reliability, reducing energy consumption and lowering operational costs, advanced monitoring systems help maintain optimal performance, extend equipment life and contribute to overall energy efficiency in power systems.
Ward: This trend uses intelligent devices to enhance operations. It is much more cost-effective and efficient to plan and manage asset outages, making sure the right parts and resources are available for maintenance activities, rather than responding reactively to unexpected downtime events.
Question: What trends or technologies can significantly increase electrical system efficiency?
u
Insights
Power and electrical insights
uIndustrial power generation sources could be shifting towards renewable sources or investments in cleaner fossil fuels.
uManufacturers are developing techniques to mitigate harmonics in facilities.
uFacilities are seeking out way to enhance overall equipment efficiency.
Additionally, optimize motor control systems and improve load management by avoiding motor overloading. Finally, ensure proper alignment and balance of motor-driven equipment to reduce mechanical losses and enhance overall motor performance.
Ward: Using intelligent motor control with modern devices, such as electronic overloads, soft starters and VFDs, provides operational and situational data that can deliver real-time motor conditions and therefore encourage efficiencies and awareness of anomalies.
Question: How can predictive maintenance and advanced monitoring systems enhance the efficiency of power systems?
Ward: Using artificial intelligence in decision-making processes provides owners and operators with valuable insights into plant and equipment operation. This leads to better management of profits and costs, as well as enhanced efficiency and, in many instances, extending an asset's operating lifecycle.
Hanson: Emerging technologies like artificial intelligence (AI), machine learning and advanced system controls are poised to significantly boost electrical system efficiency. AI-powered monitoring systems can analyze vast amounts of real-time data to predict and optimize energy consumption, identify inefficiencies and enhance decision-making. Smart grids enable dynamic load balancing, demand response and integration of renewable energy sources, improving system flexibility. IoT-based sensors offer continuous performance insights, while automation and predictive maintenance reduce downtime and optimize asset management. PE
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Jayme Leonard, Atlas Copco Compressors, Rock Hill, South Carolina
Finding balance in high-output manufacturing with low energy consumption
As manufacturers face rising global demands for efficiency and environmental responsibility, they encounter a dual challenge: how to boost output while minimizing energy consumption.
In manufacturing, companies are under increasing pressure to enhance efficiency and productivity while simultaneously minimizing energy consumption. This dual challenge is driven by the need to stay competitive in a global market and comply with stringent environmental regula-
tions. As the world grapples with climate change, energy conservation has become a critical component of both environmental and economic sustainability.
Global energy and climate initiatives, such as the Paris Agreement, are pushing industries to reduce their carbon footprints and adopt more sustainable practices. For manufacturers, this means finding ways to maximize output while reducing energy usage. This is not only important for compliance but also for gaining a competitive advantage in an increasingly eco-conscious market.
One of the most significant energy challenges in manufacturing is managing energy-intensive processes like air compression, which powers pneumatic tools, conveyors and assembly equipment. These systems often account for a substantial portion of a facility’s energy expenses, particularly if they are not optimized for efficiency.
To address these challenges, manufacturers are turning to advanced technologies, process innovations and renewable energy sources. By embracing these strategies, they can achieve sustainable productivity that benefits both their business and the environment.
Understanding energy consumption in manufacturing
To effectively minimize energy usage, it’s essential to first understand where energy is being consumed across the manufacturing industry. In manufacturing facilities, energy is typically directed toward several key areas, including machine operations, lighting, climate control and compressed air systems. Among these, air compression alone can represent 10% to 30% of a facility’s energy costs, depending on the sector and scale of production.
According to the U.S. Energy Information Administration (EIA), the manufacturing sector consumed approximately 19,436 trillion British
FIGURE 1: Atlas Copco's air quality monitor provides real-time monitoring of air purity, ensuring compliance with quality standards and enhancing operational efficiency in compressed air systems. Courtesy: Atlas Copco Compressors
thermal units (Btu) of energy in 2018. This consumption is distributed across various subsectors, with chemicals, petroleum and coal products, paper and primary metals being the top energy consumers On average, manufacturing facilities use 95.1 kilowatt-hours of electricity and 536,500 Btu of natural gas per square foot each year.
High energy consumption in manufacturing not only leads to increased operational costs but also has significant environmental impacts. The manufacturing industry accounts for about 20% of global greenhouse gas emissions. Reducing energy consumption is critical for both financial savings and environmental sustainability. By implementing energy-efficient practices and technologies, manufacturers can lower their energy bills and reduce their carbon footprint, contributing to global efforts to combat climate change.
By identifying these high-energy areas and deploying targeted solutions, manufacturers can establish more efficient workflows and reduce unnecessary power consumption.
Advanced manufacturing technologies: pathways to efficiency
Technological advancements have enabled manufacturers to boost productivity while reducing energy demands. By combining automation, data analytics and smart systems, facilities are now able to achieve precise control over energy consumption, tailoring use to real-time production needs. Key technologies in this domain include: Automation and robotics: Modern automated systems and robotics have transformed assembly lines, offering faster production with greater accuracy. These systems can operate only when needed, conserving energy during idle periods.
For example, integrating compressors with automation allows them to function only when tools are active, reducing unnecessary energy use. Automation also helps reduce human error, streamlining production and conserving power by minimizing unnecessary processes.
Data analytics and machine learning: Data-driven insights are invaluable in detecting inefficiencies, predicting equipment failures and optimizing schedules. In compressed air systems, for example, data analytics can highlight periods of peak usage, detect minor leaks and identify points where system pressure may be unnecessarily high. These insights allow facilities to adjust, lower pres-
2: Atlas Copco’s energy recovery systems capture heat generated by compressors and repurpose it for facility heating, like showers or radiators, reducing both energy costs and environmental impact. Courtesy: Atlas Copco Compressors
sure or schedule maintenance before energy losses accumulate, leading to cost savings and improved compressor longevity.
Additive manufacturing: In sectors that have adopted 3D printing and other additive manufacturing technologies, there is a noticeable reduction in both energy and material waste. By creating parts layer by layer, these methods eliminate the need for complex tooling and excess material, which traditionally require significant energy for processing and handling. Additionally, additive manufacturing often reduces reliance on air-powered equipment, contributing to lower overall energy consumption.
IoT and smart factories: Internet of things (IoT)-enabled factories use connected devices, sensors and smart equipment to monitor energy use in real-time. Air compressors equipped with IoT sensors can monitor their own performance, adapting pressure levels based on demand fluctuations. This dynamic control results in significant energy savings, especially during periods of low activity. Moreover, IoT data can be aggregated and analyzed to fine-tune equipment settings and identify further optimization opportunities across the facility.
By leveraging these advanced manufacturing technologies, companies can significantly enhance their energy efficiency while maintaining high levels of productivity. These innovations not only help in reducing operational costs but also contribute to a more sustainable manufacturing process.
‘Manufacturers are turning to advanced technologies, process innovations and renewable energy sources.’
• Understand the role of energy efficiency in manufacturing.
• Explore advanced technologies for sustainable manufacturing.
• Examine regulatory and financial incentives for energy efficiency.
FIGURE
ENGINEERING SOLUTIONS
Efficient production processes
A well-designed workflow is essential for achieving sustainable productivity. By examining and rethinking how processes are structured, manufacturers can find multiple points of improvement that reduce energy use while maintaining output levels.
Lean manufacturing focuses on waste reduction, aiming to cut out unnecessary steps and resources, including energy. In lean environments, equipment such as air compressors are programmed to operate only when required, reducing energy usage during inactive periods. By setting parameters around operational needs, lean manufacturing eliminates unnecessary energy consumption.
Air compressors and other heavy equipment generate substantial heat, most of which goes to waste. By capturing and redirecting this heat, facilities can warm office spaces, pre-heat water or use it for other on-site applications. Heat recovery is particularly beneficial in colder climates, where offsetting traditional heating costs can make a notable difference in energy costs. Manufacturers can install heat exchangers to funnel compressor-generated heat into facility-wide heating systems, creating an efficient loop that repurposes waste energy
Continuous production processes generally consume less energy than batch processes, as they
reduce the need for frequent start-ups and shutdowns. For air compressors, this approach means maintaining a steady, lower-pressure output rather than continually ramping up and down.
By implementing these efficient processes and redesigning workflows, manufacturers can significantly reduce energy consumption while maintaining high levels of productivity. These strategies not only help in lowering operational costs but also contribute to a more sustainable manufacturing process.
Renewable and alternative energy sources
Renewable energy adoption is a powerful strategy in the quest to reduce energy costs and environmental impact. By harnessing solar, wind or geothermal power, manufacturers can power their facilities and processes sustainably.
Solar and wind energy: Facilities equipped with solar panels or wind turbines can offset energy used for lighting, climate control and even air compressors. In this setup, smart control systems can prioritize renewable energy sources, switching to grid power only when renewable generation is insufficient. For example, a study by the National Renewable Energy Laboratory highlights how advanced manufacturing technologies can integrate renewable energy to power processes, thereby reducing reliance on traditional power sources.
Biomass and geothermal energy: Biomass and geothermal energy are also viable options for manufacturing facilities. Biomass can be particularly useful for energy-intensive industries that require high-temperature heat, such as the chemical and metal sectors. Geothermal energy, while less common, provides a stable and continuous energy source that can be used for both heating and electricity generation.
Benefits of renewable energy integration
Integrating renewable energy sources into manufacturing processes offers several benefits:
• Cost savings: Reducing reliance on traditional energy sources can lead to significant cost savings over time.
• Environmental impact: Lowering greenhouse gas emissions contributes to global efforts to combat climate change.
FIGURE 3: Atlas Copco's GA 450 FD 2400 VSD+ Smart AIR solution combines high-efficiency compressors with intelligent control systems, optimizing energy use and reducing operational costs for large industrial facilities. Courtesy: Atlas Copco Compressors
• Energy security: Diversifying energy sources enhances energy security and reduces vulnerability to energy price fluctuations.
Smart equipment and high-efficiency machinery
The development of smart equipment and high-efficiency machinery marks a significant shift in the manufacturing industry, enabling companies to reduce energy consumption while maintaining or even increasing productivity. These innovations are driven by advancements in technology, including the industrial IoT (IIoT), artificial intelligence (AI) and robotics.
Industrial internet of things: The IIoT involves a network of interconnected machinery, tools and sensors that communicate with each other and the cloud to collect and share data. This connectivity allows for real-time monitoring and management of equipment, leading to improved efficiency and reduced energy consumption. For example, IIoT-enabled air compressors can adjust their operation based on real-time demand, minimizing energy waste during periods of low activity.
AI and machine learning: AI and machine learning algorithms analyze data collected from IIoT devices to optimize production processes and predict equipment maintenance needs. This predictive maintenance approach helps prevent unexpected breakdowns and reduces downtime, ensuring that machinery operates at peak efficiency. AI can also identify patterns and trends in energy usage, allowing manufacturers to implement energy-saving measures more effectively.
Robotics and automation: Robotic process automation has revolutionized manufacturing by taking on repetitive and dangerous tasks, improving product quality and reducing defects. Robots can perform tasks faster and with greater precision than human workers, leading to increased productivity and lower energy consumption.
For instance, robots integrated with IIoT sensors can optimize their operations based on real-time data, further enhancing energy efficiency.
By adopting smart equipment and high-efficiency machinery, manufacturers can significantly reduce their energy consumption and operational costs. These technologies not only enhance productivity but also contribute to a more sustainable manufacturing process.
Energy regulations and incentives
Government regulations and incentives play a crucial role in promoting energy efficiency in the manufacturing sector. These are designed to incentivize companies to adopt energy-efficient technologies and practices, thereby reducing their environmental impact and operational costs.
Environmental regulations set standards that manufacturers must meet to reduce their energy consumption and greenhouse gas emissions. These regulations often include mandatory energy audits, efficiency targets and reporting requirements.
For example, the European Union’s Energy Efficiency Directive requires member states to achieve specific energy savings targets through various measures, including improving industrial energy efficiency. Similarly, the U.S. Department of Energy has established energy efficiency standards for industrial equipment, such as air compressors, to ensure they operate more efficiently.
To support compliance with these regulations, governments offer various incentives and subsidies. These can include tax credits, grants and low-interest loans for companies that invest in energy-efficient technologies.
For instance, the U.S. federal government provides tax incentives for businesses that implement energy-saving measures, such as upgrading to high-efficiency motors and installing renewable energy systems.
The benefits of these regulatory measures and incentives are manifold:
• Cost savings: Companies can reduce their energy bills and operational costs by adopting energy-efficient technologies.
• Environmental impact: Lower energy consumption leads to reduced greenhouse gas emissions, contributing to global climate goals.
• Competitive advantage: Companies that invest in energy efficiency can gain a competitive edge by reducing costs and enhancing their sustainability profile.
• Innovation: Regulations and incentives drive innovation in energy-efficient technologies and practices, fostering a culture of continuous improvement. By leveraging government regulations and incentives, manufacturers can enhance their energy efficiency, reduce costs and contribute to a more sustainable future.
‘A well-designed workflow is essential for achieving sustainable productivity.’
Insightsu
Energy insights
uMeeting energy goals requires integrating advanced technologies and sustainable practices that not only streamline operations but also contribute to long-term savings and compliance with climate-focused regulations.
uLearn strategies to balance high-output manufacturing with low energy consumption for overall sustainable productivity.
ENGINEERING SOLUTIONS
Challenges in implementing energy efficiency regulations
Implementing energy efficiency regulations in the manufacturing sector presents several challenges. These obstacles can hinder the adoption of energy-efficient practices and technologies, despite the potential benefits. Here are some of the key challenges:
Financial barriers: One of the most significant challenges is the high upfront cost associated with energy-efficient technologies. Many manufacturers are hesitant to invest in new equipment or upgrade existing systems due to the substantial initial cost. Although these investments often lead to long-term savings, the immediate financial burden can be a deterrent, especially for small and medium-sized companies.
Lack of awareness and information: Another major barrier is the lack of awareness and information about the benefits of energy efficiency and the available technologies. This knowledge gap can prevent companies from taking the necessary steps to improve their energy performance.
Technical challenges: Implementing energy efficiency measures often requires specialized knowledge and technical expertise. Manufacturers may lack the in-house capabilities to assess their energy use and identify opportunities for
improvement. Additionally, integrating new technologies into existing systems can be complex and may require significant modifications to current processes.
Market and economic barriers: Market conditions and economic factors can also pose challenges. For example, fluctuating energy prices can impact the perceived value of energy efficiency investments. When energy prices are low, the financial incentive to reduce energy consumption diminishes. Additionally, the availability of financing options for energy efficiency projects can be limited, making it difficult for companies to secure the necessary funds.
Balancing high productivity with low energy use is a critical challenge in modern manufacturing. As industries strive to meet increasing production demands while minimizing their environmental impact, the adoption of energy-efficient technologies and practices becomes essential. This balance not only helps companies comply with environmental regulations but also enhances their competitive edge in a market that increasingly values sustainability.
While the initial investment in efficient technologies and processes can be substantial, the long-term benefits far outweigh the costs. Financially, companies can achieve significant savings through reduced energy consumption and lower operational costs. Environmentally, these practices contribute to the reduction of greenhouse gas emissions and the conservation of natural resources, aligning with global climate initiatives. Competitively, manufacturers that prioritize energy efficiency can improve their market position by demonstrating a commitment to sustainability, attracting eco-conscious consumers and partners.
The journey toward energy-efficient manufacturing is not without its challenges, but the rewards — financial, environmental and competitive — make it a necessary and worthwhile endeavor. By embracing advanced technologies, optimizing production processes and fostering a culture of continuous improvement, manufacturers can achieve sustainable productivity that benefits both the business and the planet. PE
Jayme Leonard is a Digital Marketing Specialist at Atlas Copco Compressors.
FIGURE 4: Atlas Copco's ZR 315 VSD compressor, combined with the Optimizer four.0, delivers energy-efficient, oil-free air with smart monitoring capabilities, enabling optimized performance and reduced energy consumption in industrial applications. Courtesy: Atlas Copco Compressors
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ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Adam Mullen, Plex, Detroit
GEnergy-efficient manufacturing with smart technology
Smart
manufacturing
can help
manufacturers reduce energy consumption, waste and pollution while improving operational efficiency and product quality.
lobal energy consumption continues to grow at a steady rate of a few percentage points annually. Compounded over time, this trend has led to an explosion of energy use over the past several decades. One of the primary drivers of this consumption is the industrial sector.
Objectives Learningu
• Learn the role of smart manufacturing in improving energy efficiency.
• Understand the impact of manufacturing on energy consumption in thSe environment.
• See the benefits of smart manufacturing for overall operational performance.
According to the International Energy Agency (IEA), the industrial sector accounted for 37% of global energy consumption this past year. This qualifies the industry as one of the largest contributors to greenhouse gas emissions. Given the manufacturing sector's central role within the industrial sector, its energy-intensive processes significantly contribute to overall energy consumption.
To address these trends, regulatory bodies and the federal government have enacted policies targeted at reducing emissions and waste across various industries. For example, the Inflation Reduction Act aims to reduce the United States’ production of carbon emissions by 40% ahead of 2030 while the Federal Buy Clean Initiative prioritizes the purchase of lower-carbon construction materials in federally funded projects. The shift to carbon-conscious production is evident through
these overarching policies and places increased pressure on manufacturers to enact reduced energy consumption practices throughout production. As manufacturers refocus their initiatives to prioritize reduced energy consumption and increased control over greenhouse gas emissions, they must work simultaneously to maintain output and quality. This means that manufacturers will likely explore innovative solutions to better manage and monitor their industrial ecosystems. This includes investing in energy-efficient equipment, optimizing production processes and adopting renewable energy sources.
Additionally, organizations may consider implementing robust energy management systems to identify and address areas of inefficiency. By prioritizing energy efficiency, manufacturers can contribute to a more sustainable future while ensuring their products meet the highest quality standards.
Smart manufacturing for energy use monitoring and reduction
Smart manufacturing connects machines, equipment and systems to enable real-time data collection, analysis and decision making that provide
FIGURE 1: Plex programming can be easily accessed on the plant floor. Courtesy: Plex, by Rockwell Automation
significant benefits in terms of energy efficiency and operational output. Specifically, when it comes to the reduction of energy consumption, smart manufacturing is instrumental in improving:
• Waste reduction: Achieving zero-waste manufacturing requires a level of data analysis that traditional methods cannot provide. While advanced equipment is essential, it's only part of the solution. By combining new technology with precise process monitoring and control, manufacturers can make significant strides toward minimizing waste. However, this requires the advanced digital tools of smart manufacturing software.
Energy consumption: Traditional manufacturing often assumes a consistent energy consumption pattern. However, smart manufacturing software reveals fluctuations in energy use throughout the day. By identifying energy-intensive processes, manufacturers can optimize operations and reduce their overall energy consumption by having smart manufacturing manage heating, ventilation and air conditioning and environmental conditions more efficiently with real-time monitoring and automated adjustments.
• Pollution control: Sensors and advanced analytics play a crucial role in smart manufacturing, enabling automation, optimization and pollution control. By monitoring and analyzing production processes, these technologies can identify and address issues related to wastewater, carbon emissions and other sustainability metrics. This proactive approach helps reduce pollution and energy usage. Providing real-time data and alerts allows manufacturers to identify potential problems early on and take steps to prevent more significant damage or delays.
Dual benefits: energy use reduction and improved performance
Just as these smart manufacturing capabilities benefit energy consumption monitoring and reduction, they also increase operational efficiencies to deliver a competitive edge. Digital data plays a central role in mitigating waste and emissions but also reveals new opportunities for increased productivity.
While smart manufacturing software tracks production, inventory, waste and labor, the data outputs can be two-fold. These results often provide a
clear picture of where manufacturing efficiencies can improve. With improved data sources connecting the entire enterprise, organizations can make improved decisions that minimize waste and material usage. Ultimately, this leads to a more agile, profitable and competitive company.
Various aspects of smart manufacturing technology can be leveraged to track energy use but also improve performance. For example, the following technologies serve both overall operational performance measurements but can also reveal potential opportunities for waste reduction:
• Manufacturing execution systems: Monitor and document the transformation of raw materials into finished products, providing real-time production oversight to enhance enterprise-wide compliance, quality and efficiency. With insight into production data, organizations can optimize processes, reduce waste and minimize energy consumption.
• Production monitoring: Offers direct communication with factory equipment, providing realtime insights into operational performance, such as overall equipment effectiveness. This data can help identify underused or inefficient equipment that may be consuming unnecessary energy.
‘As manufacturers refocus their initiatives to prioritize reduced energy consumption and increased control over greenhouse gas emissions, they must work simultaneously to maintain output and quality.’
FIGURE 2: The Plex interface can be commonly used throughout the day via a desktop option. Courtesy: Plex, by Rockwell Automation
ENGINEERING SOLUTIONS
ENGINEERING SOLUTIONS
Insightsu
Energy insights
uThis will review how smart manufacturing is revolutionizing energy efficiency in the industrial sector, driving sustainability while enhancing operational performance.
other isolated equipment. Like fall protection requirements, If any damage is spotted, employees should tag it, remove the PPE from service, and report it to management.
The relationship between energy efficiency and overall output and quality cannot be ignored. It is evident that achieving both sustainability goals and improving overall efficiency requires a strategic approach that leverages smart manufacturing technologies to enhance energy management and product quality.
Training is another crucial factor. Ensure the team follows a detailed and regular training schedule to educate on the hazards associated with arc flash and how to properly use the equipment. This is a good place to revisit the equipment selection criteria, especially after there has been any upgrades or changes to the electrical system.
As the global energy landscape continues to evolve, manufacturers face increasing pressure to reduce their environmental impact while maintaining operational efficiency. Smart manufacturing offers a promising solution by leveraging advanced technologies and data analytics to optimize production processes.
Lastly, fostering a company culture towards safety can greatly improve employee safety. Each person is their own safety critic and having safe operations top of mind is going to mitigate the risk of serious injury or death on any job site. PE
FIGURE 4: Jarred Richter providing training on arc flash PPE safety.
Courtesy: Hedgehog Technologies
uPlant managers can learn how advanced technologies and datadriven insights empower manufacturers to reduce waste, optimize energy use and maintain a competitive edge in a rapidly evolving energy landscape.
important motivator for these policies (35%). However, based on the overlap of smart manufacturing technologies and their capabilities, it is no surprise that product quality ranks second (33%).
By adopting smart manufacturing practices, manufacturers can enhance energy efficiency, reduce waste and improve overall operational performance. This not only contributes to a more sustainable future but also strengthens the competitiveness of businesses in the global market. PE
Jarred Richter is an electrical technologist at Hedgehog Technologies, a CFE Media and Technology content partner.
Adam Mullen is Group Product Manager for Plex, by Rockwell Automation.
T.om Poczekay, Vice President of Engineering at Hitachi Global Air Power (HGAP), has always had an interest in how things work. As a mechanical engineer, Tom channels his lifelong curiosity for building, improving, and solving challenges into his role leading the North American engineering team at HGAP.
then transitioned to Hitachi Global Air Power, and it’s been a perfect fit ever since.”
At HGAP, Tom leads the North American engineering design and program management teams, focusing on new technology development and custom solutions for customers in the field. “What I love most about working here is solving customer problems,” Tom shares. “We get to work on fascinating technologies that are always evolving.”
Growing up in Michigan City, Indiana, Hitachi Global Air Power—formerly Sullair—was always a part of Tom’s life. “My grandparents’ farm was within sight of the Sullair facility,” he recalls. “I never planned to go into compressed air, but it feels like it was always in my path. I started at a competing compressed air distributor,
Under Tom’s leadership, HGAP’s engineering team has achieved significant breakthroughs, including the Sullair TS Series rotary screw air compressors featuring an all new two-stage air end with patent-pending interstage cooling and best-in-class efficiency. “We’ve pushed the limits of what’s possible in compressed air efficiency,” says Tom. “I couldn’t be prouder of our team and the creative engineering that went into this ground-breaking product series.”
Tom Poczekay
Vice President of Engineering at Hitachi Global Air Power (HGAP)
The team has also revolutionized portable air compressors with the new Sullair E1035H electric portable and on the stationary side with the new DS Series oil free air compressor line. The DS Series involved a strategic collaboration with Hitachi; Tom’s team combined proven Hitachi technologies with HGAP ingenuity to meet the specific needs of customers all over the world.
“ Our mission is clear: make our products more efficient and easier to use — without losing an ounce of the reliability we’re known for. From design to field support, we’re focused on creating smarter, environment-forward solutions that help our customers succeed. ” america.sullair.com
Telephone:
1-800-SULLAIR
ENGINEERING SOLUTIONS
MOTORS, DRIVES
Taha Mohammed, PE, and Cole Casteel, PE, CDM Smith, Fairfax, Virginia
How to ensure reliable motor operation with variable frequency drives
A variable frequency drive (VFD) is the industry’s standard technique for controlling the speed and torques of induction motors. To ensure reliable operation of motors with VFDs, the user must consider various measures and best practices.
Induction motors use the principle of electromagnetic induction to convert electrical energy to mechanical energy to rotate or turn the motor shaft. And although a variable frequency drive (VFD) can be integral to efficient motor operation, there are many factors to consider before you install one.
Objectives
• Understand the fundamental components and operations of induction motors and VFDs.
• Recognize the key factors for selecting motors and VFDs.
• Grasp important factors for VFD and motor installation.
VFDs can be used to adjust the frequency and voltage of the alternating current (ac) power applied to the stator and then control the speed, torque and power of the motor. There are two main control methods that VFDs use to control the operation (speed, torque, power) of an induction motor: vector control and scalar control. While the vector control provides more precise speed control, it is more complex and adds additional feedback devices monitoring the shaft rotation. Thus, the most common and widely control method used is scalar control, also known as volts per hertz or V/f.
The main components of a VFD (see Figure 1) are:
• The ac-dc converter, which converts the incoming 60 Hz ac signal to direct current (dc) using rectifiers or insulated-gate bipolar transistors (IGBT).
FIGURE 1: Variable frequency drive block diagram. Courtesy: CDM Smith
• A dc link that smooths the dc signal using capacitors.
• A dc-ac converter that takes the dc and converts it back to ac at the desired voltage and frequency using pulse width modulation (PWM) technique with IGBT transistors.
As energy saving and more operation controls are desired, VFDs are becoming more widespread for driving motors in industrial and commercial facilities. When using VFDs, there are extra factors and considerations to be taken for a reliable facility and system operation. Understanding and applying these factors will help prolong the lifespan of the motors and VFDs as well as minimizing shutdowns due to unexpected equipment failure.
The following are key factors and best practices to consider when selecting or using motors with VFDs.
How to coordinate VFDs with the driven equipment
For the equipment to operate reliably and properly, it is essential that the motor characteristics and application be coordinated with the driven equipment during the motor and VFD selections. In addition to voltage and phase compatibility of the motor and VFD, the VFD needs to be compatible with the motor and the driven equipment.
One main characteristic is the torque application, for example centrifugal fans and pumps are variable torque application and a normal duty VFD is adequate, while conveyors and positive displacement pumps are constant torque application and require heavy- or severe-duty rated VFDs, which have higher overloading capability.
An additional application to be discussed is the lowest speed the load will be operating at and making sure the motor turndown ratio can accommodate that application and can be safely operated at that low speed without overheating and compromising the operations. For example, a 10:1 turndown ratio for a 3,600 revolutions per minute (rpm) motor is 360 rpm.
Another important item is the motor full load amperage (FLA) and making sure the VFD can provide equal or greater current than the motor FLA. The motor horsepower should not be used to select the VFD and the motor service factor should not exceed 1.0.
Choosing the proper environment for VFDs, motors and drives
Like with anything else in industrial facilities, such as structural supports and pipes or other electrical equipment, motors and drives must be suitably rated for the environments in which they are installed. Process areas in industrial facilities can be subject to physical damage, sprayed or standing water, high humidity, dust, corrosive chemicals and extreme temperatures, all of which can damage or rapidly degrade VFDs containing sensitive electronics.
The VFDs can be protected from their environment with a properly rated National Electrical Manufacturers Association (NEMA) enclosure, such as 4X stainless steel. However, these enclosures come with their own drawbacks. They have larger footprints, add additional cost and make it harder to remove excess heat generated by the VFD. For these reasons, it is recommended to install VFDs in dedicated, climate-controlled electrical rooms (see Figure 2).
When it comes to electrical and mechanical equipment, one of the biggest reasons for degradation of equipment is heat. The power electronics that make up VFDs generate heat and if this heat builds up within the VFD enclosure, the components can be damaged, operate inefficiently or cause the VFD to shut itself down for protection, forcing equipment downtime. Most VFD enclosures are equipped with fans and air filters to ensure the flow of clean air across the components.
FIGURE 2: Variable frequency drives installed in environmentally controlled room. Courtesy: CDM Smith
ENGINEERING SOLUTIONS
MOTORS, DRIVES
‘There are multiple causes and symptoms involved with power quality issues from the VFD outputs, so there are multiple tools to address them and the best ones will depend on the situation.
As with home air filters or on-facility heating, ventilation and air conditioning equipment, the air filters will become clogged with particulates and dust, inhibiting airflow. Even when the VFDs are installed in an air conditioned space and the heat cannot escape the VFD enclosure, the damage will be done.
It may seem like a small thing, but changing the air filters on VFD enclosures regularly, as well as verifying the functionality of the fans and ensuring a clear space around the vents can extend the longevity of the VFDs.
When a VFD is installed in a harsh environment, it is important to remember that the NEMA-rated enclosure only provides protection when used and maintained appropriately. For example, a NEMA 3R outdoor enclosure protects the VFD from rain, but if the door is left ajar, it may as well have a NEMA 1 enclosure rating. Enclosures that provide stronger protection (3R, 4X, 7), tend to have more and heavier duty latches and bolts to keep the doors closed.
These are the areas where the environment can do the most damage to the VFD, so it is crucial for the longevity of the drive to make sure the doors stay closed, ensuring the integrity of the enclosure is maintained.
The importance of disconnecting contacts
Safety disconnecting means are required for each motor to be located within sight of the motor location, per NFPA 70: National Electrical Code Article 430.102. However, a code exception is included that allows for the elimination of the motor disconnect if it is impractical or would introduce additional hazards, with an informational note clarifying that motors associated with VFDs meet this condition.
Despite the exception bypassing the need for a separate disconnect, many facilities’ operational staff still prefer to have them, as they can provide a safer working environment allowing technicians to open the disconnect and maintain visuals on the disconnect while they service equipment.
A consideration when including local motor disconnects for motors driven by VFDs is to include auxiliary “break-before-break” or “early break” contacts within the disconnect switch to connect to the VFD and send a signal to the VFD immediately to shut down before the switch is opened. When the motor load is abruptly removed from the load side of the VFD while running, transient voltage and current spikes are created that can damage the transistors in the drive.
Rarely, the damage can be rapid and catastrophic, destroying the drive, but more likely the surges will wear down the VFD electronics, lowering their lifespan. The addition of these auxiliary contacts allows the drive to shut off its output immediately before the load is lost, saving it from unwanted transients. For existing installations without early break contacts, it may be worth stopping the VFD before opening the local disconnect (see Figure 1).
Gauging VFD and power quality
Harmonics in electrical systems are high-frequency sinusoidal currents that get added to the main power wave at multiples of the power frequency (60 Hz). They are created when ac power is converted to dc, which is the first stage of a VFD.
The concern with harmonics is often on their upstream effects, such as increased heating of transformers, nuisance tripping or issues with the electric utility provider. With VFDs, there are also concerns with power quality downstream. As mentioned above, the ac output of a VFD is constructed from the dc bus by PWM, rapidly turning the output tran-
FIGURE 4: Cutaway view of an induction motor. Courtesy: ABB
sistors on and off. The high-speed switching interacts with the inherent inductance and capacitance of the cable feeding the motor and the motor itself to create what are known as standing waves or reflected waves. The standing waves cause the cables and motor to experience a higher voltage than normal, sometimes higher than the rating of the insulation, causing premature breakdown of the insulation.
There are multiple causes and symptoms involved with power quality issues from the VFD outputs, so there are multiple tools to address them and the best ones will depend on the situation. To minimize reflected waves, it is best practice to keep cable runs between the VFD and the motor as short as possible.
Added length of cable increases the inductance and capacitance, also increasing the magnitude of the reflected waves. The high-frequency noise carried by the cables creates electromagnetic interference (EMI) that can affect nearby analog signals runs with power cable, like pressure or level transmitters signals. Using multiconductor, shielded VFD cable, especially when installed in cable tray or PVC conduit, will make sure those adjacent analog readings are not impacted by the EMI generated in the VFD cable.
With the prevalence of VFDs, industry leaders and motor manufacturers have designed motors with more robust insulation to be used with VFDs, as described in the NEMA MG1 standard and are labeled as inverter-duty.
The VFD output also induces stray currents in the rotor that discharges through the shaft and damaging bearings, causing vibrations bearing failure. To prevent stray currents and the unnecessary vibrations, heating and damage they cause, motors should be equipped with shaft grounding straps, insulated bearings or both.
Whether some of these extra measures are necessary will depend on individual circumstances, such as the VFD manufacturer and technology used, facility layout, motor size and process criticality. Proper protection will curb the negative effects from the PWM output of the VFD and extend the life of the motor.
Other filtering equipment such as sine wave and DV/DT filters may be used to eliminate transients between the VFD and the motor and protect the motor windings from voltage spikes. It is important to consult the VFD and motor manufacturer for recommendations on the proper filtering selection based on individual applications and setup.
Monitoring and protecting VFDs and motors
Similar to VFDs, heat buildup is an issue for the motors. The flow of electrical current is resisted by the motor windings, converting the electrical energy to thermal energy. In a motor, a fan blade is attached to the rear of the shaft to expel hot air while the motor is spinning. This kind of motor construction is called totally enclosed, fan-cooled (TEFC) (see Figure 3) and it works well to remove excess heat from the bearings and stator at rated speed.
However, when used with a VFD to reduce the speed of the motor, as the fan is attached to the shaft, it will spin slower, which reduces the effectiveness and allows heat to build up. Generally, it is not recommended to operate TEFC motors below 25% of rated speed without additional cooling or verifying the rating of the motor.
For motors driven by VFDs especially, monitoring the temperature can help identify problems before they do too much damage. The most basic
FIGURE 3: Totally enclosed, fan-cooled motor on variable frequency drive with winding thermal protection and safety disconnect. Courtesy: CDM Smith
ENGINEERING SOLUTIONS
Insightsu
Variable frequency drive insights
uVFDs are gaining widespread popularity for driving motors in industrial and commercial facilities due to their efficiency.
u It’s important that the motor characteristics and application are coordinated with the driven equipment during the motor and VFD selections.
uMonitoring the temperature can help identify VFD problems before they do too much damage.
method is to install thermostats constructed from bi-metallic switches around the stator windings. As the two distinct types of metals heat up, they expand at different rates, eventually breaking contact, letting the control circuit know the motor is getting too hot.
However, this discrete signal occurs only after reaching the setpoint and provides no additional diagnostics. Another method is using resistance temperature detectors that continuously vary their resistance as the temperature changes, which can be sensed and monitored remotely, giving more opportunity for proactive intervention to extend the life of the motor.
Routine VFD and motor maintenance considerations
All equipment deteriorates over time, so it is crucial to test and maintain it regularly to ensure it remains in good condition. Performing proper maintenance is another key item that enhances the reliability of motors/VFD operations. This includes preventive maintenance and visual inspections, cleaning filters and vents from dust and debris. Motor and VFD inspections include checking for proper ventilations, unusual noises and smells, corrosion and excessive vibrations. Some preventive maintenance measures include applying lubrication, tightening connections and replacing parts.
For detailed maintenance and testing procedures, consider following the manufacturer’s instructions and adhering to the recommended maintenance guidelines from the InterNational Electrical Testing Association and NFPA 70B: Standard for Electrical Equipment Maintenance. PE
If the facility has a supervisory control and data acquisition system that allows the networking of VFDs via Ethernet or fiber, the additional VFD parameters, signals and statuses can be remotely monitored, such as real-time voltage, current, power, output frequency, motor speed, motor torque and runtimes. This kind of data is valuable for operators and maintenance to ensure the health and longevity of their equipment.
Taha Mohammed, PE, and Cole Casteel, PE, are electrical engineers with CDM Smith.
The Importance of a Proper Lubrication Program
David Reh | Director of field engineering and training services, Lubriplate Lubricants Company
Proper lubrication is essential to maintaining the bottom line, but starting a lubrication plan can seem to be an overwhelming proposition. Not having an effective program can result in hundreds of hours of downtime and lost production. Where does one begin faced with such a daunting task? This article will discuss methods to implement a comprehensive lubrication program, or how to possibly improve one already in place.
The first thing that should be done is to define the program’s goals and objectives. Many plants want to consolidate inventory, reduce costs, and to ensure that the correct products are being used in the right places, especially in regard to any applicable legislation or food grade lubrication requirements. A qualified lubrication expert can assist with each of these goals, and advise you on what may or may not be a practical plan based on their experience.
Even a seemingly small accomplishment can be crucial. Some examples might include consolidating multiple gear oils into a single one, inventory reduction, or identifying an opportunity to save money through the advantages of using a superior lubricant. A few successes like these along the way help to keep the ball rolling.
Implementing a color coding plan, tagging equipment, and employee training are also smaller sized goals that can be accomplished fairly quickly with a moderate effort and reap much larger benefits in the long term. Another example of this is oil analysis. Oil analysis can be a good place to start, because it can be started on critical equipment without a lot of effort, and carries with it a potentially large return on the initial investment.
With each small part of the project that is completed, employees become more invested in the continuance of the program as it builds towards the conclusion a comprehensive lubrication program that saves money in the long run.
Lubriplate provides it’s customers with a complete extra services package. These services include a technical support hotline and e-mail, complete plant surveys, customized, color coded lubricant tags, lubrication maintenance software, plant user training and no charge oil, fluid and grease analysis. For more on this subject and customer assistance call 1-800-733-4755 or e-mail LubeXpert@lubriplate.com
Download the paper at: www.lubriplate.com/Resources/White-Papers/
ENERGY EFFICIENCY AND MANAGEMENT
Mike Daugird, ACS, Verona, Wisconsin
How to use energy-efficient motors and drives to save money
To cut costs and reduce carbon footprints, manufacturers have turned to variable frequency drives (VFDs) and switched reluctance (SR) motors, which offer energy savings and environmental compliance benefits.
The manufacturing industry is undergoing a significant transformation, increasingly focused on improving energy efficiency and reducing the carbon footprints of the motors and drives essential for daily operations. As manufacturers seek to lower costs and meet sustainability goals, the need for more efficient power generation and distribution systems has become a priority.
Whether you're responsible for maintaining motor-driven systems in heating, ventilation and air conditioning (HVAC), or in conveyors, pumps or other equipment, enhancing energy efficiency is key to staying competitive in today's industrial landscape.
Meeting the demand for energy-efficient drives
Manufacturers are being driven by rising energy costs, environmental regulations and the need for operational efficiency. Industrial motors, which account for a significant portion of energy consumption in manufacturing environments, offer an opportunity for improvement. One of the most effective ways to achieve energy savings is using variable frequency drives (VFDs). These drives control motor speed and torque in response to the specific demands of the task at hand, allowing motors to operate more efficiently and consume less energy.
VFDs are particularly effective in applications where motors run at less than full capacity for extended periods. For example, pumps and fans in HVAC systems often operate below their maximum output and adjusting motor speed using a VFD can lead to significant energy savings. With energy consumption representing one of the largest operating costs in manufacturing, these savings can add
FIGURE 1: Advanced industrial motors and drives are at the forefront of energy efficiency in manufacturing, helping facilities reduce power consumption.
Courtesy: ACS
Objectives Learningu
• Understand the importance of energy efficiency in manufacturing for cost reduction and environmental sustainability.
• Identify key technologies, such as variable frequency drives (VFDs) and switched reluctance (SR) motors that improve energy efficiency in industrial operations.
• Recognize the challenges and benefits of upgrading to energy-efficient systems and the role of incentives in facilitating these transitions.
up quickly. As companies aim to meet stricter environmental standards, VFDs are also helping reduce carbon emissions by lowering the overall energy demand of industrial operations.
Switched reluctance (SR) motors, though based on an older design, are also emerging as a leading technology due to advancements in cost-effective electronics. Unlike permanent magnet motors, which rely on rare-earth materials and come with environmental concerns, SR motors use a simpler, magnet-free rotor made from shaped iron. This design makes them highly efficient and robust, capable of producing up to twice the power of traditional alternating current motors. Their rugged construction and efficiency make them ideal for electric vehicles and with electronics now more affordable, SR motors are being viewed as a strong alternative to induction motors, particularly in high-demand applications like compressors, pumps and industrial systems.
The benefits of energy-efficient motors and drives
The push for energy efficiency is not just about cost savings; it's also about reliability and long-term sustainability. More efficient motors and drives offer several benefits for those who work in manufacturing environments, including:
• Reduced operating costs: Energy-efficient motors can lead to significant reductions in electricity usage, which translates into lower energy bills. This is especially important in large facilities where motors run continuously.
• Extended equipment lifespan: Motors that operate efficiently experience less wear and tear, leading to a longer operational life. This reduces the need for frequent repairs and replacements, saving both time and money.
• Improved system performance: VFDs and other motor control technologies allow for bet-
2: Real-time energy monitoring enables manufacturers to track power usage, identify inefficiencies and adjust operations to lower energy costs.
Courtesy: ACS
ter control over system performance, improving the accuracy of operations and reducing waste. This leads to more consistent production processes and higher-quality outputs.
• Environmental compliance: Many industries are facing stricter regulations around energy consumption and emissions. By upgrading to more efficient motors and drives, manufacturers can meet these standards while minimizing their environmental impact.
Addressing the challenges of upgrading industrial power systems
While the benefits of improving motor efficiency are clear, the transition to more energy-efficient systems presents some challenges. One of the main hurdles is the initial cost of upgrading equipment. Although the long-term savings from reduced energy consumption can offset these upfront costs, many manufacturers are hesitant to make the investment without clear financial incentives or regulatory pressure. Additionally, some facilities may face technical challenges when integrating new systems into existing operations.
3: Variable Frequency Drives (VFDs) in HVAC systems allow for flexible motor control, reducing energy use and extending equipment life.
Courtesy: ACS
FIGURE
FIGURE
ENGINEERING SOLUTIONS
5: Lower emissions and cleaner facilities are becoming the standard as manufacturers adopt more energy-efficient equipment.
For example, older motors may not be compatible with modern VFDs, requiring additional upgrades to ensure smooth operation. This is particularly relevant for SR motors, which can experience high torque ripple due to phase switching, complicating their integration with legacy systems. Ensuring that these upgrades are properly planned and executed is critical to minimizing downtime and disruptions to production.
Government incentives, such as tax breaks or grants for energy-efficient technologies, can help offset the cost of upgrading industrial systems. Additionally, utilities in many regions offer rebates for businesses that invest in energy-saving equipment. Taking advantage of these opportunities can make it easier for manufacturers to justify the cost of upgrading to more efficient motors and drives.
Insights
Energy insights
uEnergy-efficient motors can save manufacturing facilities electricity usage, which translates into cost savings.
uSwitched reluctance (SR) motors are highly energy efficient and capable of producing up to twice the power of traditional alternating current motors.
The future of energy efficiency
As the manufacturing industry continues to evolve, energy efficiency will remain a key focus for those who work with motors and drives, including SR motors. Technological advancements, such as improved VFDs and the development of smart motor systems, are expected to drive further efficiency gains. These systems, along with the inherent advantages of SR motors — such as their durable, low-maintenance design and enhanced thermal capabilities — will offer improved moni-
‘Technological advancements, such as improved VFDs and the development of smart motor systems, are expected to drive further efficiency gains.’
toring and control, allowing for real-time adjustments that optimize energy usage even further.
Workers responsible for maintaining motor-driven systems must stay informed about the latest technologies and best practices. Understanding how to implement and maintain energy-efficient systems can make a significant difference in the overall performance and sustainability of your operations.
The path to more efficient power systems is a critical one for all industries. By investing in energy-efficient motors and drives, facilities can not only reduce costs but also contribute to a more sustainable future. Whether you're operating equipment in an industrial plant or managing systems across multiple facilities, the steps you take today to improve energy efficiency will have lasting benefits for your operations and the environment. PE
Mike Daugird is an engineering manager with the ACS facility engineering group.
FIGURE 4: Engineers evaluate motor systems to ensure seamless integration of energy-saving technologies in industrial operations. Courtesy: ACS
FIGURE
Courtesy: ACS
Italian machine builders are set to showcase their cutting-edge ‘Breaking Necks’ solutions and technologies
Italian machine builders are the key to unlocking your strategic business potential.
How are end users leveraging Italian machinery to advance their operational goals and address significant industry trends? Machines Italia’s Spring 2025 issue will explore key trends across various sectors utilizing Italian machinery, including advancements in automation, environmental sustainability, and the increasing demand for flexible and adaptable machinery. For more details, visit machinesitalia.org.
ENGINEERING SOLUTIONS
SAFETY AND PPE
Russ Bowman, EXAIR, Batavia, Ohio
How to select PPE to protect against airborne hazards
If
airborne hazards are a respiratory concern, learn about the PPE available.
It may sound counterintuitive that the least-effective control is the one many people think of first. It is, however, the one the user will ultimately be most familiar with, so it’s critical to know if — and when — different personal protective equipment (PPE) will provide adequate safeguards for airborne hazards.
Per Occupational Safety and Health Administration (OSHA) 1910.134(d)(1)(iii), the responsibility for this rests with the employer:
The employer shall identify and evaluate the respiratory hazard(s) in the workplace; this evaluation shall include a reasonable estimate of employee exposures to respiratory hazard(s) and an identification of the contaminant's chemical state and physical form. Where the employer cannot identify or reasonably estimate the employee exposure, the employer shall consider the atmosphere to be immediately dangerous to life or health.
Objectives
• Gain resources from regulatory bodies regarding the use of respiratory protection products.
• Know situations in which respiratory protection should be used, and the different types of respiratory protection that are suitable for those specific situations.
Manufacturing safety personnel should assess the nature and magnitude of respiratory hazard(s) that personnel may be exposed to. This includes hazards present during normal operations, as well as those that may be the result of accidental releases or emergency situations. It will also identify the physical state, such as gas, particulate or both and chemical form, including toxin, corrosive element, carcinogen and biohazard, of the contaminant(s).
Oftentimes, the contaminant is a substance that’s used by the worker. In those cases, OSHA publishes a Hazard Communication Standard, which mandates hazard identification on safety data sheets. This is a valuable tool and is largely considered to be the primary source of information for any hazards associated with the sub-
stance in question. If the contamination is a result or byproduct of an operation, air sampling of the actual environment or objective information from similar operations may be necessary.
Respirator selection for air contaminants
The next consideration will be the factors that might influence the selection of which specific kind of respirator is required. These factors include:
• Physical constraints of the jobsite. This typically won’t be an issue if a simple mask or cartridge filter-type respirators are to be used, but if the environment calls for an independent supply of breathing air, hose fed breathing masks may be needed in tight quarters. Consequently, the use of respirators with air hoses could be limited if there are obstructions in the area and could be downright dangerous around moving machinery. In those cases, a self-contained breathing apparatus will be the better option.
• Certain medical conditions. Many common respirators are classified as negative pressure devices. This means that the wearer must draw air in through a restriction (like filtration media or chemical cartridges), which means it takes more effort than just “normal” breathing. These aren’t suitable for everyone — for example, they present a very real risk of undue pressure to the heart for someone suffering from lung diseases such as asthma or emphysema. Positive pressure respirators provide a restriction-free flow of breathing air and need to be used in those cases.
• User comfort. It’s not good for anyone to burden workers with awkward or unwieldy PPE of any kind. That can lead to lost productivity, high turnover and possible legal action for the employer and myriad mental and physical stresses for the employee. Fortunately, technical and material improvements continue to make safety equipment lighter, easier to don, softer on the skin — and many times even more effective than before.
• Required level of protection. Sanding drywall and cleaning up after an accident at a chemical plant present vastly different breathing hazards, and hence, need vastly different levels of protection. Agencies like National Institute for Occupational Safety and Health (NIOSH) and OSHA, as well as the American National Standards Institute, all have many standards and publications on this subject.
Know what PPE to select for airborne hazards
Once the appropriate level of protection is determined, users can select a suitable respirator from two basic categories: air-purifying respirators and atmosphere-supplying respirators.
Air-purifying respirators are self-contained devices that remove contaminants from the air to make it safe to breathe. Different kinds can remove particulates, vapors or both. They are all classified as negative pressure devices, so they may not be suitable for use by someone with medical conditions as noted above.
Particulate respirators capture airborne particles in small spaces between the fibers that make up their construction. These include simple masks that cover the mouth and nose and are typically considered disposable. They also come in a rigid frame with replaceable filter elements. As particulate accumulates in the fiber, these become more effective after some use but take care to replace them when any resistance or breathing difficulty is noted.
FIGURE 1: Here are three examples of air purifying respirators. Top: High-efficiency P100 cartridge-type respirator for organic vapors, chlorine, hydrogen chloride, sulfur dioxide or chlorine dioxide. This respirator can also be used for hydrogen sulfide but only in an emergency to escape from the contaminated area. Bottom: Two particulate mask-type respirators for general purpose use.
Courtesy: Exair
‘Once the appropriate level of protection is determined, users can select a suitable respirator from two basic categories: air-purifying respirators and atmosphere-supplying respirators.’
Vapor respirators use chemical filters (usually in a cartridge or canister) which absorb the vapor. There are different specific types for different vapors; NIOSH has a color-coding system for them:
Black: Organic vapors
Bright green: Ammonia
White: Acid gases
Yellow: Organic vapors and acid gases
Olive/brown: Organic vapors, ammonia,acid gases
Magenta: High-efficiency filter, P100 filters
Black, magenta: Organic vapors and high-efficiency filter, P100 filters
Combination respirators have both particulate and vapor filters. These are especially popular when working with pesticides, as well as other chemical or biological agents that create airborne particulate and vapor contaminants.
Specialty respirators as PPE
Atmosphere-supplying respirators provide clean breathing air from an outside source, usually an air tank or compressed air system. They’re used when a high concentration of contaminants could foul particulate elements or expend a vapor cartridge quickly. They may also be needed in areas where the oxygen level could drop below safe levels, such as confined spaces that cannot be adequately ventilated with fresh air. They’re also used for emergency situations to allow personnel to safely evacuate an area where the atmosphere is unexpectedly fouled with smoke or other pollutants.
All atmosphere-supplying respirators provide protection against particulate and vapor contaminants and come in three configurations:
• Self-contained breathing apparatuses have the same masks designed for an airtight seal but are fed with breathing air from a pressurized tank. The wearer has greater freedom of movement — they’re not restricted to the supply hose length of an air-supplied respirator — but they do have time limits.
– Open-circuit types provide breathing air that the wearer breathes right back out to the atmosphere. These are typically good for 30 to 60 minutes, because the larger the tank gets, the more cumbersome it is for the wearer to carry around.
– Closed-circuit types recirculate exhaled air through a chemical-activated “scrubber” that removes carbon dioxide and generates oxygen. These are also called “rebreathers,” and some are good for up to four hours.
• Combination atmosphere-supplying respirators combine features of the other two types. The primary supply comes from an external source (like the air-supplied ones), but they also include an air tank (like the self-contained ones). The tank is generally smaller on these, as its main purpose is to provide air while the user exits the area. They’re commonly used in confined spaces without adequate ventilation and when working for extended periods in atmospheres that could be immediately dangerous to life and health.
PPE insights
uPersonal protective equipment (PPE) is critical for worker safety.
u Air quality regulations are important considerations for the types of PPE required for worker protection.
• Air-supplied respirators consist of a mask (usually full face with straps to cinch it up for an airtight seal), with a short, low-pressure hose connected to a regulator, usually made to clip on the wearer’s clothing, belt, etc., which is fed with a hose rated for the supply pressure that has a quick connect for use with breathing air manifolds. These manifolds will normally be strategically located in facilities where contaminated atmospheres require their use. Advantages include their light weight and ability to provide clean breathing air for long periods of time. Disadvantages are limited mobility (the wearer can’t go any further than the supply hose length from a supply manifold) and failure due to hose damage.
Proper selection and use of respiratory protection is critical to your health and safety. Additionally, it’s important to your company’s bottom line. In 2021, OSHA recorded 2,521 violations of respiratory protection standards. This was second only to fall protection violations that year. The associated fines are commonly compounded per person and per day.
Know and understand the hazards you and your employees will be exposed to. Familiarize yourself with the different respirator options. Conduct regular training so everyone knows how to protect themselves and others. Fit testing of respirators should be an integral part of that training. PE
Russ Bowman is an application engineer at EXAIR.
ENGINEERING SOLUTIONS
Philip Jacklin, Diversified Fall Protection, Virginia Beach, Virginia
Fall protection equipment focus: What to know about body harnesses
The proper fit for fall protection harnesses can help employers better protect their employees when falls occur.
Falls are the third leading cause of injury and fatality among general industry workers. Additionally, fall protection violations have been the most cited Occupational Safety and Health Administration (OSHA) violations for the last 14 years.
According to the National Safety Council’s most recent data from 2022, 865 workers died in fall-related incidents with more than 80% of those deaths occurring after falls to a lower level. The U.S. Bureau of Labor Statistics has shown an average increase in fall fatalities since 2010.
While many organizations have joined OSHA’s efforts in raising awareness of the risk of workplace slips, trips and falls, the current data suggests that more must be done to decrease the number of falls that occur. If fall injuries can be mitigated or prevented, then unnecessary deaths can be avoided.
There are many strategies organizations can employ to make their workforce safer. This article will highlight how focusing on training employees on how to properly fit, inspect and use their fall protection harness is an effective strategy to protect their workers.
Ensuring a perfect fit for fall protection
Many harness manufacturers advertise body harnesses with a universal size, but each person must ensure their harness is properly adjusted to their body. Every OSHA and American National Standards Institute (ANSI)-approved fall protection harness will have five points of adjustment — two leg straps, two shoulder/torso straps and one chest strap.
The leg straps should be adjusted tightly enough to remain stationary on the user’s leg but not so tight as to cut off circulation. One common rule to determine leg strap tightness is called “flat hand, not fat hand.” This is where a user’s extended palm (flat hand) but not their fist (fat hand) can comfortably slip under the leg strap when tightened.
The shoulder and chest straps should then be fitted in unison. Users should ensure their shoulder straps fit snugly by pulling on the tensioners located near their torso. The user should feel slight tension on their shoulders from these straps and they shouldn’t be able to slip off while moving around. If the shoulder straps are properly tensioned, they should help the chest strap sit in its proper place, which is aligned with the creases created by a user’s armpit when they hold their arms flat against the side of their body.
It is important to have the chest strap set at the proper height. If it’s too high, the user risks being choked by the chest strap, as it may elevate when the user is suspended during their fall arrest. A strap that’s too low could cause the worker to not remain upright during fall arrest. If a user is not properly positioned upright during fall arrest, the user’s spine may incur more force and resulting in a greater risk of severe injury. Most chest straps are adjustable and should be tensioned to sit flat against the user’s chest.
Proper tension is crucial to ensuring a worker remains safe during fall arrest. A properly tensioned harness encourages the user to maintain a proper, upright posture. It keeps the body station-
• Discover the proper fit techniques for fall protection harnesses.
• Find out what two inspections are required by Occupational Safety and Health Administration for fall protection equipment.
• How to conduct preuse inspections for fall protection harnesses.
ENGINEERING SOLUTIONS
‘Fall protection manufacturers must ensure no more than 1,800 pounds of force are felt by a user in their harness.’
Courtesy: Diversified Fall Protection
ary during fall arrest, which best mitigates the fall forces that the harness can partially absorb during fall arrest. If a harness fits loosely, the harness will suddenly become very tight in crucial areas, like the groin or pelvic region. This sudden tightening of the harness can cause unanticipated injury and will not properly absorb forces from the user.
Fall protection manufacturers must ensure no more than 1,800 pounds of force are felt by a user in their harness. However, this can only be performed if the user wears the harness correctly, according to the manufacturer’s instructions.
Conducting pre-use inspections to ensure workplace safety
While proper harness fit is one of the most important things users can check while donning the equipment, OSHA also requires users to inspect their harness before every use. This is often referred to as the pre-use inspection. These inspections do not have to be documented each time they occur, but the existence of them and training workers to perform them should be documented in the organization’s fall protection program. In these inspections, users should check inspect three main components of their harnesses:
• Product tag
• Deployment indicators
• Damage and defects
First, users must ensure the harness’s original product tag is intact. If no manufacturer tag is present, OSHA does not permit the harness to be used. On most harnesses, this is located under an enclosed pouch either on a front torso strap or one of the back straps. After locating the tag, users must make sure the tag is legible and in good condition. The tag should contain confirmation that it complies with the latest OSHA and ANSI standards, date of manufacture and make and model of the harness. While it’s not required, it is best practice to write the date of first use on the product’s tag.
Second, users must ensure the deployment indicators do not indicate a fall has occurred with the harness they are about to use. All pieces of fall protection equipment — anchors, body harnesses and connection devices — are only rated for one fall. After they experience a fall, they must be removed from service and replaced with new equipment, per OSHA and ANSI requirements.
FIGURE 1: Rooftop worker with personal fall protection system.
Most harnesses now have two deployment indicators on the two back straps of the harness. They typically look like a piece of the webbing stitched over itself in a “Z” shape with stitches that are rated to break after about 400 pounds of pressure are applied, which is common in any fall arrest. Many manufacturers conceal a small tag that is revealed once these stitches break apart, which communicates that the harness should be removed from service. In the odd case that these stitches tear and the user has not experienced a fall, the harness still must be removed from service. This can suggest the harness has somehow been exposed to extreme forces and may not perform as expected during a fall. When it comes to fall protection equipment, being prudent can be the difference between life and death.
After the user has confirmed the product’s tag and the harness’s deployment indicators are still intact, they now must inspect the entire harness for any physical damage or defects that could hinder its performance during fall arrest. Users should check for any tears, cuts, holes, burns, burrs or damage done to the harness webbing. Harness webbing should have a smooth, sheen feeling to it if it’s in proper condition.
Overexposure to sunlight’s ultraviolet rays will not only discolor the harness but make the webbing more brittle, give it a rougher texture and erode its elasticity. If the webbing becomes too brittle, it won’t stretch properly during fall arrest and run the risk of breaking. If a harness strap breaks during fall arrest, the user could be accidentally ejected from the harness and suffer severe injury.
The user should check all the metal components of the harness, like the D-rings, buckles and grommets, for any rust or signs of corrosion. And while it is uncommon, they should pay extra attention to any area where metal comes in direct contact with webbing material because over time, the friction could deteriorate that portion of the webbing. They should also ensure all connections and fasteners function properly before donning the harness and going to their elevated work location.
If a harness or any piece of equipment fails its pre-use inspection, the item must be taken out of service and delivered to the organization’s “competent person,” defined by OSHA as someone who has the knowledge, training and experience to identify and correct hazards in the workplace. The user would then have to be provided with anoth-
er piece of equipment before their at-height work can safely be performed.
Here’s why annual inspections are critical for safety
In addition to pre-use inspections, OSHA also requires annual inspections of all fall protection equipment. These inspections must be documented when they occur and be performed by the organization’s designated competent person. Annual inspections should note the date of manufacture, serial number, manufacturer and model and indicate whether the equipment passed or failed the inspection.
These inspections can be performed by a third party, and that third-party inspector must be trained to a competent person level. This person assumes liability for the proper functioning of the system if used according to the manufacturer’s instructions.
In theory, if users perform diligent pre-use inspections of their fall protection equipment, the competent person should have almost no equipment fail their annual inspection. High failure rates during annual inspections can indicate to safety leadership that workers should be retrained on what to look for during pre-use inspections. Workers using defective, damaged or faulty equipment could be subject to injury but might think their equipment will protect them.
Best practices can ensure fall protection safety
Focusing on best practices for fall protection harnesses is just one strategy organizations can deploy to better protect their workers from falls. The simple reinforcement of corporate safety policies and encouraging workers to use their equipment properly is extremely effective in keeping workers safe.
Studies have found that employees are eight times more likely to use fall protection equipment if they believe their employer requires it. If we educate workers on the hazards they will encounter in their workplace, provide them with the resources to work safely and empower them to use their equipment every time, we can prevent falls — and avoid tragedies. PE
Philip Jacklin is the continuing education program manager with Diversified Fall Protection.
‘When it comes to fall protection equipment, being prudent can be the difference between life and death.’
Insightsu
Fall protection insights
uEnsuring best practices for fall protection harnesses will protect workers from catastrophic accidents.
uEmployers need to know about the minimum Occupational Safety and Health Administration requirements regarding body harnesses and how to encourage workers to use these harnesses to protect themselves.
uWhen employees know how to use their fall protection harnesses and feel confident in their safety, they can do their jobs without fear.
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Here are the facts and myths about appropriate PPE
Understand critical factors for selecting and using PPE to ensure you’re choosing the right equipment that meets regulatory standards and protects workers from hazards.
Most people understand the critical importance of personal protective equipment (PPE) in protecting workers from hazards that cause serious injury and illness. But with all the products available on the market today, many environmental, health and safety (EHS) practitioners don’t know where to begin or feel overwhelmed when it comes to choosing PPE.
According to the U.S. Occupational Health and Safety Administration (OSHA), employers should have PPE programs if PPE is used at their facility. PPE programs are ultimately responsible for addressing the hazards present in the workplace; the selection, maintenance and use of PPE; the training of workers on its use; and the monitoring of the program’s effectiveness.
Choosing the right PPE equipment and making sure it’s used properly is one of the most important things a company can do to protect itself and its workers. One barrier to selecting PPE is a limited understanding of how to choose the most effective equipment for the workers and facility. Which PPE is chosen can depend on various factors, such as the hazards workers are exposed to, the preferences of the workers and the availability of PPE equipment.
In many cases, though, decision-makers choose PPE based solely on cost without adequately considering the workplace hazards or other factors that may impact their use. What’s worse, decision-makers may rationalize their choices through various PPE myths. Dispelling these misconceptions and understanding the critical factors impacting PPE selection and use will ultimately help PPE
programs and practitioners choose the right PPE equipment that meets regulatory requirements and protects workers from hazards.
MYTH NO. 1: PPE is the first line of defense to protect workers from hazards. PPE is actually the last line of defense for protecting workers from hazards and should only be used after all other options for preventing exposure have been exhausted. In fact, PPE programs should be part of a much bigger hazard identification and risk reduction program, where a comprehensive approach is used to identify risks and protect workers. Programs should:
• Conduct a job hazard analysis or task hazard analysis to identify the hazards associated with each workplace process and activity.
• Use the hierarchy of controls to determine if the hazards can be eliminated, substituted or engineered out. A matrix can help identify potential mitigation actions and the type of PPE based on the hazard. For some examples of how to implement the hierarchy of controls, see Table 1.
• Evaluate and recommend PPE necessary to mitigate any residual risk that cannot be eliminated, substituted or engineered out.
MYTH
NO. 2: All PPE is created equal. PPE supplied by different vendors varies in quality, style, rating and functionality. K-95 masks are a
• Recognize that personal protective equipment (PPE) is the last line of defense in protecting workers from hazards, not the primary mode.
• Understand that PPE selection should be based on the risks associated with a task.
• Identify appropriate PPE to stock at your facility based on the diversity of the workplace as well as the facility’s unique hazards. Objectives
ENGINEERING SOLUTIONS
‘PPE is actually
the last line of defense for protecting workers from hazards and should only be used after all other options for preventing exposure have been exhausted.
’
great example of this. During the COVID-19 pandemic when N-95 masks were in short supply, people started using K-95 masks even though K-95 and N-95 masks are not made to the same standard. K-95 masks are made to the Chinese standard, while N-95s are made to the National Institute for Occupational Safety and Health standard. What’s more, some masks looked like K-95 masks but were not manufactured to either standard.
PPE should be carefully selected based on the identified hazards at the facility, making sure it conforms to appropriate standards (e.g., OSHA, American National Standards Institute, American Society for Testing and Materials) rather than looking for the lowest-cost items. Choosing lowcost PPE options cost more money in the long run.
Remember the saying, “You get what you pay for.” PPE that costs less per unit quantity may also be low-quality, which may be more prone to failure. If PPE fails more frequently, workers will use more, which will ultimately cost more. Frequent failure can lead to more incidents and accidents and a higher OSHA recordable incident rate, all of which will result in more money spent on medical expenses.
Poor-quality and inappropriate PPE can also impact worker acceptance. Workers have their own requirements for PPE comfort, perceived effectiveness and durability. If they don’t like the PPE, don’t trust it or feel it hinders them from doing their job, then they won’t wear it. And if
they don’t wear the PPE, the facility’s accident incidence rate and medical costs may go up.
MYTH NO. 3: Workers not wearing PPE causes many accidents.
This is an insidious misconception that blames workers for incidents rather than seeing it as something the facility can change or control. A good root cause analysis doesn’t blame the worker and instead digs deeper to find out which process failed and what can be fixed or changed to prevent the accident from recurring.
When asked why they weren’t wearing their PPE, workers will often say they forgot, which doesn’t get to the core of the issue. When encouraged to explain further, many cite a host of underlying issues, including poor quality, unreliability or they just don’t like it. PPE needs to be acceptable to workers in the following areas:
• Comfort. PPE must be comfortable for employees to wear. A facility PPE team can sample different PPE and make recommendations on the most comfortable options. Diverse representation is critical because what’s comfortable for one size, gender or body shape may not be comfortable for another.
• Quality and reliability. Workers become frustrated by PPE that consistently fails and breaks. Collect data from your facility on PPE failure and reordering rates. Then, interview employees
Table 1: Examples for implementing the hierarchy of controls
Noise from compressor Do you need the compressor inside, or can you remove it from the building?
Hazardous chemical splash while filling tank
Toxic gas inhalation during sampling
Hard pipe chemical feed into tank so personnel aren’t manually filling the tank
Is there a way to collect a sample without exposing personnel, using a robot or automatic means?
Is it an old compressor? Can you use a newer, quieter model instead?
Is there a safer chemical that could be used in the batch instead?
Do you really need toxic gas in your process? Is there a different, safer chemical that could be used instead?
1. Place the compressor in a dedicated compressor room.
2. Hang noise-reducing blankets around the compressor. Ear plugs or muffs
Design an automated system that opens a valve once all connections are made to the tank, removing personnel from being exposed.
Perform sampling under a hood or in a well-ventilated area.
TABLE 1: This shows examples of how to implement the hierarchy of controls. Courtesy: WTWH Media
Goggles or face shield, gloves, apron
Respirator
Table 2: Glove protection based on type, rating and material
Leather, terrycloth, aramid, acrylic, aramax 1 to 4
Electrical Insulation Class 00 to 4
regarding their perceptions about the PPE quality. Ask them about their PPE concerns and the kinds of PPE they would prefer. Finally, conduct an analysis of the data and evaluate whether a better PPE selection should be offered.
• Flexibility. Workers will be consistently unhappy if PPE interferes with them doing their jobs. Convene a PPE team consisting of representatives from every area of the facility. Ask them what they want in terms of PPE and what their current concerns are with existing PPE options.
• Size. If the right sizes aren’t available, workers won’t be able to wear the PPE. Make sure you order a variety of sizes (i.e., XS to XXL) to choose from.
• Style. Workers often use PPE to express their own uniqueness and style. If they perceive the PPE as ugly, clunky or boring, they won’t use it. Try offering PPE in a variety of colors, brands and form factors. A brand or style that works well for one worker may not work well for another.
1=Least protective
4=Most protective EN 407
00=Least insulating
4=Most insulating
ASTM D120
MYTH NO. 4: One glove is as good as another.
Gloves are designed for specific hazards. A cut-resistant leather glove, for example, will do little to protect employees from impact hazards. Before purchasing gloves for your facility, identify the types and severity of hazards. Then, select gloves that appropriately protect personnel from those hazards (see Table 2).
MYTH NO. 5: One size fits all (or most).
People come in a variety of shapes and sizes. There’s no such thing as “one size fits all.” Even hearing protection comes in different sizes for different-sized ear canals. Workers are more inclined to wear their PPE if it fits properly, is comfortable and is perceived as body-flattering. PPE suppliers are stepping up and offering a variety of shapes, sizes, proportions and colors. PPE suppliers are also recognizing that PPE designed for men does not adequately fit all genders. Best practice is to order and stock multiple sizes for each type of PPE so employees can find a size that fits their body. This applies to safety vests, gloves, hearing protection, smocks, aprons
Rubber
TABLE 2: Learn about the different types of glove protection on the market. Courtesy: WTWH Media
u
Insights
PPE insights
uThere are many considerations for when personal protective equipment (PPE) should be used in the workplace. uPPE should be selected based on identified hazards at the facility. u It’s important to consider workers’ body shapes and sizes when purchasing PPE.
ENGINEERING SOLUTIONS
Table 3: Eye protection
Impact Protection from flying solid objects
Z87 or Z87+ (high impact)
Chemical Protection from splashes D3
Dust Protection from suspended dust D4 or D5
Light Protection from light-emitting sources
TABLE 3: Eye protection is a requirement in many industrial and manufacturing facilities. The type of products manufactured or systems used will dictate eye protection.
L = Visible Light Blue light protection with high computer use
W = Welding Welding
and safety shields/glasses. If your facility provides pants, shirts, coveralls or other types of clothing, make sure your facility orders appropriate sizes and styles for the entire workforce.
MYTH NO. 6: Safety glasses protect your eyes from all hazards.
Just as with gloves, different eye protection is designed to protect employees from different hazards. If your employees routinely work with liquids, safety shields are probably not the best choice, as they do not protect from liquid ingress on the top or sides. Better choices would be goggles or a face shield. The ANSI Z87 standard is what OSHA cites in 29 CFR 1910 for eye and face protection, which includes goggles and face shields.
Identify the types of face and eye hazards at your facility and then identify the appropriate type of safety glasses, goggles or shields to protect workers from those hazards. Keep in mind that different types of safety glasses may be needed at different locations within the facility (see Table 3).
MYTH NO. 7: Workers know which protective shoes to buy.
Workers may be overwhelmed walking into a shoe store and seeing the variety of brands, styles and safety ratings. While employers often allow workers to purchase their own foot protection and be reimbursed for it, many employers do not clearly communicate the expectations for the type of foot protection that employees should be purchasing.
A variety of options can help address this problem, including:
‘A manufacturing or industrial facility’s PPE program should be part of a much bigger hazard identification and risk-reduction program.’
• On-site visits from shoe companies. Some shoe companies offer “shoe-mobiles” or other means of offering a curated selection of work shoes that meet the employer’s requirements. That way, workers can only select from approved footwear.
• Provide visual guidance. Many companies provide useful written instructions for purchasing shoes that include the standards and ratings. However, workers may not bring this guidance with them or fail to recall the full instructions. For example, they may remember that the shoe must be ASTM-rated but not recall the specifics. Best practice is for employers to supply a picture of the label on the shoe so that workers can use that picture to match it at the store.
A comprehensive PPE program
A manufacturing or industrial facility’s PPE program should be part of a much bigger hazard identification and risk-reduction program. The PPE program should identify the residual hazards in each process that have not been mitigated via elimination, substitution or engineering.
The EHS practitioner should be one member of the PPE team, which meets periodically to evaluate PPE offerings and identify the types of PPE offered to employees. The representatives of the PPE team should listen to the concerns and input of others in their work area and bring those concerns to the PPE team as a means of continuous improvement. The PPE offered to the workforce should be based on the hazards as well as on employees’ sizes, shapes, styles and preferences. PE
Gayle Nicoll, PhD, REP, ASP, CSP, is a process safety services expert with Jensen Hughes.
Angelica Pajkovic and Nelson Kavanagh, Teadit Group, Pasadena, Texas; David Wahl, Dominion Energy, Richmond, Virginia
How to build a maintenance program for expansion joints
It’s essential to develop a robust and reliable maintenance program for expansion joints, which require diligent upkeep as they play a vital role in accommodating thermal expansion, vibrations and other movements in piping systems.
To maximize the lifespan of an industrial component, each asset must follow a standard operating procedure and adhere to a specific maintenance program. These programs involve regular inspections and timely repairs to prevent unexpected breakdowns and costly downtime. By implementing a comprehensive strategy, companies can extend the lifespan of their equipment, improve safety standards and enhance overall productivity.
Maintenance programs can generally be categorized into three types: preventive maintenance (PM), condition-based maintenance (CBM) and corrective maintenance (CM).
• Preventive maintenance: This type of maintenance is time-based and scheduled at regular intervals, such as monthly, annually or biennially. It involves routine inspections and servicing to prevent equipment failures.
• Condition-based maintenance: CBM relies on monitoring the condition of equipment to decide when maintenance should be performed. Techniques such as vibration analysis, thermography and acoustic testing are used to assess the health of the equipment.
• Corrective maintenance: This approach addresses issues as they occur, focusing on fixing problems after they have been identified during regular operations or inspections. [/h3]
It is recommended that each piece of equipment have one or more of these dedicated maintenance programs. This approach ensures
maintenance tasks are performed regularly and consistently.
Preventive maintenance’s role in maintenance programs
Unlike other equipment, expansion joints are often maintained under CM programs, where issues are addressed as they arise. Implementing PM programs can significantly improve operational reliability by moving from a reactionary approach to a preventive one. Not only does it improve performance, but operators can achieve better resource allocation, maintenance staff can focus on proactive tasks rather than constantly addressing emergencies and the frequency and duration of unplanned downtime can be reduced.
1: Examples of expansion joints monitored under preventive maintenance programs. Courtesy:
When developing maintenance programs, it is important to consider the types of equipment and their operating parameters. A comprehensive inventory of all equipment and machinery must be established, including detailed records of specifications, operating conditions and maintenance history.
Once established, the development of an asset-specific maintenance program involves three key criteria:
• Determining equipment criticality. Identify and prioritize equipment based on its importance to the operation. Critical equipment that has no redundancy and can cause significant downtime if it fails should receive more attention.
• Understand the three types of expansion joint maintenance programs.
• Grasp the best practices for maintenance programs.
• Develop a robust expansion joint maintenance schedule.
FIGURE
Teadit Group
ENGINEERING SOLUTIONS
• Following manufacturer recommendations. Follow the maintenance guidelines provided by the equipment manufacturers. These recommendations are often a part of environmental or operational permits.
• Identifying operational conditions: Consider the equipment's operating environment, including temperature, pressure and the type of fluids being handled. This helps determine the appropriate maintenance actions and intervals. [/h3]
Steps to build a maintenance program for expansion joints
Five things must occur when building a maintenance program.
1. Identify equipment and assign criticality. List all the equipment, including expansion joints and assign a criticality rating based on factors like redundancy and impact on operations.
2. Determine applicable maintenance types. For each piece of equipment, decide on the appropriate maintenance type. For expansion joints, this may include:
• Visual inspections during scheduled outages.
• Thermographic inspections to detect hot spots and leaks while in operation.
• Real-time condition monitoring for critical expansion joints, which can involve sensors to detect temperature and pressure changes.
3. Establish a maintenance schedule. Develop a schedule that outlines when and how often each type of maintenance should be performed. For instance, visual inspections might be conducted bi-annually during plant shutdowns, while thermographic inspections could be quarterly.
4. Consult experts and manufacturers. Engage with subject matter experts (SMEs) and manufacturers to ensure the maintenance program is comprehensive and current. This can involve reviewing new technologies and methodologies for monitoring and maintaining expansion joints.
5. Implement and monitor the program. Roll out the maintenance program and continuously monitor its effectiveness. Adjust the program as needed based on inspection feedback and condition monitoring data.
Adhering to the manufacturer's recommendations is necessary to meet regulatory requirements. They also provide insight into some signs operators should watch for once the asset is installed in a plant or refinery. Therefore, to ensure an expansion joint PM program is as comprehensive as possible, it’s best to consider SME recommendations for each type of expansion joint.
Maintenance for metallic versus nonmetallic expansion joints
There are two primary groups of expansion joints: metallic and nonmetallic. These categories
FIGURE 3: Examples of expansion joints monitored under preventive maintenance programs.
Courtesy: Teadit Group
FIGURE 2: Examples of expansion joints monitored under preventive maintenance programs.
Courtesy: Teadit Group
encompass a range of products designed to meet various industrial needs and applications.
For nonmetallic expansion joints, the best maintenance practice involves replacing the bellows (fabric belt) and thermal insulation pillow in case of a rupture. Regular visual inspections of the bellows are crucial and, in some cases, a thermal camera inspection can be beneficial to detect issues early.
If the bellows of metallic expansion joints rupture or leak, the entire expansion joint must usually be replaced. Regular maintenance and inspection can help prevent such occurrences and extend the joints' lifespan.
Preventive maintenance for installed expansion joints
Once the expansion joint is installed, operators should perform regular preventive maintenance checks. For nonmetallic expansion joints, frequent visual inspections should include:
• Ensuring the outside bellows are free of material deposits that could obstruct air circulation.
• Checking for any missing bolts in the clamping bars.
• Looking for signs of rupture or leakage in the bellows.
• Observing any localized changes in the color of the outside bellows, which could indicate overheating or other issues.
For metallic expansion joints, preventive maintenance should involve:
• Checking for ruptures or leaks in the outside bellows.
• Monitoring the bellows’ pitch or movement indicator to identify any unexpected movements.
• Checking bellows’ convolution spoilt or local deformities.
• Checking leakage between bellows’ redundant plies.
‘If the bellows of metallic expansion joints rupture or leak, the entire expansion joint must usually be replaced. Regular maintenance and inspection can help prevent such occurrences and extend the joints' lifespan.’
• Checking pipe anchors and guides (can cause expansion joint unexpected movements).
• Comparing the theoretical fatigue life to historical expansion joint life and planning the expansion joint exchange.
When an expansion joint issue is detected, it’s wise to contact the manufacturer for assistance. They can provide guidance on the criticality of the repair and suggest the appropriate course of action. Prompt communication with the manufacturer ensures issues are addressed correctly and efficiently, minimizing downtime and maintaining the system's safety and functionality.
A robust maintenance program enhances expansion joint performance
Building a robust maintenance program for expansion joints involves understanding different maintenance types, assessing equipment criticality and following manufacturer recommendations. By shifting from a reactive approach to a preventive and condition-based maintenance strategy, facilities can enhance reliability, reduce costs and maintain safety standards. Regular inspections, condition monitoring and expert consultations are key components of a successful maintenance program that ensures the long-term performance and safety of expansion joints.
Furthermore, well-maintained machinery operates more efficiently, reducing energy consumption and operational costs. Investing in industrial maintenance not only safeguards the longevity and reliability of assets but also fosters a proactive approach to addressing potential issues before they escalate, ultimately contributing to the sustainability and competitiveness of the business. PE
Angelica Pajkovic is a client specialist at Teadit Group. Nelson Kavanagh is a mechanical engineer at Teadit Group. David Wahl is a site manager at Dominion Energy.
u
Insights
Expansion Joint Maintenance Insights
uThe three types of maintenance programs include preventive, condition-based and corrective.
uExpansion joints are maintained under condition-based programs.
uThe two types of expansion joints are metallic and nonmetallic.
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