Plant Engineering-June 2017

36 Lubrication Guide 14 CMMS success in 10 steps
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COMPRESSORS
CSuccess
USTOMERStory
Sweet Savings!
A compressed air audit opens a world of savings opportunities
PROBLEM: One of the worlds leading candy and gum manufacturers had no idea
how much their compressed air system was costing them. Four compressors (totaling
290 hp) supplied the air needed for pneumatic controls, packaging, and wax line extru-
sion applications. Excessive water in the compressed air lines, steep maintenance costs,
and high noise levels had them looking for a new solution.
SOLUTION: A comprehensive Air Demand Analysis (ADA) established a demand

profile for the plant and showed how they were using compressed air throughout the
week. It also identified areas of waste and inefficiency. By installing a 100 hp variable
frequency drive compressor and two 75 hp fixed speed compressors, they would have
all the air neededwith one of the fixed speeds acting as a back-up. This split sys-
tem solution would bring energyand noise levelswell under control. A Sigma Air
Manager 4.0 master controller could provide on demand energy reports so they would
always know how their system was performing and what it was costing.
RESULT: In just over 9.5 months, the project has paid for itself. Annual energy costs
have been cut by more than 800,000 kWh. Part of these savings came from reducing
the plant pressure from 125 psi to 100 psi. Additionally, the new energy efficient dryers
installed have taken care of the moisture concerns. Needless to say, these savings
couldnt get any sweeter.
Specific Power of Previous System: . . . . . . . . . . . . . . . . . . . . .47.16 kW/100 cfm
Specific Power of New System: . . . . . . . . . . . . . . . . . . . . . . . . .17.77 kW/100 cfm
Annual Energy Cost of Previous System: . . . . . . . . . . . . . . . . . . . . . . . . . $128,756
TOTAL ANNUAL ENERGY SAVINGS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,235
Utility Incentive:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,200
Let us help you measure and manage your compressed air costs!
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JUNE 2017
SOLUTIONS
28 Lubrication Guide
33 | Cutting through the fog on pneumatic
COVER STORY: Many suppliers are providing
software tools that can allow manufacturers to lubrication
extract the parameter set and fault log from the Choosing the right strategy to prolong the
drive. Cover image courtesy: Danfoss life of key equipment
INSIGHT 36 | Lubrication Guide

A look at the top product offerings in
8 | The clouds role in data management machine and compressor lubrications
10 | Motor insulation systems: Automation

Six testing tips 41 | An antidote to downtime
Remote monitoring protects against skill
14 | CMMS implementation: shortages, complexity.
10 steps to success
18 | To use robots effectively, get started, SPECIAL REPORT

get coaching
Energy Management
Notable 47 | Microgrids drive a new energy strategy
20 | A collection of news and other fun items Energy Master Planning provides a bridge
to the future.
Research
51 | Empowered to cut wasted energy
22 | 2016 Safety Study DOE program is designed to find and elimi-
Discrete industry safety practices nate energy waste.
INNOVATIONS 55 | Overcome the high cost of staying cool

Calculate seasonal energy efficiency for
80 | New Products your HVAC system.
88 | Soft starters an option when VFDs 58 | Control room temperatures: Strategies

dont work to beat the heat
Air-to-water exchangers can reduce VFD
90 | The ABCs of VFDs heat exposure.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 5, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
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www.plantengineering.com PLANT ENGINEERING June 2017 t 3

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REIMAGINING
PLANT ENGINEERING
By Bob Vavra, Content Manager, CFE Media
A bright, dynamic presentation

of manufacturing knowledge
I
n the 70 years since Plant Engineerings debut, one focus on everything from the latest on the Industrial Internet
goal that has guided the efforts of editors and writ- of Things (IIoT), to ways to improve safety and maintenance,
ers for this publicationplant personnel needed a and provide better training.
credible source for great information on how to run A hallmark of this section will be conversations with indus-
their facilities better, safer and more efficiently. try professionals and thought leaders on the next big trends.
All that really has changed in the last seven decades We want our readers to be prepared for tomorrow by under-
is that the means of delivering that great information itself has standing whats being discussed today.
gotten better and more efficient. The place Plant Engineer-
ing enjoys in the manufacturing sector, and the loyalty weve SOLUTIONS:
engendered over those years continue to drive our efforts every The industrys top manufacturing experts will provide their
day. I am grateful to our audience for their continued use of knowledge on how to make every part of your plant run
Plant Engineerings content, regardless of its media source. more effectively. Every plant system, from automation to
For example, our Web traffic at PlantEngineering.com is electrical, from maintenance to mechanical, will be high-
at an all-time high, and up 7% so far this year. Our online lighted each month. Plant Engineering assembles industry
content is viewed in 191 countries each month. The need for best practices each month to focus on how to operate a
great information about manufacturing knows no borders. world-class manufacturing plant today, and build a better
What also is true is that, for our readers, the printed version plant for the future.
of Plant Engineering remains a valuable tool. In an era of 24/7 We are the leader in delivering actionable solutions for
news cycles and a constant barrage of information from a vari- plant-floor issues, and in informing plant managers on the
ety of sources and in a variety of formats, the simple printed best new strategies. Were adding more data, and access to
page still carries weight and power for the plant manager. We more content online as part of this effort.
know this to be true because we asked our readers about how
they interact with print, both on its own, and in comparison INNOVATIONS:
to other media. Introducing new products to our readers has been a part of
We asked our readers to tell us how they use the print maga- Plant Engineering since 1947. As we begin the 30th year of
zine in 2017 and what types of articles they need to run their the industry-leading Product of the Year program, our Inno-
plants better. One piece of information we gained from that vations section will feature not only new products from the
study: readers are 20% more engaged with our print magazine industrys top suppliers, but also a focus on how to effectively
than with the digital product. use those product categories to improve plant operations.
The June issue of Plant Engineering marks the start of a New product introductions give plant managers a look at
fresh chapter in our 70-year relationship with manufacturing the tools they need to advance their operations, and no one
professionals. Our June issue turns those reader comments has been more proactive about bringing those products and
into a new, clean, and better-organized Plant Engineering. solutions to light than Plant Engineering.
Each month, there will be three sections to our magazine,
each created as a direct result of reader feedback and input: We believe the future of publishing, and of manufactur-
ing, is bright and dynamic. We hope to reflect that future in
INSIGHTS: this months issue of Plant Engineering, and in the issues to
A monthly look at the new trends, technologies and strategies come. As always, we welcome your comments and critiques,
that will change and improve manufacturing. Articles will and your suggestions on ways we can continue to improve. PE

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INSIG S
Motor insulation
INSIGHT systems: Six testing tips
Watch for factors that may impact
10
The clouds role accuracy.
in data management
CMMS implementation:
10 steps to success
Wireless solutions offer
14
8 flexibility, lower costs for
most users.
Standard procedures, new
technologies, and performance
metrics can ease the path.
To use robots
effectively, get started,
get coaching 18
The human touch: 3 questions with
Robotiqs David Garipy
NOTABLE
PMA names Hardy as
RESEARCH new president
2016 Safety Study Try to take this for a spin 20

Discrete industry safety practices 22 May PMI ticks up slightly
Frequency of safety meetings
at discrete manufacturing facilities
Monthly 38%
EDITOR INSIGHT
34%
Inpitch
As needed
Weekly 23%
Hollywood, they call them
Daily 19% meetingsa group
15%
Every shift
tossing around ideas for the
9%

Every other week
Quarterly 4%
next big thing.
25
INSIGHT
By Rebecca Bolt, GE Automation & Controls
The clouds role

in data management
Wireless solutions offer flexibility, lower costs for most users.
B
illions of sensors all around the world have evolved, so, too, have the analytics our
are making consumer devices smarter, machines provide. However, the data those
safer and more efficient. Wearable machines collect and analyze, up to this point,
products have revolutionized our has been limited to the memory of internal com-
understanding of wellness by providing more puters running at or inside the machine; the
information about our daily health. Appliances intelligence of those machines essentially has
and systems in our homes now are connected been limited to that memory.
and make intelligent decisions to enhance our New industrial control systems now are pro-
lives. Entire cities now are employing big data viding the same type of connectivity, commu-
and sensors to prevent crime, manage crowds, nication, and analytics for our industrial assets
reduce energy use, and much more. The con- as consumers have seen for several years. These
nectivity of and communication between these connected controllers and systems not only run
devices, as we know, is referred to as the Indus- our machines like they used to run, but they
trial Internet of Things (IIoT). But before these also now have the capability to create an outer
devices can start communicating with end users loop and custom applications that gather data
and each other, they must collect and analyze in real time and advise the controller to make
datalots and lots of data. more intelligent decisions. Just as connected
Data for many of sensors and wireless devices transport data to
By The these devices is col-

lected, stored, and
consumer clouds, the vehicles to transport big
data to the industrial cloud are edge devices and
NUMBERS analyzed in cloud-
based environments,
sensors in or near machines.
Many machines and plant systems dont
such as Amazon and offer the type of connectivity and deep analyt-
30.7 billion Google.Even our
Fitbit trackers have
ics todays industry demands. These machines
require third-party solutions to gather data and
Number of Internet of Things a cloud where our provide critical analytics. The more data gath-
health analytics are ered, and the closer to the machine you run data,
connected devices expected stored. While theres the more accurate and intelligent the decisions
a lot of data gathered the machine makes.
by 2020. This includes industrial from consumer prod- Some machines cant be reached with tradi-
ucts, theres a much tional Ethernet cables because of the distance
and consumer-based devices. larger amount of data between the internet source and the machine. Not
Source: IHM Markit found in industrial only would it be cost prohibitive to drop and run
machines and an even that wired connection, but the proximity would
greater need for the same type of connectivity make data gathered less favorable. Connecting
and analytics. IIoT will increase efficiencies, to these machines wirelessly makes sense.
reduce costs, and improve employee health and Cloud-based wireless solutions provide great-
safety while generating new revenue streams er flexibility than wired solutions. The cloud
for businesses. empowers the elasticity of data storage and per-
Controls have been managing machines all formance and is not subject to the constraints
around us for centuries. Just as our machines typical of a local computer. Connecting to the
8 t June 2017 PLANT ENGINEERING www.plantengineering.com

cloud also enables a fleet of machines to be
IIoT will increase
managed and to communicate with each other, efficiencies, reduce costs, d
providing thorough analytics for the entire fleet. improve employee health and safety
For example, theres an app that leverages the
power of the industrial internet, connects to a while generating new revenue
fleet of wind turbines and enables them to coor-
dinate the speed and direction of their blades to
streams for businesses.
maximize the wind farms overall energy output.
However, the cloud is not always a viable option
eas e
due to latency, costs, regulations, and other fac-
a d o e accu-
tors. Think also about the criticality of the data
ate.
being analyzed. If a self-driving car was required
Th e y g
to go to the cloud to make important decisions,
couldnt have imagined IIoT as it
the cars response time would be too slow. Indus-
is today. Similarly, we cant speculate on where it
trial assets are the same way. Some things can be
will be three years from now. The rate at which
done in the cloud, but other problems need to be
things are changing makes it difficult to recom-
analyzed as close to the machine as possible. Digi-
mend specific assets or systems that should be
tal industrial companies are developing products
hard-wired or should be wireless or which apps
that are designed to work on the industrial edge
should run in the cloud versus at the industri-
and make collecting, storing, and analyzing data
al edge, so its important to think the process
through strategically and go the route that
As the technology around cloud-based data man- makes the most sense for your plant. PE
agement evolves, its important to take a strategic
approach to deploying analytics on the plant floor. Rebecca Boll is a general manager of
Image courtesy: GE Automation & Controls sales for GE Automation & Controls.

INS GHT
k ll, Electrical Apparatus Service Association (EASA)
Motor insulation systems:

Six testing tips
Watch for environmental factors that may impact data accuracy.
3. Record important test conditions. Docu-
A
lt houg h t here are many ways to
assess motor insulation systems, ment the ambient temperature, relative humid-
the insulation resistance (IR) test ity, dew point, winding temperature, time since
remains a useful tool for determin- service, test voltage and connection arrangement.
ing if a motor should be removed from or
placed into service. When conducting the test 4. Simple test procedure. Energize the wind-
and e valuating the results, ing for one minute at an appropriate voltage (see
consider these six tips. Table 1) and correct the measured IR value to
40C by multiplying by a KT from Table 2. Most
1 . Discharge for safety modern insulation falls under the Thermoset-
and accuracy. Discharge the ting category. Use the Thermoplastic values
winding to ground b efore if you know it is a much older winding with an
Insulation resistance (IR) and after IR testing. A good asphaltic or shellac mica system.
tests are useful for rule of thumb is to ground
determining whether a the winding for 15 minutes 5. Watch for factors that can affect the IR
motor should be removed. or four times the test time, test. During the test, watch out for these four
whichever is greater. factors that can have an impact on the test and
During the test, the user its results:
should discharge for safety 2. Winding configuration
and accuracy and record for testing. If possible, isolate t4VSGBDFDPOUBNJOBUJPOTVDIBTPJM EVTUBOE
important test conditions. and test each phase separately salts may be conductive, causing lower IR.
and ground the two phases Cleaning and drying the winding will usu-
Users should also be aware not under test. This allows ally improve the IR.
of factors that might affect for testing of the phase-to-
the IR test. t*GUIFXJOEJOHUFNQFSBUVSFJTBUPSCFMPXUIF
phase insulation as well as
the ground insulation.
dew point, moisture may accumulate on the
surface, causing low
IR values. When the
winding is otherwise
Table 1: Guidelines for dc voltages to be applied during in good condition,
insulation resistance tests dr ying will resolve
Winding rated voltage (V)a Insulation resistance test direct voltage (V) this issue.
<100 500 t8 J O E J O H * 3

1,000 - 2,500 500 - 1,000 decreases when
winding temper-
2,501 - 5,000 1,000 - 2,500
ature increases,
5,001 - 12,000 2,500 - 5,000 which is why cor-
>12,000 5,000 - 10,000 rection to a base-
a
line temperature
Rated line-to-line voltage for three-phase AC machines, line-to-line ground (earth) is recommended.
for single-phase machines, and rated direct voltage for DC machines or field windings

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IN GHT
Table 3: Recommended minimum
Table 2: KT versus temperature for ther- insulation resistance values at 40oC
moplastic and thermosetting insulation (All values in M)
stator winding systems
Minimum insulation
Test specimen
resistance
KT KT
T(oC) For most windings made
Thermoplastic Thermosetting
before about 1970, all field
10 0.125 0.7 IR1min = kV + 1
windings, and others not
20 0.25 0.8 described below.
30 0.5 0.9 For most DC armature and
IR1min = 100 ac windings built after about
40 1 1.0 1970 (form-wound coils)
50 2 1.5 For most machines with
60 4 2.3 random-wound stator coils
IR1min = 5
and form-wound coils rated
70 8 3.3 below 1kV
80 16 4.6 Notes:
1. IR1min is the recommended insulation resistance, in
t7PMUBHFNBHOJUVEFBOEFYJTUJOHDIBSHF megohms, at 40oC of the entire machine winding.
BMTPDBOBGGFDU*3 CVUTFMFDUJOHUIFWPMU 2. kV is the rated machine terminal-to-terminal volt-
BHFGSPN5BCMFBOEGPMMPXJOHQSPQFS age, in rms kV.
HSPVOEJOHQSBDUJDFTCFGPSFUFTUJOHTIPVME
FMJNJOBUFUIJTJTTVF EPPQFSBUFCFMPXUIFTFWBMVFT)BWJOHIJTUPSJDBM
EBUBPOIBOEJTWBMVBCMF PE
6. Evaluate the test results.5BCMFTIPXT
UIFSFDPNNFOEFEWBMVFTGPSUIFDPSSFDUFE*3 Mike Howell is a technical support specialist
-PXFSWBMVFTXBSSBOUGVSUIFSJOWFTUJHBUJPOCFGPSF at the Electrical Apparatus Service Association
UIFVOJUJTQMBDFEJOUPTFSWJDF4PNFNBDIJOFT (EASA), a CFE Media content partner.
LETTER TO THE EDITOR

Level the manufacturing playing field
Editors Note: Last months Insight column by Bob Vavra -PPLXIBUUIF$IJOFTFBTXFMMBT&VSPQFBOQBQFSDPN
(Confronting the elephant in the room) produced many reader QBOJFTIBWFCFFOEPJOHGPSZFBSTEVNQJOHMPXDPTUDPBUFE
comments, evenly divided on both sides of the topic. We share BOEVODPBUFEQBQFSPOUPPVSTIPSFTBUUIFFYQFOTFPG64
one such opposing viewpoint: QBQFSNJMMTBOEUIFKPCTBOEDPNNVOJUJFTUIBUEFQFOEFE
POUIFN5IF64HPWFSONFOUIBTGPSZFBSTUVSOFEBCMJOE
*GJOEZPVSUBLFPOUIFOFXBENJOJTUSBUJPOTTUBODFPO FZFUPXBSETUIJTJTTVF
64NBOVGBDUVSJOHBCJUEJTUVSCJOH-PXFSJOHDPSQPSBUF 8IJMF*BHSFFXFOFFEHMPCBMDPPQFSBUJPOXJUISFHBSE
UBYFT MFTTSFHVMBUJPOBOENPSFGBWPSBCMFUSBEFBHSFFNFOUT UPNBOVGBDUVSJOHXFBMTPOFFEDPPQFSBUJPOXJUISFHBSEUP
UPFODPVSBHFKPCHSPXUIUPNFJTOPUEFUSJNFOUBMUPBHMPCBM GBJSUSBEF
NBOVGBDUVSJOHFOWJSPONFOU*UIFMQTLFFQVTJOUIFHBNF 5IBOLZPVGPSZPVSPWFSTJHIUPGUIFPlant Engineering
*EPOUTFFUIFNFTTBHFBTCFJOHIPTUJMFUPGPSFJHOUSBEF DPOUFOU*GJOEUIFNBHB[JOFUPCFUIFCFTUPGUIFQFSJPEJDBMT
CVUBOBUUFNQUUPMFWFMUIFQMBZJOHGJFME5IFBSHVNFOUIBTOU *SFBE
CFFOXJUI(FSNBOZCVUXJUI$IJOBBOEPUIFSTXIPIBWF Bob Tees
CFFOHVJMUZGPSZFBSTPGEVNQJOHMPXDPTUQSPEVDUTJOUPPVS vice president and general manager
NBSLFU OPUPOMZBUUIFDPOTVNFSMFWFM Mac Paper Converters Inc.

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INS GHT k k , CFE Media
CMMS implementation:
10 steps to success
Standard procedures, new technologies, and metrics can ease the path.
I
mplementing a computerized maintenance said that even after a CMMS installation, evalu-
management system (CMMS) can be easier ation and improvements should be a continuous
and more effective by paying attention process with input from all involved (See Fig.
to 10 key considerations. When shifting 1). Greens 10 steps for smarter CMMS imple-
toward condition-based maintenance, hard- mentation are.
ware and software also can help, as can defin-
ing and using standard operating procedures 1. Choose a cross-functional
and the right set of performance metrics. This implementation team
was among advice from experts at the Fluke Include executives to approve or provide funding,
Roadshow 2017, in Chicago, May 4. maintenance (a champion and the future system
Covering the 10 keys to CMMS implementa-administrator), project leaders (a manager to keep
things on track and analyst to gather requirements),
tion success, Bill Green, leader of implementa-
tion and success, eMaint (a Fluke company),subject matter experts (define how the system is
used), IT staff (provide system environ-
Figure 1: A wirelessly enabled vibration monitor can take measurements ment), and implementation consultants
from a fan, send it to a smart phone application, as shown by Dave Rob- (provide specific expertise).
ley, a field engineer for Fluke Industrial at the Fluke Roadshow 2017 in
Chicago in May. Information can also feed that information into a cloud- 2. Familiarize the core team
based computerized maintenance management system, if desired. Image A professional services team can pro-
courtesy: Mark T. Hoske, CFE Media vide upfront training to the core team,
especially with training, a framework,
experts, and involving future train-
ers. Those doing the training should
know the software details, even if the
Maintenance
and operations
personnel might
use different words
to refer to the same
things. Standard
terms must be
agreed upon.
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INS GHT
software is known to be intuitive. Online and in-
person training may be available.
3. Develop and standardize work-

flow processes
Look at the current business and standard oper- The hierarchy
ating procedures, which can be how things are
done, even if theyre not documented, apply proof maintenance
cess improvements, create a CMMS workflow Predictive maintenance activities are
using the new business processes. improving, said Alex Desselle, a Fluke
Define maintenance coding (such as work order product application specialist whose
classes, types, priorities, problems, actions, and career includes work with Monsanto and
failure codes), workflow procedures and who GE. Desselle noted that most companies
is responsible for what, and define hierarchies have a long way to go because too much
(assets, criticalities, and locations). maintenance remains reactive; that is, a
run-to-failure strategy.
4. Establish or update standard
operating procedures. In the hierarchy of maintenance, the most
efficient strategies are:
5. Prioritize the CMMS t3FMJBCJMJUZDFOUFSFENBJOUFOBODF
implementation steps t1SFEJDUJWF.BJOUFOBODF 1E.

Tackle low-hanging fruit first with a focus on t$POEJUJPOCBTFENPOJUPSJOH
critical data. Leverage experiences of a seasoned t1SFWFOUJWF.BJOUFOBODF 1.
CMMS implementer, learn from colleagues, and t3FBDUJWF 3VOUPGBJMVSF

define the implementation timeline.
nance function. Data collection can be seen as a
6. Work on the configuration service. Use available import tools rather than
Look at forms, fields, dropdowns, and tabled data manually transfer data.
derived from standards, defined in the implementa-
tion phase and documented in standard operating 8. Train the main users
procedures. Its important to differentiate the users This critical step to ensure investments follows the
of the system versus the users of data from the sys- trainers training. The person doing the training
tem and ensure data entry consistency with estab- needs to be proficient in the software and in soft
lished data standards. For instance, maintenance skills such as communication and organization.
and operations personnel might use different words
to refer to the same things. Standard terms must be 9. Develop a go-live strategy
agreed upon. Support and coaching are important steps. This
By The 7. Populate
and validate
may include soft go-live dates for certain areas of
the CMMS. Depending on the organization and
NUMBERS data
implementation, bite-sized chunks or a series of
continuous improvement projects may be the
Having the right best way. Highlight implementation milestones.
59% amount of good
quality data is criti-
If there is a hard go-live date, create a plan B, if
those involved are ready to lower risk of data loss
Percentage of readers using cal for success of a or production delays.
CMMS implemen-
CMMS as part of their overall tation. All data that 10. Establish a process auditing
goes in needs to be system for continuous improvement
maintenance strategy; it ranks maintained, and all Use intelligence from the CMMS to drive decisions
m ai nt ai n e d d at a and make continuous adjustments. Define success
behind preventive maintenance needs to go into the metrics from the start. Establish a team responsible
(78%) and run-to-failure (61%). system. Thoroughly for continuous improvements, incorporating the
test established pro- cycle of plan, do, check, act and repeat. PE
Source: 2017 Plant Engineering cesses and proce-
Maintenance Study dures developed to Mark T. Hoske is content manager, Control Engi-
support the mainte- neering, CFE Media, mhoske@cfemedia.com.

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INS GHT
To use robots effectively,
get started, get coaching
The human touch: 3 questions with Robotiqs David Garipy
A
s robots become a larger part of the manufactur- know-how skills faster and go forward with a new project
ing landscape, programming the robots may be sooner.
an early barrier to their use on the plant floor.
Quebec City, Canada-based Robotiq has intro- PE: Whats the one challenge manufacturers face
duced a series of downloadable programming templates when integrating robots into their manufacturing pro-
to help get the process started. cess? How can they meet those challenges?
Robotiq integration coach David Gari py talks with
Plant Engineering about how manufacturers are dipping Gari py: The main challenge is definitely the know-
their toes into the robotics market, some of the challenges how skills; 82% of manufacturers believe the skills gap will
of working with collaborative robots, known as cobots, impact their ability to meet the customers demand. It is 10
and some of the challenges they face. times more difficult to find robotics skills than machinist
skills in the U.S. workforce.
Plant Engineering (PE): When manufacturers are How can they meet those challenges? By getting started
first exploring using robots on their assembly line, with cobots as soon as possible. At first, they should keep
do they know what they need, or, as your job title it small and simple. Highly predictable and repeatable tasks
implies, is there some coaching to be done? are the best ones to start with. They can then build their
know-how skills and start scaling up to more robots with
Gari py: Most of the time, they want to validate the more complex applications.
possibility to automate a given task and be guided on how So start small and build on your success. Another interest-
to do it. The coaching is really useful, as we can do a proof ing fact is that once youve started, the subsequent cobots
of concept, give them the program code we used and explain implementation usually takes 30% to 50% less time than the
the programming logic so they have something to start with. first one. The free coaching service and programs templates
The coaching service is useful at the beginning of the that Robotiq is offering allow manufacturers to simplify
process but also during the implementation. We help them and speed up the implementation of cobots in their pro-
remove the blockers they might encounter and speed up duction line.
their integration process. It allows them to grow their
PE: As the concept of cobots continues to
evolve, how do we keep humans engaged and
i p the manufacturing process?
Keep it small and simple. G

p p
py: The biggest misconception
ve about cobots, and robots in
Highly predictable and g that it has to be done at the cost
o j reality, the opposite usually hap-
repeatable tasks are the p lows manufacturers to become
m ductive, so they get more orders.
best ones to start with. T mployees then can be moved to
m re rewarding jobs and eventually,
David Garipy, Robotiq new jobs are created. Our goal
at Robotiq is to free human
hands from repetitive tasks in
order to give them the free-
dom to think, to create, and
to innovate. PE

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NOTABLE
By Bob Vavra, CFE Media A collection of news and other fun items
PMA names Hardy May PMI ticks

as new president up slightly
Roy Hardy is forging a new career for himself as president of the U.S. manufacturing continued its resurgence in 2017 as
Precision Metalforming Association (PMA). the PMI Index rose slightly in May to 54.9%. The increase
Hardy was named the associations president after serving for of 0.1 percentage points ended a two-month decline
the last eight years as president of the Forging Industry Association and signaled that the manufacturing sector remains on
(FIA). He has a proven track record of leadership and a wealth of solid ground. The PMI has been above the 50% growth
industry knowledge that will be a tremendous asset to PMA mem- threshold for 11 of the last 12 months, and has not dipped
bers, our staff and our board, said PMA board chairman Dave below 54% since November 2016.
Arndt. Roy will build on recent years of solid growth and will lead Comments from the panel generally reflect stable to
PMAs continued growth at this critical time for U.S. manufacturing. growing business conditions, with new orders, employ-
Hardy succeeds Bill Gaskin, who retired after a 40-year career ment and inventories of raw materials all growing in May
with the PMA, including spending the last 17 years as president. compared to April, said Bradley Holcomb, chairman of
Bill Gaskin leaves an unparalleled legacy of 40 years of service the Manufacturing Business Survey Committee for the
to PMA and the metalforming industry, said Arndt. The board, Institute for Supply Management (ISM), which publishes
members and staff thank Bill for his leadership, and we know that the monthly PMI index.
Roy will continue to build on the tremendous work done by Bill. PE Among the committee comments:
ti4BMFTIBWFQJDLFEVQDPNQBSFEUPUIFMBTUUXP
Try to take this for a spin months. Customer demand has increased. (plastics
and rubber products)
The hottest new toy of 2017 is the fidget spinner, a three-pronged ti&DPOPNZJTTUJMMTUSPOH CVU UIF
QPMJUJDBMDMJNBUF
magnetic device that is held between the thumb and a finger and can change things very quickly. (transportation
simply spins, with the magnets creating an almost perpetual force to equipment)
keep the spinner in motion. Its advertised as a way to relieve stress. ti(MPCBMQSJDFJODSFBTFTGPSDPNNPEJUJFTw FMFDUSJDBM
A fidget spinner built by the creative guys at Ohio-based Ham- equipment, appliances and components)
ilton Caster isnt going to be mass-produced, but it provides a look ti#VTJOFTTJTCPPNJOH BOEHFUUJOHEJSFDUFNQMPZFFT
into the bigger science surrounding the toy. Fidget spinners work is increasingly difficult. (fabricated metal products)
through torque and friction reduction, said Jevon Lambright, a ti%JGGJDVMUUPGJOERVBMJGJFEMBCPSGPSGBDUPSZQPTJ
mechanical design engineer at Hamilton who helped design what tions. (food, beverage and tobacco products)
they called the Hamilton
Spinfidgeter. When you May marked another milestone for the index. It has
hit the outer leg, the now been eight years since the index registered a reading
force applied spins the below 43.3%, which is the indexs threshold to indicate
central bearing, and growth in the overall economy. The May PMI figure
the three weighted legs translates to an annual growth rate of 3.7% in domestic
keep some torque going gross products, according to ISM officials. PE
due to the initial force
input.
The Spinfidgeter was
scaled to match the size
By The
of the companys stan- NUMBERS
dard 6205 ball bearings,
This is Hamilton Casters super-
sized fidget spinner. Image cour-
so the finished product is
7.5 in. long, about three
54.9%
tesy: Hamilton Caster times larger than the May reading for the Institute for
typical fidget spinner.
Mark Lippert, a member of the ownership group at family- Supply Managements monthly
owned Hamilton Caster, told Plant Engineering that the company
has made five of the supersized toys to give away to respondents PMI Index. It rose 0.1 percentage
who offer the five best ideas in the companys online new prod- points, as manufacturing growth
uct survey.
One small issue is these spinners really cant easily be held remains solid.
between your thumb and finger, and that might be frustrating. PE

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M More
RESEARCH
Plant Engineering covers several
research research topics each year.
All reports are available at

2016 SAFETY STUDY www.plantengineering.com/research
Discrete industry safety practices
T
he Plant Engineering 2016 Safety Study indicated 64% of safety executives/managers do not feel threat-
that 35% of plant personnel work for a company ened at work, while 66% of engineering staff and 53% of
serving a discrete industrysuch as automotive, operations personnel feel very safe.
aerospace, or electronic product manufacturing.
Below are five key findings from this study regarding safety 3. Safety training: The average discrete manufacturing
practices within discrete manufacturing facilities: facility send their employees to 18 hours of job-related
safety training, 12 hours of first-aid/personal safety
1. Commitment to safety: Sixty-eight percent of opera- training, and 10 hours of ergonomics training.
tions and senior management are very committed to
safety within their facilities, while 57% of line supervi- 4. Enforcement: In an effort to implement safety proto-
sors and 49% of line workers are equally dedicated. cols, 68% of facilities will penalize personnel (suspen-
sion, termination, etc.) when procedures are not fol-
2. Work groups: When it comes to feeling safe on the lowed properly. Conversely, only 28% of facilities have
job, 72% of plant management/corporate executives and incentive-based programs in place to encourage a safe
environment.
Frequency of safety meetings
at discrete manufacturing facilities 5. Strategies: Looking at proactive
tactics, 79% of facilities hold regu-
Monthly 38%
lar safety meetings with all employ-
As needed 34% ees and 66% have organized a
safety committee. Another 68% fol-
Weekly 23%
low a job safety analysis (JSA) pro-
Daily 19% cedure in which safety is integrated
Every shift 15% into current tasks and potential
hazards are easily identified.
Every other week 9%
Quarterly 4% View more information at

www.plantengineering.com/2016Safety
Mandatory safety meetings are typically held monthly or weekly at discrete
manufacturing facilities, but 34% will call a meeting to review safety proce- Amanda Pelliccione is research director
dures as needed/at undefined intervals. Source: Plant Engineering at CFE Media.
Average number of hours that plants spend Average annual salary
19: on schedule maintenance each week.

Source: Plant Engineering 2017 Maintenance Study
$150,000
or more
12%
Less than
$70,000
18%
54% ofmajority
facilities conduct regular energy audits, the
of which occur yearly or every other year.
$100,000 to
$149,999 37%
21%
$70,000 to
$89,999
Source: Plant Engineering 2016 Energy Management Study

12%
$90,000 to
78% of facilities have observed a decrease in

the cost of insurance claims over time as a
$99,999
The average plant/facility engineering pro-

result of their safety program. fessional earned $104,000 in 2016. Source:
Source: Plant Engineering 2016 Safety Study Plant Engineering 2016 Salary Survey

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Being knowledgeable of the proper safety
measures, codes, and regulations in both new
and existing facilities is an absolute necessity.
It just might even save your life one day.
Safety First: Arc Flash 101 is a new online and on-demand course CFE Edu is offering
for you to stay up to date on the latest electrical safety information. CFE Edu is an interactive
online platform taught by industry experts that offers exclusive, multi-media content on
engineering topics that are critical to your work.
Safety First: Arc Flash 101 will:

Explain the importance of electrical safety
Define codes and standards as they relate to electrical safety
Explore arc flash and safety measures
Summarize codes and standards for electrical safety (i.e. NFPA 70E)
Led by industry experts Lanny Floyd and Hugh Hoagland, this on-demand online course offers
instructor-led discussions, videos, and high-quality presentations on an interactive and intuitive
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unit and one (1) HSW credit.
Whats included in all CFE Edu courses:

Exclusive content--not found anywhere else--that includes research and expert knowledge
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Course cost is $39.99
Learn more and register at CFEedu.cfemedia.com

*Contact CFE Edu Manager, Emily Guenther, at eguenther@cfemedia.com for more information
or with any questions about CFE Edu.
INSIGHT
By Bob Vavra, Content Manager
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph. 630-571-4070, Fax 630-214-4504 Welcome to the summer of innovation
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager Summer has arrived, and with it the
630-571-4070 x2212, BVavra@CFEMedia.com new staple of the warm weather months
EMILY GUENTHER, Associate Content Manager the summer blockbuster movie. Many
630-571-4070 x2220, EGuenther@CFEMedia.com
are sequels or remakes, so youre already
AMANDA PELLICCIONE, Director of Research
860-432-4767, APelliccione@CFEMedia.com familiar with the plot and the characters
CHRIS VAVRA, Production Editor youve pretty much seem this show before.
630-571-4070 x2219, CVavra@CFEMedia.com The season got started early with the latest
in the Fast and Furious franchise and the
Editorial Advisory Board brilliantly named Guardians of the Galaxy
H. LANDIS LANNY FLOYD, IEEE Life Fellow
H.Landis.Floyd@gmail.com
Vol. 2as if you might somehow not con-
nect it to the money machine from a couple
SHON ISENHOUR, Partner, Eruditio LLC
sisenhour@EruditioLLC.com of years ago.
DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC
While there are a few original stories
Industrial Internet Consortium (IIC) board member floating around out there, the biggest bud-
shiwanlin@thingswise.com get films are retreads of the same old story:
DAVE REIBER, Senior Reliability Leader, Reliabilityweb.com sequels to Pirates of the Caribbean, Cars, improvement. We have not settled for the
dave.reiber@reliabilityweb.com and Despicable Me, a movie versions of the same; we have innovated and invented and
DAVID SKELTON, Vice president and general manager old TV series Baywatch, and reworkings dreamed and created new ways of doing
Phoenix Contact Development and Manufacturing of the scary movie classics The Amityville what we do and have improved on what
dskelton@phoenixcontact.com Horror and The Mummy. weve already done.
BILLY RAY TAYLOR, One definition of insanity is doing the As summer arrives and plants around the
Director of commercial and off-highway manufacturing
same thing over and over and expecting country prepare for some downtime and
The Goodyear Tire & Rubber
Billytaylor@goodyear.com a different result, but that old saw wasnt maintenance, this is a good time to stop and
LARRY TURNER, President and CEO, Hannover Fairs USA
coined by a Hollywood producer. There are evaluate what you do and why you do it. We
lturner@hfusa.com just a just a few dozen movies that made did that this month with Plant Engineering,
MARK WATSON, Senior director, manufacturing technology, more money than the original, and thats and you can see the results in this issue. We
IHS Markit hard to qualify because ticket pricesand didnt depend on history nor instinct; we
Mark.watson@ihsmarkit.com therefore revenuescan change from year evaluated the data and asked our audience.
to year. While we prepare to retool this summer,
CFE MEDIA CONTRIBUTOR
Only eight movie sequels received Acad- we should take the time to think not just
GUIDELINES OVERVIEW emy Award nominations for Best Picture; about the physical plant, but our people
Content For Engineers. Thats what CFE Media stands for,
and what CFE Media is all aboutengineers sharing with their both Godfather sequels and both Lord and especially our processes. As we begin
peers. We welcome content submissions for all interested of the Rings sequels were among them. But to embrace data as a driver of change in our
parties in engineering. We will use those materials online, on
our Website, in print and in newsletters to keep engineers
as this summers movie list demonstrates, plants, summer is a good time to take the
informed about the products, solutions and industry trends. sometimes its just easier to do what youve data as a place to start the discussions with
* www.plantengineering.com/contribute explains how to done before as long as its profitable. And manufacturing and organizational teams
submit press releases, products, images and graphics, bylined
feature articles, case studies, white papers, and other media. on the surface, thats a logical philosophy. throughout our enterprise.
* Content should focus on helping engineers solve prob- The challenge is that your customers want In Hollywood, they call them pitch
lems. Articles that are commercial in nature or that are critical
of other products or organizations will be rejected. (Technol-
an improved product, not just the same meetingsa group tossing around ideas
ogy discussions and comparative tables may be accepted if product. You cant have the same plot in all for the next big thing. The easy thing to
non-promotional and if contributor corroborates information of your sequels, although you take the best do is say, Lets make another Spider Man
with sources cited.)
* If the content meets criteria noted in guidelines, expect
aspects of those productsJohnny Depps movie! (They are, incidentally.)
to see it first on our Websites. Content for our e-newsletters outlandish performance or the ability to find Take away all the glamor, and every
comes from content already available on our Websites. All creative ways to turn fast cars into smolder- movie is at its core the same thingplots
content for print also will be online. All content that appears
in our print magazines will appear as space permits, and we ing heaps of metal. and people, sets and stages, sound and film.
will indicate in print if more content from that article is avail- We all crave familiarity. We like our week- What makes one movie a blockbuster and
able online.
* Deadlines for feature articles intended for the print maga-
end jeans and shirt, root for our favorite another a flop is what one does with those
zines are at least two months in advance of the publication teams and enjoy comfort foodespecially tools. Manufacturing a car is no different,
date. Again, it is best to discuss all feature articles with the moms home cooking. We are creatures of and the summer is a good time to step back,
content manager prior to submission.
habit, and breaking out of those habits can take stock, and see how you can take those
Learn more at: be hard and uncomfortable. fundamentals and create something better.
www.plantengineering.com/contribute Yet what has advanced our society, and Welcome to your summer of innovation.
our manufacturing industry, is the idea of Enjoy the show. PE

CFE Medias
New Products for
Engineers Database
Looking for new products?
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The New Products for Engineers Database is a platform that
provides an opportunity for engineering and
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SOLUTIO S
COVER STORY AUTOMATION
An antidote to
A drive to succeed downtime
Remote monitoring protects
41
against skill shortages, complexity.
28 Turn into a detective

to troubleshoot drives
SPECIAL REPORT
Microgrids drive
a new energy strategy
Energy Master Planning provides a
47
bridge to the future.
To control future energy

costs, improve resiliency, and
become more sustainable,
LUBRICATION
plant managers need a plan.

GUIDE Empowered to cut
wasted energy
Cutting through the fog DOE program is designed to find
51
on pneumatic lubrication
Choosing the right strategy to
33 and eliminate energy waste.
prolong the life of key equipment

Overcome the high cost
of staying cool
55
Oil aerosol delivered in
compressed air reduces
Calculate seasonal energy
efficiency for your HVAC system.
the effects of these

Control room
factors and extends temperature: Strategies
the life of pneumatic to beat the heat 58
components.
Air-to-water exchangers can reduce
VFD heat exposure.

COVER
STORY
By Tim Park, Danfoss Drives
Proper handling of spare units can

help limit the risk of sensitive shelf
life in repair efforts. All images
courtesy: Danfoss
A drive
to succeed
Turn into a detective to troubleshoot ac drives.
A
c drives are an integral part after commissioning? Did the unit function
of any manufacturing plant, acceptably for some period, e.g., a month? Is
as they often are responsible there any data on the commissioning process
for controlling critical pro- available for reference (i.e. setup sheets, sche-
cesses. The proper operation matics, or configuration files)?
of ac drives can mean reliable
and efficient plant performance, less downtime, 2. Has the process changed? Has any other
and reduced energy costs, all of which equate to equipment been added in the same vicinity,
saving substantial money. perhaps sharing the same source? The perfor-
However, when a possible problem arises with mance and calibration of the drive may need
a drive, it is imperative that quick action be taken to change with these changes.
toward problem resolution.
When approaching a problem with an ac drive, 3. What is the performance complaint? Is the
its realistic to make some assumptions. Consider problem really drive-related, or is other equip-
these things initial points of investigation: ment involved?
1. Was the operator or the process owner happy The point here is to troubleshoot an application,
with the way the drive worked for some time not just a drive. Keeping an open mind is critical.

By The Many such soft-
NUMBERS ware tools allow
you to trend data on
a screen to allow you
75% to use your PC as a
virtual oscilloscope
Percentage of ac drives used on for more detailed
pumps, fans, and compressors. analysis of condi-
tions.
Source: Danfoss
E ach of thes e
datafiles are very
Fault codes important if you
Each manufactured product will have a specific want to solicit input
set of fault codes; the list of these codes is an from a technical
integral part of your troubleshooting kit. Many support contact at
manufacturers have several series of drive prod- the factory. Having
uct; there is a great deal of consistency in the these files available
meaning of these codes from compact to pre- to email a support
mium products. engineer can allow him to become familiar enough Many suppliers
You typically can look for fault codes to fall with your application to provide effective and prompt are providing
within the four general categories in the table: support from a remote location. software tools
that can allow
Description Application related? Solution Repairs and manufacturers
No, memory-related faults are logistics to extract the
specific to the drives hardware and
Drive problems firmware. Internal calibration and
Once the facts have been parameter set and
Repair/replace drive gathered, the next step is fault log from the
internal option board problems are not
related to the way the controller is to assess what makes sense drive.
being employed.
to handle the repairs of the
Possibly power supply overload, Verify or remove field wiring
Drive problems drives. Many times, keep-
external interlocks and safeties and see if the fault can be
external
require attention or resetting. cleared ing a spare drive on the
Source power No, voltage imbalance indications Work with an electrician or shelf makes sense. Many
problem are no fault of the drive. power company to correct
power ratings typically are
Yes, ground fault and overcurrent
Motor or load Validate/replace motor or delivered in the same physi-
are faults with the origin in the
related problem motor wiring
motor circuit. cal frame. That means you
might want to have a 2hp
Fault logs also are available to allow the techni- on the shelf to support the lower end of the power
cian to extract information about how the drive ratings, and 5hp, 20hp, 40hp, etc. applying the same
was running at the time of each of the faults logged logic. However, this is not an insignificant invest-
by the drive. ment and is not always practical.
Furthermore, most drives do have a shelf life, so
Data extraction with PC stocking units for replacement spareswhile an
While interpretation is still required, many manu-
facturers are providing software tools that can allow AC drives
you to extract the parameter set and fault log from An ac drive is a device used to control
the drive. When dealing with 20-50 faults logged by the speed of an electrical motor to
the drive, along with related operational parameters, enhance process control, reduce
this data can be difficult to gather. energy usage and generate energy
These tools also offer you the chance to compare efficiently, decrease mechanical stress
the current parameter set with where it was on com- on motor control applications, and
missioning day and how varied it may be from fac- optimize the operation of various
tory default values. applications relying on electric motors.

WEBCAST SERIES
The Industrial Internet of Things (IIoT) is a transformational strategy that is

revolutionizing manufacturing operations across the world.
CFE Media publications take an in-depth look at IIoT-related issues, strategies, and opportunities
in the 2017 IIoT Webcast series.
The 2017 Industrial Internet of Things (IIoT) Webcast Series:
Webcast One: Get your head into the cloud

Available On-Demand
This Webcast focuses on how emergent IIoT technologies change the way process and automation engineers execute projects and
sustain productivity in todays, and tomorrows, cyber-physical world.
Sponsored by:
Webcast Two: Sensing and control at the edge: Microcontroller kits

Thursday, June 8, 2017
Microcontroller kits emerge as a go-to tool in IIoT-based industrial automation.
Sponsored by:
Webcast Three: IIoT transforms predictive maintenance

Thursday, August 24, 2017
Connecting complex machinery and equipment to operations and enterprise systems enables machine learning, predictive maintenance
and secure monitor and alarm. IIoT addresses significant integration challenges posed by the unique data types generated by the many
kinds of machinery and equipment found in plant environments, from CNC machines to robotics.
Sponsored by: Bosch Rexroth, Deublin, GTI Spindle Technology, IBM, Rittal
Webcast Four: How IIoT helps cybersecurity efforts

Thursday, October 19, 2017
Cybersecurity is a threat to enterprises large and small, at risk of being attacked from unexpected sources both inside and outside the
enterprise. IIoT can reduce the cybersecurity risks inherent in legacy automation, instrumentation, equipment, and devices.
Register for the IIoT series today at www.plantengineering.com/lloT

COVER
STORY
Properly troubleshoot-
ing and maintaining
VFDs equipment can
improve the manage-
ment process.
attractive ideacan present problems. Either some

inventory controls on the part of your supplier or
your own may make this less of a problem. Proper
uct size and complexity, its easier
to provide component parts that
make sense rather than opting for
M More
SOLUTIONS
handling of spare units can help limit the risk of full replacements. Your drive manu- KEYWORD:
sensitive shelf life on repair efforts. For more infor- facturer can supply you with a parts Drives at PlantEngineering.com
mation on these risks, research capacitor reforming. breakdown of what makes sense to
ARTICLE: Still relevant: dc drives
There are commonly three classes of standard ac stock in support of your equipment.
important in an ac age
drives: compact, standard, and premium. Smaller The more important replacement
units of all these product classes frequently are con- parts are the ones that have things ARTICLE: VFD trends and solutions
sidered non-repairable. As you move up in prod- connected to them, like control for drive systems
boards, or touch, like keypads and WEBSITE: Under the Mechanical
Suppliers are developing service contracts, adjustments. Also, having replace- tab on our Website is a complete
planned replacements, and upgrade plans ment cooling fans as a field replace- rundown of current products and
along with extended warranties. ment is a good idea. articles around the subject of
Like most industries, the main- motors and drives.
tenance of drives is developing into
a bit of a specialty. Suppliers, working with local
contractors, are developing service (depot repair
and on-site) contracts, planned replacements, and
upgrade plans along with extended warranties. These
can run up to five or six years, if that makes sense
for your operation. Onsite repair is a necessity when
the size of the unit grows to greater than about 50HP
to 100HP.
Its important to remember that ac drives are com-
plex electronic equipment and that they operate as
part of an application. Properly troubleshooting and
maintaining this equipment can help you to be more
effective in managing the process in your facility and
keeping your plant running effectively. PE
Tim Park is senior applications engineer for

Danfoss Drives.

THE PEOPLE
THE PRODUCTS AND
THE SERVICES
TO KEEP YOUR PLANT
RUNNING SMOOTHLY
Lubriplate
COMPLIMENTARY ESP SERVICES PACKAGE
With 147 years of lubrication experience, we know what it takes to improve productivity, extend maintenance schedules,
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Complimentary Plant Surveys

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LUBRICATION
GUIDE
By Charles Werdehoff, IMI Precision Engineering
Cutting through the fog

on pneumatic lubrication
Choosing the right strategy to prolong the life of key equipment
P
neumatic devices that push, pull, amount oil to be delivered to downstream
lift, position, or convey last lon- equipment.
ger and perform better when sup- Operating manuals for pneumatic equipment
plied with compressed typically specif y the
air that is clean, dr y, amount of oil required
pressure-regulated, to keep the device
and lubricated. The ser vice life of op erating optimally.
many air tools, cylinders, valves, air Lubricators should be
motors, and other air-driven equip- adjusted to deliver the
ment can be extended by consistent amount of oil speci-
aerosol lubrication. fied at defined oper-
Why lubricate? Environmental ating conditions and
factors like extreme temperatures then validated after the
and excessive moisture, along with equipment is in opera-
operational factors such as start- tion.
up and operational friction, reduce
the life of most working pneumatic Oil-fog, direct
devices. Oil aerosol delivered in to the tool
compressed air reduces the effects The mostly widely
of these factors and extends the life used type of lubrica-
of pneumatic components. tor is oil-fog, some-
times called direct
How aerosol feed. These lubricators
lubricators work deliver 100% of the oil
Aerosol lubricators automatically deliv- drops seen in the dome
M More
er a metered amount direc tly into t he air
of oil into the air path
of operating pneu-
SOLUTIONS matic equipment. A standard oil-fog or
Lubricators function direct feed lubrica-
KEYWORD:
by creating a pres- tor delivers oil drops
Pneumatics at PlantEngineering.com
sure drop that causes 2 microns or larger
ARTICLE: Pneumatic systems: 10 oil to be siphoned directly into the air
ways to save energy into an adjustable stream. They are best
dome. Us i n g t h e located near the tool
ARTICLE: Storing pneumatic energy
d om e a dj u s t m e nt they are lubricating.
for emergency situations
and obser ving the All images courtesy:
ARTICLE: Six steps to energy drip rate allows an IMI Precision Engi-
efficiency in pneumatic systems operator to set the neering

BRICATION
GU DE
stream. Oil particles traveling downstream are
normally 2 microns or larger. Because of grav-
ity, these particles only will remain airborne
By The
for a distance up to about 15 feet, and they NUMBERS
normally will not travel up or follow intri-
cate flow paths. As a result, oil-fog lubricators
should be located in-line and near the tool $5 billion
they are lubricating. They are very efficient at Amount estimated each year
delivering the right amount of oil directly to
the cylinder, valve, or tool. spent by U.S. manufacturers
It is not always possible to meet optimal
conditions for oil-fog lubricators. When these on energy for compressed
conditions are not met, the oil will collect in air systems. The same report
the air line instead of travelling to the equip-
ment. The result is reduced air found that manufacturers waste
flow and either inadequate or
excessive tool lubrication.
between 30% and 35% of that
Standard oil-fog lubricators energy.
are not efficient for applica-
Source: 2012 U.S. Department of Energy
tions where the air line has
vertical air paths, multiple study/Plant Engineering article.
tool lines, or bends in the air
stream that prevent larger oil
particles from reaching a tool. require better adjustability of small amounts of
In these situations, a micro- direct lubrication.
fog lubricator provides better
lubrication results. Filter-regulator-lubricator
A lubricator is almost always used together with
The micro-fog path a filter and regulator pre-conditioning the air.
Wit h a micro-fog lubr ica- These can be stand-alone components or an
tor, the oil drip is atomized integrated filter-regulator-lubricator. Air leaving
into particles smaller than 2 a compressor contains water and contaminants
microns. Approximately 10% that can cause damage and shorten the life of
of the oil drip seen in the downstream equipment. Even pre-lubricated
dome is transported into the components can fail when contaminated air
airflow and the rest of the oil is degrades the lubrication or washes it out. Allow-
returned to the bowl for future ing contaminated air into a lubricator can result
use. Because the particles are in reduced oil feed.
small, they can travel long dis- Filtering ensures that clean dry air is sent
tances, vertically, and through through the lubricator and on to the operating
intricate flow paths. Because equipment. Regulating air flow to meet con-
only 10% of the oil is being ditions specified by the equipment operating
delivered downstream, they manual ensures the equipment performs opti-
are good for applications that mally. Aerosol lubrication is the final step after
filtration and regulation.
A micro-fog lubricator atom- Proper lubrication protects equipment, pro-
izes oil into droplets smaller longs tool life, helps control costs, and keeps
than 2 microns. These can processes running efficiently and productively. PE
travel vertically, over long
distances, or through intri- Charles Werdehoff is a precision engineer-
cate flow paths and can be ing and product marketing manager for IMI
used to lubricate multiple Norgren Filter/Regulator and Lubricant (FRL)
tools. Products.

LUBRICATIONGUIDE
Ingersoll Rand Compression
Lubriplate Lubricants Co. Lubrication Engineers Inc. MIL-COMM Products Co.
Technologies & Services
Newark, N.J. Wichita, Kan. East Rutherford, N.J.
Davidson, N.C.
www.lubriplate.com www.lelubricants.com www.mil-comm.com
www.ingersollrandproducts.com
General Purpose Lubricant

Viscosity,
ISO Viscosity Grade
SUS at 100 F
32 135-165 HO-0 - Multilec Industrial Oil MC2500 Synthetic Oil
46 194-236 HO-1 - Multilec Industrial Oil -
460 1935-2365 HO-6 - - -
Antiwear Hydraulic Oil

32 135-165 HO-0 - Monolec Hydraulic Oil -
Spindle Oil
2 29-35 GG Oil - - -
10 54-66 No. 0 - - -
22 95-115 No. 1 - - -
Way Oil
32 135-165 10-R - - -
68 284-346 Way Lube 68 - - -
220 900-1100 SPO-255 - Monolec Way Lubricant -
Extreme Pressure Gear Oil

Duolec Vari-Purpose Gear
68 284-346 APG-80 - -
Lubricant

150 630-770 APG-90 - MC3000 Synthetic Oil
Lubricant

320 135-1650 APG 80W-140 - -
Lubricant
Worm Gear Oil
460 1935-2365 SPO-277 - Almasol Worm Gear Lubricant -
Pyroshield Syn Hvy & XHvy Open

Cling Type Gear Shield - Gear Shield Extra Heavy - -
Gear Lubricants
General Purpose Extreme Almagard Vari-Purpose

NLGI 2 No. 1242 - -
Pressure Lithium Base Grease Lubricant
Molybdenum Disulfide Extreme

NLGI 2 No. 3000 - - -
Pressure Grease
H1 Quinplex Food Machinery

HI Grease - FGL-2 - -
Lubricant
H1 Quinplex White Gear

H1 Fluid - FMO-2400AW - -
Lubricant
General Purpose Synthetic Fluid - Syn Lube 460 - Monolec Syn Industrial Oil -

MACHINE LUBRICANTS
Shaeffer Manufacturing Co. Sullair LLC Summit, Klber Lubrication NA LP Ultrachem Inc., Fuchs Corp.
St. Louis, Mo. Michigan City, Ind. Tyler, Texas New Castle, Del.
www.schaefferoil.com www.sullair.com http://klsummit.com http://ultracheminc.com
112 HTC ISO 32; 254 HTC Supreme ISO 32 - - P-ACO 32
112 HTC ISO 68; 254 HTC ISO 68 - - P-ACO 68
- - - P-ACO 460
112 HTC ISO 32; 254 HTC Supreme ISO 32 - HySyn - 163 Chemlube AW 32
- - - -
324 Spindle Oil ISO 10 - - -
324 Spindle Oil ISO 22; 112 HTC ISO 22 - - -
160 Moly Slide & Way Lube ISO 32 - - -
203B ISO 68, 203C ISO 68 - SH-10068 - 9.9 @100C, cSt Omnigear 68 EP
167 ISO 150; 203B ISO 150, 203C ISO 150, 267 ISO 150,
- SH-1015 - 17.8 @100C, cSt Omnigear 150 EP
293 ISO 150; 293A ISO 150
167 ISO 320;268 ISO 320; 294 ISO 320; 294A ISO 320 - SH-1032 - 32.8 @100C, cSt Omnigear 320 EP
147 Steam Cylinder Oil - Syngear WT - 52.6 @100C, cSt Chemlube 634
200S Silver Streak Special - - -
- - - -
221 #2, 274 #2, 274M #2, 238 #2, 260 #2 - - -
195 , 271, 272 - - Omnilube FGM2
280 ISO Grade 22-220, 269 ISO grade 32-100, 276 ISO
- - Omnilube FGG 1220
Grades 100-1000
264 Pure Synthetic Hydraulic Fluid ISO Grades 32-150 - - Chemlube 630

LUBRICATIONGUIDE
Ingersoll Rand Compression
Lubriplate Lubricants Co. Lubrication Engineers Inc. MIL-COMM Products Co.
Technologies & Services
Newark, N.J. Wichita, Kan. East Rutherford, N.J.
Davidson, N.C.
www.lubriplate.com www.lelubricants.com www.mil-comm.com
www.ingersollrandproducts.com
Polyalphaolefin (PAO) Compressor Oil

32 140 Syn Lube 32 - Monolec Syn Industrial Oil -
Partial Synthetic Compressor Oil

32 146 - - - -
46 145 - - - -
68 87 - - - -
100 99 - XL-700 - -
150 105 - All Season Select, XL-740HT - -
220 105 - - - -
Centrifugal Compressor Oil

32 127 - Techtrol Gold III Monolec Centrifugal Compressor Oil -
46 136 - - - -
15 120 - -
32 160 - - - -
Engineering is personal.
So is the way you use information.
CFE Media delivers a world of knowledge to you.
Personally.
CFE Media is home to some of the most trusted names in the business.
To do your job better each day, you need a trusted source of information:
CFE Media Content for Engineers
www.cfemedia.com
COMPRESSOR LUBRICANTS
Shaeffer Manufacturing Co. Sullair LLC Summit, Klber Lubrication NA LP Ultrachem Inc., Fuchs Corp.
St. Louis, Mo. Michigan City, Ind. Tyler, Texas New Castle, Del.
www.schaefferoil.com www.sullair.com http://klsummit.com http://ultracheminc.com
158 Pure Synthetic Compressor Oil ISO 32 Sullube SH-32 - 163 Chemlube 221
158 Pure Synthetic Compressor Oil ISO 46 Sullube SH-46 - 220 Chemlube 228
158 Pure Synthetic Compressor Oil ISO 68 - SH-68 - 339 Chemlube 268
254 HTC Supreme ISO 32 SRFII/8000 - PS 32
254 HTC Supreme ISO 46 SRFII/8000 - PS 46
254 HTC Supreme ISO 68 - - PS 68
- - Supra-32 - 185 Chemlube CF 32
- CCL - Chemlube CF 46
- - - -
- - - -
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CFE Medias
Global System Integrator Database
CFE Medias Global System Integrator Database is an interactive community

of global end-users and system integrators hosted by Control Engineering, Plant
Engineering, and our global partners in Asia and Europe.
The newest version of the online database is even easier to use.

Features and updates:
Relevancy score indicates how closely New feature allows an end-user to
an integrators qualifications match a request a quote for a project directly
users search criteria from the database site
Users can now preview the most The most relevant data about an
pertinent data of a System Integrator integrators engineering services appear
before clicking to view the full on one page on their corporate profile
corporate profile other details are organized by tabs.
As a Systems Integrator there are quite a few options available

for online advertising. They vary in functionality and design,
but the Global System Integrator Database has been our go to.
It is easy to use, professionally designed, and has given us a great
deal of exposure to clients we wouldnt normally be able to reach.
We have had more clients contact us with this solution than any
other System Integrator database combined. We not only going
to renew our profile this year, we plan on upgrading.

William Aja, Panacea Technologies
Find and connect with the most suitable service

provider for your unique application.
www.plantengineering.com/global-si-database
AUTOMATION
SOLUTIONS
By Ante Tomicic and Phil Bush, Rockwell Automation
An antidote to downtime
Remote monitoring protects against skill shortages, complexity.
A
voiding downtime is a fundamental flexible manufacturing processes has introduced
goal in any industrial operation. its own complexity. Today, many companies need
Improving uptime drives mainte- to produce multiple products in one facility
nance strategies, influences equip- while minimizing changeover disruptions.
ment purchases and sales goals, and it is To keep operations up and running amid
entrenched in the minds of workers. these challenges, more companies are turning
Even with a concerted effort to fight down- to remote monitoring and support services.
time, some companies are finding it more diffi-
cult than ever to control. There are a few reasons Support is always there
for this. Remote monitoring begins with collect-
First, the jobs that are most vital to preventing data from a companys industrial assets.
ing downtimeindustrial maintenance techni- This datawhich includes voltage, vibration
ciansare becoming harder to fill. Experienced parameters, temperature readings, and warn-
maintenance technicians are retiring and too ing and fault informationthen is contextual-
few skilled young technicians are entering the ized into actionable information and delivered
workforce to replace them. This is part of a to workers.
larger industrial skills gap that is expected to Remote monitoring can be internally man-
result in 2 million manufacturing jobs going aged, with automated systems that deliver infor-
unfilled between 2015 and 2025, according to mation directly to on-site workers. It also can
report from Deloitte Consulting and the Manu- be externally managed by a remote-monitoring
facturing Institute. service providers team of off-site specialists.
S e c on d, c on n e c te d These specialists monitor critical equipment and
op e r at i on s a re a d d - systems, and they can quickly notify on-site
ing greater complexity personnel of any detected issues and potential
to industrial environ- responses to those issues, or even predict some
ments. Production sys- failures before they happen.
te ms are c onve rg i ng These remote-monitoring services can be
Remote monitoring with information sys- scaled to address a companys exact needs,
Understanding asset performance tems, and production whether it is monitoring a single machine in a
is key to optimize your operations d ow nt i m e n ow g o e s plant, several pieces of equipment, a full produc-
and prevent costly downtime hand in hand with net- tion line, or applications, systems, and networks
events. Remote monitoring and work downtime. Theres across multiple plants.
analytics provides a simple and a significant opportuni- Some companies also choose to build addi-
secure approach to help monitor ty to use data available tional services on top of remote monitoring.
equipment and collect valuable from connected opera- These services can include various forms of
performance analytics. It can give tions to help reduce or administrative support, such as system back-
you valuable insights into how prevent downtime, but ups, recovery support, and patch and update
well your assets are working and that opportunity only recommendations. They also can include parts
alert you when performance falls can b e realized with and on-site engineering support being delivered
outside of acceptable performance the right resources and within specific response-time windows.
standards. expertise in place. Its not only manufacturing and industrial
Source: Rockwell Automation Finally, t he simul- producers that can reap the rewards of remote
taneous move to more monitoring. Machine builders can use it to gain

CALLING ALL SYSTEM INTEGRATORS...
2018
System Integrator
call for
of the Year entries
Entries are due August 18, 2017
Control Engineering and Plant Engineerings annual

2018 System Integrator
of the Year Awards
Questions?
Contact Bailey Rice
Director of Business
and Market Development
Who should enter? CFE Media
If youre a system integrator with demonstrable industry success, Control brice@cfemedia.com
Engineering and Plant Engineering urge you to enter the 2018 System (630) 571-4070 x 2206
Integrator of the Year competition. Past System Integrator of the Year win-
nersClass of 2017, Class of 2016, and Class of 2015are not eligible to
enter the 2018 System Integrator of the Year program. 2017 System Integrators of the Year 15 | 2016 SI Giants 29
Whats in it for the winners?

The chosen System Integrator of the Year winners will receive worldwide
recognition from Control Engineering and Plant Engineering. The winners
also will be featured as the cover story of the Global System Integrator
Report, distributed in December 2017.
How will the competition be judged? Finding the right recipe

Control Engineering and Plant Engineerings panel of judges will conscien- People, processes are
crucial to SI success story
tiously evaluate all entries. Three general criteria will be considered for the 23
selection of the System Integrator of the Year:

r#VTJOFTTTLJMMT
r5FDIOJDBMDPNQFUFODF A supplement to CONTROL ENGINEERING
and PLANT ENGINEERING magazines
r$VTUPNFSTBUJTGBDUJPO
Tell us how you measure up in these three areas.

Get the application: www.plantengineering.com/SIYApplication
AUTOMATION
SOLUTIONS
M More
new insights into the performance of their dis- had limited access to engi-
tributed assets. They can also use it to expand neers with knowledge about
their service offerings, with the option to either
manage the monitoring in-house or outsource
the new technology.
The company decided to
SOLUTIONS
it to a third party. use a remote service provider KEYWORD:
Industrial companies struggling to fill main- for around-t he-clo ck sys- Remote Monitoring at
tenance positions face a higher risk of downtime tem monitoring. The remote PlantEngineering.com
or even full plant shutdowns. In these cases, team monitors about 2,500
remote monitoring services can be used for data points from controllers, ARTICLE: Remote monitoring
key maintenance tasks when local talent isnt drives, HMIs, and regulatory technologies lower costs, improve
available. compliance parameters, and operations
can notify on-site staff of any ARTICLE: Advances in wireless
Case study: Distance learning issues.
remote monitoring
A coating company recently modernized the In addition to augmenting
production lines at one of its facilities with on-site staff, the remote moni- WEBCAST: Information Management
new automation technology to increase capac- toring support has provided for IIoT
ity and address obsolescence issues. The proj-
ect included installing new HMI systems on
each line, and transitioning a paint line from Remote monitoring can take place either in a control room envi-
decades-old motor generators and dc motors ronment, as seen below, or by using internet and cloud capabili-
to new integrated controllers and drives. But ties. Either way, the goal is to centralize data capture and man-
because the facility is in a rural area, the company agement. Image courtesy: Rockwell Automation

Plant Engineering
Webcasts help you
obtain educational
information on
Webcasts specific topics and
learn about the latest
industry trends.
Check out some of our
Webcasts on topics like:
r Maintenance
r lloT series: OT/IT convergence,
collaboration
r Energy Management
r lloT series: Edge, cloud, fog
computing
r lloT series: Maintenance
optimization
r System Integration case studies
r lloT series: Network integration,
cyber security
r Safety
www.plantengineering.com.com/webcasts
AUTOMATION
SOLUTIONS
predictive maintenance benefits to the facility.
The remote support team can track the prog-
ress of maintenance issues, monitor trends and
tolerances of devices, and track lifecycles. The To keep operations
team can then alert on-site staff of issues as they up and running amid
arise, and help them head off problems before
a line stoppage occurs. these challenges, more
After implementing remote monitoring, the
coating company saw a 50% reduction in main- companies are turning to
tenance downtime at the facility.
remote monitoring and
Case studies: Improved response
Other companies have used remote support to
help manage the added complexity of modern
support services.
operations where traditional IT support may
not be a good fit.
This was the case for a large food manufac- system, but lacked the technical expertise to
turer that deployed Ethernet and managed manage and support the system.
switches on the plant floor. The manufactur- The company made the move to a ser vice
er initially decided to use its traditional IT provider for remote technical support and
provider to support the equipment, but they troubleshooting. The support significantly
couldnt provide the response time needed to reduced downtime, resulting in an annual
keep things running on the plant floor. revenue increase of $630,000. The mill also
As a result, the manufacturer switched to realized hundreds of thousands of dollars in
an industrial remote support provider. The additional savings in training and support
support included monitoring of more than 400 costs.
switches, alarm profiles to monitor eight key
parameters in those switches, and a 10-min- A secure approach
ute guaranteed response time to any critical Remote support is so widely used now that
alarm. After the change, the company saw a service providers have largely developed stan-
significant improvement in uptime. dardized services that can meet the needs of
In another case, a paper mill was experi- most industrial companies. Before selecting a
encing challenges with instability and sheet service provider, however, companies should
breaks when switching between products. The be sure the provider meets certain security
company had recently installed a new drives requirements.
Companies should make it a point to work
By The
with a trusted service provider, one that follows
core security principles when designing prod-
ucts. They also should confirm the providers
NUMBERS platform delivers secure remote access, such
as by limiting entry points, using outbound-
$24.7 billion only connections, and limiting access by user,

site, and device.
By addressing security upfront, industrial
The estimate of the global companies can worry less about the risks of
remote access and focus more on how it can
remote monitoring market help them keep their operations running in
in 2015, which includes todays fast-changing world. PE
commercial and industrial Ante Tomicic is remote support services super-

visor and Phil Bush is remote monitoring and
applications. analytics product manager for Rockwell Auto-
Source: IHS Markit mation.

2017 Global Automation
& Manufacturing Summit
November 7, 2017
Presented in
Registration partnership with:
opening soon!
Under the theme Empowering Manufacturing Future, CFE Media will

produce its 2017 Global Automation and Manufacturing Summit (GAMS)
on Tuesday, November 7, 2017. The now-annual GAMS event will be co-
located with Hannover Fairs USAs Industrial Automation/MDA Pavilion at
the 2017 FABTECH Show at McCormick Place, Chicago.
The event will begin at noon with a networking luncheon on the show
floor. Three sessions will follow, focusing on three key aspects of the adoption of the Industrial Internet of
Things (IIoT) in manufacturing. The event will conclude with a cocktail reception and networking event.
The three GAMS sessions include:
1:00 pm to 2:00 pm: CYBERSECURITY: HOW FAR DO WE NEED TO GO?

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nology solution. Well look at the real issues, perhaps debunk a few myths, and talk about the common-sense
ways manufacturers can secure their data and their operational integrity.
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Chief Executive Officer of OMG (Object Management Group) executive director of the Cloud Standards Customer
Council.
2:15 pm to 3:15 pm: IIoT IN DISCRETE MANUFACTURING: MANAGING THE PROCESS

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have a different set of expectations from those in the process industriesand a different set of challenges. Well
talk with industry experts to look at how to get the most out of IIoT, and how to use data to improve operations,
supply chain and safety.
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CEO and president, Beckhoff Automation North America and Derek Harper, vice president of information technol-
ogy at Faurecia North America.
3:30 pm to 4:30 pm: MAINTENANCE AND IIoT: FOLLOW THE NUMBERS

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the right numbers at the right time. More sophisticated analytics are helping maintenance teams focus on the right
data at the right time, and well talk with them on how this strategy can lead to more uptime and better safety.
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SPECIAL REPORT
ENERGY MANAGEMENT
By Philip Barton, Schneider Electric
Microgrid systems can be implemented

to minimize downtime, lower costs, and
increase sustainability all in one project. All
images courtesy: Schneider Electric
Microgrids drive
a new energy strategy
Energy Master Planning provides a bridge to the future.
T
he steady increase in energy usage across zation of energy. Microgrids are an attractive
North America is forcing users to con- tool to help manufacturers integrate renewable
tend with high and variable energy energy resources as part of an energy master
costs. Total energy production in the plan. Microgrids are synonymous with allowing
United States increased for the sixth consecutive customer-sited generation to work grid-tied and
year in 2016, according to the U.S. Energy Informa-
By The
tion Administration (EIA).
During the same period, electricity generation
from wind, solar, and other distributed energy
resources also grew, ushering in a new energy NUMBERS
landscape.
To control future energy costs, improve resiliency,
and become more sustainable, plant managers need 62%
a plan. This detailed process is often referred to as Number of manufacturers
an Energy Master Plan, comprised of enterprise-
level strategies designed to manage energy costs working with their utilities to
while also mitigating the risk of downtime from
power outages. develop energy strategies.
Microgrids enable manufacturers to adapt Source: 2016 Plant Engineering Energy
to the new energy landscape, driven by greater Management Study
decentralization, decarbonization, and digiti-

SPECIAL REPORT
ENERGY MANAGEMENT
independently of the infrastructure. With microgrids, systems can be
grid. Microgrids also implemented to minimize downtime, lower costs,
enhance the resiliency and increase sustainability all in a single project.
of operations while Energy storage increasingly complements the new
helping manufactur- distributed resources and doubles as a power sys-
ers generate new value, tem backup for added resiliency.
Energy management drive benefits in mod- While battery energy storage systems alone work
Total U.S. energy production ernization, avoid costs, as an excellent anchor resource, battery systems are
increased for the sixth consecutive and meet new share- still relatively expensive unless they can serve mul-
year in 2016, according to the U.S. holder requirements tiple use cases. Where electric power and natural gas
Energy Information Administration.
for sustainability and are expensive, batteries and solar work well finan-
The U.S. energy production reached
reporting. cially. Centralized power is 30% to 40% efficient at
91% of total U.S. energy use, with
the point of use, and cogeneration plants often have
increases in crude oil and natural
gas production offsetting a 10%
No need to rip a 55% to 80% combined efficiency at the point of use.
decrease in coal production.
and replace Through microgrids, manufacturers can leverage
O n e of t h e m o s t cleaner and more efficient resources all while using
The United States saw little exciting trends in less grid infrastructure and helping these disparate
change in production from nuclear microgrids is mixing cogeneration resources work in harmony.
electric power and renewable the old with the new. Renewables also can be used as a less expensive
energy (across all sectors) in 2015. Microgrids allow for form of generation as they help establish applications
However, the United States saw seamless moderniza- of virtual power plants. These applications innovate
shifts in the sources of electricity tion of aging electri- by combining variable wind and solar with dynamic
generation from renewable fuels, as c a l i n f r a s t r u c tu re, load management and storage to present a flatter load
declines in hydroelectric generation upgrading a facil- curve from the utilities point of view. And storage
were mostly offset by increases in itys legacy electrical must be thought of as not just batteries, but thermal
electricity generation from wind system to optimize inertia and flexibility in loads and processes.
and solar EIA officials said in its energy use, without Flexibility in microgrid design is of increasing
Monthly Energy review in April 2017. needing to rip and importance because many plants are in off-grid
replace the existing areas of the worldmost notably in fields such
as energy production, distilleries, or
Installations of solar panels and other advanced microgrid programs at miningand its just as pivotal for
Schneider Electrics Boston One Campus in Andover, Mass., is an example those facilities to remain functional
of how to incorporate distributed energy into an existing facility. and cost effective as on-grid enter-
prises. For many plant
managers in remote
locations, using renew-
able energy via a solar-
assisted microgrids is
more cost-effective than
transporting other fuel
and establishing new
distribution and trans-
mission infrastructure.
N e w, a d v a n c e d
microgrids couple solar
photovoltaic (PV) with
other distributed energy
resources as an anchor
resource to islandor
separatefrom the grid

To control future energy costs,
improve resiliency, and become
and enhance resiliency, helping to power campuses

sustainable, plant managers need a
and small communities independent of the grid plan. This detailed process is often
during an outage.
In addition to the economic benefits, microgrids referred to as an Energy Master Plan,
also contribute to the sustainability of a corporation.
Many Fortune 500 manufacturers have instituted comprised of enterprise-level strategies
sustainability goals. In fact, shareholder interest
in sustainability is another key factor driving designed to manage energy costs while
microgrid adoption within the new energy land-
scape. With an increased commitment to sustain- also mitigating the risk of downtime from
ability, shareholders require more renewable energy
use than ever, and microgrids help incorporate
power outages.
renewables within their budget.
As sustainability becomes a higher priority, share-
holders also are requiring accurate measurement of ment of renewables and other distributed energy
renewable energy usage. Microgrids can integrate resources.
advanced monitoring, software and reporting tools
to help provide more detailed, accurate reporting, Implementing microgrids
and greater understanding of energy spend and usage Though microgrid implementation can seem
across the operation. daunting for facilities that have been operating
Additionally, an increased focus on sustainability the same infrastructure for decades, the industry
enables access to green funds, which provide lower continues to remove the barriers to entry, mak-
cost to capital for modernization efforts but are ing it easier to incorporate renewables and enter
only available for manufacturers and other large the microgrid market. New funding mechanisms
corporations that can demonstrate social respon- such as Microgrid as a Service models enable
sibility, primarily through sustainability. upgrades without upfront capital expenditure.
Shifting to renewable-powered facilities seems Through advanced microgrid tools, end-users
simple, however manufacturers often face per- can incorporate more inverter-based resources
ceived barriers when implementing renewables that enable renewable energy usage and leverage
with legacy infrastructure that contends with con- software solutions to better monitor, analyze and
temporary energy requirements. Greenfield man- report on energy use while also easing scale.
ufacturing projects are rare; As plant managers look to
M More
manufacturers often need to modernize their plants in all
incorporate solar and renew- aspects, the way they source,
able energy sources within an SOLUTIONS manage, and control energy
existing electrical infrastruc- cannot and should not be
KEYWORD:
ture to meet peak loads, build Energy Management at
ignored. Microgrids are an
employee engagement and sat- PlantEngineering.com effective solution to upgrade
isfy shareholders. electrical infrastructure
Finally, modern microgrid RESEARCH: 2016 Energy while helping manufacturers
tools offer additional auton- Management Study: Six findings on to achieve more sustainable
omy and scalability as plant energy management programs business practicesgenerat-
operators modernize opera- WEBCAST: Energy Management ing tangible value that can be
tions. Contemporary advanced Strategies for Manufacturing reinvested in other areas of
microgrid tools bring together the operation. PE
ARTICLE: Implementing energy
hardware, software, advanced
management for machinery and
controls, and electrical dis- Philip Barton is director of
processing plants
tribution into a single-source the North American Microgrid
solution that simplifies the 2016 PRODUCT OF THE YEAR Competency Center for Schnei-
i nt e g r at i on an d m an a ge - FINALISTS: Energy Management der Electric.

Reimagining
Plant Engineering
The use of the pictures, descriptions
and accounts of this magazine...
Is fully encouraged.
COVER
STORY
COVER M More
INSIGHT
ADVICE
STORY
By Michael Risse, Seeq Corp. Regardless of what a sensored, connected, integrated instead of being already recognized in
WEBCAST: Arc Flash Univer-
sity: Safe Use of Electrical
factory is called, IIoT continues its march forward as bottom line results. Testing Devices. Now on
the expected architecture for process manufactur- demand at plantengineering.
com
ing facilities. The competitive advantages enabled by Part of this gap may be due to the oft-
increased and consistent visibility, accuracy and data- cited advice that companies should start ARTICLE: Improving arc flash
driven insights on production results are simply too small and have IIoT deployments prove safety through design
important for most firms to ignore, hence the growth their value and impact before moving on ARTICLE: New solutions
in IIoT deployments. to more widespread implementations. address arc flash energy
This is great advice and hard to argue reduction
Dont get caught behind with, and aligns with the limited num- KEYWORD: arc flash
INSIGHT
By Rebecca Bolt, GE Automation & Controls
As we look ahead in 2017, there are many ways to
discuss whats ahead for IIoT. For example there are
ber of large IIoT deployments within
companies. Certainly an early success will bode well
new IIoT technologies to consider, such as drones, for organizational enthusiasm for continued IIoT
typical of a local computer. Connecting to the
IIoT
robots, voice-powered artificial intelligence (AI) and investments.
cloud also enables a fleet of machines to be man- efficiencies,
virtual reality solutions. And while those will likely
aged and to communicate with each other, pro- improve emplo
The clouds role viding thorough analytics for the entire fleet. For
example, theres an app that leverages the power
of the industrial internet, connects to a fleet of
wind turbines and enables them to coordinate the
while gener
streams fo
have a future in IIoT, there is also an important issue
we need to address first: most firms need to catch up to
the technology opportunities available today.
End users should be complimented for any IIoT
investments or trial deployments they have completed,
because at the end of the day they have done something
in data management speed and direction of their blades to maximize

the wind farms overall energy output.
However, the cloud is not always a viable option
due to latency, costs, regulations, and other fac-
eas e
a d o e accu-
ate.
Analyst research shows a large gap between the
expectations and advantages of IIoT, and the state of
and at least tried.
In the world of software startups there is an expres-

tors. Think also about the criticality of the data Th e y g current deployment efforts. Further, IIoT deployments sion: fail fast. This means its better to try something
Deck is needed... being analyzed. If a self-driving car was required couldnt have imagined IIoT as it
are generally piecemeal rather than broadly applied and learn it doesnt work than to wonder if it might have
to go to the cloud to make important decisions, is today. Similarly, we cant specul
B
the cars response time would be too slow. Indus- will be three years from now. The across a plant. What this means is that IIoT enthusiasm
illions of sensors all around the world Controls have been managing machines all trial assets are the same way. Some things can be things are changing makes it diffi and potential benefits are not being realized by many Delivering IIoT: Pioneer Energy Mobile Alkane Gas Separators
are making consumer devices smart- around us for centuries. Just as our machines have done in the cloud, but other problems need to be mend specific assets or systems t
end users, with the opportunity still ahead of them, produce both methane and natural gas liquid streams at well sites.
IIoT arrives:
er, safer and more efficient. Wearable evolved, so, too, have the analytics our machines analyzed as close to the machine as possible. Digi- hard-wired or should be wireless
products have revolutionized our provide. However, the data those machines collect tal industrial companies are developing products should run in the cloud versus a
understanding of wellness by providing more and analyze, up to this point, has been limited that are designed to work on the industrial edge al edge, so its important to thin
information about our daily health. Appliances to the memory of internal computers running at and make collecting, storing, and analyzing data through strategically and go the ro
and systems in our homes now are connected or inside the machine; the intelligence of those the most sense for your plant. PE
and make intelligent decisions to enhance our machines essentially has been limited to that
lives. Entire cities now are employing big data and
sensors to prevent crime, manage crowds, reduce
energy use, and much more. The connectivity of
and communication between these devices, as
we know, is referred to as the Industrial Internet
memory.
New industrial control systems now are pro-
viding the same type of connectivity, commu-
nication, and analytics for our industrial assets
as consumers have seen for several years. These
Caption is also needed...
Rebecca Boll is a general mana
GE Automation & Controls.
Its time to get started
of Things (IIoT). But before these devices can connected controllers and systems not only run
start communicating with end users and each our machines like they used to run, but they Implementation is not only practical, but now its a competetive necessity.
other, they must collect and analyze datalots also now have the capability to create an outer
and lots of data. loop and custom applications that gather data in
T
Data for many real time and advise the controller to make more he Industrial Internet of Things (IIoT) t/FXBTTFUNPOJUPSJOHTFSWJDFTGSPNWFOEPSTXIP
By The of these devic-

es is collected,
intelligent decisions. Just as connected sensors
and wireless devices transport data to consumer
has progressed from dream to hype to
reality. Today, the basic deployment
are leveraging IIoT to provide remote predictive
analytics capabilities for their assets installed at
NUMBERS stored, and ana-
lyzed in cloud-
clouds, the vehicles to transport big data to the
industrial cloud are edge devices and sensors in scenarios of the IIoT solutions we customer sites.
based environ- or near machines. implement for our end user manu-
30.7 billion ments such as
the Amazons
Many machines and plant systems dont offer
the type of connectivity and deep analytics todays
facturing customers include: The enthusiasm and growth in IIoT momentum
Number of Internet of Things and Googles of industry demands. These machines require third- over the last year is obvious in the pages of this maga-
the world. Even party solutions to gather data and provide critical t( SFFOGJFMEEFQMPZNFOUT XIJDIBSFQSJNBSJMZ zine, as there continue to be IIoT-related articles in
connected devices expected by our Fitbit track- analytics. The more data gathered, and the closer
ers have a cloud to the machine you run data, the more accurate found in smart solutions related to advanced FWFSZJTTVF#VUUIJTEPFTOPUNFBOUIFJOEVTUSZIBT
2020. This includes both industrial where our health and intelligent the decisions the machine makes. monitoring and visibility agreed on its naming conventions.
analytics are Some machines cant be reached with tradi-
and consumer-based devices. stored. While tional Ethernet cables because of the distance
Source: IHM Markit theres a lot of between the internet source and the machine. Not t#SPXOGJFMEVQHSBEFT XIJDIBSFUIFJOUSPEVDUJPO So we continue to refer to digital transforma-
d at a g at h e r e d only would it be cost prohibitive to drop and run of IIoT technologies and approaches to existing tion, smart manufacturing, the fourth indus-
from consumer products, theres a much larger that wired connection, but the proximity would
amount of data found in industrial machines and make data gathered less favorable. Connecting
facilities to expand asset and process visibility trial revolution, and Industrie 4.0, in addition
an even greater need for the same type of con- to these machines wirelessly makes sense. and analytics to IIoT.
nectivity and analytics. IIoT will increase effi- Cloud-based, wireless solutions provide great-
ciencies, reduce costs, and improve employee er flexibility than wired solutions. The cloud
health and safety while generating new revenue empowers the elasticity of data storage and per- 2 t January/February 2017 PLANT ENGINEERING www.plantengineering.com www.plantengineering.com PLANT ENGINEERING January/February 2017 t 3
streams for businesses. formance and is not subject to the constraints
8 t June 2017 PLANT ENGINEERING www.plantengineering.com www.plantengineering.com PLANT ENGINEERING June 2017 t 9
INNOVATIONS MAINTENANCE
INNOVATIONS SOLUTIONS
Adjustable LED lamp
The Lotus Lamp is designed for versatility with a 180 F adjustable mounting arm that allows the lamp to be
Submit new product releases to our New Products for Engineers Database gspplatform.cfemedia.com/pe
Compressed air pipe MAINTENANCE

installed in multiple positions and at different lengths for use in a wide variety of applications. The lamp is
designed for use with recessed cans, canopy lights, parking garage fixtures, parking lot lights, flood/spot
The SmartPipe is a modular, aluminum compressed air distribution system designed with lightweight
materials and simple connectors that can be installed without threading, welding or sweating. Available
in multiple sizes from 1/2 to 6 inches, SmartPipe is ideal for headers and branch lines all the way down to
SOLUTIONS
lights, high ceilings and high/low bays. The LED Lotus replaces anything up to 400 W By Jason Dea and Gary Edwards, Intelex Technologies
the point of use. SmartPipe is made from smooth, calibrated aluminum and
metal halide and high-pressure sodium lamps with up to 80% energy savings. The Lotus
will not rust. It has a low coefficient of friction and provides laminar flow.
has 60,000 hours of rated life and comes with a 20 kA in-line surge protection device
Full bore fittings minimize pressure drop and leak-free connectors prevent
to protect the lamp against disruptive and damaging power surges and transients. The
costly compressed air loss. SmartPipe can be easily integrated into existing
Lotus is completely protected from contact, dust and water splashes.
HyLite
www.hyliteledlighting.com
Input #200 at www.plantengineering.com/information
steel or copper systems and modified to accommodate changing needs.
Kaeser
www.us.kaeser.com
Mobile safety strategy:
Handheld camera
The X6570sc handheld camera is a part of the X6000sc series and is designed
to provide researchers, engineers and scientists with measurement accuracy,
Outdoor IP camera dome
The IKS-WR7413 IP is designed to monitor everything that is happening outdoors
Six things to consider
advanced processing algorithms and connectivity. The longwave perfor-
mance camera records 640 x 512 full frame video at 234 Hz (up to 14,550 Hz
even in complete darkness. With its 3-megapixel video resolution and LED IR illumi-
nators, the camera dome provides high video quality with four simultaneous video
Combine smart devices with flexible technology to provide real-time alerts.
with windowing) with the rapid integration times needed to analyze high- streams. The IKS-WR7413 can be adjusted to cover a wide field-of-view or narrow
speed processes or monitor fast temperature spikes. The camera is sensitive its focus to a smaller area for additional detail, and it is outfitted with four adaptive
enough to distinguish temperature differences down to 20 mK and offers infrared LEDs to capture images up to 25 feet away in the complete absence of light.
O
connection options. The X6570sc also has saved user configurations for effi- Additional capabilities include: recording in two different codecs, integration with rganizations go through significant tools to leverage real-time connectivity, native apps,
cient transfer between test teams. ONVIF-compliant recorders, and memory storage up to 64 GB. evolutions in many areas of their busi- and easy in-the-field data entry, are game changing.
Flir
nesses. The technical challenges in They place employees, not the safety manager, in the
Toshiba
www.flir.com
managing risks around workplace safety center of influence. With mobile devices, data can be
www.toshiba.com
Input #201 at www.plantengineering.com/information Input #205 at www.plantengineering.com/information
are similar in many respects to other parts of the collected on the fly from all personnel. Conversely,
Biodegradable coatings system enterprise: there is software to minimize the hurdles these same field staff and their managers can receive
Handheld production control system The biobased and biodegradable system replaces haz- that impede getting information from a source into data-driven insights and alerts as they go. Mobile
a system which in turn enables the right people to devices unleash potential by exposing and reducing
The Commander XT1000 is a handheld production control system designed as an assembly Belt-type oil skimmer ardous synthetic chemicals with safe, green alternatives
make informed, proactive and actionable decisions. hazards and unsafe behaviors, facilitating broader
aide while collecting critical hydraulic bolting data. The wireless control device will lead the for corrosion protection in metalworking industries. Bio-
The Mini-Skimmer is a belt-type oil skimmer employee (and contractor) adoption and by trans-
operator through each bolt to the correct torque and in sequence and store the data real-time Corr is water-based and designed for preservation of met-
designed to collect over a quart of oil per hour Archaic environmental health and safety (EHS) forming real-time source data lifted from the field
to the cloud. It can also control and operate the pump and tool independently. The Com- als by combining film-forming additives with Vapor phase
despite its tiny housing, measuring just 3 in. x 3
mander XT1000 has its own software, but it can also interface with others. The Commander Corrosion Inhibitors (VpCIs). Ecoline 3220 is a canola oil- programs rely on employees to collect data manu- into instantly actionable intelligence.
in. x 2.75 in. It also is designed to skim unwanted
XT1000 includes a high-resolution camera for recording images of the bolting operation. based, temporary coating that clings to metal surfaces for ally, transpose the information into spreadsheets
tramp oils from coolants and clean wastewater.
Torq-Comm vapor corrosion inhibition and lubrication. Ecoline 3690 is or disparate, disconnected software productsor In the case of incident management, for exam-
The oil skimmer has an on/off switch to allow
www.torq-comm.com an open-air solution for marine and high humidity condi- worse yet, paper bindersand perpetually repeat ple, no reports are complete without some form
users to easily monitor its activ-
Input #202 at www.plantengineering.com/information tions and has no effect this process. Such programs may suffice in meeting of location-based data. GPS and mapping services
ity for machine shops, ultrasonic
on rubber, plastics, or minimum regulatory standards, but they typically are embedded into almost all current smart mobile
cleaners and parts washers. The
Mobile portable compressor skimmer for small machining
paint. Ecoline Cleaner/ fall short due to human error and the sheer quantity devices (phones and tablets) as native apps. Criti-
Degreaser is a soya- of information involved. Absent adequate software, cal location data can be pushed to managers and
The M58 is designed to deliver 210 cfm at 100 psig for rental houses, construction, demoli- operations is portable, with a
based solution designed actionable intelligence is not available to inform employees instantly when on-device apps connect
tion, sandblasting, repair trucks and other demanding applications. The portable compressor stretch-resistant, fiberglass-
for tough cleaning jobs proactive decision-making and preventive actions. with EHS tools.
has a powder coated, fully weatherproofed steel cabinet built to withstand harsh conditions. reinforced cogged belt. It has a
and can be used on all
It also has a single-point lifting ball for easy mounting or dismounting. The eye-level curbside liquid tight housing made of anodized
metals and alloys. The
instrument panel is equipped with a smart electronic controller with a protective metal cover. aluminum and a motor with the high- Mobile devices integrated with EHS
Similarly, all smart mobile devices feature some
cleaner is non-flammable, and all the products in the sys-
The 28-gallon fuel tank is designed to provide extended operation up to 10 est torque for a skimmer of its size. form of a camera capable
tem are VOC, chromate and nitrite free.
hours. Wayne Products of capturing high-quality
Cortec Corporation
Kaeser www.wayneproducts.com photos and videos. Both
www.us.kaeser.com
www.cortecvci.com
Input #207 at www.plantengineering.com/information Beautiful scorecards might light up a c ap a b i l i t i e s a l r e a d y
are frequently used to
80 t January/February 2017 PLANT ENGINEERING www.plantengineering.com www.plantengineering.com PLANT ENGINEERING January/February 2017 t 81
safety managers interest, but the real enrich incident and audit
reporting, but when tied
question to ask is: Does this tool work to EHS systems they
instantly provide essen-
in the hands of my workers who are at tial visual support.
No mobile device is
the frontlines and highest risk? complete without a series
of apps designed to fulfill
Gary Edwards, Intelex Technologies its main purpose: com-
munication. B etween
www.plantengineering.com PLANT ENGINEERING January/February 2017 t 63

SPECIAL REPORT
ENERGY MANAGEMENT
By Kitt Butler, Advanced Energy and Jay Wrobel and Pete Langlois, U.S. Department of Energy
Empowered to cut
wasted energy
DOE program is designed to find and eliminate energy waste.
ISO 50001
I
ndustrial and commercial facilities are big
energy consumers, but they are also big energy ISO 50001 was first developed in 2011 by the Inter-
wasters. According to the Lawrence Livermore national Organization for Standardization, based on
National Laboratory, the industrial and com- the successful ISO 9001 and ISO 14001 standards, to
mercial sectors used approximately 33.5 quads of ener- help organizations establish and maintain an EnMS.
gy in 2016. (One quad is equal to 1 quadrillion British Implementing an ISO 50001 EnMS prepares organi-
thermal units.) Of those 33.5 quads, nearly half15.7 zations to continually improve their energy perfor-
quadswere wasted due to inefficient energy systems mance through holistic and systematic energy man-
or end use. The loss is more than $340 billion dollars, agement that promotes best practices and behaviors.
including $247 billion in the industrial sector. ISO 50001 adoption is proven to produce long-
One way to seek continual and sustained energy term, persistent energy savings through the estab-
performance improvement is through implement- lishment of a culture of managing energy, said Pete
ing a formal energy management system (EnMS). Langlois, energy efficiency and sustainability manager
An EnMS incorporates energy management into an for the DOEs Advanced Manufacturing Office.
organizations day-to-day culture and routine, using Starting with determining the scope and bound-
a framework of procedures and practices that enables aries of the EnMS, the ISO 50001 standard outlines
better monitoring, managing, and improvement of requirements that the management system covers.
energy use. Critically, an EnMS can help ensure these Broadly, these requirements include establishing an
improvements are maintained. energy policy and objectives, supporting a responsible
The U.S. Department of Energy (DOE) and U.S. energy team with executive commitment and develop-
Environmental Protection Agency (EPA), including ing plans to achieve identified energy opportunities.
expanding support from the DOEs Advanced Manu- The primary steps identified in ISO 50001 include:
facturing Office, offer many resources to help more t4FUBOFOFSHZQPMJDZ
organizations do just that. t)BWFNBOBHFNFOUDPNNJUNFOU
Establishing a practice of managing energy com- t&NQPXFSBOFOFSHZUFBN
prehensively allows plants and facilities to be more t*EFOUJGZXIFSFFOFSHZJTVTFE
competitive and functional, saves money, and sup- t$SFBUFQMBOTUPJNQSPWFFOFSHZVTF
ports organizations in meeting sustainability or t)BWFNBOBHFNFOUBQQSPWFQMBOT
energy-related goals. An established energy culture t5SBDLQSPHSFTTBOESFBTTFTTFOFSHZBDUJPOQMBOT
helps produce big dividends by enabling companies
to use their energy more efficiently and reduce losses Although pursuing ISO 50001 requires staffing and
and waste. organizational change, any organization regardless of
Through its 50001 Ready program formed around size or geographical location can implement the stan-
the ISO 50001 energy management standard, the DOE dard and capture savings. The DOE estimates more
is enhancing its ongoing support for EnMS adop- than 12,000 facilities are currently ISO 50001-certified,
tion and allowing more facilities to realize and be and ISO estimates that the standard has the potential
recognized for their long-term energy improvements. to affect 60% of the energy used throughout the world.

SPECIAL REPORT
ENERGY MANAGEMENT
Plan-Do-Check-Act (PDCA) certification. To fill this gap, the DOE has developed
ISO 50001 relies on the Plan-Do-Check-Act (PDCA) 50001 Ready to provide recognition, along with sup-
cycle of continual improvement. porting tools and resources, freely available to a wider
t1MBOIFMQTFOTVSFUIBUUIFBQQSPQSJBUFTUFQTBSFJO QPPMPGPSHBOJ[BUJPOTJOUFSFTUFEJOJNQMFNFOUJOHBO
place to meet a facilitys energy policy. EnMS based on the ISO 50001 structure, whether they
t%PGPDVTFTPOJNQMFNFOUJOHUIFFOFSHZNBOBHF want to ultimately become certified or not.
ment action plans through training, documenta-
tion, operational control, and more. Getting 50001 Ready
t$IFDLJOWPMWFTBOBMZ[JOH NFBTVSJOHBOENPOJ After receiving feedback from facilities certified in the
toring performance and processes in light of the SEP program, the DOE began developing resources for
energy objectives and policy. facilities to have a do it yourself method for institut-
t"DUFOTVSFTUIBUFOFSHZQSPKFDUTBSFDPOUJOVBMMZ ing an EnMS, called the 50001 Ready program. The
considered as a course of business and that energy program emphasis is on broader ISO 50001 process
performance remains an executive level priority. adoption and energy improvement to encourage more
GBDJMJUJFTUPQVSTVFUIF*40TUBOEBSEBOESFBMJ[FFOFSHZ
As the demand for ISO 50001 in the U.S. industrial savings.
and commercial sectors increased, the DOE with sup- Facilities can be part of the 50001 Ready program
port of the U.S. Council for Energy-Efficient Manu- by using the recently released 50001 Ready Navigator
facturing (U.S. CEEM), created the Superior Energy online tool (more information can be found at energy.
Performance (SEP) recognition program. The SEP gov/50001ready). This implementation management
program adds a third-party process to verify the actual resource is free and can be adopted by facilities and
energy performance improvements from ISO 50001 PSHBOJ[BUJPOTBTUIFZBJNUPJODSFBTFFOFSHZTBWJOHT*U
certification. Through SEP, the DOE provides recogni- helps align the best practice guidelines outlined by ISO
tion of ISO 50001-derived energy improvement. 50001 and allows facilities to self-direct and self-attest
While the EPA has developed energy management to their implementation progress by providing work-
guidelines that contain most of the elements of ISO sheets, templates, and team management resources. The
50001, there has been no DOE recognition available 50001 Ready Navigator tool also is structured as an open
for those facilities not interested in pursuing ISO 50001 system so that utilities, trade associations, and others
Getting started with 50001 Ready

Establishing an EnMS requires effort and resources. Accessing t3FDPNNFOETDFSUJGJDBUJPOUPUIF4&1MFBEBVEJUPS
DOEs new 50001 Ready Navigator tool (energy.gov/50001Ready) and
becoming 50001 Ready is a great way to get started for a company ISO 50001 Lead Auditor
of any size. Many helpful resources are available, and experienced t$FSUJGJFEUPMFBE*40DFSUJGJDBUJPOBVEJUBOEQPUFOUJBMUP
consultants with DOE-developed materials and certifications make also support SEP.
great partners for achieving savings.
SEP Trainer
Just as pursuing ISO 50001/SEP requires a commitment of time, t3FGFSFODFEBOEFOEPSTFECZUIF%0&0GGJDFPG&OFSHZ&GGJDJFODZ
effort and resources, so too does being qualified to assist with cer- & Renewable Energy
tification. A number of specialized credentials are needed to walk t"CMFUPMFBE*404&1USBJOJOHFWFOUTGPSJOEVTUSJBMBOEDPNNFS
facilities through the steps. The Institute for Energy Management cial sites
Professionals (ienmp.org) maintains databases of current profession- t$BQBCMFPGGPSNJOHBOEMFBEJOHDPIPSUTXJUIBDDFTTUPBMM%0&
als with these credentials. ISO/SEP presentations and instructional materials
Credentials Overall, systematic energy management allows an organization to

Certified Practitioner in Energy Management Systems- develop a sustainable culture of energy performance improvement and
Industrial energy efficiency. It is an excellent way for commercial and industrial
t*40TZTUFNEFWFMPQNFOUGPSJOEVTUSJBMBOEDPNNFSDJBMTJUFT facilities to elevate their energy management practices, reduce their
t$PBDIJOHBOEDPOTVMUJOHPO*40JNQMFNFOUBUJPO environmental impact, and increase competitiveness.
Superior Energy Performance-Performance Verifier- With the announcement of the 50001 Ready program, the DOE is
Industrial expanding its support to help more facilities realize the savings and
t$BQBCMFPGTFSWJOHPOBO*404&1UIJSEQBSUZBVEJUUFBN benefits from an energy management system.
t$FSUJGJFTUIFFOFSHZTBWJOHTMJOFBSSFHSFTTJPONPEFMUIBUJTEFWFM
oped to SEP standards

can rebrand and use it as they see fit. It is an extremely 1VSTVJOH*40BOE4&1DFSUJGJDBUJPODBOCFB
flexible resource that is ready for wide adoption. SPCVTUQSPDFTT5IF4&1DFSUJGJDBUJPOQSPDFTTJTEFUBJMFE
The 50001 Ready Navigator tool lines up directly with and thorough, so a commitment must be made top-
the EnMS requirements of ISO 50001. It includes 25 tasks EPXO"UBHFOFSBMMFWFM 4&1DFSUJGJDBUJPOSFRVJSFT
that facilities must complete, divided into four sections: three main steps:
t1MBOOJOH 1. Implementing an ISO 50001 EnMS,
t&OFSHZ3FWJFX 2. ( FUUJOH*40DFSUJGJFECZBO4&1RVBMJGJFE
t$POUJOVBM*NQSPWFNFOU lead auditor
t4ZTUFN.BOBHFNFOU 3.3FDFJWJOHBDFSUJGJFEBVEJUGSPNBO4&1WFSJGJDB
tion body showing continued improvement in
The tasks range from setting the scope and boundar- energy performance.
ies of an EnMS to determining significant energy uses
and progressing through management review. When all 5IF4&1 BOE*40
DFSUJGJDBUJPOJTBUISFFZFBS
tasks are complete, the organization can send a request, certification with recertification audits to evaluate whether
if desired, to the DOE for recognition of its 50001 Ready 4&1SFRVJSFNFOUTBSFTUJMMCFJOHNFU
EnMS. The DOE will add the organization to a list of all Many organizations have realized the extensive benefits
50001 Ready facilities, with the option to have this status BTTPDJBUFEXJUI*40BOE4&1$VSSFOUMZ JOEVT
publicly available on the programs website. Although trial and commercial facilities of all sizes in 19 U.S. states
50001 Ready is built around the ISO 50001 standard, BOE8BTIJOHUPO %$BSF4&1DFSUJGJFE BOEUIPVTBOET
having a 50001 Ready-EnMS does not signify ISO 50001 worldwide have an EnMS that more generally meets ISO
PS4&1DFSUJGJDBUJPO5IFTFSFRVJSFBEEJUJPOBMTUFQT 50001 requirements.
including audits and third-party verification. .$PNQBOZ GPSFYBNQMF TBWFTNJMMJPOCZIBWJOH
six locations certified to ISO 50001. The proven perfor-
The value of ISO 50001 mance of our ISO 50001-certified facilities has led 3M
%0&NFBTVSFESFTVMUTPGGBDJMJUJFTBDIJFWJOH4&1DFSUJGJDB UPJODMVEF*40BOE4VQFSJPS&OFSHZ1FSGPSNBODF
tionfor which ISO 50001 is requireddemonstrate that among our strategies to meet our next set of corporate
facilities can attain up to 30% improvement in energy per- energy efficiency goals, said Jean Bennington Sweeney,
formance over three years with paybacks under 2.5 years 3M chief sustainability officer.
(with many facilities reporting less than a 1-year payback). Schneider Electric has at least 21 certified sites. The
The long-term energy and cost savings produced ISO 50001 framework not only builds upon our energy
through such a holistic framework are greater and more management systems, but also help us drive consistency
consistent than those associated with a project-by-project and performance improvements across our locations,
energy improvement system. Many of the savings are said Steve Sacco, Schneider Electric, vice president, Safety,
generated through no- and low-cost operational and pro- Environment & Real Estate. Another example is North
cedural changes. The broader result is a comprehensive, $BSPMJOBCBTFE$VNNJOT XIJDIBDIJFWFEHSFBUFSUIBO
standardized, systematic, and rigorous way to achieve 12% reduction in energy consumption and savings of
verified energy savings and sustain growth for the future. QFSZFBSXJUIBTJNQMFQBZCBDLPGNPOUIT
ISO 50001 allows business leaders to establish a prac- Many utilities also support strategic energy manage-
tice around the use of energy that reduces business risk ment as an energy efficiency program and offer incentives
and improves productivity and operations, said Jay Wro- for performance. However, increasing program participa-
bel, technical assistance manager, for the DOEs Advanced tion continues to be a primary goal. Utilities are beginning
Manufacturing Office. to use the DOE cohort model to add customers, with
The benefits go beyond solely energy and cost sav- utility efficiency and customer engagement resources to
ings, though. Investing in this type of EnMS promotes support coaching. PE
energy efficiency throughout an organization. It leads
to increased employee awareness and stewardship and a Kitt Butler is senior program manager at Advanced
stronger understanding of energy use and consumption. Energy. Jay Wrobel is the manager of technical assis-
Organizations are better able to identify and integrate tance and Pete Langlois is a program manager, both
future projects into their new framework, fostering con- with the U.S. Department of Energys Advanced Manu-
tinual improvement. facturing Office in Washington D.C.

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SPECIAL REPORT
ENERGY MANAGEMENT
By Eric Corzine, Rittal Corp.
Overcome the high cost

of staying cool
Calculate seasonal energy efficiency for your HVAC system.
C
onfusion about the application and The SEER 13 standard is estimated to limit air
accuracy of the Energy Efficiency pollution and reduce fossil fuel consumption by
Ratio (EER) and the Seasonal Energy up to 33 million metric tons of carbon, accord-
Efficiency Ratio (SEER) leaves many ing to the Washington, D.C.-based Environmental
plant engineers struggling to ensure their energy and Energy Study Institute. The U.S. Department
calculations will deliver the most value to plant of Energy estimated 4.2 quadrillion Btu would
operations. be saved between 2006 and 2030 with a SEER 13
Understanding the definitions, calculations, standard. While legislation on the standard has
regulations, and key considerations can provide not been approved, the concepts of SEER are being
clarity on saving energy and money on cooling applied in the industry.
industrial enclosures.
Why does SEER matter?
The difference between Its true that SEER does not apply to industrial
EER and SEER enclosure air conditioners, as theyre deployed
Introduced by the Air Conditioning & Refrigera- to run year-round to cool installed equipment.
tion Institute in 1975, EER measures and compares However, that doesnt mean SEER shouldnt be a
the efficiencies of HVAC unit to another. SEER consideration when calculating potential savings
was signed into law by President George H.W. from energy energy-efficient enclosure cooling
Bush in 1992. SEER is considered an improve- systems. For example, when comparing costs and
ment because it takes seasonal temperatures into benefits of a cooling system retrofit, SEER can be
account to better approximate what happens in useful as a variable to calculate energy savings, a
the actual end use application for the cooling unit. critical consideration in overall plant efficiency.
SEER is calculated by dividing the BTU of cool- Consider the following scenario to demon-
ing output during its normal annual usage by the strate how understanding SEER can be useful in
total electric energy input in watt hours (Wh) an industrial enclosure air conditioning purchas-
during the same period. ing decision. In this example:
t:PVSQMBOUJTMPDBUFEJOUIF(SFBU-BLFTSFHJPO
SEER=(BTU / h) W
t:PVSFSVOOJOHFODMPTVSFDPPMJOHVOJUT GPS
Every air conditioning unit is assigned a SEER three shifts a day, five days a week.
rating. The higher the SEER (for the climate), the
more energy energy-efficient the cooling unit. For t:PVTXJUDIPVUZPVSFODMPTVSFDPPMJOHVOJUT
example, upgrading from a SEER 9 to a SEER 13 with energy-efficient 2600W, wall-mounted
unit can reduce power consumption by 30%. cooling units with a SEER rating of 6.2 (adjust-
A SEER 13 standard was to take effect starting in ed for your temperate climate)
2006 as the standard for optimal energy efficiency.

SPECIAL REPORT
ENERGY MANAGEMENT
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#MVFFBOE#MVFF
Cooling Coefficient = Net Capacity (Watts)
Power Input (Watts)
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PGUIFDPOUJOFOU Total Power Input (Watts)
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Taking steps to upgrade

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SEER ratings is calculated by dividing the

BTU of cooling output during its normal
annual usage by the total electric energy
input in watt hours (W-h) during the same
period. Image courtesy: Rittal

Understanding the definitions,
calculations, regulations, and key
energy performance ratings through EPAs Energy

considerations can provide clarity on
Star Portfolio Manager, an interactive online tool saving energy and money on cooling
that tracks energy and water consumption. The
energy performance of a building is expressed on
a scale of 1 to 100. For example, a rating of 50 indi-
industrial enclosures.
cates that the building performs better than 50%
of all similar buildings over the course of a year. trial enclosure with energy-efficient air condition-
When it comes to evaluating the cooling efficiency ing units can significantly prolong the life of your
of enclosures, its important to know how much heat equipment, save energy, and reduce downtime, its
energy the air-conditioning system must remove. time to address the purchasing process.
One way to figure this out is to add up the heat Besides EER, SEER, AND SCOP measurements,
loads of all electronic components as specified by here are some other factors to consider before mak-
their respective manufacturers. Another is to add ing your purchase.
up the power, P, that the electronics consumes and tC ooling Output Measured in watts, this is
then multiply it by one minus the efficiency, E, of the ability of the cooling device to remove heat
the system: from a system. Also sometimes measured in
tons, as 1 ton of refrigeration is freezing 2,000
P(1-E) pounds of water at 32F for 24 hours.
The number you reach will define the need for tInternal Heat Load the This is the amount
cooling capacity. of heat energy that the electronics inside the
Also, several sizing software tools are available enclosure produce. Its important to know how
to help you figure out how enclosure air condition- much heat energy (in Btu/hour or in watts/
ers will perform. Some even walk users through hour) is generated in the enclosure before shop-
the application factors and determine the need for ping for an air conditioner that has enough
cooling, and can calculate the internal enclosure capacity for your needs.
temperature and suggest an appropriate air con-
ditioner with the best cooling capacity relative to tMains Operating Frequency In North Ameri-
power consumption. ca, 60 Hz is the norm (compared to 50 Hz in the
For example, consider an enclosure air conditioner rest of the world), so when an air conditioner
with a cooling capacity and power consumption at operates at 60 Hz, its fans and compressor rotate
95/95, 60 Hz of 2,700 W and 1,500 W, respectively. faster and cools somewhat more efficiently. If
Then = 2,700/1,500 = 1.8. shopping outside of North America, its helpful
This energy cooling factor was arrived upon by to know that some units are dual-rated so they
taking the ratio between useful cooling capacity and can operate at both 50 Hz and 60 Hz.
power consumption:
Industrial plant operators and managers are pay-
= k/Pel ing more attention to enclosure climate control,
(k = useful cooling capacity, W and Pel = power and the most efficient means of keeping equip-
consumption, W) ment housed within them cool. This is a good
thingeven if we dont yet have formal standards
We also know that with enclosure air conditioners, for testing and establishing cooling capacities in
internal and external humidity affect performance. North America.
As you consider systems with the most reliable ways Whats important is to get ahead of existing and
of discharging condensate from the enclosure, you future air conditioning unit ratings and regulations,
may want to investigate advanced fan and filter units and educate yourself on making the best decision
with condensate evaporators to eliminate moisture. that fits your plants operating needs and budget. PE
Making the right decisions Eric Corzine is climate control product manager at
Now that we have established that cooling indus- Rittal Corp.

SPECIAL REPORT
ENERGY MANAGEMENT
By Mark Harshman, Siemens
Control room temperatures:

Strategies to beat the heat
Air-to-water exchangers can reduce VFD heat exposure.
he installation of large, medium-voltage Unfortunately, high-horsepower medium-voltage
T VFDs in mechanical equipment rooms

creates the problem of harmful ambient
room temperatures. This means facil-
ity managers and plant engineers must mitigate the
heat generated by VFDs. The room temperature must
VFDs generate large heat loads into the equipment
room, requiring large air conditioning units. For
example, a 6000Hp VFD might require an HVAC
unit at an initial cost of more than $200,000, as well
as additional operating costs associated with utility
remain low enough not to harm equipment and to meet use, and relatively low reliability.
OSHA standards for technicians who must operate Some VFD topologies allow remote location of
or maintain equipment in the room. primary heat generators such as transformers. How-
Most electrical equipment of this type is speci- ever, this removes only 50% of the heat load and
fied to operate at a 104F ambient air temperature, requires additional site work to locate the transformer
which may be too warm for operators working over remotely, and it increases the cost of running power
an extended time. Automation and computer equip- cables from the transformer to the power electronics
ment, which share the equipment room, may not be section of the VFD.
rated to operate at these temperatures. Although the use of air-to-air heat exchangers has
Several methods have been used to address the heat been a relatively new approach, it has been used
load caused by electronic power systems in enclosed successfully to eliminate the need for air condition-
M More
rooms. These include: ing entirely by creating a closed-loop air system for
7UDGLWLRQDODLUFRQGLWLRQLQJ the VFD and a secondary loop which is exhausted
SOLUTIONS 5HPRYLQJODUJHUKHDWJHQ
externally to the environment. These systems have
been around for several years and can quickly provide
KEYWORD: erators (e.g., transformers) a two- or three-year payback when compared to an
Heat Exchangers at equivalent air-conditioning systems initial cost and
PlantEngineering.com +HDWH[FKDQJHUV yearly operating utility costs.
ARTICLE: Applying heat exchanger
These approaches all have Air-to-water exchangers
control strategies
a place and are dependent on A recent improvement to the problem of equip-
ARTICLE: Cabinet electronics: several variables including ment room heating is the modification of air-to-air
Thermal considerations plant location, environmental heat exchangers to air-to-water exchangers. The
ALSO: OSHA recognizes heat conditions, VFD topology, exchanger is integral to the VFD and provides a
stress as an area covered under its equipment type, desired reli- much smaller footprint, lower capital, and operating
General Duty Clause Section 5(a) ability, and available space. costs. It also can provide additional cooling benefits
(1), requiring employers to mitigate The use of conventional air when a VFD is running at lower than rated loads
recognizable hazards. The full text conditioning units has been and speeds.
of the General Duty Clause is at implemented the most fre- This approach can be applied in plants where
osha.gov. quently. process water is available. The water can be used

VFDs
Variable-frequency drives control the speed of an ac motor, which provides flexibility to
the process since speed can be changed easily for process optimization. It takes the fixed
power supplied to it and converts it into a variable frequency and variable voltage source
which then feeds a motor. This allows the drive to control the speed and torque the
motor produces. A VFD may enhance the users profitability by improving the process,
which in turn produces a faster return on investment.
Source: Plant Engineering Website
to circulate in a heat exchanger and remove heat The use of air-to-water heat exchangers allows
generated by a VFD. the room air to cool a VFD and hot exhaust air.
The use of air-to-water heat exchangers allows Image courtesy: CFE Media archives/McGuire
the room air to cool a VFD and hot exhaust air, Engineering
which normally exhausts into an equipment room
and is cooled by an air-conditioning system, to
flow through a radiator where the heat is carried
away by the water while the cool air is returned
into the room. This is a completely closed loop
air system which maintains the temperature in
an equipment room. The approach also isolates a
VFD and other equipment from potentially haz-
ardous or caustic environmental contaminants,
eliminates air conditioning requirements for the
VFD, and can cool the room and other equip-
ment if the VFD is running lightly loaded or at
a reduced speed.
This approach is applicable only where plant
water is readily available. In those cases, chilled
water, when sufficiently cooled, can improve the
operation further and eliminate all HVAC require-
ments. The exchanger is sized to handle the heat
generated by the VFD when it is running at its
full rating. The design allows for up to 95F inlet
water at 15-30 gallons per minute (gpm), but the
air exhaust temperature will be approximately
41F warmer than the inlet water temperature.
Chilled water below 77F will yield a lower
exhaust temperature and can lower the ambient
temperature of an equipment room.
New designs aimed at reducing HVAC costs are
available now and can be tailored to a specific
plant location and site environment. These new
ideas can eliminate costly HVAC and improve
plant economics in terms of energy costs, reli-
ability, and efficiency. PE
Mark Harshman is a power electronics engineering

leader for Siemens.

We proudly salute manufacturing innovation
and invite you to explore and celebrate
the success stories of these participating
manufacturing innovators:
AutomationDirect Mapcon
AVO Training Institute Mil-Comm Products Co.
Baldor MovinCool
Caml Air Pollution Control Phoenix Contact
Carlo Gavazzi Inc. PRUFTECHNIK Inc.
Century Spring Corporation Rittal Corporation
Eruditio Rogers Machinery
Flexicon Corp. SEW Eurodrive Inc.
GTI Spindle Technology SPM Instrument Inc.
Kaeser Compressors Vac-U-Max
Lubriplate
Look for the special Innovations videos at:

www.plantengineering.com/innovations
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Designed for Food Safety: Dodge Mechanical Products

and Baldor-Reliance Motors
Food and Beverage processing equipment should be designed, used, and maintained with
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Long before we invested in the people, equipment and

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!$'/!#($,#*)-"$)$'(,#+()$*')
and attention in listening to equipment designers, operators a
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%'$((#%%!)$#(#)$$#+'#*()'- $
notes when they shared their wish lists of product capabilitie
That was over 30 years ago, and were still listening to customer input.
That is why Baldor-Reliance Stainless Steel motors and Dodge Ultra Kleen gear reducers are
engineered to meet the toughest demands of food production and processing. These products
have been designed, tested and certied to meet IP69K requirements for water protection, and
provide the necessary protection from severe washdown conditions without allowing caustic
chemicals or water to enter the product.
Baldor-mediarelations@abb.com | 479-646-4711 | www.baldor.com

Camfil APC Helps Keep Plants Safe, Clean and Compliant

Caml APC designs quality, technologically operating expenses. They can perform a battery
advanced equipment to help plants clean up the of tests on dust samples and simulate specic
dust, mist and fume created from manufacturing challenges to make more informed decisions on
processes. They improve employee health and equipment, lter cartridges and engineered controls
help plants go green by stopping thousands of to mitigate dust hazards. Tests include particle size
different pollutants from entering the workplace analysis, moisture analysis, abrasion and terminal
and outside air. velocity testing.
Dust, Mist and Fume Collectors for all The company also has a rig dedicated for ANSI/
Plant Applications ASHRAE Standard 199 testing. The test rig
Caml APC offers a complete provides manufacturers with real world, apples-
line of dust, mist and fume to-apples comparison data on emissions, pressure
collectors for use in many drop, compressed air usage, energy consumption,
industries. All equipment and and emission readings for Caml APC dust
lters are manufactured at collectors. They can see what it really costs to
the ISO 9001 certied facility operate the collector over time and make accurate
in Jonesboro, AR. system comparisons.
The agship dry dust Comprehensive Training

collector is the Farr Gold Caml regularly conducts two-day training sessions
Series , used in hundreds of on the operation and maintenance of its Farr Gold
manufacturing plants. The Series dust
Quad Pulse Package is a collector system,
compact dry dust collector. proper techniques
The Handte EM Pro and Oil for industrial
Expert systems collect coolant and oil mist, and the ventilation, and
Handte Vortex wet scrubber is a low maintenance compliance with
dust-collecting option that uses water as the lter. National Fire
Protection As-
sociation (NFPA)
standards
for explosive dust.
Trainees learn
about dust
collection
technology
through hands-on,
interactive sessions. Topics include: Types of
Dust testing and ASHRAE Standard industrial dust collectors, lter options, ammable
199 Testing and combustible dust, NFPA regulations on dust,
Caml APC offers testing services that help variable frequency drive programming, and start-up
manufacturers select the best dust collector for procedures. Attendees will also visit the test labs,
their application, with the lowest energy and showroom and manufacturing facilities.
800-479-6801 or 870-933-8048 | lterman@caml.com | www.camlapc.com

Eruditio: Education, Application, Innovation

Inspired Blended Learning for Reliability Leaders
The rst of its kind, the iBL platform has received exemplary reviews from all those who have
journeyed through the program. iBL is a self-paced, project based, blended learning curriculum that
mixes classroom learning, online learning, professional coaching, and on-the-job execution for maxi-
mum results. It can be used to train Reliability and Maintenance Engineers, Planners and Schedulers
and Maintenance Managers just to name a few. Graduates enroll expecting to see at least a 10X
return on their training investment, however the last graduating class averaged a 30X ROI! It is the
only Blended Learning curriculum indorsed by the University of Tennessee RMC
and graduates can receive the RMIC credentials from UT upon completion of
their improvement project.
To see the students talk about their experience visit ibltraining.com.
Augmented
Reliability
Eruditios augmented
reality platform, Augmented
Reliability , is a shining
example of how this team
innovates and develops
new and exciting ways to
bring education into the
modern age. Using a mobile
device, users can scan a
target image and experience
a lesson using 3D animations,
audio, videos, and more, right
there in their environment.
The application goes beyond typical educational lessons. Imagine scanning a motor, pump, or
electrical panel, and seeing a bill of materials, or an inspection procedure that shows you where to
perform each action. No more guess work, and fewer mistakes.
AR is the future. I believe it is going to be as big a part of our lives as cell phones today.
The demand is growing and the technology is evolving and improving constantly, said Creative
Director, Jon Bailey.
Cutting Edge eLearning Development
One of the staples of Eruditio has been eLearning. As working adults, its hard to take weeks to
travel the country for training. eLearning allows the users to take the courses anywhere, and at their
pace. They also offer a level of standardization and repeatability of content that does not exist in
the traditional instructor led world. Eruditio is constantly building content for their students, let them
build custom content for you too.
info@eruditioLLC.com | 843.375.8222 | www.erudtioLLC.com

Flexicon stand-alone bulk handling equipment

to engineered, plant-wide systems
Choose from a broad range of reliable, high
performance equipment:
2 Flexible Screw Conveyors 2 Bulk Bag Dischargers
2 Volumetric Feeding 2 Bulk Bag Conditioners
Conveyors 2 Weigh Batching Systems
2 Tubular Cable Conveyors 2 Manual Dumping
2 Pneumatic Conveying Stations
Systems 2 Drum/Box/
2 Bulk Bag Fillers Container Dumpers
Continuous growth required the company to recently double
the size of its US headquarters.
A separate Flexicon
Flexicon provides an unparalleled level of service Project Engineering
through its administrative, engineering and manufac- Division manages
turing capabilities on four continents, and extensive large-scale bulk
worldwide network of applications engineers, authorized handling projects
representatives and eld support techniciansa unique across the chemical,
consolidation of bulk handling specialists with hundreds mineral, food, dairy
of years of combined experience. and pharmaceutical
industries worldwide.
An extensive research and development program
continually sets new standards for bulk handling Supervised by
equipment performance with entirely new designs, dedicated Project Managers, these custom-engineered,
product improvements and equipment that complies with automated systems integrate Flexicon equipment with
chemical, food, dairy and pharmaceutical requirements bulk handling and process equipment of other
nationally and internationally. manufacturers including:
Flexicons design engineering staff devises efcient 2 Gravimetric/Volumetric 2 Screeners

solutions to the most unusual problems with highly Feeders 2 Crushers/Grinders
custom equipment, endowing the company with a depth 2 Silos and other 2 Packaging Machines
and breadth of bulk handling experience unequalled by storage vessels 2 Other bulk
any other manufacturer. 2 Dryers/Coolers processing equipment
2 Mixers/Blenders
Equipment overview
Flexicon is a world leader in the design and manufacture Basic, stand-alone
of bulk handling equipment and custom-engineered and machines to
integrated plant-wide systems that transport, discharge, automated
ll, weigh, blend, deliver and/or feed a broad range of plant-wide systems,
powder and bulk solid materials. all Flexicon
equipment is backed
Products range from individual equipment to automated by Flexicons Lifetime
systems that source bulk material from interior and Performance
exterior plant locations, transport it between process Guarantee.
equipment and storage vessels, weigh it, blend it, feed it
to packaging lines, extruders, molding machines and
storage vessels, and load it into railcars and trailers.
+1 610 814 2400 | sales@exicon.com

www.exicon.com

Custom Solutions from a Tradition of Innovation

With a heritage that extends back to 1919, the built-for-a-lifetime
Kaeser Compressors is a leader in manufacturing reliability you expect
compressed air equipment and helping customers from the Kaeser name.
around the world assemble those components into
the most reliable and energy efcient systems Energy efciency and
possible. With a cutting edge research and remote operations are
development team committed to building industry- supported by our Sigma
leading products, innovation is our lifeblood. Air Manager 4.0, which
Kaesers custom engineered compressed air precisely controls air
systems are yet one more way we deliver lasting production to meet your
value to our customers. pressure needs as well
as offering energy
consumption and opera-
tional information via Solutions for rental systems or whenever
your choice of industrial portability is critical are also available.
communications interfaces.
Kaeser isnt intimidated by demanding applications.

Our commitment to designing the best engineered
solutions results in compressed air systems that
remain reliable even in the toughest of applications
in the harshest of environments.
Our custom enclosures are ideal for installations where floor space is limited.
There is nothing cookie-cutter about our

engineered air solution envelopes. Our team of
designers works with you to determine your
system needs, select the optimal mix of equipment
and then design a skid, container or custom
enclosure to suit the operating environment. We
can also produce 2D and 3D CAD drawings of the kd k l ly
proposed system to facilitate installation planning. piped and wired, ready for operation.
Our turnkey enclosures and skids integrate our We invite you to watch the Custom Containerized
superior quality air compressors, blowers, Systems by Kaeser Compressors time-lapse video:
dryers, lters, and other system components www.youtube.com/watch?v=leHRqSGnib8
into rugged systems built to specication for any
climate or location. Each and every component Contact us today for a custom solution for your
is selected for optimal efciency and is backed by compressed air needs.
866-516-6888 | customer.us@kaeser.com | www.us.kaeser.com/engineeredsolutions

Lubriplates Complimentary ESP Extra Services Package

helps maximize your lubrication maintenance program
Complimentary Value Added

Services Offered Include...
A Toll Free Technical Support Hotline and E-mail

You can call Lubriplates technical service center toll free at 800-347-5343 for
quick answers to tough lubrication questions by phone, or you can e-mail
questions to LubeXpert@lubriplate.com seven days a week.
Complete Plant Surveys and Lubricant Inventory Consolidation

Complete plant surveys by Lubriplates professional staff of lubrication engineers
are also available to determine your exact lubricant requirements and identify
opportunities for lubricant inventory consolidation.
Color Coded, Lubricant Specification, Machinery Tags

Lubriplate offers customized, color coded machinery tags to help prevent lubricant
misapplication and ensure that the proper lubricant is used when servicing a
particular piece of equipment. Based on a complete plant survey, tags can be
provided for each piece of equipment in your plant.
Lubrication Maintenance Software

Lubriplate offers a PC based computer software program that puts your entire
lubrication and maintenance schedules at your ngertips. This service is based
on a complete survey of your entire plant. Contact Dan Moroses (Newark ofce)
for details at 973-589-9150.
No-Charge Follow-up Oil/Fluid and Grease Analysis

Lubriplates Oil|Fluid and Grease Analysis Program is offered at no-charge on all
Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment
and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO
Cleanliness (optional). An interpretation of the results is included along with
suggested actions to take.
In Plant User Lubrication Training Programs

We offer training programs tailored to your needs. These educational training
sessions focus on all facets of machinery lubrication and are not a sales
presentation. Seminars are graphically presented with overheads and other
support material. Available on-site at your facility or in a local conference room.
Contact us at 800-733-4755 for more information.
/XEULSODWH/XEULFDQWV&RPSDQ\
1-800-733-4755 | www.lubriplate.com | LubeXpert@lubriplate.com
MAPCON Mobile
Lets You Bring Your CMMS Anywhere!
Mapcon Technologies, Inc. has been creating CMMS
software since 1982. Many innovations have come
along in the past 35+ years, but perhaps none more
important than mobile technology. In order to adapt
to the growing demand, Mapcon created their own
mobile CMMS - called MAPCON Mobile.
Despite common complaints that people spend too

much time on their phones, making use of a mobile
app can help companies save time and money.
Portability
MAPCON Mobile allows users to carry their CMMS
system with them wherever they go! Maintenance
professionals can create work requests from the
oor, and even attach images for added clarity
and accuracy. Sending requests instantly from the
oor instead of wasting time trekking back to a PC
can help decrease machine downtime, and save
companies money.
Take your reports on-the-go! With MAPCON Mobile,

reports can be generated straight from a users
mobile device. Reports display as PDF documents
right on an employees smartphone or tablet.
MAPCON Mobile makes creating Mobile Alerts

work requests with pictures a breeze! For added convenience, MAPCON Mobile also
includes notications. Even when a user doesnt have
the app open, they will receive notices when something requires their attention. Knowing
immediately when a purchase order needs approval or when a work order has been sent
can really help get repairs made and parts reordered in a timely manner.
Attachments
MAPCON Mobile allows images to be added to work requests, which can help with repairs.
A picture of needed repairs can be attached, which will help clarify the exact issue for
the maintenance technician. Additionally, a document such as an instruction manual or
warranty can be brought up on a users mobile device if it has been attached to equipment
or work requests. Staff equipped with a mobile device and MAPCON Mobile can carry all
the power of an unlimited maintenance library right in their pocket.
Phone: 800-922-4336 | sales@mapcon.com | www.mapcon.com

Protecting people, processes and equipment

MovinCool brings cool, refrigerated air to
production lines without the need to spend hundreds
of thousands on 100 or more tons of cooling. Movin-
Cool portable AC units help reduce the risk of heat
exhaustion and increase employee morale, leading to
improved manufacturing quality and productivity.
MovinCool spot cooling

units prevent product
defects by eliminating
warping and conden-
sation due to excess
MovinCool, the worlds largest manufacturer of heat and humidity. Our
commercial spot air conditioners, offers a wide portable AC units reduce
range of models, with capacities from 10,000 to 60,000 processing time for most
Btu/h. MovinCool protects people, processes and heat-related production
equipment from their hottest environments as well as processes by up to 94%.
provides moisture removal.
Within the air condition-
MovinCools portable models can be quickly wheeled ing industry, MovinCool has a reputation for highest
into place whenever needed, with virtually no quality. Dealers who specialize in spot air condition-
installation required. The companys latest portable ers, and who stand to lose signicant prot if they
heat pump models combines both cooling and have to replace a unit once it is installed, consistently
heating capabilities in a single, self-contained unit. say they prefer MovinCool air conditioners because
Applications include: of their superior reliability.
< IT data centers, computer rooms, server and MovinCool is a brand of DENSO, one of the
telecom closets worlds largest manufacturers of automotive parts.
< Hospitals, laboratories DENSO supplies advanced automotive technology,
< Ofces, schools, temporary buildings systems and components, including air conditioners,
< Warehouses, factories, food-processing facilities to all of the worlds major car manufacturers.
< Outdoor sporting and other events, movie sets In the 1980s, DENSO pioneered the concept of
< Moisture removal (disasters, construction sites) workspace spot cooling to meet its own factory
needs. Since then, MovinCool has developed spot
For more than thirty years, MovinCools Classic & cooling systems to accommodate many different
Classic Plus series of industrial air conditioning units applications. For more information, please visit
has provided effective cooling solutions for factories, www.movincool.com/industrial-cooling
warehouses and workplaces.
(800) 264-9573 | info@movincool.com | www.movincool.com

Smart Redundancy Modules

Save Critical Applications
The high degree of availability of machines and systems installed across the world is a key
prerequisite for business success in any industrial sector. Increased protability can only come
from continuously powered control-cabinet components. For this reason, users are increasingly
implementing redundant
power supplies. These
are frequently combined
with redundancy modules,
such as ORING modules
from Phoenix Contact.
Monitoring the
load current
If one of the two power
supplies in a system fails,
the second unit must be
able to support the entire
load. If the load current
exceeds the output
capability of that single power supply, the system will fail. For that reason, the load must be
monitored to indicate the loss of redundancy when the load current surpasses the output of any
single power supply. Phoenix Contact ORING modules inform users of this overload remotely.
Increase service life

As a result of irregularities when output voltages are congured unevenly, often only one power
supply unit feeds the load while the other device idles. This places thermal stress on the power
supply, which reduces the life of the device. If both power supplies are operated at half the rated
power, their temperature would decrease, which increases service life. Phoenix Contacts proprietary
Auto Current Balancing (ACB) technology integrated in the ORING modules effectively doubles the
service life of the redundant power supplies, ensuring that both power supply units load evenly.
ORING modules monitor the complete redundant system extending from the output voltages of the
power supplies through the wiring and the decoupling section up to the load current . The oating
Redundancy OK and ACB OK signal contacts, as well as the LED displays, are used to monitor the
units proper operation. The load utilization of the power supplies is transparently displayed as a bar
chart. Users are quickly informed about various states, allowing them to immediately spot and
resolve problems.
In sensitive applications, a redundant conguration of the power solution ensures high availability.
In this context, corresponding power supply concepts are recommended. Depending on the
application, ORING modules provide the highest form of redundancy and monitoring
(800) 888-7388 | info@phoenixcon.com | www.phoenixcontact.com/oring

High-Quality, Affordable Enclosure Solutions

for Any Industrial or IT Application
only is energy consumption far less than with
conventional technology, but the improved cooling
leads to longer service life of the components inside
the enclosure and the cooling unit itself.
TS 8: The Worlds
Most Adaptable Enclosure
The TS 8 has sold more than 10
million units around the world
and is one of Rittals most
popular enclosure products.
Available in carbon, 304 and 316
stainless steel varieties for
various environments, this
enclosure cabinet has the ability
to bay with other cabinets on all
sides, can be assembled by one
individual, and has a remarkable
Rittal designs and manufactures the worlds number of congurations
leading industrial and IT enclosures, racks and possible for internal
accessories, including high efciency, high density electronics placement.
power management and climate control systems
for industrial, data center, outdoor and hybrid Combined with Rittals climate control and power
applications. Rittals off-the-shelf standard, modied distribution systems, the TS 8 enclosure safely and
standard and custom-engineered products are efciently protects electronic equipment, control and
known throughout the world as high-quality, processing systems in the harshest environments.
affordable solutions for practically any industrial or
IT infrastructure application from single Versatile, Durable Wallmount Enclosures
enclosures to comprehensive systems. Rittals wallmount portfolio is available in over 100
standard sizes in both carbon and stainless steel
Up to 75% Savings in Energy Costs models. NEMA-rated for
Rittals Blue e+ is a completely new generation of strong protection with
cooling units that represents a quantum leap in terms knife-edge perimeters,
of cost-effectiveness and energy conservation due to they also feature secure
its speed-regulated components and patented heat locking systems and
pipe technology. As well as providing far higher energy foamed-in-place gaskets
efciency than existing cooling solutions, the units also for dust and moisture
offer a range of powerful new features that provide prevention. Easy to
longer component life, exibility and ease of use. install, these wallmounts
offer vast exibility due
Unique inverter technology provides to maximum use
cooling output that is always exactly of interior space.
the amount needed at the time. Not
customerservice@rittal.us
(800) 477-4000
www.rittalenclosures.com

SEW-EURODRIVE Power Transmission Innovation

MOVIGEAR
The MOVIGEAR Mechatronic Drive System for horizontal-
materials handling from SEW-EURODRIVE sets new standards
in terms of efciency and functionality. MOVIGEAR not only
combines the gear unit, motor and drive electronics within one
highly reliable, efcient, and hygienically designed unit, it also
reduces total start-up cost and annual operating costs in your
material handling systemby as much as 50%!
IE3 Compliant DRN.. Motor

Our new DRN.. induction motors meet the stringent IE3 super-p
energy efciency standard. They also t existing gear units g
for easy upgrades and retrots of existing DRE (IE2) gearmoto
The weight and dimensions of the new DRN motors have only
marginal changes as compared to the DRE series. Due to its
outstanding system stability, tight control, and high-cycling
capacity, the DRN.. electric motor can replace a servo motor
in many cases. Plus, its multiple brake sizes allow a higher torq
for a stopping brake or a lower torque for a VFD holding brake
nally, its wide HP range and various connector options enab
DRN motor to be used in a wide variety of new and retro-t applications.
DRC Electronic Motor

The DRC electronic motor provides an ultra-efcient motor a
electronics package for those gear units already installed in y
system. Like MOVIGEAR, the DRC electronic motor consists
permanent-eld synchronous motor with integrated drive
electronics in a completely enclosed housing. The DRC
electronic motor offers greater exibility allowing it to moun
to any gear unit plus, offers an optional mechanical brake.
About SEW-EURODRIVE
Engineering excellence and customer responsiveness disting
a leading manufacturer of integrated power transmission and motion control systems.
SEW-EURODRIVE solutions set the global standard for high performance and rugged reliability
in the toughest operating conditions. With its global headquarters in Germany, the privately held
company currently employs over 16,000 employees with a presence in 48 countries worldwide.
U.S. operations include a state-of-the-art manufacturing center, ve regional assembly plants,
more than 63 technical sales ofces and hundreds of distributors and support specialists.
This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-
coast and around the world.
SEW-EURODRIVE, Inc. | Tel: 864-439-7537 | www.seweurodrive.com

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Electrical Safety Compliance Assessment

Electrical accidents are described by OSHA as one of their Fatal Four.
Thats why it is essential to have an Electrical Safety Program that meets the
comprehensive compliance standards and regulations established by OSHA,
NEC, NFPA, IEEE, NESC, ANSI and other governing bodies.
Because these assessments can be time-consuming, complex and confusing,

AVOs team of Electrical Safety Specialists are ready to walk you through it.
We will come to your facility and conduct an audit that covers all ve key
components of the Electrical Safety Program (illustrated below) or assess
the individual components you choose.
The components of an assessment Be prepared for an OSHA Drop-Out random

visits. Staying safe and compliant isnt a choice,
1. Assess installation for NEC and OSHA compliance
but whom you choose
2. Electrical Hazards Audit for NFPA 70E, NESC and
as your electrical safety
OSHA 1910.269 Standards
partner is. Choose
3. Review facilitys Electrical Safe Work Practice for
AVO Training Institute.
compliance with current standards and regulations
4. Assess Personal Protective Equipment for
safety compliance Please visit
5. Recommend Electrical Safety Training for www.avotraining.com
employee: the next step to compliance for more information.
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A Global Force With Electronic Automation Components

Founded in 1931, CARLO GAVAZZI is a multinational electronics group
active in the design, manufacture and marketing of electronic and electrical
components for industrial automation and building automation.
With several ISO9001 and ISO14001 certied manufacturing and R&D

facilities throughout Europe and Asia, and dozens of sales ofces spanning
the globe, you are assured that product support, service, and inventory are
only a phone call, email or mouse click away. CARLO GAVAZZI products
are developed and manufactured in full compliance with the most important
standard regulations, such as UL and CSA.
Typical customers are original equipment manufacturers (OEMs) of

packaging machines, injection molding (plastics) machines, agriculture machines, food and
beverage production, conveying and materials handling equipment, door and entrance
control systems, parking guidance systems, elevators and escalators as well as
heating, ventilation and air conditioning devices. System
integrators and distributors are typically the channels
we utilize to reach the market.
sales@CarloGavazzi.com | 847.465.6100
www.GavazziOnline.com

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Century Spring Advances Custom Capabilities

Including Ultra-Durable Exotic Alloys
Springs manufactured with exotic alloys can lead to longer lasting parts
that resist severe environmental strains better than traditional materials
For decades, Century Spring has been the premier supplier of American made
in-stock spring solutions, with over 35,000 spring designs ready for same day
shipment. Century has also served the unique needs of OEM and MRO markets
through ever expanding, on demand, manufacturing capabilities. Century Spring
produces a broad variety of custom parts to serve virtually any need and in recent
months has added an array of state-of-the art CNC coiling and bending machines capable of producing incredibly
accurate parts at very high speeds. These machines are equipped with advanced measurement tools that ensure
every part produced meets quality and consistency expectations.
Century has also worked extensively to advance expertise in the production of parts using exotic alloys
such as Elgiloy, Inconel and 316 Stainless Steel materials useful for high/low temperature and corrosive
environments. They can also be used to produce more durable parts for simple
applications. Exotic alloys have a higher initial price tag, however, when used for
the right application, can result in signicant savings over time and ensure better
operating efciency and dependability. Centurys team of skilled engineers are
available on-demand to help identify and design the best part for any need.
Century welcomes any questions about these new advancements. Contact them
today at custom@centuryspring.com, 800-237-5225, or visit www.centuryspring.com.
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iPad and the IIoT

When you think about leading innovators of the 21st century, Apple is always
at the top. Through the creation of the iPhone, iPad and apps, Apple has changed
the way we interact and monitor our world. GTI Predictive leverages technological
advances like the iPad to bring the industrial reliability maintenance community
a powerful, affordable, and industry changing solution.
Combining different technologies as apps for the iPad, the GTI Predictive Platform
is changing predictive technology. The iPad platform provides apps for vibration
data collection and analysis, eld and shop balancing, infrared thermography,
laser shaft alignment and more. Data is stored in our Cloud-based web app for
ubiquitous analyzation and dissemination.
Using many tools already found in the iPad, GTI Predictive Technology can provide unique solutions within our
powerful apps integrated reporting, GPS location, photos in route mode and reports, communication through
email and data sharing between apps.
VibePro7: route data collection, onsite analysis and remote web based vibration data analysis.
BalancePro: single and two channel balancing for both inboard and overhung machines.
ThermoPro: capture thermal images and in-app reporting with the FLIR One
camera attachment for iPad.
GTI@lign: after diagnosing misalignment through vibration
and phase correct with wireless laser shaft alignment. info@gtipredictive.com | 603.669.5993
www.gtipredictive.com
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Machine-Tough Synthetic Lubricants

Advanced Technology for Problem Machines and Equipment
Use MIL-COMM Extreme Performance lubricantsengineered for U.S.
Military heavy weaponry systems requiring the ultimate in heavy load,
extreme pressure, anti-corrosion and extreme temperature performance.
Now available for your ght against friction and equipment failure. Proven to
signicantly outlast and outperform traditional commercial lubricants
delivering quality improvements and cost savings to your business.
Make machinery and friction parts
work to maximum efciency. Drastically reduce downtime.
Improve parts durability Save electricity and fuel costs. MIL-COMM lubricants for the most demanding
machine and equipment applications.
extend the life of machinery. Boost return on investment.
MIL-COMMs propriety micro-particle technology and uniquely engineered synthetic oils and
performance additives go to work on problem machinery and plant equipment, solving issues
other lubricants simply cannot. Corrosion-resistant and cold-weather tough at 70 F to + 450 F.
Used globally in Arctic, desert and tropical environmental conditions.
Available in a range of viscosities and formulations for ideal use, including TW25B synthetic
grease; MC2500 synthetic oil; MC3000 synthetic semi-uid lubricant, ideal for lubricators,
and MC1210 Heavy Grease. Custom-engineered lubricant solutions for specic machine 201-935-8561
tasks are also available. info@mil-comm.com
FREESAMPLESTOINDUSTRY-QUALIFIEDPROFESSIONALS www.mil-comm.com
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ROTALIGN touch: Precision meets Connectivity

Cloud-based shaft alignment system that combines
precision measurement with mobile connectivity
ROTALIGN touch achieves optimal machine performance and

product quality. Its features include Softfoot diagnosis, thermal
growth trending, and vibration spot check to measure overall
values, vertical machine alignment, and cardan shaft alignment.
Its tablet-like touchscreen with 3D display enables a fully intuitive and visual work sequence.
Additionally, the device includes a 5 Megapixel camera, RFID system, and a Cloud-based alignment
structure. The RFID reader allows unique identication of each machine and facilitates retrieval
of its last alignment le stored on the ROTALIGN touch computer. The built-in camera lets users
customize reports with photos. The onboard WiFi and Bluetooth feature enables devices to send
measurement results back from any location directly via the Cloud.
PRUFTECHNIK offers trainings and free rmware upgrades for the ROTALIGN touch.

www.pruftechnik.com/us

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World Leader in Oil-Free Air Compressors

The Kobelco KNW Series Kobelco KNW Series oil free
compressors are designed, assembled, manufactured and tested in
the USA by Rogers Machinery Company and Kobelco Compressors
Manufacturing Indiana. Together, we are the premier manufacturer,
packager, and supplier of oil-free, rotary screw air compressors in
North America.
Proudly, we provide industry with the highest quality, oil-free, risk-free
air compressors on the market today The Kobelco KNW Series.
The Kobelco KNW Series can be custom built to your specications and is also available as a standard
design package. We provide nationwide parts and service support through our authorized distributor
network. We also provide air system energy audits, air dryers, lters, receivers, and sequencers.
Oil Free Risk Free Industries such as Food and Beverage, Pharmaceutical, Electronics, Medical
Products and Packaging have discovered that the higher the quality of compressed air that they use,
the better their product and lower cost to produce it. Kobelco KNW Series oil free compressors provide
ISO 8573.1 Class 0 compressed air quality. All Kobelco KNW Series oil free compressors
are delivered ready to run and are designed for 24/7 operation. They are available in
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INNOVATIO S
NEW PRODUCTS
Soft starters an option
when VFDs dont work
Motor damage takes place as a 88
result of mechanical wear and tear
and huge inrush currents.
80 A soft starter is a viable

option if it is impossible
to use a VFD with a motor.
A soft starter minimizes the
initial impact that a motor
receives upon starting.

The ABCs of VFDs
Find the right application to match 90
the motor need.
Many plants are shifting to

ac motors from hydraulic
motors and in some cases
dc motors when powering
See more products in the New Products
heavy loads, which were
for Engineers Database.
gspplatform.cfemedia.com/pe
more popular in the past.

INNOVATIONS
Gas chromatograph
The PGC5009 fast process gas chromato-
graph offers simulated distillation analysis
using fast temperature programmed pro-
cess chromatography. With a patented
Reliability
resistively-heated column design and rapid
cooling system, the PGC5009 provides
superior chromatography. This creates accu-
is everything rate and reproducible retention times and
weight percentage measurements required
Gerald Gerry Bauer
President, EccoFab - Rockford, IL for boiling point curve calculation, enabling
f Sullair.com/GerrysStory optimized refinery process control.
ABB
www.abb.com
Waste ejector pump

The Model 700 industrial vertical non-clog waste ejector pump is
designed for use in industrial, sanitary process, and rendering wastes.
The Model 700 features heads to 100 feet total dynamic head (TDH) and
flows to 1,500 gallons per minute. The impeller is an enclosed two vane
non-clog design with wiping vanes which reduce axial
loading and prolong bearing life. Wiping vanes aid in
keeping particles from behind the impeller and pump
bearing assembly. There is a flanged discharge on all
sizes. Designed specifically for solids handling, the
700 Series incorporates a long radius elbow, reducing
It doesnt quit.
It doesnt even think about quitting.
friction loss and allowing smooth flow through the dis-
In fact, it doesnt think of anything charge pipe.
but the job at hand. Vertiflo Pump Co.
www.vertiflopump.com
Sound familiar?
Our compressors are a lot like the people who use them.
Discover the complete line of Sullair stationary air

compressors, featuring the legendary Sullair air end. Motion control stepper products
A new line of motion control stepper products includes controllers,
To learn more about our complete line, including air
treatment products, contact your local distributor or stepper motors, an integrated controller/drive, an
visit our website. integrated drive/stepper motor, and an integrated
controller/drive/stepper motor. The integrated
controller/drive and drive/stepper motor units save
space and money, and simplify installation by com-
input #16 at www.plantengineering.com/information bining multiple components into one unit.
IDEC
www.idec.com
Sullair.com 80 t June 2017 PLANT ENGINEERING www.plantengineering.com

2017 Sullair, LLC. All rights reserved.
Submit new product releases to our New Products for Engineers Database
gspplatform.cfemedia.com/pe
Motor control
The motor control devices of the Simocode pro product series were
developed specifically for the management of motors in the low-volt-
age range. The system
operates indepen-
dently of the controller
and offers compre-
hensive protection,
monitoring, safety,
and control functions
between the motor
feeder and the auto-
mation system. The
motor control devices
can be integrated simply into virtually any control system, given the
flexible connectivity options. The motor control centers with the Ether-
Net/IP option in Simocode can be supplied with star or redundant-ring
network topologies. Because the EtherNet/IP communication protocol
is provided on the individual communicating device, no additional
communication devices, such as protocol converters or adapters, are
required.
Siemens
www.usa.siemens.com/simocode
Flowmeter
The Optimass 2000 S400 16-inch Coriolis mass flowmeter features the
highest flow capacity of any Coriolis meter on the market. The large
diameter mass flowmeter is ideal for bulk measurement of petroleum
and oil, as well as syrup, molasses, and raw chemicals. The meter
has been approved for custody transfer of liquids and gases. With its
unique four straight tube
design, the Optimass
2000 S400 features the
smallest installation
footprint in its class
and offers significant
energy savings with a
lower pressure drop. The
meters small installation
footprint makes it ideal for applications where space is limited, like
offshore platforms, or where alterations of existing pipework otherwise
would be necessary.
Krohne
http://cdn.krohne.com/dlc/

CO C S
INNOVATIONS
UST.
D S Gear motors
A full line of gear motors and gearheads has been
VALUE. designed to pair with every servo motor in the full

Sigma-7 range, creating complete gear motor solu-
tions rated from a low of 50 watts to as high as 15
Is your dust collector locking up kilowatts. Five gear ratios are available, ranging from
your prots? Free your cashow with 3/1 to 50/1. The
the game-changing performance of the new gear motors have
Downo Evolution (DFE) that offers the lowest
been designed
cost of total ownership. It delivers up to:
with precision heli-
cal gearing with a
40% greater tooth
surface area for
smoother, quieter,
and more accurate
operation, an
enhanced system of bearings, including 45% larger
planet bearings for guaranteed alignment, and bal-
anced, concentric shaft couplings to minimize vibra-
tion during high speed operation and reduce the
inertia of the gear motor system.
Yaskawa
www.yaskawa.com
Serial console
The Avocent ACS800 serial console models have
two, four, or eight serial ports with multi-protocol
serial support, four USB ports, an environmental sen-
Donaldson Torit sor port and a digital output port. Networking con-
DFE Dust Collectors
nectivity is available through dual Gigabit Ethernet
20% LOWER 28% SMALLER
ports, an optional internal analog modem, as well as
EQUIPMENT EQUIPMENT
COST FOOTPRINT through an optional external 4G/LTE cellular router.
Mounting of the Avocent ACS800 can be either
40% LOWER 66% LESS
SYSTEM FILTER COMPRESSED desktop-based, or with one of three available mount-
REPLACEMENT AIR ing kits.
COST CONSUMPTION
Vertiv
From the originator of the cartridge collector, www.vertivco.com
the new DFE takes dust collection to a new
level of quality, cost-savings, and clean air
for your operation.
LEARN Visit DonaldsonTorit.com for

information on the DFE and
MORE other great Torit products.
m
800 365 33
G g
E C OU .
.
82 t June 2017 PLANT ENGINEERING
CLE A N OR
NEVER ZE HARD
Submit new product releases to our New Products for
SANITI GAIN.
Engineers Database gspplatform.cfemedia.com/pe
Coating thickness tester HATS A

The CG206 coating thickness tester is designed
P O SA BLE
to accelerate condition monitoring inspections of DIS Y HARD
R
SANITALINERS.
industrial storage equipment, tanks, and vessels in
manufacturing and petrochemical sites. It can be
used to inspect plant equipment that is prone to
damage, corrosion, or deterio-
HAT
Savetimeandmoneycleaningand
ration, including chemical or
sanitizingtheinsideofhardhatsandsuspensions.
oil storage tanks, boilers, and
pressure vessels. In addition
HARDLINERisasoftdisposableclothlinerthatfits
insidethehardhatsuspension.
to examining newly-installed
equipment for quality control, HelpspreventthetransferofhairandscalpdLsease.
plant maintenance technicians
Hardlinerisanaidtohelpcomply
withOSHA29CFR1910.132(a).
can use the CG206 for periodic
TM
HARDLINER
condition monitoring to identify
changes that indicate a poten-
tial structural weakness or fail- For a Free Sample mention PE12
ure. It features a measurement For information or a free sample contact: GKR Industries, Inc. 13653 S. Kenton Ave., Crestwood,IL 60445
range of 0 to 1350m (0 to or call 800-5267879 www.gkrindustries.com
53mils) and automatically powers down after three
minutes of inactivity. When constant-on functioning
is required, users easily can disable the automatic
power-off mode
Extech
www.extech.com/cg206
Automated guided vehicle

The Agile1500 is the first automated guided vehicle
(AGV) that is modular, scalable, and reconfigurable. It
can carry more than 1.5 tons, with a maximum speed
of 5 feet per second. It also can increase overall plant
safety thanks to advanced security features and an
integrated laser
scanner that stops
the AGV upon
detection of an
obstacle along
its route. It works
with multiple
navigation systems that use both natural landmarks
(walls, objects, etc.) as well as predefined points
(magnetic spot and magnetic tape).
Comau
www.comau.com
PLANT ENGINEERING June 2017 t 83 input #20 at www.plantengineering.com/information

REPAIR. INNOVATIONS
RESTORE.
RETURN. Potable water solenoid valves
The NS-Series National Sanitation Foundation (NSF) certified potable
water solenoid valves can be used in food and beverage grade potable
water applications. Stainless steel or thermoplastic bodies and synthetic
seating and sealing materials makes NS series valves suitable for use
Concerned about the condition of with a variety of liquids, oils, and gases. Valve operation is normally
your telescopic way covers and ball closed and open when electrically energized. The valves can be mount-
screws? Dynatect can bring them ed in any position and a spring-loaded plunger assures positive shutoff.
back to new condition at a fraction NS201 and NS211 series are piloted diaphragm valves; NS201 series
of the cost. valves also can operate under zero pressure differential.
AutomationDirect
3 For all brands of way covers and www.automationdirect.com
ball screws Input #209 at www.plantengineering.com/information
3 Expedited turnaround available
3 Custom design and reverse
engineering services
3 Over 65 years in manufacturing
equipment protection
3 We have the correct OEM parts in
stock to rebuild your cover
WAY COVERS
Resistance testers
A new series of insulation resistance testers is capable of safely testing
both high- and low-voltage equipment. The MIT515, MIT525, MIT1025
BEFORE AFTER
and MIT1525 feature testing techniques
that provide valuable diagnostic informa-
BALL SCREWS tion to the user. Rated at 5 kV and 10 kV,
the MIT515, MIT525 and MIT1025 are engi-
neered to ensure the highest precision pos-
sible. The MIT525, MIT1025 and MIT1525
perform spot tests, step voltage tests,
dielectric discharge tests, ramp tests and
dielectric absorption tests for QA testing in
manufacturing processes, diagnostic tests to
BEFORE AFTER isolate faulty components for repair, as well
as routine preventative/predictive mainte-
nance. Each unit has a noise filter that can
reject up to 3 mA on the 5 kV and 10 kV models and 6 mA.
Megger
www.megger.com
FOR MORE INFORMATION: Input #210 at www.plantengineering.com/information
800-298-2066
sales@dynatect.com
Dynatect.com/Repair-Services
Looking for new products by category?
Check out the New Products for Engineers Database
and search hundreds of products, with new innovations
added every day.
Look for this logo on the Plant Engineering home page.
4FFBMMPVSQSPEVDUTBU
klsummit.com
Pressure
calibrator
The 729 series automatic pressure
calibrator simplifies the calibra-
tion process by automatically
generating precise test pressures,
improving calibration integrity by
compensating for leaks, and auto-
matically documenting the pres-
sure calibration process to help
meet compliance and regulatory
requirements. With the rugged,
portable 729, technicians simply
input a target pressure and the
calibrator automatically pumps Quality
to the desired set-point while
the internal fine adjustment con-
Service
trol stabilizes the pressure at the Expertise
requested value, delivering more
accurate results and speeding the
calibration process. It also features
automatic pressure generation Save Time and Money by Using Ultima Series
and control for multiple tests to &OKPZUIFFDPOPNJD NBDIJOFBOEMVCSJDBOUMJGFCFOFUTPG
300 psi and measurement of mA VTJOHUIFSJHIU4VNNJUTZOUIFUJDPJMJOUIFSJHIUBQQMJDBUJPO
signals on transmitter outputs and 4VNNJUnT TZOUIFUJD 6MUJNB 4FSJFT BJS DPNQSFTTPS
MVCSJDBOUTPGGFSESBJOJOUFSWBMTPG QMVTIPVSTVOEFS
sourcing and simulation of mA
OPSNBMPQFSBUJOHDPOEJUJPOT5BMLUPPVSFYQFSUTBOEOE
signals. PVUJG6MUJNBJTUIFSJHIUMVCSJDBOUGPSZPVSDPNQSFTTPS
Fluke Corporation
www.fluke.com
800.749.5823
Klber Lubrication NA LP
PLANT ENGINEERING June 2017 t 85

Olive oil is good for you.
Compressor oil is not.
INNOVATIONS
Protect your product, your packaging and your reputation.
7YLTP\T,MJPLU[ OIL-FREE Compressors

800-394-6151
knw-series.com
Rogers Machinery Company, Inc. Proudly Made in the U.S.A.
Mi i t leads to increased vibration, premature seal EASY-LASER E-Series

or i ilures, and increased power consumption.
Laser Alignment, Geometric
h s no excuse to let misalignment cost you money. Measurement and more!
P t t r machines and minimize costly downtime
th h ision laser shaft alignment.
O r i nt and support are the industry benchmark.
K i ing.
3 1.8935 | www.KeepItRunning.com

Level switches
The G Series level switches are specifically designed
for special problem applications that involve
extremely light or fluffy products, or for heavier bulk
solids that tend to pack or bridge easily. It provides
consistent results on applications of pharmaceuti-
cal powders, powder materials for coating beads
and tablets, fillers and other substances that vary
widely in bulk density or particle size and many other
materials with a tendency to pack. The uncovered
paddle is free to vibrate, producing an output signal.
This signal operates a relay indicating the paddle is
uncovered. When the paddle is covered a dampen-
ing of the oscillations occurs and the relay indicates
that a high level exists.
DYNATROL
www.dynatrolusa.com
Advertorial
New Filtration Technology

Algae Insects
Airborne
Keeps Cooling Water Clean
Leaves Particles
Pollen
Protect: heat exchangers, spray nozzles,
Heat
Exchanger instrumentation, pump seals, I.E. & R.O.
Cooling
units, air compressors and the environment.
Tower Spray
Nozzles
Remove: airborne particles, sand, gravel,
algae, pollen, silt, scale, rust, microbiological
Instrumentation
Rust
growth, zebra mussels and other dirt
Water
particles down to micron size.
Filter
Applications: anywhere that dirt is
a problem cooling water, process water,
O
R
reclaim water, effluent water, intake water,

IV
A
waste water, wash water, potable water.

L
Users: U.S. government, municipalities,

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213 S. Van Brunt St., companies, commercial buildings, food,
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(800) 567-9767 car /rail washes, mines, power.
Automatic Self-Cleaning (201) 568-3311 5 Fax (201) 568-1916
WATER FILTERS www.orival.com 5 filters@orival.com

INNOVATIONS
By David Manney, L&S Electric
M
RWRUGDPDJHWDNHVSODFHDV
Soft starters an option DUHVXOWRIPHFKDQLFDOZHDU
DQGWHDUDQGKXJHLQUXVK
FXUUHQWV7\SLFDOO\YDULDEOH
when VFDs dont work IUHTXHQF\GULYHV9)'VKHOSSUHYHQWZHDU
DQGWHDUWRPHFKDQLFDOFRPSRQHQWV9)'V
VORZVWDUWLQJDQGVWRSSLQJRIWKHGULYHWUDLQ
A soft starter is a viable option if it is
impossible to use a VFD with a motor. A
soft starter minimizes the initial impact that
a motor receives upon starting.
How do soft starters work?

Motor-driven applications rely on VFDs or
soft starters. These devices prevent dam-
age, or a significant amount of stress, to
the product transported by the machine.
Among the types of equipment that ben-
efits from a soft starter are pumps, fans, and
conveyors. This equipment stops and starts
on an automatic basis when necessary.
Soft starters increase the voltage in steps,
depending on the application. There are
thyristors such as silicon controlled rec-
tifiers (SCRs), or a pattern of solid state
switches in a soft starter. These compo-
nents allow the voltage to increase at a
slower rate and cause the motor to run at
full speed at differing intervals.
One, two, and three phases

Three-phase motor applications use
SCR-SCR and SCR-diode designs. The
SCR-SCR offers a full wave control. The
SCR-diode tends to generate undesirable
harmonics and requires a higher start cur-
rent. In a single-phase unit, it fails to reduce
the start current, although it controls the
start torque. This issue is why this unit is
not suitable for applications that handle
high inertial loads or frequent cycling.
PRUFTECHNIK is a leading single-source solution provider for machine For a two-phase unit, a motor needs a
laser alignment, condition monitoring and nondestructive testing. circuit breaker or thermal relay for protec-
tion. Moreover, this unit does not isolate
PRUFTECHNIKs technical innovations optimize the availability of your
all the phases of the motor.
production assetsand stop small amounts weighing heavily on your Unlike the single- and two-phase unit,
bottom line. three-phase units can provide full and
maximum control. Thus, these units pro-
www.pruftechnik.us vide the best control of both the torque
and the current.
Working with open

or closed loops
A soft starter either runs an open or closed
loop. An open loop design does not pro-

Submit new product releases to our New Products for Engineers Database gspplatform.cfem e
vide any current feedback loop. The open Other reasons to install a soft starter David Manney is a marketing admin-
loop controls the starting phase with a in a motor include improved efficiency istrator at L&S Electric. This article orig-
pre-selected voltage profile without pro- and controlled acceleration. These ben- inally appeared on L&S Electrics Watts
tecting the motor. On the other hand, a efits translate to increased productivity New blog. L&S Electric is a CFE Media
closedloop design provides current func- due to fewer breakdowns in motors and content partner.
tions and motor protection. This combi- unplanned downtimes. PE
nation allows users to select the preferred
start current level.
The start voltage profile on openloop
systems follows a pre-determined ramp
regardless of the motor speed or the
current drawn. The most suitable set-
ting offers the breakaway torque to the
electric motor upon starting. Although
these starters make the motion gentler,
they are not capable of producing any spe-
cific torque. In the case of a closedloop
starter, it monitors the output and adjusts
the input voltage automatically to reach
the target voltage.
Other closed-loop units only adjust the
Engineered for precision and power, the Model 850 picks up even
voltage to maintain the constant accelera-
the finest powders, anywhere in your plant. With clean, HEPA-filtered
tion. There are voltage ramp systems that exhaust air, a streamlined filter cleaning system, a continuous bagging
monitor the input current on one phase. system, and a performance guaranteeits more than a cleaning
The next step is a comparison to a set system; its a business asset.
point. The final step includes ramping
once there is a higher amount of current !
-,0),1-1/104
generated. ,%1/0.)#*#$11+
When it comes to machines that require , "!&!'"'%!%+%&
, !&% !'' #!"$' %"&"!"!&!$%
varied onset torque such as load convey-
,(! !

ors, a current-ramping type of soft starter ,&'$%"&#$ $+&$%&!$
is advisable. This device takes the current HEPA secondary filter
from the start value to a predetermined ,%&$%$& ""&'%&$%
limit over a specific length of time. , "%%#$(!&'&('%&"'%
For the most part, applications that
use 75 HP or more benefits from soft &01//-*2&4-1.,%1/0.)#*
starters. Some of these include grinding #$11+ *&#,),' (#**&,'&/
mill machines and paper manufactur- )/)02#$1+#3$-+2#$11+
-.$#**
!
ing machinery. This equipment needs to
reach the full load within a defined period
to prevent damages to certain equipment
located in the drive train. A limited level
of acceleration is necessary to avoid too
much gear teeth stress on heated cylinders
on paper dryers, as an example.
Why install soft starters

There are several advantages linked with
the installation of soft starters working
with motors. As a primary benefit, these
devices promote the smooth starting of
a motor without glitches or jerks. This
method of starting motor results in con-
"5 5 "5
trolling the starting current in steps by "5 55
altering the initial voltage. 5"
"5 5 5
PLANT ENGINEERING June 2017 t 89

INNOVATIONS
By Kevin Goodsell, Valin Corp.
I
nside of plants today, ac motors
are becoming the industry stan-
The ABCs of VFDs dard. Many plants are shifting to ac
motors from hydraulic motors and
in some cases dc motors when powering
Find the right application to match the motor need. heavy loads, which were more popular
in the past. This shift can be attributed
to a variety of reasons and most have to
do with cost. AC motors are more com-
pact and require less maintenance than
a hydraulic motor or a dc motor with
brushes.
With cost being a driving factor, opera-
tors need to have more precise control over
the ac motor. It is important to understand
the practical applications of a variable fre-
quency drive (VFD) to an ac motor.
Among the questions to be asked:
t8IFOJTB7'%CFOFGJDJBM
t6OEFSXIBUDPOEJUJPOTTIPVMEB7'%
CFVTFE
t8IBUTUIFEJGGFSFODFCFUXFFOB7'%
BOEBTPGUTUBSUFS
6OEFSTUBOEJOHUIFBOTXFSTUPUIFTF
RVFTUJPOTXJMMNBYJNJ[FUIFVTFBOENJOJ
NJ[FUIFDPTUPGPQFSBUJOHBOBDNPUPSJO
a plant setting.
Full voltage starters, soft

starters, and VFDs
5IFSFBSFTFWFSBMXBZTUPQPXFSBOEDPO
trol an ac motor. In addition to a VFD,
one could alternatively apply a full voltage
starter or a soft starter. The most basic
motor control involves using a full voltage
starter. With this approach, full voltage is
applied to the motor and it ramps up to
NBYJNVNTQFFEBTRVJDLMZBTJUDBO
5IFQSPCMFNPQFSBUPSTSVOJOUPXJUIB
full voltage starter is the inrush of current
can be up to seven times the full load cur-
rent of the motor. For a very short period
of time, a very high in rush of current is
applied to the motor and its control com-
ponents. If a large motor needs to do a
frequent amount of starting and stopping,
JUDBOXFBSPVUFRVJQNFOUGBTUFSBOECF
BDPTUMZCVSEFOPOUIFGBDJMJUZTVUJMJUJFT
In contrast, a soft starter eliminates this
burden by reducing the load and torque
PVUQVUUPUIFNPUPS5IJTBQQSPBDIBMMPXT
the motor to ramp up at a speed that is
determined by a setting on the soft starter
itself. An operator can set a specific ramp-
Submit new product releases to our New Products for Engineers Database gspplatform.cfemedia.com/pe
up time, and from the time it is turned on output current on the motor. This desired exceeding these limits by over torqueing
to the time designated, the motor runs at outcome is completely driven by process. can lead to heavy damage or costly mal-
full speed. This allows reduced current There is a need to protect whatever it is function.
inrush, reducing the risk of premature that the motor is driving, and many pieces Most VFDs are manufactured to be
failure and additional burden on the facil- of equipment in the plant setting have extremely flexible so they can be config-
itys utilities. mechanical limitations. Because of this, ured to use the inputs and outputs (I/O)
A VFD takes this concept a step fur-
ther by allowing the operator to always
control the inrush current and the speed
of the motor. The VFD can control the
motor both during the start/stop cycle
and throughout its runtime. A VFD is
necessary where complete speed control
is required and a key concern is energy
consumption. A soft starter will be the
less expensive option, but in large horse-
power situations, savings can be realized
over time with a VFD.
Basic VFD applications

Flow control is one of the most common
applications of a VFD inside of a plant
setting. The ability to change the speed
of a pump to control flow is paramount.
System conditions will often require a
reduced flow rate. Dampers and valves
often are used to accomplish this reduc-
tion, but this strategy does not help ener-
gy conservation. Conversely, a VFD can
control flow rate while at the same time
optimizing the energy required to do so.
There may be a situation where an oper-
ator needs to run the motor at less than
maximum speed at certain times of the day,
but then crank it up faster at other times.
This is the real driver with the popularity
of VFDs in todays environment: saving
energy and reducing operational costs. If
an operator is simply looking to run an ac
motor at a constant speed that is less than
the motors full speed rating, a gearbox can
be used. However, if an application is such
that it is a variable torque load, a VFD is a
fitting solution.
On a very basic level, for example, imag-
ine an ac motor is used to run a fan on
a cooling tower. The faster the operator
wants the fan to run, the more horsepower
and energy it will require.
Additional benefits
In addition to cost savings due to energy
conservation, most VFDs will allow the
operator to set different parameters to
limit torque. This is done by limiting the
PLANT ENGINEERING June 2017 t 91 input #30 at www.plantengineering.com/information

INNOVATIONS
that are integrated into them. These I/O log outputs can be configured to provide the plant control system can adjust the
can be used for any number of different feedback to the plant control system for signal to the drives designated speed
functions, including start/stop func- parameters, including power consump- input. In the case of flow control, VFDs
tionality, direction change, constant tion, actual speed, frequency, torque, etc. have evolved to the point where many
speed selection, macro selection, speed If a process changes, for example, and it of them can be integrated with a pump
adjustment, etc. Additionally, VFDs ana- now needs to be run at a different speed, right out of the box using a pre-defined
macro. In this case, a flow meter would
connect directly to a drives analog input.
An operator may adjust the desired flow
remotely and the drive will maintain that
flow by executing an internal PID loop.
Some drives allow the operator to set up
flow schedules and may also be set up to
bring additional pumps online as demand
requires.
A VFDs built-in I/O is not the only
way to control a drive. Many drives offer
flexibility that allows for a variety of dif-
ferent communications protocols that can
control the VFD from most manufactur-
ers controllers. All standard protocols are
available for most VFDs. This allows the
operator to have bi-directional commu-
nications with one communications cable
as opposed to multiple wires.
Why is this important? By utilizing a
single cable, as opposed to multiple wires,
installation costs are kept at a minimum
and a much larger amount of data can be
transmitted. This data does not just apply
to advanced control, but monitoring as
well. Typically, operators are looking to
monitor the speed, torque, current, and
temperature of the drive. Far more data
can be communicated over this one cable
than a VFDs built-in I/O can accommo-
date. When a situation calls for multiple
TSUBAKI TOUGH.
pieces of data, involving numerous I/O,
many VFDs today can handle the require-
ment.
TSUBAKI BACKSTOPS ARE JUST AS TOUGH AND RELIABLE AS THEIR CHAIN. Finally, the maintenance benefits are
a major part of the appeal of effective-
The top companies in the world use Tsubaki products. Tsubaki Backstops, just like ly utilizing a VFD for an ac motor in a
the full range of Tsubaki products provide the winning combination: UNMATCHED plants operation. Maintenance costs can
QUALITY, DURABILITY, RELIABILITY, AND SERVICE & SUPPORT. Tsubaki has been be lowered significantly due to reduced
making backstops for over 50 years. They know whats at stake wear and tear on the equipment because
if equipment is down for any length of time. So why wouldnt of controlled starts.
you use the best? Eliminate that weak link by ordering VFDs are continuing to gain popularity
Tsubaki backstops today! in the industry as the different benefits
they provide grow, most of which will be
associated in one way or another with cost

and energy savings. PE
Kevin Goodsell is an engineering

manager at Valin Corp.
Total Package

20157U.S. Tsubaki Power Transmission, LLC All Rights Reserved.
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2014 t t 93
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2017
June
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Place next to your computer or go online to plantengineering.com for hot links to these companies.
For more information on how to advertise in 3(

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abb.us donaldson.com rogers-machinery.com
ABB is a leader in power and automation technologies that Compressed air purifications solutions, compressed air Manufacturer of rotary screw and reciprocating air com-
enable customers to improve performance while lowering filters, dryers and process water chillers. pressors, fixed and variable speed drives, rotary and cen-
environmental impact. Donaldson Company Inc. trifugal compressors, blowers, and vacuum systems.
ABB Inc. Rogers Machinery
dynatect.com
aitkenproducts.com Dynatect designs and manufactures a complete line of seweurodrive.com
Aitken Products manufacturers and distributes high-qual- components to protect equipment and people. One of the largest global suppliers of drive technology,
ity industrial heaters. Aitkens products are for a variety Dynatect SEW-EURODRIVE specializes in gear reducers, motors
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Aitken Products Inc. emaint.com SEW-EURODRIVE USA
eMaint improves the way over 50,000 users worldwide
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The Association for Advancing Automation is the global world. Solon Manufacturing Co. engineers and manufactures
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flexicon.com
atlascopco.us Flexicon designs and manufactures bulk handling equip- uecorp.com
Atlas Copco produces and markets compressed air equipment and custom-engineered and integrated plant-wide UEC provides innovative, customizable power distribution
ment and generators, construction and mining equipment, systems. and monitoring solutions.
industrial tools, assembly systems, services and rentals. Flexicon Corp. Universal Electric Corp.
Atlas Copco
us.kaeser.com vac-u-max.com
automationdirect.com Manufacturer of air system products, including rotary VAC-U-MAX specializes in design and manufacture of
AutomationDirect offers over 16,000+ industrial automa- screw compressors, portable compressors, rotary lobe pneumatic systems and support equipment for conveying,
tion products through their free catalog and online super- blowers, vacuum packages, refrigerated and desiccant weighing and batching of dry materials.
store including PLCs, operator interfaces, drives, enclo- dryers, filters, and condensate management systems. VAC-U-MAX
sures, sensors and more. Kaeser Compressors Inc.
AutomationDirect yaskawa.com
lubriplate.com Yaskawa is the worlds largest manufacturer of ac inverter
avotraining.com Lubriplate manufactures more than 200 high quality lubri- drives, servo and motion control, and robotics automation
For almost 50 years, AVO has been helping organizations cants, including high performance synthetic lubricants and systems.
create safe and reliable electrical systems. NSF-H1 lubricants for food processing and beverage. Yaskawa America Inc.
AVO Training Institute Lubriplate Lubricants Co.
baldor.com mhia.org
Baldor Electric designs, manufacturers, and markets a MHIA is the leading non-profit trade association represent-
broad line of industrial energy-efficient electric motors, ing the U.S. material handling and logistics industry.
mechanical power transmission products, and more. Material Handling Industry of America
Baldor Electric Co.
noria.com
camfilapc.com Noria is a worldwide leader in providing lubrication con-
Camfil Air Pollution Control (APC) is a leading global sulting services and training.
manufacturer of industrial dust, fume and mist collection Noria Corp.
equipment and is part of Camfil, the worlds largest air fil-
tration company. orival.com
Camfil APC Orival is a leading manufacturer of self-cleaning water
filters, automatic water filters and strainers, for use as
centuryspring.com industrial water filters, irrigation filters, cooling tower fil-
Century Spring has been supplying quality stock and cus- ters, and more.
tom springs, metal stampings, and wire forms for MRO Orival Inc.
and OEM applications since 1927.
Century Spring Corp.

CONTACTS Advertiser Contacts
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BOB VAVRA, Content Manager
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630-571-4070 x2220, EGuenther@CFEMedia.com
CALLING ALL SYSTEM INTEGRATORS 42 630-571-4070 www.plantengineering.com/SIYApplication
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Camfil APC 4 4 800-479-6801 www.camfilapc.com 860-432-4767, APelliccione@CFEMedia.com
CENTURY SPRING CORP 81 17 800-237-5225 www.centuryspring.com CHRIS VAVRA, Production Editor

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Flexicon Corp 6 5 888-353-9426 www.flexicon.com 630-779-8910, MSmith@CFEMedia.com
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GTI Spindle Technology 91 30 603-669-5993 www.gtipredictive.com
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HARVARD CORPORATION 83 20 500-523-1327 www.harvardcorp.com/ml 717-766-0211, Fax: 717-506-7238
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IEX 2017 15 8 203-840-5847 www.iexusa.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions
IIoT Webcasts 30 630-571-4070 www.plantengineering.com/lloT 847-378-2275, maria.bartell@infogroup.com
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Kaeser Compressors, Inc 1 2 866-516-6888 www.us.kaeser.com/PE
303-246-1250, REllis@CFEMedia.com
Lubriplate Lubricants Co 32 13 800-733-4755 www.lubriplate.com LETTERS TO THE EDITOR
Please e-mail your opinions to BVavra@CFEMedia.com
LUDECA, Inc 86 24 305-591-8935 www.ludeca.com
INFORMATION
MAPCON 87 25 800-922-4336 www.mapcon.com For a Media Kit or Editorial Calendar,
e-mail Trudy Kelly at TKelly@CFEMedia.com
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Reimagining Plant Engineering 50 630-571-4070 www.plantengineering.com Charlotte, NC 28209 Fax 630-214-4504
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Rogers Machinery 86 23 800-394-6151 www.knw-series.com
1111 W. 22nd St., Suite 250, Tel. 630-571-4070 x2221
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SEW-EURODRIVE, Inc. 2 3 864-439-7537 www.seweurodrive.com 246 South Franklin St. Tel. 216-409-8314
Siemens 19 10 www.sea.siemens.com Chagrin Falls, OH 44022 Fax 440-348-1980
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SPM Instrument 78 15 800-505-5636 www.spminstrument.us 12 Pine St. Tel. 774-277-7266
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Summit Industrial Products 85 22 800-749-5823 www.klsummit.com 6746 E. Tyndall Circle Tel. 602-369-3037
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Stuart Smith, International stuart.smith@ssm.co.uk
Vac-U-Max 89 28 973-759-4600 www.vac-u-max.com SSM Global Media Ltd. Tel. +44 208 464 5577
Fax +44 208 464 5588
Yaskawa America, Inc C-3 32 800-927-5292 www.yaskawa.com

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36 Lubrication Guide 14 CMMS success in 10 steps

NEW TAP SERIES

TAP Series Total Air Prep

Research, price, buy at: www.go2adc.com/tap

Order Today, Ships Today!

SOLUTION: A comprehensive Air Demand Analysis (ADA) established a demand

Specific Power of Previous System: . . . . . . . . . . . . . . . . . . . . .47.16 kW/100 cfm

Specific Power of New System: . . . . . . . . . . . . . . . . . . . . . . . . .17.77 kW/100 cfm

Annual Energy Cost of Previous System: . . . . . . . . . . . . . . . . . . . . . . . . . $128,756

TOTAL ANNUAL ENERGY SAVINGS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,235

Utility Incentive:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,200

Why gain 2-3% energy savings with a

Solution: Use a helical-bevel gearmotor

INSIGHT 36 | Lubrication Guide

10 | Motor insulation systems: Automation

18 | To use robots effectively, get started, SPECIAL REPORT

INNOVATIONS 55 | Overcome the high cost of staying cool

88 | Soft starters an option when VFDs 58 | Control room temperatures: Strategies

www.plantengineering.com PLANT ENGINEERING June 2017 t 3

Farr Gold Series

Dust, Mist and Fume Collectors

000 (#&'+ *(1"(&' #&'.",() (#&' *(1

A bright, dynamic presentation

www.plantengineering.com PLANT ENGINEERING June 2017 t 5

Project Managers Engineering Teams Effectiveness Only a Major

USA CHILE 

2016 Safety Study Try to take this for a spin 20

The clouds role

By The these devices is col-

8 t June 2017 PLANT ENGINEERING www.plantengineering.com

www.plantengineering.com PLANT ENGINEERING June 2017 t 9

Motor insulation systems:

3. Record important test conditions. Docu-

<100 500 t8 J O E J O H * 3

10 t June 2017 PLANT ENGINEERING www.plantengineering.com

Learn more about MovinCool: 800-264-9573

MovinCool and Spot Cool are registered trademarks of DENSO

LETTER TO THE EDITOR

12 t June 2017 PLANT ENGINEERING www.plantengineering.com

Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_oring

PHOENIX CONTACT 2017

For more information, visit iexusa.com

INTERESTED IN EXHIBITING? FOR MORE INFORMATION OR TO BOOK

3. Develop and standardize work-

CMMS implementer, learn from colleagues, and t3FBDUJWF 3VOUPGBJMVSF

16 t June 2017 PLANT ENGINEERING www.plantengineering.com

Achieve business excellence with

SAFE CONNECTED FLEXIBLE EFFICIENT

Understanding smart machines How will they shape the future?

Keep it small and simple. G

18 t June 2017 PLANT ENGINEERING www.plantengineering.com

PMA names Hardy May PMI ticks

20 t June 2017 PLANT ENGINEERING www.plantengineering.com

Get your business set for growth at:

input #11 at www.plantengineering.com/information

All reports are available at

Discrete industry safety practices

Quarterly 4% View more information at

Average number of hours that plants spend Average annual salary

19: on schedule maintenance each week.

Source: Plant Engineering 2016 Energy Management Study

78% of facilities have observed a decrease in

The average plant/facility engineering pro-

22 t June 2017 PLANT ENGINEERING www.plantengineering.com

000 (#&'+ (1"(&'#&'.",() (#&' (1

USA CHILE

CMMS implementer, learn from colleagues, and t3FBDUJWF 3VOUPGBJMVSF