2012 - 06 - Plant Engineering

In-house integration?
Ignoring electrical myths
Financial asset planning
High-quality
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COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
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June 2012
Whats INside
Volume 66, No. 5
7 Interactive
9 In Focus
25 In Practice
53 Innovations
58 Product Mart
59 Internet Connection
60 Advertiser Contacts
61 In Conclusion
62 Featured Innovations
PLANT ENGINEERING (ISSN 0032-082X, Vol.
66, 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,
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omissions in the material contained herein, regardless of whether such errors result from negligence,
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2012
Synthetic
Lubrication Guide
28 More than meets the eye

The latest lubricant technology is a secret weapon in the battle for
efficiency.
30 Lubrication Guide
A sound lubrication strategy is essential to keep all the gears in your
operation running at their best.
In Practice
25 Take a step-by-step approach

to system troubleshooting
Proper test instruments make troubleshooting smoother and easier to
identify secondary problems where they exist.
PLANT ENGINEERING
June 2012 3
Automation Solutions
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37 System integration services:
In-house or hired out?
Should automation and process control services

and system integration projects be performed
in-house or hired out? Read the advice from
system integrators working on the front lines
of project management.
Electrical Solutions
43 Industrial efficiency:
Debunking the myths
Where to begin? By ignoring these myths

on energy use, the necessary equipment,
and the economys impact on your investments.
Maintenance Solutions
47 Financial planning for
asset management
The world around us is changing and

we have entered into a new age of
competitiveness.
9 In Focus
Manufacturing experts to address summit
Manufacturings steak rolled at a slower pace in May
ISM forecast: Spending, revenues both expected to keep climbing
Siemens teams with community college to develop workforce
Strength in U.S., China drives growth in industrial automation
CMMS takes the guesswork out of safety inspections
Sweatman: Let manufacturers adapt without policy changes
Raymond Corp. celebrates youth apprenticeships
PLANT ENGINEERING
June 2012 5
IF WE DONT HAVE YOUR FILTER,
NOBODY DOES
One call to Donaldson Torit is all it takes to fulfill all your
filtration needs. Your call will be answered quickly by a live
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INTERACTIVE
www.PlantEngineering.com
Time to link into

award recognition
Plant Engineering recognizes three
essential elements to a successful
manufacturing operation:
The right people
The right equipment
The right process.
Thats why Plant Engineering has
three special recognition programs
throughout the year.
The Plant Engineering Leaders Under
40 program accepts
nominations from
individuals and manufacturers who
want to highlight the work of their
up-and-coming manufacturing professionals. These people have chosen
manufacturing as a career, and they
will lead us into the next generation of
manufacturing.
The annual Product of
the Year competition,
celebrating its 25th
anniversary in 2012,
receives nominations
for the best new products in
manufacturing and turns the decision
for the best of the best over to our
readers.
The 2012 Top Plant
program recognizes
the outstanding manufacturing facilities
around the U.S. for
their dedication to safety, maintenance,
productivity and energy management.
In just its eighth year, this award has
quickly become among the most prized
in the manufacturing sector.
Deadline for Leaders Under 40 is
Aug. 1, 2012. Deadlines for Product
of the Year and Top Plant are Sept. 14,
2012. All three entries are available at
www.PlantEngineering.com
VIDEO:
CSIA attorney offers tips for

maintenance, service contracts
Service and maintenance agreements are
important for engineers and system integrators
who can provide those services. Those involved
should carefully define warranties, scope, deadlines, and payment structure.
Mark Voigtmann, general counsel for Control System Integrator Association (CSIA), and
attorney with Faegre Baker Daniels, outlines
key points to remember when considering maintenance and service contracts for automation,
controls, or operations engineering. Voigtmann
made the comments after a presentation on the same topic at the 19th annual
CSIA 2012 Executive Conference, in April, in Scottsdale, Ariz.
WEBCAST:
Next Arc Flash University

event is Aug. 23
The next class in Arc Flash University, Plant Engineerings continuing series of Webcasts that covers the issues
of electrical safety on the plant floor, will take a look at
the present and the future of NFPA 70E.
The Webcast, sponsored by Fluke and Westex, will take
place Thursday, Aug. 23 at 1 p.m. CST. Registration for Arc Flash University,
and an archive of previous Arc Flash University Webcasts, is now available
under the Webcast tab on the home page at www.PlantEngineering.com.
Arc flash is one of the most serious plant floor hazards, and one that can be
minimized with the proper training and strategy. Viewers from more than 60
countries have registered for Arc Flash University over the past four years.
You also can get more information about arc flash issues by typing Arc
Flash into the search engine at www.PlantEngineering.com.
In your opinion...
Which metric do you give the most weight to when evaluating your lift truck operations?
Your responses at www.PlantEngineering.com:
74%
Cost of operations
13%
Dependability
5%
Productivity
4%
Serviceability
4%
Ergonomics
Check out this months poll at www.PlantEngineering.com

PLANT ENGINEERING
June 2012 7
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IN FOCUS
GLOBAL AUTOMATION AND MANUFACTURING SUMMIT
Manufacturing experts to address summit

Two-day global event attracts industry leaders.
With the landscape of manufacturing
changing on a continuing basis, information is needed on the best ways to adapt
to those changes. The Global Automation
and Manufacturing Summit will provide
strategic knowledge to attendees looking
to get ahead on some of the most important issues in manufacturing.
Sponsored by Beckhoff, Molex and
SAP, the inaugural Global Automation
and Manufacturing Summit will take
place Sept. 12-13, 2012 as part of the
Industrial Automation North America
(IANA) event at the 2012 International
Manufacturing Technology Show (IMTS)
at McCormick Place in Chicago. The
IANA event is presented by CFE Media
and Hannover Messe.
There will be three keynote addresses
during the two-day conference. Billy Taylor, recently named director of commercial tire manufacturing for Goodyear Tire
and Rubber Co., will open the conference
on Wednesday, Sept. 12 with a look at his
career at Goodyears Fayetteville, N.C. plant and its successful transformation in the
last two years.
At the Sept. 12 luncheon
keynote address, Karen
Kurek, a partner and managing director with McGladrey
and head of the firms National Manufacturing & Distribution Practice, will
discuss global manufacturing trends. She
is considered the voice of manufacturing for McGladrey and its manufacturing professionals across the nation.
The Wednesday, Sept. 13 sessions
will open with a keynote speech from
Doug Woods, president and CEO of the
Association for Manufacturing Technology (AMT), the host organization at the
IMTS 2012. Woods will present his views
on manufacturing, and its strengths and
weaknesses heading into the rest of 2012.
Manufacturing executives and plant
floor leaders who attend the Global
Automation and Manufacturing Summit will get a chance to hear from some
Agenda for the two-day Global Automation and

Manufacturing Summit on Sept. 12-13, 2012:
of the top experts in their

field. Those experts include
WEDNESDAY, SEPT. 12
Rick Griffin of Molex, Joey
8:00 a.m.: Keynote address: Billy Taylor,
Goodyear Tire and Rubber Co.
Stubbs of EtherCAT Tech9:30 a.m.: Treating energy as a raw material
nology, Avi Bedi of SAP,
11:00 a.m.: Integrating operator knowledge
Meeta Kratz of Grainger,
Robert Bruce Lung of the
12:30 p.m.: Luncheon keynote: Karen Kurek,
McGladrey
Alliance to Save Energy,
2:00 p.m.: Stay ahead of the technology curve
Chuck Edwards of Lenze,
3:30 p.m.: Gaining, training, retaining the next
Corey Morton of B&R
generation of workers
Automation, Raj Batra of
Siemens, June Ruby of
THURSDAY, SEPT. 13
Motorola, Mary Bunzel of
8:00 a.m.: Keynote address: Douglas Woods, AMT
IBM, and Peter Esparrago
9:30 a.m.: Empowering the mobile worker
of Maverick Technologies.
11:00 a.m.: Securing your data
They will discuss six
TO REGISTER for the IANA event and IMTS 2012,
key topic areas that readgo to http://www.imts.com/education/ianaSummit.
ers of Control Engineerhtml
ing and Plant Engineering
have identified as areas of
interest:
workers to manage the technology Treating energy as a raw material
based manufacturing platforms. How
Understanding the true cost of energy in can manufacturing take the lead on this
all its forms throughout your plant helps critical issue?
manage product prices and
plant profits.
Empowering the mobile worker
Smartphones, tablets, and wireless sys Integrating operator tems put knowledge in the hands of your
knowledge
line operators. Top mobility experts will
There is a tremendous examine when and how to make the data
amount of information stored available and which systems should be
in your workforce. Experts employed to empower a more productive
will look at downloading that knowl- employee in a safer and more profitable
edge to your systems so that it is available plant.
to everyone today and in the future. Asset
management needs to include workforce Securing your data
expertise and processes.
If your data is available and mobile,
its available for viral attack and corrup Stay ahead of the technology curve
tion. Protecting your data is the same as
Remember when I/O was the biggest protecting any other physical asset, and
technological breakthrough? Whats com- experts will look at the most effective
ing next, and how should you prepare ways to safeguard your data to increase
now to take advantage of the technol- safety and security and lower the risk. PE
ogy and get ahead of the next wave of
Registration for the IANA event and
innovation.
the Global Automation and Manufac Gaining, training and retraining the turing Summit is now open at www.
PlantEngineering.com.
next generation of workers
Registration for IMTS 2012 is open
With a worker shortage looming, America is waking up to the need for skilled at www.IMTS.com.
PLANT ENGINEERING
June 2012 9
IN FOCUS
Manufacturings streak rolls
at a slower pace in May
SAVE ENERGY.
REDUCE DOWNTIME.
EXTEND COMPONENT LIFE.
anufacturings three-year growth streak continued in May, albeit at a slower pace than in April,
according to the latest Institute for Supply Management manufacturing report.
The manufacturing sector expanded for the 34th
straight month and the nations overall economy hit the
three-year mark in growth, according to the report, issued
by the ISMs Manufacturing Business Survey Committee.
The PMI registered 53.5% a modest decrease of 1.3
percentage points from
IMS Report: The last 12 months
Aprils reading of 54.8%
indicating expansion in
Month
PMI
Month
PMI
the manufacturing sector
May 2012
53.5
Nov 2011
52.2
for the 34th consecutive
Apr 2012
54.8
Oct 2011
51.8
month, said committee
Mar 2012
53.4
Sep 2011
52.5
chair Bradley J. HolFeb 2012
52.4
Aug 2011
52.5
comb, CPSM, CPSD.
Jan 2012
54.1
Jul 2011
51.4
The New Orders Index
Dec 2011
53.1
Jun 2011
55.8
continued its growth
trend for the 37th conAverage for 12 months 53.1
High 55.8
secutive month, registerLow 51.4
P
ing 60.1% in May. E
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ISM forecast: Spending, revenues

both expected to keep climbing
Manufacturings strong rebound
from the depths of the 2008 recession
is expected to continue throughout the
rest of 2012, according to the semiannual Institute for Supply Managements
Economic Forecast. Expectations for
the remainder of 2012 continue to be
positive in both the manufacturing and
nonmanufacturing sectors.
These projections are part of the forecast issued by the Manufacturing Business Survey Committee of the ISM.
The forecast was presented by Bradley
J. Holcomb, CPSM, CPSD, chair of
the Business Services Committee and
Anthony S. Nieves, C.P.M., CFPM, chair
of the ISM Non-Manufacturing Business
Survey Committee.
Two-thirds of the ISM Manufacturing Business Survey Committee respondents said they foresee a 9.5% increase
in revenues for the rest of 2012, while
15% expect a double-digit decline and
19% forecast no change. The aggregate
4.5% increase, while 1 percentage point
lower than Decembers forecast, is still
in line with ISMs monthly manufacturing report, which has shown growth in
the manufacturing sector for almost three
straight years.
With 16 out of 18 industries within
the manufacturing sector predicting
growth in 2012 over 2011, manufacturing continues to demonstrate its strength
and resilience in the midst of global economic uncertainty and volatility. Capacity utilization is at historically typical
levels and manufacturers are continuing
to invest in their businesses. The positive
forecast for revenue growth and modest
price increases will drive a continuation
of the recovery in the manufacturing sector, said Holcomb.
Purchasing and supply managers report
that their companies are currently operating at 81.6% of normal capacity, representing an increase from the 79.2% reported in December 2011, and a decrease from
the 83.2% reported in April 2011.
Production capacity in manufacturing
is expected to increase 5.2% in 2012.
This increase is slightly less than the
5.6% increase predicted in December
2011 for 2012, but greater than the 4.6%
increase reported in December for 2011.
Survey respondents expect a 6.2%
increase in capital expenditures in
2012. This is considerably greater than
the December 2011 forecast when members predicted an increase of only 1.9%
for 2012. Currently, 42% of respondents
predict increased capital expenditures
in 2012, with an average increase of
23.4%, while the 13% who said their
capital spending would decrease expect
an average decrease of 25.8%, and 45%
say they will spend the same in 2012 as
they did in 2011. PE
Siemens teams with community college

to create workforce development program
iemens PLM Software has

launched a new community college best practice program to
enhance the effort to revitalize manufacturing throughout the U.S.
The program, developed in conjunction with Iowa Western Community College, provides resources
to interested community colleges
and local manufacturers including a
recommended associates degree
curriculum and a guide for obtaining
in-kind software grants.
Now community colleges around

the nation have a proven blueprint to
meet the needs of local employers
and prepare local students for highpaying careers in design technology,
said Dr. Dan Kinney, president, IWCC.
As the baby boom generation
retires and product complexity continues to grow, students who are able to
use PLM technology are expected to
be highly recruited, said, Bill Boswell,
senior director, Partner Strategy, Siemens PLM Software. PE
PLANT ENGINEERING
June 2012 11
Fry Communications, Inc. printed this unique cover!

A combination of Spot Gloss UV, Spot Dull UV, and Foil colorized with UV inks in
one pass on the first of its kind press at the Fry WOW Factory.
INVESTED IN YOUR FUTURE
IN FOCUS
Strength in U.S., China drives
industrial automation growth
he relative strength of the U.S. and Chinese markets

is forecast to drive healthy market growth of 9.5%
in the global industrial automation market to reach
$159.8 billion in 2012, according to IMS Research (recently
acquired by IHS Inc.). The global industrial automation market
is predicted to reach more than
$200 billion by 2015. Market
growth will be buoyed by healthy economies worldwide this
year, despite individual countries in Europe slipping back
into recession.
Industrial automation equipment is purchased largely
for manufacturing processes, a key element in a countrys
GDP. Machinery production output drives demand for nearly half of the total industrial automation equipment market.
Early indicators for first quarter machinery production output show slowed growth in most regions, with the exception
of the U.S. market.
Though austerity measures in Europe and in the U.S.
have impacted public investment...large declines in these
markets are unlikely as most investment in industrial automation comes from the private sector, said Sarah Sultan,
research analyst at IMS Research. PE
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Other tools tell you:
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What it is
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IN FOCUS
SPECIAL REPORT: THE AGE OF INDUSTRIAL SECURITY
Why a production process

needs information technology
By David Heinze, Siemens AG
Only by ensuring the smooth interaction

of all these aspects can the production
Information technology has changed process effectively manage each indimore radically over the past 20 years vidual customer order and comply with
than practically any other field has. Par- every specific request.
ticularly in connection with the Internet
To ensure trouble-free interlinking of
and mobile communication
the countless different process
technologies, IT has progressed
steps, a large number of data
at breakneck speed to become
records must be exchanged
firmly entrenched in every
between the various stations of
aspect of the modern factory.
a process chain. To stay with
in a series
It is only with the widethe example of car production,
spread application of these
this starts by assigning each new
technologies that it has been possible cars floor assembly a unique number,
to network production facilities, plants, comparable to the engine or chassis serial
and machines across different locations, number used later for vehicle registrasupply chains, and national boundaries. tion. This identifier is applied during the
This development has brought a boost assembly phase and stays with the vehito productivity comparable only to the cle until it rolls off the production line.
advent of automation technology.
At every station, from the body in
Henry Ford famously said: People white, through the paint shop to the
can have the Model T in any color trim shop, during interim storage at the
so long as its black. In Germany, a various stages of variant production or
potential buyer looking to purchase a during final assembly and inspection, the
small two-seater car back in 1924 had control system and line operatives know
the choice of just two producers and two exactly which vehicle is being produced
colors: light green or yellow.
when and in which location.
Buying a car in this day and age means
This is not as straightforward as it
choosing between a seemingly infinite sounds, as every scanning process has
number of options: style, passenger to take place at every stage of production
capacity, colors and finishes, engine sizes, and in all types of adverse conditions,
interior trim, and equipment variants. even at temperatures in excess of 392 F
The variety is so enormous that statisti- (200 C) or continuous movement of the
cally speaking, a year will pass before an assembly line.
automaker will manufacture precisely the
A robot manufacturer has described
same car twice. Controlling this enormous how its robots are required to weld
model diversity requires a high degree of 6,000 different seams with an accuracy
automation in production and an equally of 0.2 millimeter on a single car body,
high degree of networking on every on noting 150 different model variants.
level of the automation pyramid.
Data picked up by the sensors relating
This starts on the business administra- to welding point accuracy, energy contion level with purchase order processing sumption, torque levels, rotary angles,
and the rough planning of material input and so on keeps operators informed at
and production, through the control and all times about the status of production
automation level with detailed produc- and manufactured products. Considering
tion planning, operation and monitor- that one new car rolls off the line every
ing, quality management, formulation minuteadding up to 1,400 times every
management, and so on, as far as the single daythis information is vital.
field level that forms the interface to the
technical process itself with its execu- Controls and networking
When the first programmable logic
tion, control, and regulating functions.
First
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IN fOCUS
controllers were used in production 50 years ago, they had
one objective: to provide an electronic and freely programmable alternative to the failure-prone relay. Up until this
point, relays had controlled all the automatic processes of
a production line, in a similar way to their function in the
Konrad Zuses first binary computer, the Z1. What followed
were durable, compact units that could be distributed around
the plant and linked by means of networks.
Initially, these were proprietary networks that afforded little
compatibility to the devices supplied by other manufacturers.
But still, the use of distributed intelligence represented an
We know from experience that companies
that ignore these key indicators generally

work well below their actual capacity.
However, determining the OEE is not quite
this simple.
enormous step forward in the development of machine and

plant engineering. The precision, speed, and durability with
which processes could now be controlled were also impressive. Since this time, automation systems have controlled not
only robots, machine tools, agitators and filling stations, rotary
kilns, sewage pumps, rolling stand drives, paper machines,
and trucks used in open-cast mining, but also turbines and
generators, power distribution plants, and traffic lights. In
short, automation technology is in use everywhere, in every
factory, in every infrastructure facility and every building.
The connection of different devices to each other using
Fieldbus systems represented an important leap forward in
innovation. This development was driven by the need to reduce
wiring costs. Using a single thin two- or four-wire cable, it
was now possible to transmit signals within just milliseconds,
paving the way for significantly faster response times.
Higher-level control systems in particular could now be
more selectively integrated into the production process using
bus systems. This allowed control or production planning
systems to directly govern what was produced when, where,
and how, starting with orders and bills of material arriving
from higher-level business administration and order management systems.
This type of networking has now become so established
in production that almost every other machine or plant is
networked on the basis of standards such as Ethernet, TCP/
IP, and real-time Ethernet.
Seen in this light, automation and production are becoming
totally interlinked, transforming into a whole new digital world.
The individual automation networks are turning from hierarchical
systems into networked systems on every level. These can not
only be adjusted with extreme flexibility and timeliness to fit in
with existing or future plants and assignments, but also be relied
upon to transport data in real time to its respective destination,
so increasing the transparency of production.
For job planning and logistical processes, this is creating
a boost to productivity on a par with that experienced by the
2011 Donaldson Company, Inc. All Rights Reserved.
16 June 2012
plant engineering
production process itself back at the beginning of the 1980s

with the advent of automation technology.
Information from the digital factory
The power to save energy

is at your ngertips.
The German Engineering Federation (VDMA) and Tetragon

Consulting in 2006 carried out an analysis of packaging
machine productivity in the pharmaceuticals industry. The
results make for sobering reading: With effectiveness averaging just 24% to 29%, existing systems are not operating
under optimum conditions.
Technically speaking, although the machines used in many
filling and packaging lines offer a very high level of availability, production supervisors still suffer the effects of stress.
The cause? Reasons include the diversity of products, container types and variants, dwindling batch sizes, and filling
quantities. These factors not only give rise to faults at the
machines themselves, but also compromise productivity as
a result of time spent on adjusting and cleaning as well as
machine setup processes.
Successfully implemented examples clearly demonstrate
that the investment pays off. By a simple analysis of the data
alone, output can be increased by up to 10%. But this requires
the availability of information derived from the process. The
most important key process indicator is overall equipment
effectiveness, or OEE for short. OEE analyzes availability,
plant performance, and quality and reduces these to a numeric
value which is shown relative to the achievable optimum.
Using up-to-the-minute key indicators for capacity utilization, efficiency (volume per hour, production per hour
of work, per employee), production figures (target /actual
comparison, machine run time, production output, machine
cleaning time) and target figures, order throughput times and
inventories of raw materials or cost-intensive input materials
can be optimized.
We know from experience that companies that ignore these
key indicators generally work well below their actual capacity. However, determining the OEE is not quite this simple.
Manually this is a highly cost-intensive process, the collected
data offers little scope for statistical verification, and only
retroactive conclusions can be drawn.
While the key to successful implementation is complete
networking of production facilities, interlinking the thousands
of components at work in production is not without security
risks. Unlike an office environment where a continuously
updated and standardized virus scanner works hand-in-hand
with a suitably configured firewall to create intrusion protection and a demilitarized zone, industrial applications require
their own dedicated security solutions. The principle is the
same, but the execution calls for quite a different approach:
Where plant IT infrastructures are concerned, early detection
of an intrusion is paramount. PE
Heinze is the marketing manager for the Industrial Automation Systems at Siemens AG. Heinze studied electronics
engineering, and after a career in research and development
and in product management, he now is responsible for the
global marketing for industrial security for Siemens.
plant engineering
June 2012 17
Compressed Air Solutions

IN fOCUS
CMMS takes the guesswork
out of safety inspections
By Paul Lachance,Smartware Group
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If you want to score points with the Occupational Safety

and Health Administration (OSHA) auditor next time he pays
a surprise visit to inspect your plant, show him an on-demand
preventive maintenance (PM) report from your computer
maintenance management system (CMMS) and watch the
corners of his mouth turn slightly upward.
CMMSs have long been recognized for automating PM
tasks on operations equipment to improve labor efficiency,
asset effectiveness, and certification assistance with the
International Standards Organization (ISO). A CMMS also
plays an important role when it comes to safety compliance
and liability protection with regulatory bodies like OSHA,
the Environmental Protection Agency the Food and Drug
Administration, the U.S. Dept. of Agriculture, the Joint Commission on the Accreditation of Healthcare Organizations,
and a variety of other quasi-government agencies.
A decent CMMS will not only alert maintenance operators
when its time to change a motor bearing, but the PM calendar
can tag the repair if it also belongs on a safety compliance
checklist. OSHA auditors, for example, care about a trackable
history of what was done on a piece of equipment; when it
was done; who did it; how often it has been inspected; and
whether clear instructions and safety procedures were documented. For OSHA, if its not documented, it didnt happen.
1:46 PM
Case in point: A giant linen rental company runs industrial washers, dryers, and folders that clean and press about
40,000 lbs. of laundry each day. It uses a CMMS to make sure
all production equipment is in compliance with safety and
environmental regulations, as well as insurance policies and
company rules. Regularly scheduled PMs trigger notifications
to maintenance technicians to not only tune up and repair
machines but to perform environmental and occupational
safety tasks, including:
n Lock out/tag out
n Extension cord inspections
n Fire pumps testing
n Tier II environmental checklists
n Machine guarding safety switch checklists
n Blood-borne pathogen exposure controls.
Half of the mission of meeting safety standards is simply
remembering to complete the tasks; a CMMS becomes the
brains behind maintenance operations and safety compliance.
Besides OSHA safety inspections, food processing plants
can expect random inspections from both regulatory agencies
and original equipment manufacturer (OEM) customers who
add the plants dietary ingredients to their products.
A Midwest dairy manufacturer must adhere to strict USDA
guidelines to combat bacterial contamination from E. coli
or risk the health and safety of consumers and a public relations nightmare that could lead to the plant being shut down.
Continued on p. 22
18 June 2012
plant engineering
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IN fOCUS
Sweatman: Manufacturing needs a clear path
Roy Sweatman, President of Southern Manufacturing Technologies in
Tampa, Fla., and a member and former
Chairman of the National Tooling and
Machining Association (NTMA), joins
24 other U.S. manufacturing leaders
as new members of the Manufacturing
Council. The Council provides advice to
U.S. Commerce Secretary John Bryson
on issues related to manufacturing sector competitiveness, as well as government policies and programs that affect
the industry. Sweatman is vice chairman
of the National Institute for Metalworking Skills, an organization founded by
metalworking trade associations to
maintain a globally competitive workforce. He discussed his appointment and
the manufacturing issues that should be
communicated to the administration with
Plant Engineering:
Plant Engineering: There are two
issues that seem to be running neckand-neck among manufacturers: the
need for more skilled workers and the
need for tax reform. Which one in your
view is more crucial, and how do we
address it effectively?
Sweatman: Its simply not possible
to prioritize one of these issues over
another since both are essential to the
long-term future of manufacturing in
America.
Roy Sweatman
On the issue of skilled workers, manufacturing has been tainted by an outdated perception of dark and dangerous
plants of yesteryear; todays facilities
are efficient, high-tech environments
where we make sophisticated products
ranging from satellite parts to cuttingedge medical devices. We need to do a
better job of marketing manufacturing
and attracting workers to our industry
in order to have a viable employee base
in years to comeand were working
on it now.
For example, my company, Southern
Manufacturing Technologies, gives tours
to high school and even middle school
groups, works with various groups advocating STEM education, supports robotics competitions such as the National
Tooling and Machining Associations

National Robotics League championships in Indianapolis in early May, and
other similar ongoing initiatives.
Manufacturing is a very viable career
path for todays young people, and
theres no reason that should remain the
best kept secret in the U.S. economy
for much longer. But its our industrys
responsibility to start changing misperceptions about manufacturing.
As far as tax reform goes, the farreaching effects of the policy decisions
were starting to discuss today cannot be
overstated. They say there is no greater
determinant to a firms behavior than tax
policy, and thats something that policymakers need to keep in mind over the
coming months.
Unfortunately, some who claim they
want to tax the rich need to be reminded that many of these are small business
owners who report a certain income due
to the way they file taxes but reinvest
most of their profits back into the plant,
equipment, and employees. They are not
the Bill Gates or Gordon Geckos of the
world; they are ordinary citizens and
entrepreneurs in towns across the country who pay their taxes and reinvest their
profits into their companies.
As a group these companies are some
of this countrys greatest job creators.
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will stop growth. Policymakers need to
understand who theyre really affecting
when they talk about tax reform.
PE: How do the efforts at NTMA align
with those of the Manufacturing Council? What specific issues at NTMA do
you think the Manufacturing Council
needs to hear more about?
Sweatman: Policymakers and business
leaders should be working together to
ensure that small businesses are able to
continue to hire the workers and invest in
the new technologies that allow us to stay
competitive with businesses overseas. Its
in the interest of our country to do so, and
Im glad that the work of the Manufacturing Council recognizes this fact. After
all, small and medium businesses like
ours are the job creators of this country
and the backbone of our communities.
The Manufacturing Council has
four subcommittees: Competitiveness,
Workforce Development, Export/Import
Issues, and Energy, all of which affect our
industry and are aligned with the work of
NTMAs priorities. I am assigned to the
Workforce Development subcommittee,
since it gets right to the heart of one of our
top priorities today, as I discussed above.
More generally, manufacturing competitiveness is an issue that reflects our
industrys concerns across the board. The
IT INFRASTRUCTURE
fundamental question we need to ask is:

how do we ensure that U.S. manufacturers are not placed at a disadvantage
by our own government against our foreign competitors? We need to ensure our
government doesnt make our companies
uncompetitive by saddling them with new
They say there is no greater
determinant to a firms behavior than tax policy, and thats

something that the policymakers need to keep in mind over
the coming months.
taxes and higher healthcare, energy, and

other costs.
PE: What does manufacturing need
to do that doesnt involve government
assistance or guidance? What do manufacturers need to do for themselves?
Sweatman: The many initiatives that
I have outlined in the other questions are
all private-sector led initiatives that are
being undertaken by NTMA or by my
company without any government assistance. We are not asking for a government
handout. In fact, our efforts as an industry
over the past several years have been to
try and convince government not to enact
SOFTWARE & SERVICES
policies that hurt our ability to compete.

Manufacturersparticularly small and
medium-sized shops like the members
of NTMAhave had to stay nimble and
adapt over the years in order to thrive in
a competitive industry. I strongly believe
that we as an industry need to keep on
adapting as we look to the future, and
make sure to embrace technology, automation, and training that makes us better
equipped to deal with the market conditions and other challenges that well face
tomorrow.
I would also add that manufacturers
as a group need to be proud of what we
contribute to this country, and we need
to remind people about our role creating
jobs, making products, and contributing
to our communities.
PE: On a personal level, talk about
the appointment and your reaction to it.
Sweatman: I am honored to join the
Council. I am looking forward to making
a differenceto help strengthen manufacturing in the U.S.
I am proud to represent the metalworking industry and all manufacturers, and
I will certainly be a strong advocate for
small and medium-sized manufacturers, including metalworking companies.
These thousands of small businesses are
the job creators leading this country back
to economic health and prosperity. PE
IN fOCUS
Continued from p. 18
With a CMMS, the maintenance team
sets up PMs to check all bacteria lab testing equipment, including water filtration
systems, air quality systems, and metal
detectors that look out for foreign objects.
There are numerous opportunities
to gain a positive return on investment
using a CMMS: improved operations,
asset preservation, etc. Another is fine
avoidance. Many companies decide to
purchase a CMMS package only after
theyve suffered the consequences of
fines levied for lack of proof or some
other failure during a regulatory audit.
While the initial appeal of a CMMS is
to automate and schedule routine maintenance tasks, why not add the tasks on
your regulatory checklist to your PM
schedule and avoid noncompliance penalties before they happen? PE
Lachance is president and chief technology officer for Smartware Group,
which produces Bigfoot CMMS. Contact
him at paul.lachance@bigfootcmms.com.
Raymond Corp. celebrates Youth Apprenticeships
he Raymond Corporation recognized high school seniors who have spent

the past year contributing to Raymond through its Youth Apprenticeship
Program at an apprenticeship senior night in Greene, N.Y., on May 23,
2012. Established in 1991, the apprenticeship program prepares students for
careers in the manufacturing industry. Held in conjunction with Broome-Tioga
Board of Cooperative Educational Services (BOCES) and the Greene School
District in New York, the apprenticeship program includes of 56 students this
year.
The Raymond Corporation does an outstanding job of mentoring and coaching the high school students who participate in the Youth Apprenticeship Program, says Sandra Watkins, career development center supervisor at BOCES.
The program has become part of the business culture at Raymond because it
sees the value in our partnership and how it benefits not only the students but
the business, the industry and the school.
Following each apprenticeship term, Raymond holds a yearly apprenticeship
senior night, where student apprentices share the skills they have acquired as a
result of the program. Students typically highlight increased knowledge related
to areas such as workflow process, quality improvement and material handling.
The Youth Apprenticeship Program, coordinated through BOCES, is part of
Raymonds commitment to improve the future of manufacturing. It allows junior
and senior high school students to explore multiple career options in the material handling industry. PE
For more information on the Youth Apprenticeship Program, call
(607) 763-3254.
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IN PRACTICE
Take a step-by-step approach
to system troubleshooting
By Hilton Hammond, Fluke and Glen Mazur, ATP
roubleshooting is a step-by-step procedure

the equipment is on or off. A difference indicates a
whose purpose is to quickly and easily identify
power distribution system that is overloaded, or cona problem in a system or process. Proper test
ductors that are undersized or else delivering power
instruments make the process smoother and
for too long. High voltage drops typically require
in a series
make it possible to more easily identify secondary
system testing.
problems where they exist.
When performing basic voltage tests, it is important
To troubleshoot a system, process, or equipment, start by col- to ensure correct grounding, as well as that measurements are
lecting technical records from relevant sources. These include taken between each phase-to-hot conductor, phase-to-neutral
the OEMs, suppliers, contractors, operators, and maintenance (underground) conductor, and phase-to-ground (grounded)
departments.
conductor. These phase-to-phase measurements should not
Choose suitable personal protective equipment and test vary more than 1% to 3%. If fuses are present where taking
instruments for the job, then isolate the portion of the system voltage measurements, test them to ensure that they are operor equipment to be tested. Take readings on this portion to test ating correctly.
for malfunction. Multiple readings may be necessary in order
If the voltage into and out of the fuse is equal, and the voltto either verify proper operation or to identify a problem.
age across the fuse is 0V, then the fuse is good (closed). If, on
Once located, repair and test the problem area to ensure the other hand, no voltage is measured out of the fuse, then it
proper function. The repair process may require technical ser- is bad (open). This same measurement should also be taken at
vice, parts replacement, or redemption of a warranty. Perform individual load points within the equipment, such as motors. The
additional measurements after the initial repair is completed to voltage delivered should fall within 110% to +5% of the motors
determine whether any secondary problems still exist.
nameplate rating when it is measured with the equipment on.
When all repairs are completed, document the processes
performed. Include the original problem, all tests and measure- Current tests
Current tests are important because they can reveal things
ments conducted, and the steps taken to repair the problem
if one was found. Also include any secondary problems, if that voltage tests do not. A current test can detect whether a
they exist, along with suggestions for solutions. Service and motor is delivering full power or half power, or is even inoperinventory all PPE and tools used while troubleshooting, and able, while the voltage measurement may be consistent at the
note anything that would have improved the process, such as motor and the load.
A current test will accurately indicate just how loaded a
additional tools or training.
When it comes to electrical problems, troubleshooting can motor actually is. When at full power, the motor should match
range from as broad as a building or system to as specific as an the listed current rating on the motor nameplate. Typically,
individual component. Troubleshooting electrical equipment though, most motors should draw less. It is also important to
starts with basic tests first and moves toward more advanced measure current over time; unlike voltage, which generally
testing as necessary. Voltage and current tests are the most stays the same, current changes as the required load changes.
Current and voltage tests can detect basic problems includcommon, and typically are first conducted at easily accessible
ing open fuses, power loss, and overloaded motors. In order
points of measurement or access.
to understand how a motor or system functions over time,
Voltage tests
however, more complex tests and measurements are necesBecause all electrical systems and components require power, sary. These can include minimum, maximum, relative, and
voltage testing is a logical first step in the troubleshooting peak temperature measurements, which can be taken using a
process. For comparison, voltage should be measured both digital multimeter (DMM) or portable oscilloscope. Portable
while the equipment is on and while it is off. When off, voltage oscilloscopes, in addition to power quality meters, can test for
delivered to the equipment in question should fall within -10% waveform distortion problems. Portable oscilloscopes are ideal
to +5% of the equipment nameplate rating,
for taking advanced measurements because of their advanced
When on, the operating voltage should not change by more test functions. PE
Excerpted from the book, Motor and Drive Troubleshootthan a maximum of 3% of the voltage measured while the
equipment is off. Ideally, in an appropriately sized power distri- ing, written by Glen A. Mazur and Hilton Hammond and
bution system, the voltage measured should not change whether published by Fluke Corp. and American Technical Publishing.
First
PLANT ENGINEERING
June 2012 25
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Have a
Lubrication
Question?
Newark, NJ 07105 / Toledo, OH 43605 / 1-800-733-4755
www.lubriplate.com / LubeXpert@lubriplate.com
E-mail
LubeXpert@lubriplate.com
Photo courtesy: Shell Global Solutions
Synthetic
2012
Lubrication Guide
sound lubrication strategy

is essential to
ke e p a ll t he
gears in your
operation running at their best. The emergence of synthetic lubricants
has helped improve the performance of machinery and
has become an important part of any
maintenance managers arsenal in the
fight against friction.
This latest edition of Plant Engineerings Synthetic Lubrication Guide
offers not just a listing of the major
synthetic lubrication suppliers, but also a look at

the strategies behind a
successful lubrication
program.
Synthetic lubricants
offer great opportunities
for enhanced productivity
and cost-efficient use, but
they need to be deployed
as part of an overall plan that analyzes
the needs of the machines.
The right lubrication products and
the right strategy can reduce friction,
both on your plant floor and with your
management.
Friction is the enemy of efficiency.
PLANT ENGINEERING
June 2012 27
2012 Synthetic Lubrication Guide
More
eye
than
meets the
The latest lubricant

technology is a secret
weapon in the battle
for efficiency.
By Steve Slack, Shell Global Solutions
28 June 2012
PLANT ENGINEERING
oday, plant engineers are under

more pressure than ever before to
ensure that capital equipment is
kept in optimum working condition
for a productive and cost-effective
operationavoiding unnecessary
damage to equipment, minimizing maintenance costs, keeping machinery running, and
improving efficiency are all challenges that
have to be managed and balanced as part of
the day job.
Much of the time, lubricants are an afterthought, understood as a necessary part of dayto-day working, but not always recognized as a
vital component to the entire operation. Ensuring correct lubrication use can help generate
cost savings by minimizing downtime and
enhancing machinery protection, particularly
in environments where optimum productivity is
critical for delivering against peaks in demand.
For example, Shell works with a range of customers across many sectors of industry that
have benefited from significant cost savings
as a result of using the correct products.
The role of any lubricating oil is to provide
the optimum protection to the equipment and
other moving parts. This involves reducing
friction and protecting against acids, deposits, and wear throughout a range of operating
conditions. By opting for lubricants that offer
enhanced levels of protection and mitigate
other operating factors such as fluctuations in
temperature, plant engineers can help ensure
not only that their machines are working to
optimal service levels, but that they are safeguarded against premature wear and tear, and
unnecessary maintenance downtime.
More goes into the production of modern
lubricants than first meets the eye. Extensive
investment, along with an army of scientists
and engineers, are enlisted to continually innovate and improve product performance. This is
not new; Shell, for example, has been undertaking lubrication research and development
since 1940. We have technical experts all over
the world working closely with OEMs every
day to help customers tackle productivity and
efficiency challenges in their operations.
Synthetic technology
Through extensive and ongoing testing,
scientists are building a more detailed understanding of the physical characteristics and
demands placed on modern-day oils. Alongside this, advancements in synthetic technologyparticularly over the last 10 yearshave
resulted in a significant leap in the benefits

lubricants can deliver.
Today, synthetic lubricants are the highest
performing lubricants and are based on manmade technologies that offer a wide range of
benefits that nonsynthetic products simply
cannotenhanced protection, and thus greater
durability of your equipment, and longer oil
life through reduced deposits and oxidation,
all help contribute to tangible improvements
in your plants/equipments efficiency, down-
Ensuring correct lubrication use can help generate
cost savings by minimizing downtime and enhancing

machinery production, particularly in environments
where optimum productivity is critical.
time, and maintenance costs. In addition, they

can be manipulated to maintain protection in
harsh environmentsfor example, where
machinery experiences dramatic temperature
fluctuations or where it may be submerged
in water.
Synthetic lubricants start with high-grade
synthetic base oils. Traditionally, lubricants
have been based on mineral oil, a component
of whole crude oil. Thanks to modern refining
technology, todays high-quality mineral oils
provide adequate protection. But mineral base
oils are complex mixtures of naturally occurring hydrocarbons and may contain impurities.
On the other hand, synthetic base oils have
been chemically altered to reduce impurities
and are engineeredusing specialist additivesfor excellent low-temperature flow
properties, high resistance to thermal degradation, and low oil consumption. Depending
on the product, additives can account for 1%
to 30% of the lubricant and achieving the right
blend is what sets a quality lubricant apart
from its competitors.
Synthetic lubricants have also been proven
to deliver extended lifecycles compared to
other oils without impacting quality or performancein some cases lasting up to two or
three times longer than they did just a decade
ago. This means that engineers do not have
to contend with replenishing oil levels as frequently, thereby reducing costs and time spent
on upkeep.
Recognizing the importance of correct lubrication choice and application is one thing, but
I imagine many of you reading this article lack
plant engineering
June 2012 29
Lubrication Guide
LUBRIPLATE
Lubricants Company
Newark, N.J.
www.lubriplate.com
Schaeffer Manufacturing
St. Louis
www.schafferoil.com
Gear and bearing circulation oil

ISO Viscosity Grade
Viscosity,
SUS at 100 F
32
135-165
LUBRIPLATE SYN LUBE 32
264 Pure Synthetic Hydraulic Oil ISO 32
46
194-236
68
284-346
100
420-520
150
630-770
220
900-1100
320
1350-1650
460
1935-2365
Extreme pressure gear oil

100
420-520
LUBRIPLATE SYN LUBE HD 100
150
630-770
167 Moly Full Synthetic Gear Lube ISO 150
220
900-1100
320
1350-1650
460
1935-2365
High-pressure (antiwear) hydraulic oil

32
135-165
46
194-236
68
284-346
100
420-520
Fire-resistant hydraulic fluid

Synthetic water glycol
265 Glygo Torque Fluid
Compressor lubricant
32
136-165
158 Pure Synthetic Compressor Oil ISO 32
46
194-236
68
284-346
100
420-520
150
630-770
Multipurprose extreme pressure grease (without moly)

150/220
NLGI2
LUBRIPLATE SYNXTREME HD2/220
Multipurpose molybdenum disulfide extreme pressure grease

150/220
NLGI2
LUBRIPLATE SYN 3002
Multipurpose high temperature grease (without moly)

150
30 June 2012
NLGI2
PLANT ENGINEERING
LUBRIPLATE SYNXTREME HD-2
197 Moly Pure Synthetic Grease #2
AMSOIL
Superior, Wis.
www.amsoil.com
CITGO Petroleum Corp.

Houston
www.citgo.com
Castrol Industrial North

America
Naperville, Ill.
www.castrol.com/industrial
Sentinel Lubricants
Miami, Fla.
www.sentinelsynthetic.com
Compressorgard PAO 32
S MPO 32
S MPO 46
CITGEAR Synthetic HT 68
S MPO 68
S MPO 100
Alphasyn T 150
Alphasyn T 220
Alphasyn T 320
Alphasyn T 460
PolySi Technologies,
Inc.
Sanford, N.C.
www.polysci.com
CITGEAR Synthetic EP 100

Dimension 46
Dimension 68
CITGO FR-40 XD
Aircol SR 32
Aircol SR 46
Aircol SR 68
Aircol SR 100
AMSOIL Synthetic PultoiPurpose Grease (GLC)
Mystik JT-6 Synthetic 220

Grease #2
Tribol 4541
AMSOIL Synthetric Polymeric Off-Road Grease

(GPOR2)
PST-4700
Mystik JT-6 Synthetic 220 Grease #2
Tribol 4541
PST-433
PLANT ENGINEERING
June 2012 31
2012 Synthetic Lubrication Guide

the time to keep up-to-date
with the latest products
and technologies. There is
help available, and engineers or those responsible
for purchasing should take
full advantage of their
suppliers expertise. For
example, Shell LubeMatch is an online service
that helps to identify the
most appropriate lubricants for each individual
operation, and it can help
to make the selection process more manageable in
a marketplace that covers
a wide array of products.
Application
Lubrication
servicing should
be considered a
standard procedure
in the ongoing care
of an oil and the
machine components
it is protecting.
32 June 2012
In operational environments the use of synthetic

lubricants, compared to
nonsynthetics, has demonstrated cost and time
savings for many plant and manufacturing
operations. Reported savings, from extensive
field trials as well as directly from customers
around the world, reinforce the benefits to be
had from using synthetic lubricants.
For example, a plastics plant in Turkey,
Wavin Pilsa, which was dissatisfied with the
poor performance of its existing compressor lubricant, used a range of Shell support
services to help identify the best oil for its
operation. Oil sample analysis indicated the
oil it was using had poor thermal and oxidation
stability, which necessitated an oil drain every
5,000 hours. As a consequence, operating and
maintenance costs were much higher than they
needed to be.
The Shell Lubricants technical team recommended that Wavin Pilsa change to Shell
Corena S4 R 68, a synthetic air compressor
oil incorporating a unique high-performance
additive system. The switch reduced operational costs by 50% and increased the oildrain intervals from 5,000 to 10,000 hours.
The company reports saving $12,185 a year,
resulting from lower oil consumption and
labor costs, less oil waste for disposal, and
improved maintenance practices. The savings
indicated are specific to the calculation date
and mentioned site. These calculations may
vary from site to site and from time to time,
depending on, for example, the application,
the operating conditions, the current products
plant engineering
being used, the condition of the equipment,

and the maintenance practices.
Storage, temperatures, and ongoing care
When considering that lubricants are a relatively small part of total operating expenditures, they can add incredible value to the
working life of a plant, so ensuring they are
monitored regularly and stored adequately can
lead to further cost savings and efficiencies.
Lubricant servicing should be considered a
standard procedure in the ongoing care of an
oil and the machine components it is protecting. Such checks can mean avoiding unnecessary oil changes; the technology is designed
to identify potential oil or component failures
before they become critical, but allows engineers to rest assured that until that time, the
oil will work to optimal levels.
For example, Shell LubeAnalyst is an oil and
equipment condition monitoring service that
involves taking samples directly from working
equipment, which are then analyzed and tested
in an accredited laboratory. The results of these
tests are provided along with a diagnosis and,
if necessary, recommendations for adapting oil
use to resolve any problem areas.
Storing lubricants correctly can also ensure
that the oil does not deteriorate or become contaminated and, as a result, provide inadequate
protection or become waste that requires disposal. It is very important that the drums which
contain the lubricant are kept in a safe, indoor
location where they do not risk being punctured or damaged, and are not near heaters,
steam lines, or places of extreme refrigeration.
Reducing moisture buildup inside oil tanks
that may condense is also important. Desiccant breathers can help to decrease the extent
of this happening, as can the use of a bottom
drain, or bottom-fed pumps that pump out the
moisture promptly.
In short, if you want to make lubricants
work for your business, you must implement
an active process of selecting and applying the
right product, combined with the appropriate
maintenance. Your efforts will be rewarded. PE
Slack is a scientist at Shell Global Solutions, a network of independent technology
companies in the Royal Dutch Shell Group.
In this material the expression Shell Global
Solutions is sometimes used for convenience
where reference is made to these companies in
general, or where no useful purpose is served
by identifying a particular company. For further advice on selecting the right lubricant,
visit lubematch.shell.com.
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IANA
Global Automation
& Manufacturing
Summit
Discover strategies for plant improvement
that you can take back to your plant and
implement immediately.
September 12 - 13, 2012

Chicago, McCormick Place - East Building
CFE Media and Hannover Fairs International partner
to present a two-day senior-level conference program
at the inaugural Industrial Automation North America
expo, September 12-13 in Chicago.
WEDNESDAY, SEPT. 12
Goodyear Tire and Rubber Company
9:30 a.m.: Energy as a Raw Material,
Speakers: Bruce Lung, ASE; and Greg
Bodenhamer, Schneider Electric
11 a.m.: Integrating Operator Knowledge,
Speakers: Mary Bunzel, IBM; Beckhoff
Automation; and Grainger
12:30 p.m.: Luncheon keynote:
Karen Kurek, McGladrey
2 p.m.: Stay Ahead of the Technology
Curve, Speakers: Chuck Edwards,
Lenze Americas; and B&R Automation
3:30 p.m.: Gaining, Training, Retaining
the Next Generation of Workers,
Speakers: AMT; and Raj Batra, Siemens
THURSDAY, SEPT. 13
Key topics in global automation and manufacturing

will be highlighted including: enterprise asset
management, process optimization, energy
management and sustainability manufacturing.
8:30 a.m.: Keynote address:

Douglas Woods, AMT
9:30 a.m.: Empowering the Mobile
Worker, Speakers: Joe Granda, Syclo;
and June Ruby, Motorola
11 a.m.: Securing Your Data,
Speakers: Greg Hale, ISS Source; and
Peter Esparrago, MAVERICK Technologies
Case studies on how plants have automated for

profitability, improved performance of existing assets,
and reducing maintenance costs will also be presented
at the conference.
Register today at
www.imts.com/education/ianaSummit.html
IANA Global Automation & Manufacturing Summit: Early Bird Rate of $165
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ENTER a drawing to
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A drawing will be held for a
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Sullairs Air Quality System

Delivers White-Glove Clean Air.
Why use a dryer and filter with your air

compressor? Because clean, dry
compressed air is essential to your
production process.
Moisture can ruin finished product and foul the
process. In addition to moisture, compressed
air may contain dirt, wear particles and
lubricating fluid.
The Sullair Stationary Air Quality System matches a

Sullair compressor, a Sullair dryer and Sullair filters.
Sullair assures that its Air Quality System will meet
specific performance levels throughout its
operational life.
For more information about how Sullairs air
quality products can extend the life expectancy
of your compressors, contact your local Sullair
distributor: www.sullair.com/stationary
Scan code to find your

Sullair Distributor.
www.sullair.com
www.facebook.com/SullairCorporation
Cut downtime, lower installed costs

BlueKote
Conduit Bodies
BlueKote internal surface coating
reduces force required to pull wires

3 layers of corrosion protection
including two layers of epoxy
coating
E-Z-Ground
Grounding Connectors
Eliminates need for exothermic
welding; reduces risk of poor
connections caused by moisture
Can be installed in any weather
conditions
No special training required
Trap-Eze
Connector
MaxGard
Interconnection System
Easily installs above

or to the side of an existing
assembly, eliminating the need
to disassemble and reassemble
the trapeze
Connectors can be
reused upon
disassembly
of a trapeze
Metal plugs and receptacles

with standard Neoprene
O-ringed interior components
for watertight seal
30, 60, 100, 200 and 400
amp connecting system with
cast aluminum NEMA 4X
interlocks. Steel 30, 60 and
100 amp for NEMA 12
Change out electric motors faster, safer

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Quicker disconnect no cutting
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Faster assembly
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High-Temperature
Wire Joints
Rated for temperatures up to

150 C / 302 F, 660V maximum
Molded, one-piece nylon
construction for electrical
insulation, UL94-V2
Easier insulation
simply slide on
reusable
insulation boot.
Greater reliability high-conductivity

tin-plated copper, compression-crimp
disconnects from 600V to 5kV.
Extra High-Temp
Cable Ties
Made of extra high-temperature

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Innite adjustability with the
exclusive Grip of Steel lock
Looking for more uptime and lower installed costs? Look to Thomas & Betts. Our portfolio
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Wire & Cable Management Cable Protection Systems Power Connection & Control Safety Technology
2012 Thomas & Betts Corporation. All rights reserved.
AUTOMATIONSOLUTIONS
System integration services:

In-house or hired out?
Should automation and process control services and system integration
projects be performed in-house or hired out? Advice follows from system
integrators working on the front lines of project management for automation
and process control.
By Mark T. Hoske
CFE Media LLC
Smaller companies may

benefit the most from
supplementing in-house
staff for automation services
or project-based support.
Courtesy: Optimation
eciding whether to keep an automation

integration project or process control
services in-house or out-source some or
all, depends on many criteria, perhaps
most obviously workload, but also risks of an
implementation gone awry if inside experts
bite off more than they can chew.
While it may seem logical to keep as many
services in-house as possible, factors to consider include workload, forecasting work,
schedule, deadlines, expertise, design quality,
liability, and risk, according to John Koehler,
director of sales, and Melissa Striet, technical
marketing coordinator, Process Plus.
It may seem like common sense to keep as

much work in-house as possible, Koehler and
Striet noted. Why would you hire someone to
complete work that you can do yourself? If
automation and operational engineering services are your core competencies, then keeping those services in-house may make sense,
they said.
However, if these are services that do not
make up the majority of your business, Koehler
and Striet said, you may want to reconsider.
Providing a service that is not at the core of
your business practice may detract from your
bottom line.
PLANT ENGINEERING
June 2012 37
AUTOMATIONSOLUTIONS
Considerations checklist for services: In-house or hired out?
Use this checklist to help decide if automation engineering services should be in-house or hired out.
Yes
No Consideration questions

Are automation and operational engineering services a core competency for your company?

Do automation and operational engineering services make up the majority of your business?

By taking on this project in-house, will there be missed opportunities to take on more profitable projects?

Considering your current workload and staff size, can your in-house staff support this project?

Does the one-time cost of a hired-out consultant outweigh the cost of hiring additional inhouse staff?

Does your in-house staff have the ability to meet the critical deadlines dictated by the project
schedule?

Is the project schedule flexible enough for the work to be forecasted to help fill in gaps in your
in-house workload?

Does your in-house staff have the special expertise or specific project experience necessary
to complete the project?

Will you receive the same quality of work in-house as you would by hiring out the engineering
services?

Are you willing to take on the risk and potential liability associated with this project?

TOTAL
If the majority of answers are yes, then you may consider keeping the service in-house. If the majority of answers are
no, then consider hiring out your engineering services, suggests ProcessPlus, www.processplus.com.
You need to consider factors such as

overhead costs for these employees, costeffectiveness, as well as missed opportunity costs related to your staff who are not
contributing to your core competency,
they said.
With every design project, there are
two basic cost elements: the cost of the
services, and the overall lifecycle cost
of the project. Hired-out engineering
costs equal the price of the purchase
order. In-house costs are more than
just salaries and benefits, depending
on accurate record-keeping of time
spent on the project, and other activities
associated with the project, such as
travel and supplies, profit, as well
an accurate estimate of overhead.
Comparison can be difficult over
a projects lifecycle, Koehler and
Striet said.
Considerations, said Koehler and
Striet, include the following.
Workload peaks, valleys
Project schedule and capacity
Project expertise
Quality and innovation
Liability and risks
38 June 2012
PLANT ENGINEERING
For more details on each, read this

article online at http://bit.ly/IcBIMO.
Outsourcing business case
left behind, often overlooked during

the planning stages of the new solution,
and the last to receive training, she said.
And career advancement opportunities
are limitedunless they are willing to
move out of their chosen field and into
the mainstream of the companys business. Outsourcing these highly skilled
electrical and automation support services is growing in popularity as a way
of improving quality and responsiveness
of these services while reducing the total
cost of acquiring them.
In-house, outsourced, hybrid

Faced with these challenges, manufacturers have a variety of staffing options
available, Schmidt said.
At one extreme, they keep all of the
electrical and automation engineering,
for capital projects and maintenance, inhouse. At the other extreme, they outsource nearly all such services. Increasingly, however, the most successful
companies have seemed to settle on a
hybrid approach, keeping the missioncritical engineering skills in-house and
outsourcing the more general purpose
services.
For more justification citing product
variety, customization, cost, quality, safety, regulations, and enterprise resource
planning integration, debunking in-house
arguments, and helping human-resources, managing outsourcing risks, read this
online: http://bit.ly/Ifxu5Z.
Make a business case for getting help

with automation support services and
ensure you get the right skill sets for the
processes and technologies needed, said
Cherri J Schmidt, strategic account man- Process control
maintenance services
ager, TEC Systems Group.
System integration and maintenance
As the manufacturing environment
becomes increasingly
automated, companies
often focus their investments on improving the
Best practices when outsourcing
skills of the production
system integration: Manage risks
team to use the new
1. Treat existing employees with respect
technologies, Schmidt
said. But what about
2. Keep the mission-critical work in-house
the skills and knowl3. Use clearly defined, performance-based contracts
edge of the resources
4. Preserve your best resources
that have to support
5. Choose a reliable and established service provider
and maintain these new
Hedge your bets: Consider keeping at least two sersystems? The electri6.
vice providers on long-term contract
cians, technicians, and
Courtesy: TEC Systems Group
engineers who make up
the plant services organization are frequently
aUTOMaTIONSOLUTIONS
services for process control systems
and IT infrastructure extend through
the full lifecycle of a project. When
deciding between in-house or hiredout integrator, consider the quality
and type of services available, and ask
the following questions, according to
Vladimir Morenko, director-general,
Industrial Automation Systems LLC
(Insist Avtomatika), Russia.
What does the customer receive if he
gets an engineering company involved
in service maintenance at all stages of
a control system lifecycle? What essential components determine the quality of
services? What criteria should be used
to choose service contractor? What to
choose: services of an automation vendor or services of an independent system integrator? How can one reconcile
While oil-field storage tanks provide a repository for products, system integrators
can provide steady stream of process control, services, and project management
talent. Courtesy: Industrial Automation Systems LLC (Insist Avtomatika), Russia
Finding the right balance: In-house or hired out?
eed automation engineering services? Value and

involve in-house automation engineers, select
the right outsourced team, help the hired system
integrator understand the business, and play an
active role with everyone focused on clearly defined project
results for preserving value of control systems, one of the
most important parts of your plant. Whats the right balance
of inside or hired-out services? Optimation system integrators explain when it makes sense to maintain a team of
your own, and when to seek assistance.
When considering whether or not to hire your own automation engineers, consider the benefits of keeping this
capability in-house.
An in-house staff will be familiar with specific manufacturing operations and company requirements better than
an outside firm, said Jim Cummings, general manager of
Optimations Philadelphia office.
That familiarity can be a valuable asset to companies
with sensitive information, such as trade secrets, new products in development, and special processes.
An in-house team can be leveraged to keep proprietary
information internal to the company, said Mike Triassi,
business development manager at Optimation.
While secrecy may be a factor for some companies, size
may be a concern for others. Smaller companies probably
find that the smaller in-house staff will not have all of the
capabilities to do a wide range of short-term projects with
specific technical needs, said Greg Gacioch, regional sales
manager for Optimations Minnesota office.
Dan Purvis, general manager of Optimations Southwest
offices, recommends, a small group of people that really
40 June 2012
plant engineering
know their way around it all. But your automation needs will
ebb and flow. You may hire up for a major implementation
project, but then after thats complete, then what?
Cumming cautioned that internal staff may not be able to
keep up with the latest technologies as easily as an outside
firm.
Even with an in-house team, consider schedule and
project complexity, the two biggest reasons to hire out,
said Purvis. And when the new project needs outpace the
capacity of internal resources, the choice is to hire more
staff, delay projects, or contract services.
Therefore, the outsourced team selection process should
include a review of project methodologies and evidence of
adherence to best practices, such as those advocated by
the Control System Integrators Association (CSIA). They
will often leverage proven efficiency techniques, such as
requirements traceability and risk mitigation documentation,
conferencing capabilities for design and system reviews,
and remote webcam witnessing of factory acceptance tests.
In the end, Cummings, Gacioch, Purvis, and Triassi concede that even the best outsourced team with the greatest
skills is still going to have a learning curve when it comes to
understanding your business, over and above the in-house
staff. The key to a successful project with an outside firm
is to play an active role every step of the way, with all team
members focused on clearly defined project results.
Online, see how to use the expertise of an outside firm,
benefit from best practices, and take the right approach to
outsourcing: http://bit.ly/IfvSuH.
Written by Jennifer Palumbo, a marketing communications specialist at Optimation Technology Inc.
INTERACT
Go online now for the latest insight.
requirements for the independence of

the system integrator and his loyalty to
the vendor?
Morenko, drawing on input from
Andrey Perminov, Sergey Faruntsev, and
Elena Kholina, offers the following process control system contractor services
checklist to help with the decision.
and examples. As of this submission, Insist

Avtomatika said it is the only Russian
member of the Control System Integrators Association. PE
Hoske is a content manager for Control
Engineering, CFE Media LLC. Contact
him at MHoske@CFEMedia.com.
Q: When and why do you use a system

integrator to help with your projects?
Anatomy of service quality

What should a contractor be able to
do? Based on service maintenance experiences, the following tasks should be
fulfilled at the stage of process automation systems, information systems, and
instrumentation operation:
Minimize risks related to control
systems of various levels (instrumentation, field facilities control, supervisory
control level, manufacturing control)
Secure the required level of accessibility and reliability of control systems
Minimize downtime of main process
equipment (production, injection wells,
booster pump stations, central processing
facilities, pipelines, etc.)
Increase energy efficiency and
equipment productivity
Increase quality of products
Minimize repair time and ensure
high quality of repair
Reduce cost of equipment maintenance
Continuously modernize system
hardware and software, responding
quickly to changes in technologies and
requirements of regulating authorities
To reach these goals a service contractor should be able to:
Schedule preventive maintenance of
process automation systems, information
systems, and instrumentation
Do unscheduled repair work
Perform system modification including design, manufacturing, supply,
assembly, start-up, and checks
Start up facilities operations
Investigate equipment failures
Maintain operating documents and
manuals for maintained systems
Maintain reasonable levels of spare
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Submit reporting documents for
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June 2012 41
PLANT ENGINEERING
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Dismounting
ELECTRICALSOLUTIONS
INTERACT
Industrial Efficiency: Debunking the myths
Where to begin?
By ignoring the myths
Myth No. 1: Energy is just another component of my overhead.
By Greg Bodenhamer
Schneider Electric
Q: What can and should your plant be doing

to better measure and manage your industrial
energy output?
The industrial sector uses approximately one

third of the total energy consumed globally.
Energy intensive industries represent 83% of all
The fourth step is to establish a plan to fix
manufacturing energy use. Energy costs have
been rising increasing the need for manufac- the basics address the low hanging fruit
turers to become more efficient consumers of opportunities for energy improvement, such
as lighting control.
energy.
Finally, automating and standardizing
Energy prices whether electrical or fuel
cost for transportation impact industrial across equipment, processes and metrics will
manufacturers bottom line. Some of the enable continuous improvement.
Energy use is one of the largest
largest savings can come from the
operating expenses on a business
industrial processes themselves. The
income statement; reducing energy
more energy-intensive manufacturing
consumption can also provide sigprocesses are, the more benefit can
nificant fringe benefits including
be realized from an energy managein a series
increased operational visibility to
ment plan and its implementation. We
optimize performance, enhanced
need to look at how we can control the
energy demand and consumption in the process management capabilities across domains such
understanding where the big consumers and as IT and building automation, and improved,
proactive maintenance to reduce costs and
wasters are.
It is estimated, due to inefficiencies inherent downtime.
in the transmission of electrical energy, that
for every three units of energy produced, only Myth No. 2: If I install all the necessary
one actually arrives at point of consumption. equipment, I can sit back and watch my
Therefore, one of the simplest solutions is to energy bill magically decrease.
save energy at the point of use.
Every industrial facility has a building inforImplementing a comprehensive energy management plan would not only help avoid energy mation management system, power meters,
waste, but also improve equipment efficiency. automation equipment and the like. Integrating
But where does an industrial manufacturer these systems via over-arching management
and communicative software platforms not
begin?
The first step in addressing the energy only guarantees compatibility between them,
dilemma is to define the problem make but optimizes the available resources to reduce
energy consumption visible, measure where energy costs and increase efficiency.
Active energy management involves moniyou are today and look at it as a variable cost
of production stop treating it like a fixed or toring, reporting, controlling and adjusting
systems and processes to save energy. Its an
overhead cost.
The next step is to establish a plan for ongoing cycle, and an active process. Typical
energy efficiency, how to reduce the amount plant projects involve switching to more efficient lighting or updating HVAC systems but
of energy consumed per unit produced.
The third step is ensuring appropriate levels we must go further than just fixing the basics.
of energy measurement and reporting stick- In order to maximize savings opportunities,
ing with the what gets measured, gets done we have to go to the process lever, looking at
flows, layout, machines and equipment such
approach.
First
PLANT ENGINEERING
June 2012 43
eLeCTRICALSOLUTIONS
as motors, drives, pumps, etc.
The energy management process really
comes to life with Senior Management,
even C-level sponsorship and involvement the effort to reduce energy use
needs sponsorship and reinforcement and
it needs to be the responsibility of the
entire organization. Having a plan and
executing that plan, as you would with

any operational improvement, is critical.
The approach to energy management
has evolved as manufacturers look for
more visualization, intelligence and control over operations management. Collaborative frameworks enable a more
comprehensive strategy which impacts
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productivity, responsiveness, lifecycle

costs and profitability. It is a continuous process that requires leadership
commitment, reporting, accountability
and ongoing improvements to maximize
long-term gains.
Myth No. 3: This is a bad economy
I cant possibly make this investment
now.
It is important to think about energy
savings activities like any other investment opportunity. A 1530% return on
investment would make these activities
attractive against most competing alternatives. Energy projects can offer organizations this type of return and many have
Implementing a comprehensive
energy management plan
would not only help avoid
energy waste, but also improve
equipment efficiency. But
where does an industrial
manufacturer begin?
payback periods of only 1-2 years. When
you look at it this way, energy efficiency
programs can be highly valuable even
during times of economic uncertainty or
downturn the opportunities are there,
you just have to take advantage of them.
Energy efficiency is one of the easiest ways for companies to maximize
short and long-term cost savings. The
technologies exist today to make energy
visible and manageable driving not
only efficiency in your process but also
efficiency of your assets and your workforce, optimizing production across the
board.
The companies that are using energy
management and sustainability as a
strategic advantage are differentiating
themselves from their competitors, not
only saving money but attracting a more
talented and engaged workforce, increasing their brand value and, potentially,
enhancing the market valuation of their
business. PE
Bodenhamer is the vice president of
Industry End User Marketing, Solutions
& Services, Industry Business, at Schneider Electric.
44 June 2012
plant engineering
IDENTITY THEFT.
IF ITS NOT FROM DUPONT, ITS NOT TEFLON.

Teflon is not another name for a fluoropolymer, and its not a name for a finished product. Teflon is a DuPont
registered trademark and brand. If you sell products using the Teflon brand for ingredients without a license
from DuPont or you call your finished product Teflon, youre stealing a name and misleading your customers.
At DuPont, were proud of the Teflon brand. Its a brand that says quality and performance. And it should
only be used for properly licensed products that contain authentic DuPont ingredients. This is the best way
to protect our good name and yours. To learn more, visit www.plant.realteflonbrand.com
Copyright 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont, The miracles of scienceand Teflon are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affiliates.
DuPont
Teflon
Were not called

pro Services for nothing.
Whatever you need, ITT PRO Services has the experts to get the job done right.
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is call your ITT PRO Services representative. Or visit us at ittproservices.com
to learn more. Were always here. Because reliability has no quitting time.
ITT PRO Services and Goulds Pumps. A powerful combination.
MAINTENANCESOLUTIONS
Source: CMRP
Figure 1: Return On Net Assets model
Financial planning for

asset management
By Darrin J. Wikoff
CMRP
he world around us is changing and we

have entered into a new age of competitiveness. Businesses that need capital
investment to sustain growth are forced
to dramatically reduce the cost of operating in
order to improve their image, while those with
capital are routinely investing inappropriately
and thus skewing their financial image.
Competing organizations, even if internally
focused, are measured on managements ability to maximize profits through effective utilization of their fixed assets. Said more simply,
how effectively is the plant utilizing its assets
to generate revenue? This type of financial
comparator is known as Return on Net Assets
(RONA). In many organizations, RONA is the
indicator that supports the decision-making
process to determine which locations will
receive capital investment from the corporation, or additional market share as a result of
their demonstrated efficiency.
RONA is a very dynamic metric and works
like a pendulum swinging from a fixed point
based on fluctuations in net income or net
assets. The idea is to create a balance by
increasing revenue to offset the cost of consuming fixed assets, or reducing costs to
improve margins per unit produced while
reducing your net asset value through depreciations. This brings us to the point of this
article. When developing your improvement
strategy, it is important to begin with a clear
understanding of the Financial Plan for Asset
Management. Here are a few questions to get
you started:
At what point will improvements to
PLANT ENGINEERING
June 2012 47
mAINTENANCESOLUTIONS
only drive greater increases your net asset base and makes
downturns in opera- your RONA weaker if revenue remains
tional performance. constant, or worse, Cost of Goods Sold
I look at it this way: (COGS) increases. Ideally, the invested
If we dont focus capital should increase the capacity of
on removing the the plant to further offset the current
volume of work, COGS. What about the cost to mainbe that operational tain the new or upgraded assets? It has
workloads or main- been my unfortunate experience to have
tenance workloads, witnessed the best-laid plans for capithen how can we tal improvement go unrecognized as a
expect to reduce result of unforeseen costs to operate and
the labor that has maintain the new or refurbished assets
been mediocre at after commissioning. In some extreme
c o m p l e t i n g t h e cases, the plant was worse off financially
workload within after a significant capital expansion due
the current business to the fact that engineering and plant
system?
management failed to consider the susC o s t c u t t i n g taining costs associated with the new
also refers to the assets relative to the marginal increase
Source: CMRP
rapid reduction of in capacity.
reserve inventorieswork-in-process inventories or Defining the financial strategy
There are two main strategies you and
maintenance supplies that are required
within the existing business systems due your organizational leaders must conto the lack of process control and insta- sider before embarking on your asset
bility. These reserve inventories are in management journey. The first is the
place today because our current asset Asset Strategy.
The Asset Strategy is a balancing
management practices require them.
Without these inventories, the operat- act between short-term and long-term
ing process would suffer from extended financial objectives. The task of reducdowntime periods or, at minimum, fre- ing capital requirements is contingent on
quent interruptions
in flow or service.
Figure 3: Asset Strategy model
If financially we can
justify removing the
reserve inventories,
then financially we
can justify improving how we manage
assets so we dont
need the reserves.
Buying your
way to success is
an equally ineffective strategy for
long-term growth
and performance
improvement.
Although capital
investments can
improve existing
technologies, which
in turn improves
your ability to maintain a reliable plant
Source: CMRP
short-term, it also
Figure 2: Cost Cutting to Prosperity model
operating practices and business processes impact my ability to maintain

costs at a favorable level?
n At what point do my current costs
overcome my ability to depreciate assets
effectively?
n At what point is it no longer economical to maintain existing plant
assets, therefore causing me to invest
capital?
n How much additional production
volume is required to offset the impact
of capital investment, assuming that the
cost of maintaining these assets will
remain constant or certainly not increase
above current cost ratios?
n At what point does market value
impede my ability to offset costs and
eliminate the possibility of capital
investment as a viable solution?
Two fundamentally bad financial
models are those that focus narrowly
on cost cutting to prosperity or buying your way to success. Neither of
these strategies will sustain long-term
growth benefits for your company. Cost
cutting refers to the popular opinion that
it is financially justified to slash fixed
overhead expenses such as wages, compensation, and benefits. Lets face it;
we need qualified and competent people
to sustain the growth of our business,
and cutting headcount for the sake of
minimizing short-term expenses will
48 June 2012
plant engineering
MAINTENANCESOLUTIONS
your organizations ability to minimize
working capital by increasing inventory turns and systematically eliminating reserves based on varying product
demand and material availability. The
short-term goal of the Asset Strategy is
to compress the overall cash conversion
cycle, and in effect turn inventory into
revenue faster.
On the other hand, the long-term view
of the Asset Strategy should consider
how your organization will effectively
reduce fixed capital by eliminating
redundant equipment trains, innovating equipment configurations in order
to improve your organizations ability to
meet several product specifications with
fewer fixed equipment requirements, or
consolidating non-physical assets, such
as information management systems.
The second strategy that must be considered is the Expense Strategy. This
is a given.
point is this: Turn your attention, relative to cost reduction, on those aspects
of your business that are within your
control and will have a positive, longterm effect. If supply chain expenses
are not within your control, then focus
your attention on extending the performance life of your fixed assets and
lowering your lifecycle expenses. If
you feel lifecycle costs are already
optimum, then focus the asset management improvement strategy on energy
reduction to gain control of overhead
expenses.
Lifecycle costing
Expenses are the most commonly

misunderstood strategy, as most of our
business upbringing has focused on
labor and inventory cost reductions as an
adequate means of controlling the shortterm financial performance. Cost cutting, as stated earlier, is inadequate when
a long-term solution is required.
Figure 4: Expense Strategy model
Focusing on the
various stages of
the asset lifecycle
to identify opportunities to reduce
expenses is the
preferred strategy of world-class
organizations.
Each asset within
your business
accrues expenses
from initial acquisition to final
decommissioning.
Lifecycle costing
enables your orgaSource: CMRP
nization to refine
internal practices
Why do we focus our precious and processes that manage plant assets
resources on improvement projects? We as sales and capital requirements flucdo it because we need to reduce costs. In tuate. For example, lets assume your
this view, our focus is on the long-term stakeholders need to expand production
financial performance picture only, as a capacity in order to gain additional sales
short-term focus on expenses can easily volume. You will inevitably realize that
turn into a cost-cutting exercise. Do not your fixed capital requirements will
concern yourself with those expenses increase as well. Your strategy must then
outside of your control, like the price of look towards offsetting the increase in
raw materials. Instead, focus your atten- capital by decreasing other expenses,
tion on how frequently you order and lifecycle expenses. However, as your
ship raw materials, or how much energy organization adds equipment to an
you consume storing these materials. My already burdensome footprint, the cost
50 June 2012
PLANT ENGINEERING
INTERACT
Q: How much time do you spend on

financial planning? How much time
should you spend on it?
of operating and maintaining equipment

becomes overwhelming in relation to
RONA. Throughout the expansion
project, you must quantify expenses
long-term to decide if the short-term
gain in capacity will generate enough
cash to withstand a realistic downturn in
demand. Through lifecycle cost analysis,
your organization can first determine
the rate of return on your initial capital investment, then quantify the time
period required to sustain sales growth in
order to compensate for the increase in
expenses over time. If the rate of return
on the sustaining costs is insufficient,
practices that govern lifecycle expenses
like utilities and maintenance must be
refined.
To conclude, financial planning is not
just for accountants and savvy investors;
it is an integral part of the asset management system. Be careful of embarking on an improvement journey that is
solely based on a return on investment.
Instead, develop your asset and expense
strategies to guide improvements made
throughout the enterprise to ensure a
stronger financial image after implementation. PE
Wikoff specializes in organizational
leadership, change management, business process management, and reliability engineering. With more than 20
years experience as a business owner,
business management consultant,
and certified reliability professional,
he has earned the respect of business
leaders around the globe as an educator and mentor. To learn more about
how you can strengthen your asset
management strategy, please contact
him at dwikoff@gpallied.com, or visit
www.gpallied.com.
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The U.S. MOTORS brand NEMA

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IN NOVATIONS
Send New Product releases to: peproducts@cfemedia.com
Wireless monitoring, alerting system

Quick Talk RQT is an industrial-grade radio transmitter with sensor inputs and
voice recording storage that automatically alerts radio-equipped personnel when
plant conditions change. This technology accepts inputs from up to four switches
or sensors to monitor conditions so that when a change is detected, a prerecorded message alerts plant personnel to that specific sensor variance. Virtually
any sensor or switch input can be accommodated, allowing this unique technology to monitor conditions like an emergency motion, liquid level, temperature,
vibration, power interruption, door or window ajar, obstructions, and many others
found within manufacturing environments.
Ritron, Inc., www.ritron.com
Input #200 at www.plantengineering.com/information
EDM line
The wire EDM MV Series features allencompassing, game-changing engineering
improvements, many of which are industry
firsts, and none as poignant as the Cylindrical
Drive Technology. The round magnetic shaft
of the linear motor creates a 360-degree
magnetic flux for a revolutionary, no-contact
design. The drive also prevents friction, wear
and tear, and reversal error and does not
need lubrication. The system also works with
servo drivers and is not affected by shop
or metal grinding dust. The MV machines
offer a hardened stainless steel table and
larger travel size without leaving a significant
impact on machine footprint.
MC Machinery Systems, Inc.
www.mitsubishi-world.com
Zero-configuration
Android app
Opto aPAC is an application for monitoring and
managing the companys SNAP PAC System using
mobile devices running the popular Android operating system. It provides real-time control system
access and information to authorized automation
professionals equipped with wireless, Android-based
smartphones or tablets. Opto aPAC allows users
to discover SNAP PAC controllers and I/O systems
and then view, debug, and fine-tune them, saving
time and money during commissioning and ongoing
maintenance. Authorized users with proper security credentials
can monitor values in a SNAP PAC control system such as temperatures, pressures, machine status, voltage, and PIDs. Opto
aPAC users can also perform control functions such as changing
setpoints, turning lighting on and off, and controlling motors.
Opto 22
www.opto22.com
Polycarbonate enclosures
The EK series of NEMA 4X polycarbonate enclosures are designed to
house and protect DIN rail-mount IEC components, such as DIN rail-mount
circuit breakers, timers, switches, meters, and other control devices. This
CE-compliant product features a shrouded cutout and tinted transparent
hinged door with push release door latches for quick access and visibility. The
EK series enclosures are high in mechanical strength as well as corrosion- and
maintenance-free. They are ideal for chemical, plastic, and water industries.
Omega Engineering
www.omega.com
PLANT ENGINEERING
June 2012 53
IN NOVATIONS
Wall-mounted
power supply
Transducer series
The ITZ Transducer Series provide galvanically isolated measurement of ac, dc, and
pulsed currents. The high-accuracy product
range, which employs advanced closed-loop
Fluxgate technology, comprises 14 models
for nominal current measurements from 600
A to 24 kA with apertures from 25.4 mm up
to 150.3 mm diameter. Overall accuracies at
ambient temperature (25 C) are a few ppm.
The initial offset error is under 2 ppm. The
transducers are configured as measurement
head plus rack-mounted electronics. They
deliver measurements as an output current
or voltage. In addition to these normal signal
outputs, the transducers also provide outputs
indicating the transducer state.
LEM
www.lem.com
The screw-mounted
PSU100D eliminates the need
for traditional rail mounting
while affordably meeting the
basic power supply requirements. Ideally suited for wall
mounting in apparatuses and machines, the PSU100D features a
rugged, low-profile aluminum casing with IP20 degree of protection
that requires little space while enhancing mounting flexibility. A wide
temperature range from -10 to 70 C accommodates a broad range
of applications in harsh environmental conditions. Electronic shortcircuit, overload, and overvoltage protection features ensure safety
in the event of a fault.
Siemens Industry, Inc., www.siemens.com
Retractable belt
The 2-Axis retractor series permits
360-degree rotation on the belt as well as
180-degree swing-away from the body
for a full range of motion accessibility. In
addition, because of the universal movement of the dual action mechanism, resistance
and line wear are minimized and the life of the tether
is extended. Once mounted on the belt, the retractor can be easily
moved to different positions but remains impossible to dislodge.
Optionally, the retractor/belt combination can be user-converted to a
slide on/off unit for any belt while still maintaining the same security
that prevents unwanted dislodging.
Hammerhead Industries, www.hammerheadindustries.com
Turret truck forklift

The EKX 410 man-up turret truck forklift, which operates exclusively in narrow
aisles, can be used for full pallet put-away and retrieval as well as for picking
individual boxes or pieces. The EKX 410s many updates over the previous forklift
model include increased lift heights of more than 30 ft and improved residual
capacities. Energy efficiency and performance were important components to
the design of the EKX 410. It also features advanced regenerative braking, and
lowering allows reclaimed energy to return to the battery, which helps reduce the
amount of downtime needed for charging.
Jungheinrich, www.jungheinrich-lift.com
54 June 2012
PLANT ENGINEERING
THE ULTIMATE POWER TRANSMISSION COMPONENT PACKAGE
Differential
pressure
transmitters
The ProSense SPT25
pressure transmitter
series is engineered to
meet many industrial,
commercial, and OEM pressure measurement applications. Compatible with many different media sensing
applications, the all stainless steel welded thin-film sensing element provides very fast response time. With a pressure sensing range from vacuum to 5,000 psi, transmitters
are designed to resist vibration, shock, and EMI/RFI while
providing high accuracy.
AutomationDirect, www.automationdirect.com
Bionic gripper
NanoForceGrippers cling reliably
and permanently to the surfaces
of the object to be gripped, thanks to
tiny, intermolecular forces of attraction
called van der Waals forces. A key component
of the gripper is the Gecko Nanoplast tape on its
underside with 29,000 gripping elements per cm. Once
a part is gripped, it is permanently held by the gripper.
A counteracting force is only needed when it is time to
release the bond and set down the gripped object.
Festo, www.festo.com
Desktop power supply
When its all about uptime

its Tsubaki time.
Stop the clock on downtime. Start getting the productivity you
deserve with the drive-system products you need. Let Tsubakis
family of Chains, Sprockets, POWER-LOCK and Overload Protection
products provide a single-source solution for your drive-system
needs. Tsubaki components and customer support will keep you up
and running with superior performance, design, build quality and
compatibility. When time is money, its time you turned to Tsubaki.
www.ustsubaki.com/pe
The PSAD36 Series of ac/dc desktop switching power

supplies provide 36 W of output power in a compact
case with a C14 input receptacle (a C8 input receptacle
is an option). All models meet EN55022 and FCC Class B
emissions limits, and are approved to UL, CSA, CCC, and
European safety standards. The PSAD36 Series meet the
requirements of Efficiency Level V. This desktop adapter
has a 2.0 x 4.72 x 1.34-in. footprint. This Series features
3,000 Vac input-output isolation.
Power Partners, Inc., www.powerpartners-inc.com
2012 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.
PLANT ENGINEERING
June 2012 55
RIGHT CHAIN RIGHT SPROCKET RIGHT PROTECTION RIGHT CALL

IN NOVATIONS
Polycarbonate
shields
Chip Shields on Safety Air Guns
are used to protect workers and
to help businesses comply with
OSHA safety standards. They can
be used on Safety Air Guns with
or without an extension pipe. Chip
Shields are polycarbonate shields that protect operators from flying debris off machine parts. Chip Shields
are great for keeping coolant from splashing everywhere
during drying operations and Chip are available to fit the
Safety Air Guns you currently have in use. Safety Air Guns
use engineered air nozzles for high performance and
safetythey are designed to maximize entrainment of
room air while minimizing compressed air consumption.
The Precision Safety Air Gun is extremely lightweight and
comfortable to operate during periods of extended use.
Exair Corporation
www.exair.com
Contamination
magnet, separator
Magnetic Humps and Round Pipe Separators provide a simple and effective way
to remove tramp iron contamination from
gravity or pneumatically conveyed dry, freeflowing products such as feed, grain, wood chips,
food stuffs, sand, or plastic. Materials entering
the Magnetic Hump are abruptly forced to change
direction against the face of the powerful series
SD Plate Magnet. As the materials tumble
in the housing, they change direction once
more against the face of a second plate
magnet. The Magnetic Hump design takes
advantage of the ferrous material density.
Magnetic Humps are simple to operate and
maintain. The ferrous contamination remains on the face
of the magnet until the operator swings the magnet out of
the product flow and physically removes the metal.
Eriez, www.eriez.com
Large
ac motors
EtherCAT box
Reliance stock
and custom motors
are available up to
15,000 hp, while induction and synchronous
motors are available
up to 100,000 hp.
This large ac motor
offering includes both
NEMA and IEC configurations, assuring customers
they will get the motor that meets frame, enclosure,
and duty cycle standards for any application, anywhere in the world. Every large ac motor is designed
and built for superior reliability, energy savings, and
rugged performance.
Baldor
www.baldor.com
Leaves
Beckhoff Automation
www.beckhoffautomation.com
Algae
The EP1908 EtherCAT Box

with TwinSAFE technology is
designed to distribute safety
I/O technology in more form
factors and protection levels.
With the EP1908, the open
safety technology of TwinSAFE has been expanded to
include a flexible, IP 67-rated
variant that is ideal for use
outside of electrical cabinets
and in harsh environments.
The EP1908 EtherCAT Box
has eight 24 Vdc safety inputs, which can be used to
connect safety sensors via rugged and reliable M12
connectors.
New Filtration Technology

Keeps Cooling Water Clean
Insects
Airborne
Particles
Protect:
Pollen
Heat
Exchanger
Cooling
Tower
Spray
Nozzles
Instrumentation
Rust
Water
Filter
heat exchangers, spray nozzles,

instrumentation, pump seals, I.E. & R.O.
units, air compressors and the environment.
Remove: airborne particles, sand, gravel,

algae, pollen, silt, scale, rust, microbiological
growth, zebra mussels and other dirt
particles down to micron size.
Applications:
O
L
A
IV
R
anywhere that dirt is

a problem cooling water, process water,
reclaim water, effluent water, intake water,
waste water, wash water, potable water.
Users:
Automatic Self-Cleaning
WATER FILTERS
213 S. Van Brunt St.,

Englewood, NJ 07631
(800) 567-9767
(201) 568-3311 Fax (201) 568-1916
www.orival.com filters@orival.com
U.S. government, municipalities,

big 3 automakers, steel mills, major oil
companies, commercial buildings, food,
chemical, pharmaceutical, plastics, paper,
car / rail washes, mines, power.
PRODUCTMART
LUBE-IT Users Say It Best
TM
II estimate were getting

about 25% more equipment
uptime with fewer staff,
with ROI in about one year.
James Wanstreet
Reliability Engineer, KapStone Paper
Join an upcoming webdemo of the LUBE-IT software
Call today 425-391-9046 Ext 375

www.generationsystems.com
The most widely

used lubrication
software in the world.
Input #101 at plantengineering.hotims.com
The RX Series
Safety Gate:
Replaces Old
Plastic Gates
Made in America, FabEnCos RX Gate is a rugged, spring-loaded metal
safety gate designed to
replace aging and/or deteriorating plastic gates
with solid, weather-resistant metal gates, conveniently bolting into the same mounting holes
used to secure old plastic gates. These gates
are competitively priced and easy to install on
all types of handrails (angle and pipe).
www.safetygate.com/ple
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PlantMail:
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meltric.com
800.433.7642
58 June 2012
PLANT ENGINEERING
ple1003jh_enewslttrs.indd 1
3/1/2010 2:56:53 PM
Place next to your computer or go online to plantengineering.com for hot links to these companies.
Remove at
Line
2012
June
For more information on how to advertise in Plant EnginEErings

Internet Connection, call Jim Langhenry at 630-571-4070 x2203
adalet.com
flexicon.com
omega.com
Manufacturing explosion proof enclosures, ATEX enclosures and electrical enclosures for over 80 years.
Adalet
Designs and manufactures bulk handling equipment and

custom-engineered and integrated plant-wide systems.
Flexicon Corp.
Omega offers products for measurement and control of

temperature, humidity, pressure, strain, and more.
Omega Engineering Inc.
aggreko.com
fluke.com
orival.com
Generator rental, providing efficient and cost effective

industrial generators and power distribution.
Aggreko plc
Fluke Corp. is the world leader in the manufacture, distribution, and service of electronic test tools and software.
Fluke Corp.
Self-cleaning water filters, automatic water filters and

strainers, for use as industrial water filters, and more.
Orival, Inc.
agilent.com
gardnerdenver.com
seweurodrive.com
Agilent offers the broadest range of innovative measurement solutions in the industry.
Agilent Technologies Inc.
Global manufacturer of industrial compressors, blowers,

pumps, loading arms, and fuel systems.
Gardner Denver
SEW-EURODRIVE specializes in gear reducers, motors

and electronic motor controls.
SEW-EURODRIVE USA
atlascopco.us
geindustrial.com
usa.siemens.com
Compressed air equipment and generators, construction

and mining equipment, industrial tools, and more.
Atlas Copco
The reliable parts and services you need. GE has thousands of quality electrical parts that you can count on.
GE Energy Industrial Solutions
Providing complete electrical, engineering, and automation solutions.

Siemens Industry, Inc.
ame.org
grainger.com
stanleyproto.com
Organization for the exchange of knowledge in Organizational

Excellence through the implementation of techniques.
Association for Manufacturing Excellence
Industrial supplies, MRO equipment, tools, materials,

manufacturing, and more for the ones who get it done.
Grainger Inc.
Our industrial hand tools are built to be precise, durable

and make work easier.
Stanley Proto
automationdirect.com
hyster.com
sullair.com
AutomationDirect offers industrial automation products,

including PLCs, operator interfaces, sensors, and more.
AutomationDirect
Hyster offers a range of warehousing equipment, industrial

lift trucks, and quality material handling parts.
Hyster Co.
AirTility delivers air as needed with no capital expenditures

and no maintenance worries.
Sullair Corp.
baldor.com
inpro-seal.com
tapeswitch.com
Baldor Electric manufacturers industrial electric motors,

mechanical power transmission products, and more.
Baldor Electric Co.
The inventor and original patent holder of the Bearing Isolator, a compound labyrinth oil seal.
Inpro/Seal
Tapeswitch designs and manufactures innovative sensing,

switching, and control products.
Tapeswitch Corp.
bigassfans.com
goulds.com
tnb.com
Preeminent designer and manufacturer of 6-ft to 24-ft

diameter HVLS ceiling and vertical fans.
Big Ass Fan Co.
Diverse and innovative products range from complete air

compressor systems, tools, ARO pumps, and more.
ITT Goulds Pumps
Thomas & Betts provides electrical, commercial heating,

and commercial ventilation products.
Thomas & Betts Corp.
camfilfarr.com
lubriplate.com
ustsubaki.com
Camfil Farr is the worlds largest and leading manufacturer

of filters and clean air solutions.
Camfil Farr
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants.
Lubriplate Lubricants Co.
U.S. Tsubaki is a leading manufacturer and supplier of

power transmission and motion control products and is the
worlds market share leader in roller chains.
U.S. Tsubaki, Inc.
donaldson.com
martinsprocket.com
Compressed air purifications solutions, compressed air

filters, dryers and process water chillers.
Donaldson Company Inc.
Machining, fabrication, forging, casting, powdered metal

technology, and more.
Martin Sprocket & Gear, Inc.
dupont.com
motionindustries.com
Proven quality, innovation and research go into DuPont

KEVLAR, NOMEX, TYVEK and TYHEM.
DuPont
Motion Industries is a leading distributor of industrial MRO

supplies.
Motion Industries Inc.
est-static.com
movincool.com
EST specializes in mitigating static charges, moving surfaces, and all types of manufacturing equipment.
Electro Static Technology
Responsible for pioneering the use of portable air conditioning solutions for a wide variety of markets since 1982.
MovinCool
yaskawa.com
Yaskawa manufactures ac inverter drives, servo and
motion control, and robotics automation systems.
Yaskawa America Inc.
plant engineering
June 2012 59
CONTACTS
Advertiser Contacts for plant engineers
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
Page
Number
Advertiser
Adalet Wireless
216-267-9000
10
Aggreko LLC
866-215-7966
Agilent Technologies, Inc.
866-436-0887
12
51
ALL-TEST Pro, LLC

860-399-4222
AME Chicago 2012
224-232-5980
11
49
Atlas Copco Compressors

866-688-9611
AutomationDirect
800-633-0405
Big Ass Fans

877-Big Fans
Camfil Farr Air Pollution Control
800-479-6801
Donaldson Co., Inc
800-365-1331
Flexicon Corp
888-353-9426
Fluke Corp
888-443-5853
Fry Communications, Inc
800-334-1429
Gardner Denver
800-682-9868
GE Energy
203-373-2211
Send
Info

www.adalet.com
10

www.aggreko.com
35

www.alliedelec.com/agilent
9

www.alltestpro.com/c/199
34

www.amechicago.org
24
23

www.atlascopco.com/drivenbyefficiency
C-2
1

www.automationdirect.com
Baldor Electric Company

800-828-4920
DuPont
800-207-0756
Electro Static Technology, Inc
866-738-1857
RSC
Number
C-4
60

www.baldor.com
33
25

www.bigassfans.com/pe
6, 16
5, 15

www.farrapc.com

www.donaldson.com
45
32

www.plant.realteflonbrand.com
41
29

www.est-aegis.com
8

www.flexicon.com
13, 15
11, 13

www.fluke.com
12

www.frycomm.com
17
16

www.savewithgardnerdenver.com
2
3

www.geindustrial.com/services
Grace Engineered Products, Inc.

16
14

800-280-9517
www.graceport.com
Grainger
23
22

847-535-1000
www.grainger.com
Hyster
19
19

800-HYSTER1
www.hyster.com
IANA Global Automation &
Manufacturing Summit
34, EN16

630-571-4070
Advertiser
Industrial Automation
North America at IMTS 2012
312-924-1688
Page
Number
RSC
Number
80
Send
Info

www.ia-na.com
Inpro/Seal Co.
800-447-0524
22
21

www.inpro-seal.com
ITT
315-568-7659
46
33

www.ittproservices.com
Lubriplate Lubricants Co
800-733-4755
LUDECA, Inc
305-591-8935
26
24
18
18

www.lubriplate.com

www.ludeca.com
44
31
Martin Sprocket & Gear, Inc

817-258-3000
Master Bond, Inc
201-343-8983
Motion Industries Inc
800-523-9328
NuStar, Inc
800-800-9274
Omega Engineering, Inc
888-556-6342
Orival, Inc
800-567-9767
Pfannenberg USA
716-685-6866
Plant Engineerings
Electronic Newsletters
630-571-4070
Rittal Corporation
800-477-4000
SEW-Eurodrive, Inc.
800-241-4453
Stanley Proto
860-225-5111
Sullair Industrial Products
219-879-5451
Tapeswitch Corp
800-234-8273
Thomas & Betts Corporation
901-252-8000
U.S. Tsubaki
800-323-7790
Yaskawa America, Inc
800-927-5292
14
52
18

www.martinsprocket.com
12

www.masterbond.com
36

www.MotionIndustries.com
17

www.powerpusher.com
57
39
10

www.omega.com

www.orival.com

www.PfAdvantage.com
EN11

20, 21
20

www.rittal-corp.com
42
30

www.seweurodrive.com
EN2, EN9
57, 58

www.usa.siemens.com/energyefficiency
39
28

www.stanleyproto.com
35
26

www.sullair.com
56
38

www.tapeswitch.com
36
27

www.tnb.com
55
37

www.ustsubaki.com/pe
C-3
59

www.yaskawa.com
Need More Info? FAX this page to: 630-214-4504
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
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Telephone
Fax
Title
Address
State
e-mail
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PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.
60 June 2012
PLANT ENGINEERING
INCONCLUSION
The endless journey of innovation
Bob Vavra
Editor/Content Manager
Innovation has not

always
been achieved
as simply as by pressing a button. It has been
by trial and many, many
errors. Innovation is far
more about overcoming
failure than it is about
achieving success.
hile it is not true that I knew

Johannes Gutenberg personally,
I have been in this business long
enough to remember blocks of
lead letters being used for typesetting. Our content management system
was a clipboard and the design tools were
a pair of scissors and some hot wax. Photoshop was a small darkroom at the back of the
press room. Im not even an editor anymore;
Im a content manager. (Thats pronounced
both ways: CON-tent manager and con-TENT
manager.)
If you take time to look back at your time on
the job, you probably can recall some similar
primitive tools that were replaced by new ideas
that were going to make your job better. And
as those innovative ideas continue to multiply
at an ever-increasing pace, its good to reflect
on how we innovate, and how we use our
innovative tools to further innovate.
All weve really managed to do is improve
on the six basic simple machines that were first
catalogued during the Renaissance: the lever,
the wheel and axle, the pulley, the inclined
plane, the wedge, and the screw. But thats
the nature of innovationtake what you have
and make it work better.
The means of propulsion have changed; so
have the devices designed to set that propulsion in motion. Manual labor has become more
automatic. The materials, both natural and
man-made, have become more sophisticated,
stronger, more durable.
We are better at every aspect of our work
day. Our workers are more engaged with not
just their task but also the impact that work
has on the company as a whole. They are safer,
and that allows them to be more productive.
The tools we give them have evolved from
chalkboard scribbling to clipboard notations
to bulletin board postings to iPad notifications.
In that evolution, I feel we sometimes forget
that it wasnt always this easy. Innovation
has not always been achieved as simply as by
pressing a button. It has been trial and many,
many errors. Innovation is far more about
overcoming failure than it is about achieving
success. It is never achieved, either. We never
conclude something is as good as it could ever
be. We strive for better, always.
In that effort to get better, we have slowly,
steadily improved what we make. A car is still

a car, but only the most ardent collector would
prefer a 57 T-Bird to a modern vehicle. The
safety, fuel efficiency, and entertainment features have turned the family car into a globally
connected environment all its own.
Take away all of that innovation, and the
cars primary function still is to get us where
we want to go. And as it turns out, thats the
primary goal of innovation, too.
Weve been reflecting on innovation this
month at CFE Media as we mark two years as
a company. Plant Engineering is, of course,
much older. In fact, we mark 65 years as a
publication this year. The light distances weve
traveled since 1947 are vast. The distances
CFE Media has come since 2010 also are substantial. In the process of building this organization, we are rebuilding the way information
is delivered to you.
From our new ContentStream tool that will
connect supplier, end users, and information
in an exciting new platform to Apps for Engineers, which provides a one-stop shop for the
latest mobile applications, were delivering
content through new channels that didnt exist
six years ago, let alone 65 years ago. Imagine
Gutenbergs reaction; his movable type was
created in 1439.
This months special cover gives you an
idea of how far the printing business has come.
The thicker stock, dynamic colors, and special
foil are all possible because printers werent
content with Gutenbergs original idea of
moveable type. They found better ways to
print, and better materials on which to print.
We manufacture ideas, and deliver them as
words and pictures. We still deliver the same
kinds of ideas each issue, all designed to help
you do your job better. Today, your choices
to receive that data are vastprinted magazines, Website blogs, interactive Webcasts,
or a calculator uploaded to your smartphone.
So thats what weve thought of over the
past two years. Were not done innovating
for our readers, and were not done delivering the innovations in manufacturing to you.
You are our partner in that innovation, and
we always want to hear more about how we
can get better at this. After two years, or 65,
or 573 years, its the quest for innovation that
keeps us moving forward. PE
PLANT ENGINEERING
June 2012 61
As we proudly celebrate our two-year anniversary,

we invite you to also celebrate the success stories
of these participating manufacturing innovators:
Atlas Copco Compressors
Automation Direct
Big Ass Fans
Camfil Farr Air Pollution Control
Flexicon Corp.
Fluke Corp.
GE Energy
ITT Goulds Pumps
MovinCool
Omega Engineering, Inc.
SEW-EURODRIVE
Stanley Proto
Sullair
Thomas & Betts
Yaskawa America, Inc.
Look for the special Innovations videos at:

www.plantengineering.com/innovations
A DV E R T I S E M E N T
Helping customers operate

with greater efficiency, economy, and productivity
manufacturing, distribution and training for customers
nationwide. Our sales and service representatives are
right where our customers do business.
Atlas Copco Compressors has a focus on exceeding

customer needs with a culture built on ongoing
interaction, long-term relationships, and a commitment
to understanding each customers process and
objectives. As a result, every compressed air solution
we create helps customers operate with greater
efficiency, economy, and productivity.
The Atlas Copco Group was named tenth among the
Top 100 sustainable companies in the world, and has
been recognized by Forbes, Thomson-Reuters and
Newsweek, among others, for our commitment to
innovation and sustainability.
In each of the past five years, we have invested in
opening new U.S. facilities to further support
Satisfying customer needs with ground-breaking

integrated compressed air technology, quality air
accessories and 24/7 service support enhanced with
remote monitoring tools positions Atlas Copco as a
leading global compressor manufacturer. Our unwavering commitment is to be First in Mind First in Choice
for all your compressed air requirements.
Need help with your compressed air system?

Help is at hand with the Compressed Air Manual from
Atlas Copco. Now in its seventh edition, the updated
Compressed Air Manual includes updates and new
content to reflect the latest trends and developments
in the compressed air industry. Importantly, the
Compressed Air Manual is written by engineers, for
engineers. For any company that uses compressed air,
it is a must-have reference document.
For a free copy of Atlas Copcos Compressed Air
Manual 7th Edition, please e-mail Paul Humphreys at
paul.humphreys@us.atlascopco.com with Air Manual
in the subject line.
Visit Atlas Copco at: www.atlascopco.us | Telephone: 866-546-3588 | Fax: 803-817-7450

Award-winning services satisfy customers

AutomationDirect has always maintained a huge
inventory, allowing us to ship 99.7% of orders complete
the same day. We were among the first to offer free
2-day shipping, recently made available for any order
over just $49. Shipment confirmations and any backorder status and estimated delivery information is
communicated electronically to keep you informed.
AutomationDirect Headquarters, Cumming, Ga
Our online store is one of the most exhaustive in the

industry all technical documentation can be downloaded free of charge, as well as software and firmware
updates. Hundreds of instructional videos are available
for viewing without registration.
AutomationDirect takes the best ideas from

the consumer world to serve industrial market
As a direct seller of industrial automation products for
over 15 years, AutomationDirect has led the industry in
offering many customer services not typical with
traditional distributors. We created a print catalog, and
later an online store, that provides complete product
information and pricing so that customers can make
informed decisions on their automation purchases
quickly and independently.
AutomationDirects standard for products is that they
are practical, easy to use, and offer a low cost of
ownership. We offer quality products at prices up to
50% lower than those of more traditional distributors.
Most of our products programming software is free,
requiring no initial or upgrade costs, and no software
maintenance contracts.
99.7% orders shipped complete the same day
Online access to your account includes viewing and

changing account information, viewing order history
and making payments. Customers can also obtain return
authorizations online for quick and easy product returns
or exchanges.
Our phone technical support staff has garnered top
honors in service from industry magazine readers 11
years in a row. And with tens of thousands of active
customers, our online technical forum taps into that
knowledge base by encouraging peers to help each
other with applications and other questions.
Practical automation products, including

programmable controllers
Other online help includes frequently asked questions,

application examples, and product selection guides.
www.automationdirect.com | Email: sales@automationdirect.com | Phone: 1-800-633-0405

Innovations increase comfort, efficiency, durability

The Powerfoil X2.0 and Powerfoil 8 introduce a unique
new patented airfoil system a system that combines
patented airfoils and winglets with patent-pending
AirFence technology to increase overall coverage
by 28%. The winglet improves airfoil effectiveness by
eliminating efficiency-robbing turbulence at the tip,
while the AirFence captures air that would otherwise
slip off the end of the airfoil.
For more than a decade, the Big Ass Fan Company

has been the preeminent designer and manufacturer of
large diameter, low speed ceiling and vertical fans for
industrial spaces.
Big Ass Fans range in size from 6 to 24 feet in diameter
and use low-horsepower motors to generate energyefficient air movement for large spaces. Big Ass Fans
can be used year round to provide occupant comfort and
energy savings. There are more than 60,000 Big Ass Fans
installed worldwide in applications from manufacturing
plants and distribution centers to restaurants and homes.
A new line of industrial fans, including the
PowerfoilX2.0, Powerfoil 8, and Basic 6, allow
engineers to select the exact airflow solution their space
requires. These fans incorporate numerous performance
and durability upgrades to previous models and are
backed by warranties ranging from 12 to 15 years.
With a history of focusing exclusively on premium fans,

the Basic 6 is the companys first entry-level offering
for the industrial market. Although the fan was designed
for those on a more modest budget, it features the same
quality engineering and proven performance of all
Big Ass Fans.
Two new mobile misting fans take
cooling on the move. Optional
misting packages now available
for the tried-and-true 8-ft. vertical
AirGo and smashingly durable
Yellow Jacket provide the same
cooling effect of tons of air conditioning exactly where its needed,
and for pennies per hour.
Developed by a team of engineers
in the Big Ass Fan Companys
custom-built research and
development facility, the new line AirGo 8-ft. vertical fan
of industrial fans underscores its
commitment to innovation while providing a full range of
flexible options to provide comfort and energy efficiency
to facilities worldwide.
Powerfoil X2.0 fan

with unique AirFence
technology
Contact a Big Fan Expert for more information.

Call 877-BIG FANS (244-3267) or drop us a line at info@bigassfans.com.
Gold Series Dust and Fume Collectors

Ensure a Clean Workplace
Lee Morgan, president,
Camfil Farr APC
Just about every manufacturing process makes dust and the Gold Series cartridge
dust collector from Camfil Farr APC can ensure a clean workplace in just about any
application. Superior performance features plus exceptional ease of installation and
service have made the Gold Series a popular choice.
Key features include:

Modular design: Each module accommodates airflows up to
5,000 cfm. Multiple modules can be combined for optimum
field flexibility and shorter manufacturing lead time.
Built Like a Safe construction: The module is constructed of
7 gauge carbon steel. The door, hopper, inlet and panels are
all 10 gauge steel. Components are powder painted for
unsurpassed corrosion resistance.
Vertical mounting of filter cartridges enables efficient pulse
cleaning of dust and eliminates uneven dust loading associated with horizontally mounted cartridges.
Long-life filter media: The exclusive HemiPleat filter has a
breathable, open-pleat uniform media pack that results in
more efficient pulse cleaning, lower energy use and longer
filter service life.
Gold Cone in the center of the cartridge expands the usable
media in the filter by 25%, helping the Gold Series dust
collector to deliver clean air while utilizing the smallest floor
space of any dust collector available today.
Low emissions: The Gold Series meets the 5 mg/m3 or
less emissions requirement to recirculate air back on
non-hazardous dusts in most cases. For hazardous or toxic
dust applications, special media and pleat spacing options
allow customers to achieve near-zero emissions.
Two Gold Series collectors with HemiPleat filters
Applications
Key applications include mining, welding
smoke/fume, pharmaceutical, powder/bulk
materials, sand blasting, nuisance dust
ventilation, carton folding and printing,
woodworking, seed processing, chemical
processing, foundry, paper scrap, plasma/
laser cutting, thermal spray, grinding, and
powder painting/pigments.
Ease of service: Simple, quick-open heavy gauge door(s)

provide access to a fast cartridge change out system that
does not require use of tools or worker entry into the collector.
Options: Numerous options are available for fire and explosion
protection, containment of toxic dusts, air recirculation
downstream of the collector, and other special safety or
performance requirements.
Gold Series collector at Camfil Farr APC Jonesboro, AR facility
A new Gold Series brochure is available for download from the company web site at www.farrapc.com.
Phone: 800-479-6801 or 870-933-8048 | Email: filterman@farrapc.com | www.farrapc.com

Flexicon stand-alone bulk handling equipment

to engineered, plant-wide systems
Flexicon is an international organization with
administrative, engineering and manufacturing capabilities on four continents, and an extensive worldwide
network of applications engineers, authorized representatives and field support technicians to serve you
a unique consolidation of bulk handling specialists with
hundreds of years of combined experience.
Equipment overview
Flexicon Corporation is a world leader in the design and
manufacture of bulk handling equipment and customengineered and integrated plant-wide systems that
transport, discharge, fill, weigh, blend, deliver and/or feed a
broad range of powder and bulk solid materials.
Flexicon products range from individual equipment to automated systems that source bulk material from interior and exterior plant locations, transport it between process 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.
An extensive research and development program

continually sets new standards for bulk handling equipment performance with entirely new designs, product
improvements and equipment that complies with
certifications required by governmental and industry
associations for chemical, food, dairy and pharmaceutical applicationsboth nationally and internationally.
Flexicons design engineering staff devises efficient
solutions to the most unusual problems with highly
custom equipment, basing solutions on unique
customer requirements, not merely on existing product
Choose from a broad range of reliable, high performance

equipment in carbon steel with durable industrial finishes, or
in stainless steel designed and constructed to industrial, food,
dairy or pharmaceutical standards:
Flexible Screw Conveyors

Pneumatic Conveying Systems
Volumetric Feeding Conveyors
Bulk Bag Fillers
Bulk Bag Dischargers
Bulk Bag Conditioners

Weigh Batching Systems
Manual Dumping Stations
Drum/Box/Container Dumpers
Storage Vessels
Flexicon can also custom-engineer automated, plant-wide

bulk handling and processing systems that integrate Flexicon
equipment with bulk handling and process equipment of other
manufacturers:
Gravimetric/Volumetric
Feeders
Silos and other storage
vessels
Dryers/Coolers
Mixers/Blenders
Screeners
Crushers/Grinders
Packaging Machines
Other bulk processing
equipment
line offerings. This approach provides each customer

with the most efficient solution to his or her individual
problem, and endows Flexicon with a depth and
breadth of bulk handling experience unequalled by
any other comparable manufacturer in the world.
Flexicon Corporation | Tel: +1 610 814 2400

sales@flexicon.com | www.flexicon.com
The Fluke 805 Vibration Meter.

What vibration pens
want to be when they grow up.
Meet the new Fluke 805 Vibration Meter.

The easy, reliable answer for frontline mechanical troubleshooting.
Much more than a vibration pen, the 805 is a Fluke meter that
gives you results you can trust, time after time.
What makes the Fluke 805

the most reliable vibration
screening device available?
Provides a more complete picture Measure overall
vibration as well as specific variables like bearing
condition and temperature
Easy-to-use Red and green lights indicate how much
pressure to apply when taking measurements
Quickly assesses the severity of the problem
The simple, four-level scale makes
results easy to understand
Covers most machine and
components types Get reliable
results over a wide frequency
range from 10 to 1,000 Hz and
4,000 to 20,000 Hz
Exports and trends data Easily
export data via a USB and trend using
built in Microsoft Excel templates
425-446-5415 | www.fluke.com/805
Other tools tell you theres a vibration.

The Fluke 810 Vibration Tester tells you where it is,
what it is and how severe it is.
The Fluke 810 Vibration Tester is the most
advanced troubleshooting tool for everyday
mechanical maintenance. Specifically
designed for maintenance professionals
who need to troubleshoot mechanical
problems quickly, the 810 analyzes common
equipment such as motors, fans and blowers,
belts and chain drives, gearboxes, pumps, compressors
and spindles, to identify four common equipment faults:
misalignment
unbalance
looseness
bearing condition
You learn exactly what the

problem is, where it is and
how to fix it. An easy-to-interpret color scale provides an immediate fault
severity assessment and makes repair recommendations, allowing you to
prioritize maintenance activities, prevent unplanned downtime and manage
resources. All for a fraction of the cost of a full predictive maintenance program.
425-446-5415 | www.fluke.com/805
GE Energys Industrial Solutions business

GE Energys Industrial Solutions is leading the future of electrification
with advanced technologies that distribute, protect and control a
buildings electrical infrastructure. We provide customers, across
various industries, with end-to-end product and service solutions that
ensure the reliability and protection of their electrical infrastructure;
from the substation, throughout the building, and including sustainable power technologies. A GE heritage business, our story started
130 years ago with Thomas Edison. Today, we apply that same
entrepreneurial spirit to create innovative product and service
solutions that enable customers in more than 60 countries to overcome their electrical distribution challenges.
Luis Ramrez, CEO
Our engagement with customers starts at the design stage and

Industrial Solutions
advances through product installation with ongoing service offerings
designed to optimize the lifecycle of their equipment. Our customizable approach to providing a
reliable electrical infrastructure creates opportunities for customers to maximize their electrical
system reliability and create a safer working environment.
Entellisys Low Voltage Switchgear

Synchronized System Functionality
The Entellisys low-voltage switchgear is a breakthrough in power
distribution protection, control, monitoring, diagnostics and easeof-use. System functionality is based on synchronized, real-time
information from every circuit breaker, simultaneously processed in
one place. Entellisys provides arc flash mitigation, reliability and
flexibility over the life of the equipment. It mitigates arc flash in two
ways; by allowing the operator to monitor and control the gear from
outside the arc flash boundary and by employing bus differential
and zone selective interlocking protection to reduce the incident
energy selectively.
EntelliGuard R Retrofill
Make the most of your existing equipment
EntelliGuard R Retrofill provides a streamlined solution to update
your legacy circuit breakers and gives your existing switchgear a
new lease on life. The EntelliGuard R Retrofill solution includes
the EntelliGuard TU Trip Unit for both arc flash protection and
selectivity at the same time. It offers a means to increase reliability
and enhance the protection of your existing electrical system.
For more information, please visit geindustrial.com, check us out on Facebook at

GE Energy Industrial Solutions or follow us on Twitter @GEIndustrial.
Delivering innovation across the globe

Continuous Improvement
Maintains ITT Goulds Pumps
Leadership
A Goulds Pump undergoes testing at the companys

R&D facility in Korea.
ITT Goulds Pumps is the worlds leading manufacturer

of pumps for a wide range of industrial markets
including oil and gas, chemical, mining, power
generation, pulp and paper, and general industry.
As the only manufacturer to make digital monitoring
standard on every process pump, ITT Goulds Pumps
consistently delivers innovations in both mechanical
pump design and adoption of smart technologies.
XHD Slurry Pump Named

Technical Innovation of the Year
Value Based Lean Six Sigma

(VBLSS) and continuous
improvement are the hallmark
of operations at ITT Goulds
Pumps, and are recognized
as crucial to providing a
premier customer experience.
Employees apply advanced
manufacturing and quality techniques, and the latest designs,
materials and machinery to
produce the highest quality
and most reliable products.
View the story of ITT Goulds

Pumps and the remarkable
men and women who stand
behind our products at
www.gouldspumps.com.
A longstanding commitment to aggressive research

and development and significant capital investments
enables Goulds Pumps to help its customers improve
their competitiveness. Customer satisfaction is
systematically monitored to provide direction for ITT
Goulds Pumps operations, and has empowered us to
reduce lead times, and continuously improve on-time
performance and product quality.
An ITT Goulds Pumps product serving the mining

industry, the XHD Heavy Duty Slurry Pump, took top
honors at this years Pump Industry Awards, presented by the British Pump Manufacturers Association.
It was chosen from among eight finalists as the
most innovative pump, pumping system or other
pump related product introduced onto the market
within the last 12 months, with effectiveness being
demonstrated via application details.
The XHD Pump allows mines and related operations to move heavy slurries with improved reliability
at lower operating cost. It can be maintained even
while running, and requires less downtime for service
procedures with parts that are more accessible and
adjustable than in other slurry pumps.
The Goulds XHD Slurry Pump was named Technical Innovation

of the Year by the British Pump Manufacturers Association.
Visit www.gouldspumps.com
for product information and technical literature on our extensive range of industrial pumps.
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. MovinCool portable
AC units help reduce the risk of heat exhaustion and
increase employee morale, leading to improved
manufacturing quality and productivity.
MovinCool, the worlds largest manufacturer of

commercial spot air conditioners, offers a wide range
of models, with capacities from 9,000 to 60,000 Btu/h.
MovinCool protects people, processes and equipment
from their hottest environments as well as provides
moisture removal.
MovinCools portable models can be quickly
wheeled into place whenever needed, with
virtually no installation required. The companys
latest compact, ceiling-mounted models allow easy
installation in tight spaces. Applications include:
IT data centers, computer rooms, server and
telecom closets
Hospitals, laboratories
Offices, schools, temporary buildings
Warehouses, factories, food-processing facilities
Outdoor sporting and other events, movie sets
Moisture removal (disasters, construction sites)
For more than thirty years, MovinCools Classic &
Classic Plus series of industrial air conditioning units
has provided effective cooling solutions for factories,
warehouses and workplaces.
MovinCool spot cooling

units prevent product
defects by eliminating
warping and condensation due to excess
heat and humidity.
Our portable AC units
reduce processing time
for most heat-related
production processes
by up to 94%.
Within the air conditioning industry, MovinCool
has a reputation for highest quality. Dealers who
specialize in spot air conditioners, and who stand to
lose significant profit if they have to replace a unit
once it is installed, consistently say they prefer
MovinCool air conditioners because of their
superior reliability.
MovinCool is a brand of DENSO, one of the worlds
largest manufacturers of automotive parts. DENSO
supplies advanced automotive technology, systems
and components, including air conditioners, to all of
the worlds major car manufacturers. In the 1980s,
DENSO pioneered the concept of workspace spot
cooling to meet its own factory needs. Since then,
MovinCool has developed spot cooling systems to
accommodate many different applications. For more
information, visit http://www.movincool.com
(800) 264-9573 | info@movincool.com | www.movincool.com

A Force in Domestic Manufacturing

Because Omega Engineering
offers over 100,000 products,
many customers have the
erroneous impression that the
company is simply a catalog
house, distributing products
made by others. Actually,
Omega is a major manufacturer
in its own right, making over
80% of the products it offers,
with this percentage
continuously increasing.
Wire Production
Manufacturing at Omega starts near the bottom of the supply
chain. The company actually produces its own thermocouple wire
at a manufacturing operation that turns out tens of millions of
feet per year. Starting with bare wire stock in a wide range of
compositions and diameters, finished cable is made for a myriad
of Omega products. Specialized machines turn out braided, extruded, glass-wrapped, shielded, single conductor, multi-conductor,
twisted shielded pairs, Kapton coated, and PFA coated cable in
both solid and stranded styles.
Thin Film Fabrication

RTD elements used in temperature
sensors and probes are made in
Omegas own thin film fabrication
facility located in a class 10 clean
room. Here the RTD elements are
created on substrates, 2000 at a time.
Omega is a major manufacturer in its own right,

making over 80% of the products it offers
Temperature Probes
Omega boasts an
automated probe manufacturing facility that is
unequalled. Starting with
coils of flat metal stock
and a wide range of wire
types, a highly automated
production line fabricates
probe sheath, with wiring
enclosed, in coils which
can be hundreds of feet
in length. Sheath sizes range from an incredibly thin 0.010 inches
up to a robust 0.375 inches. While other manufacturers make the
probes individually to a specific length, Omega can make any
desired length by simply cutting it from the probe coil.
Benefits of
In-House Manufacturing
Omega products are used in many
critical applications in manufacturing,
food processing, medicine, aerospace,
and science, to name a few.
By making the individual components
within the company, Omega can
achieve a measure of control not
possible when critical parts are
supplied by a variety of vendors with
a variety of reliabilities. This is key to
the high esteem Omega enjoys among
its customers and its reputation for
highly consistent, top quality products.
For sales and service call 1-888-826-6342 | email: sales@omega.com | www.omega.com

A trusted leader in the field of drive technology

PT Pilot Drive Selection Tool
Now compatible with smartphones and tablets!
TIME = MONEY. That is why SEW-Eurodrive developed PT Pilot. This online
program quickly provides a complete quote with options, parts lists, and
2D/3D CAD drawings for a gear unit or gearmotor.
The entire process is intuitive from start to finish and completely paperless.
It is accessible via a standard web browser no special software or plug-ins.
Plus, PT Pilot is now compatible with smartphones and tablets so it can be
accessed anytime, anywhere!
PT Pilot contains a special section for design engineers. Its engineering
calculator automatically sizes a drive for conveyors, travel cars, and hoists with or without an
inverter. Just enter the design parameters and let PT Pilot do all the work.
TorqLOC
TorqLOCs patented keyless hollow shaft and taper bushings eliminate
inefficient belts, chains, and spockets thus reducing maintenance and
energy costs while enhancing system safety.
Its spacious air gap provides easy mounting. Its tightening bolts provide easy
dismounting. No more tight tolerances. No more keys. TorqLOC even mounts
onto an existing shaft that has a keyway.
TorqLOC is available in carbon steel or stainless steel to meet all wet or dry
requirements. In addtion, its numerous bore sizes provide maximum flexibility
for new installations or retrofits.
Stainless Steel Gear Units

Upgrade to stainless and get rid of chipping paint, rust, and bacteria!
The new SEW stainless steel gear units are designed for high pressure
washdown. Features include:
Stainless steel TorqLOC hollow shaft

C-face or IEC adapter
PTFE seals
95.5 97% efficiency
Smooth body
U.S. Headquarters Lyman, SC | Telephone: 864-439-7537 | cslyman@seweurodrive.com

www.ptpilot.com | www.seweurodrive.com
Siemens Industry, Industry Automation Division

The Siemens Industry Automation Division supports
the entire value chain of its industrial customers from
product design to production and services with an
unmatched combination of automation technology,
industrial control technology and industrial software.
With its software solutions, the division can shorten
the time-to-market of new products by up to 50 percent.
Industry Automation comprises four Business Units:
Industrial Automation Systems, Control Components
and Systems Engineering, Sensors and Communications, and Water Technologies.
How does Totally Integrated Automation

drive maximum productivity?
Totally Integrated Automation (TIA) has been the
core intelligence of over 100,000 automation products
(drives, motor control centers, energy management
and control, PROFINET/PROFBUS networking, and
much more) for nearly 15 years. This is the foundation
for open flexible technology
and maximum interoperability
across multiple devices to
transform them into a totally
integrated automation
system. TIA, when
synchronized with customer
requirements, optimizes
factory, machine and process
operations allowing you to
not only produce more, more
efficiently,
but increase
Raj Batra, Vice President,
your
innovation
and
Siemens Industry
competitiveness.
Automation Division
TIA Portal one engineering framework

for all automation tasks.
Siemens has redefined engineering with the Totally
Integrated Automation (TIA) Portal. The TIA Portal is
the most intuitive, efficient, and proven engineering
framework, enabling you to integrate PLC, PC-based
control, HMI and Network configuration in a single
engineering environment.
This ground breaking innovation can shorten your
engineering cycle, save commissioning time, reduce
maintenance costs, and reduce your total cost of
ownership. This has resulted in up to 40% reduced
engineering time, thus reducing your time to market.
The TIA Portal is the key to unlocking the full potential
of Totally Integrated Automation.
Safety Siemens Safety Integrated increases

safety and reduces complexity.
The SIMATIC Safety Integrated solution provides
proven technology, as part of your overall safety
program, to save lives. This safety solution blends
seamlessly into Totally Integrated Automation and
lowers initial and operating costs, reduces down-time,
increases productivity and much more. This results in
savings up to 30% in total cost of ownership.
www.usa.siemens.com/automation
Keeping Torque On Target

With todays machinery, getting torque wrong can have serious
consequences for production, safety, and liability.
Accurate torque measurements are critical. Too little tension can cause a
connection to come loose; too much tension and the fasteners can strip out,
the bolt heads can shear off, or the fasteners can prematurely fail. Either way,
applying the wrong torque to a critical fastener can cause an expensive piece of
machinery to fail, halting production and possibly causing injury to workers.
Proto Torque Multiplier Display Unit
Maintaining accurate torque is a challenge in all industries, but its especially so

in high torque environments where torque multiplication needs to be used on large
fasteners. Fortunately, Proto has introduced new equipment that makes it easier
to maintain accurate torque in any setting - the Proto Torque Multiplier Display
Unit (J6352). Its placed between the output of the torque multiplier and the
socket itself.
Because it measures and displays the actual applied torque to the fastener up
to 2700 Nm theres no need for calculations or guesswork. It has an accuracy of
+/- 1%, exceeding the ASME standard and virtually eliminates final torque errors.
The user just needs to set the target torque level and apply the input torque (even
with a standard ratchet); a green light will illuminate and a buzzer will sound when
the target torque is reached.
New tools like these make it easier for everyone to meet the torque accuracy
requirements so crucial to maintaining safety and keeping production going.
For more information on the Proto Torque Multiplier Display Unit or other Proto
Tools, please visit protoindustrial.com.
www.protoindustrial.com | Telephone: 1-800-800-TOOL

A Company Profile
Sullair Corporation is one of the worlds leading
manufacturers of rotary screw air compressors.
An innovator since 1965, Sullair offers the broadest
range of air compressors in the world today. The
Company sets the standards for stationary air
compressors for industrial applications and portable
air compressors for the construction, mining and
energy-related segments. Sullair is also a globally
recognized manufacturer of compressed air
treatment equipment, and vacuum systems.
Sullair is focused on conservation and

committed to providing air compressors that
will use energy most efficiently.
Green Initiative
Fundamental to Sullairs leadership is a dedication to
reduce the amount of natural resources consumed to
create electrical energy and to minimize environmental impact, both in the manufacture and use of all our
products. We are constantly exploring new ideas and
seeking new technologies to meet the ever-increasing
need for energy-efficient compressed air solutions,
quality and environmental sustainability.
We are doing this in a number of ways. For example,

weve designed EES compressors to capture heated
air, normally wasted, and use it for comfort or process
heating. Sullair refrigerated compressed air dryers
use the most environmentally compatible refrigerants.
Another example is our genuine replacement parts
and fluids. Coreless, nonmetallic fluid filters can be
incinerated or crushed, eliminating disposal concerns.
Sullair offers environmentally compatible compressor
fluidsbiodegradable
Sullube, and 24KT,
a life-long fluid with zero
environmental impact
because it never needs
to be changed.
As a company, we are
passionate about reducing our products
energy use to help our
customers decrease
their environmental
impact. We find that
these green initiatives
go beyond good
corporate citizenship.
They translate to business opportunities and
bottom line savings that
can contribute financial
value to the organization
while meeting demanding
customer requirements.
This 100 hp Sullair compressor

generates 1,649,000 BTUs
per year. Energy savings
may reach $10,993.00*,
with a 7 month payback.
Committed to Innovation and Excellence

At Sullair, a commitment to innovation and a dedication
to excellence form the foundation of leadership. Sullair
is continually exploring new ideas, seeking new ways
to engineer and produce reliable, energy efficient
compressed air and vacuum products to meet the
needs of our customers worldwide.
sullairsolutions@sullair.com | 219-879-5451 | www.sullair.com

Thomas & Betts the source for innovative products

Thomas & Betts
Corporation is a
global leader in the
design, manufacture
and marketing of
essential components
used to manage the
connection, distribution, transmission and
reliability of electrical
power in industrial,
construction and
utility applications.
PMA nylon flexible cable protection systems
for power and data cable provide superior
corrosion protection in harsh environments.
Thomas & Betts products are designed to

perform dependably under a variety of manufacturing
conditions:
constant moisture
harsh chemicals
extreme temperatures
high-pressure wash down
ultraviolet exposure
hazardous areas
high-vibration equipment
continuous operation
These products are rigorously tested for use in harsh
environments, with proven results in thousands of
installations.
For more than a century, Thomas & Betts has provided

customers with electrical system solutions to help
protect employees, assets, brands and customers,
while meeting applicable codes, lowering installed
costs and providing overall value.
T&B Fittings Stainless Steel Form 8 Conduit

Outlet Bodies are constructed of polished,
marine-grade Type 316 stainless steel,
providing protection for electrical systems in
the harshest environments.
With a portfolio of
more than 200,000
products marketed
under more than
45 premium brand
names, Thomas &
Betts products are
found wherever
electricity is used,
including in manufacturing facilities where
they help power
industrial machinery.
Thomas & Betts is the source for innovative products

in wire and cable management, cable protection
systems, power connection and control products,
safety technology, HVAC building solutions, and
engineered transmission structures.
OCAL-BLUE
Type 4X Form 8
conduit bodies
offer double-coated
exteriors for
enhanced protection
in corrosive
environments, as
well as excellent
protection in washdown applications
and harsh outdoor
environments.
Thomas & Betts trained sales representatives and

technical services experts are available at every
stage of a project, from planning and site preparation
through construction and MRO. Thomas & Betts also
conducts training programs on specific products and
systems, and works closely with accredited electrical
industry associations.
The companys brands are asked for by name and
trusted by electricians, installers and engineers for
their unmatched record of product firsts.
The company maintains an active role in shaping safe
and consistent electrical standards and practices.
Thomas & Betts Corporation

8155 T&B Boulevard | Memphis, TN 38125 | (800) 816-7809 | Fax: (800) 816-7810
elec_custserv@tnb.com | www.tnb.com
Yaskawa Quality: More than a Measurement... Its an Experience.

AC Drives
Yaskawa Industrial AC drives cover every automation
application need in the industrial plant, offering the
greatest selection of size and performance available,
with power ranges from fractional HP to 1750 HP.
We take quality personally at Yaskawa. Our drives and

servo packages offer the highest MTBF in the world.
The relationships we have with our customers ensure
mutual benefits. The partnerships we cultivate with our
distributors add value to the way we work with you.
We hire great people and continuously train them to
be able to serve your needs better. We deliver product
on time. It works out of the box. We answer questions
promptly and never back down from challenges.
Our Commercial AC drives for HVAC applications

combine reduced size and cost with step changes
in performance and quality. They feature extensive
parameter selection to enhance energy efficiency and
closed loop control for Building Automation Systems.
To us, quality means doing everything we can to

make our customer, partner and employee
experiences great ones. We commit to that
philosophy every day. We make it happen.
We can because, to us, ITS PERSONAL.
Were the only industrial drives and motion control
manufacturer to win the Deming prize the most
prestigious quality award in manufacturing. But we
know that tells only part of the quality story. What
about innovative design, knowledgeable, responsive
engineers who understand your business, and superior
support and training?
Those crucial assets are a vital part of how a company
is ultimately judged and what we mean by the Yaskawa
Quality Experience. At Yaskawa, Quality is more than
numbers, more than awards its the total experience
of purchasing and owning Yaskawa products and
working with Yaskawa people.
Motion Control
Our broad product range of servo systems includes
rotary, linear, and direct drive motors matched with
digital SERVOPACKS. These best-in-class servo
systems can be matched with our single or multi-axis
programmable automation controllers for a system
solution with the best quality and reliability in the
industry.
www.yaskawa.com | http://www.yaskawa.com/site/Home.nsf/home/home.html
NEXEN is the leading manufacturer of precision motion control components,

power transmission and web tension control products. They are showcasing their
products at IANA 2012! Visit them at booth E-4306 or www.nexengroup.com.
INDUSTRIAL AUTOMATION
NORTH AMERICA at IMTS 2012
International Trade Show for Factory, Process and
Building Automation Systems and Solutions
at
September 10 - 15, 2012 McCormick Place, Chicago, Illinois
To register for IANA and IMTS, please visit industrialautomation-na.com
Organized by:
www.ia-na.com
Partner:
For more information, please contact

Aryan Zandieh at (312) 924-1688 or azandieh@hfusa.com.
06/12
Industrial Energy
Management
Energy
in motion
Goods makers address the cost of
keeping things moving
EN3 Machine tool energy
efficiency
EN6 Energy-saving automation
at Nissan
EN10 Chillers and VFDs
EN13 A template for energy
management software
SUPPLEMENT TO
Energy efficiency starts with

realizing the potential
Lower your costs without compromising productivity
IndustrialEnergyManagement
EN3
Discussions
about the
efficient use
of energy are
becoming
pervasive in
many industrial
sectors,
including
more efficient
deployment
of machine
tools. Courtesy:
Heidenhain
Machine Tool
Division
Current Issues in
Machine-tool Energy Efficiency
A range of energy consumers including pneumatics, hydraulics and
lubricant processing influence a work centers power profile.
MACHINE TOOLS INCLUDE numerous motors and auxiliary components. Energy consumption varies significantly
during operations. The main spindle drive and the coolant
system, for example, work near rated power while roughing
at a high stock-removal rate, but power consumption during finishing is significantly lower. Close interdependence
exists between individual components and subassemblies
on the one hand and productivity and quality measures on
the other. From the process itself to individual component
power consumption, savings potential can be evaluated
and measures defined for more efficient energy use.
One area of potential savings comes from the machine tool base load, which consumes energy even in
nonproductive phases. The base load is determined substantially by the machines auxiliary components. Besides
use of energy-efficient motors in these components, many
opportunities for reducing the base load can be found.
Some energy consumers, for example, can be switched off
by the machine control during nonproductive phases.
WWW.PLANTENGINEERING.COM
Scrap inevitably increases energy consumption per

good part. Manufacturing with accuracy from the very first
part can therefore be decisive for energy efficiency. Machine
designs with balanced thermal behavior and precise position measuring technology have a distinct advantage here.
Energy demand during milling

Power requirements of a milling process fall into the following consumer groups:
Cooling lubricant processing
Compressed air generation
Electrically powered milling-machine auxiliary
components
CNC control package with main spindle and feedaxis motors
Proportionally calculated energy for lighting, ventilation, and air conditioning must be added to these groups.
Milling process energy demand depends primarily on the
size of the milling machine and the machining task.
SUPPLEMENT TO PLANT ENGINEERING
EN4
Dry machining has great potential for improved energy
and resource efficiency. In many milling applications, however, doing without cooling lubricant increases scrap rate
and, therefore, raises mean energy consumption.
Compressed air is required for minimum spindle lubrication, tool changing, and work piece cleaning. Small
quantities are required as sealing air. Mean compressed
air power changes only slightly across production readiness, roughing, and finishing.
Machine electricity consumers include the CNC control with main spindle and feed-axis motors, as well as numerous auxiliary components, including the pallet changer
and cooling, hydraulics and automation systems.
Drive component efficiency

Spindle and feed-axis motors are among the central components of a machine tool. Drive-component energy efficiency depends on the ratio of delivered power to consumed power. The network of drives converts consumed
electrical energy to delivered mechanical power. Drive
network components include a power supply module,
drive modules, motors and mechanical components. Data
on efficiency typically refer to the rated power. For other
Components of machine tool

energy efficiency
Power consumed by a CNC control with feed-axis and spindle
motors frequently comprises as much as 30% of the total required
for a metal-cutting process. Its the auxiliary components that play a
dominant role in the energy balance.
Whether a CNC control operation benefits from energy recovery
to line power depends on the frequency of tool changing during
milling operations or of workpiece changes during turning.
Further energy savings are possible depending on whether
spindles can be closely adapted in their speed and torque to the
machines range of operations. If a universal spindle design is
required, its motor may have to run at low efficiency rateswith the
expected consequences for energy consumption.
Position encoder selection can have a decisive impact on
spindle-motor and direct-drive efficiency. Insufficient resolution and
accuracy generate high current values in the position control loop.
Position encoders with high line counts are essential for servocontrolled drive efficiency.
Linear encoders increase accuracy and therefore contribute
to precise and reproducible machining. This makes it possible to
reduce production waste and energy requirement per good part.
Processing cooling lubricants, supplying compressed air and hydraulics, and accomplishing cooling command a dominant share of
total power used. Efficient pump motors save significant amounts of
energy. With the relatively high base load of machine tools, minimizing nonproductive phases is a high priority.
rated values, individual component efficiency can vary

significantly. Supply modules and drive modules can attain efficiency values of more than 95%.
Comparing power consumption during rough-face
and circular-pocket milling reveals that feed drives consume only a small share of the CNCs total power usage.
On the other hand, spindle selection can significantly affect energy consumption. If a spindle drive operates far
below its rated power, the drives intrinsic losses increase
in proportion, with negative effects on the energy balance.
If the spindle limits the maximum possible metal removal
rate, the milling process inevitably takes longer. The result:
energy efficiency decreases due to the base load generated
by the auxiliary components.
Regenerative supply modules

Every drives acceleration requires a braking process in
return. Energy from the drives moving masses is largely
reconverted to electrical energy. In a non-regenerative
supply module, kinetic energy released by braking is
converted to heat by the braking resistors. A regenerative supply module returns this energy to the power grid.
However, the path required for returning the energy and
the necessary components for smoothing the grid power
generate losses even when the drives have no power requirement. Power loss increases slightly even when power is not being regenerated. Thus, a regenerative supply
module operates more efficiently than a non-regenerative
module when the regenerated energy more than compensates the higher power loss. Machine operation therefore
determines what type supply module to employ.
Tool change frequency also impacts this decision.
A regenerative supply module works more efficiently
as soon as the time interval between two tool changes is
less than 100 seconds (equals 0.6 tool changes per minute).
In processes with many tool changes per minute, a regenerative supply module often proves to be the better choice.
During contour milling with infrequent tool changes, the advantages are on the side of the non-regenerative system.
Deactivation of auxiliary components

In the ready condition, energy use of several consumer
groups is only slightly reduced. Therefore, these nonproductive phases must be kept as brief as possible. With
machining centers for smaller production batches, energy
consumption can be significantly reduced by the selective
deactivation of auxiliary components. Beyond this, potential savings result from the use of energy efficient pumps
in the coolant and lubricant circuit.
However, consistent switch-off of auxiliary components such as hydraulics and spindle cooling or of
the compressed-air supply can also have a deleterious
effect. If sudden removal of waste heat from auxiliary
components, or of temperature-stabilizing media, leads
EN5
to thermal displacement in the machine frame, scrap can
result. Selective auxiliary component switch-off therefore
functions best on machines with little inclination to thermal displacement.
CNCs can be the central control unit for machine tool
energy management, taking advantage of special PLC functions for linking events in the production process (such as
NC stop) with outputs for controlling auxiliary components.
Delay times can be assigned to events so that, for example,
motors can be locked and disconnected from current after
standstill. Functions for deactivating various auxiliary devices, axes, light in the working space, etc., can be generated on this basis. These basic functions are the responsibility of the machine tool builder. For users, it is helpful to
adapt energy management to specific usage habits.
Control loop with rotational direct drive (torque motors)
Measuring servo-controlled motors

In the control loops of spindle motors and direct-drive
feed axes, even the smallest feedback signal disturbance
can result in large motor current fluctuations.
Signal interpolation of a position encoder includes
short-range deviations within one signal period (interpolation error), typically of approximately 0.5% of the
signal period. If interpolation error frequency increases,
the feed drive can no longer follow the error curve. However, additional current components are generated by the
interpolation error. Therefore, if torque remains constant,
energy consumption and motor efficiency get worse. Additional energy required is converted to heat that must
typically be dissipated by a motor cooling system, which
itself consumes energy.
Comparing the effects of an optical and a modular
magnetic encoder on a direct-drive rotary table drive illustrates the point. An angle encoder with 16384 lines
generates only barely noticeable motor-current disturbances and generates little heat. Because of the magnetic
scanning principle, the encoder has notably fewer signal
periods. Significant disturbances occur in the motor current with the same controller settings. For example, at a
shaft speed of approximately 30 min1 the effective value
of the current is 15 A greater than for an optical encoder.
The result is greater motor heat generation.
An encoder with low signal quality can lead to greater motor energy loss. The additional energy requirement
for active cooling also has to be included in the energy
balance. To increase the energy efficiency of the motor,
the encoders need high-quality signals.
www.heidenhain.us
The information in this article was provided by Dr. Johannes Heidenhain GmbH and edited by the Control
Engineering staff
Motor current of a direct drive with position encoder: A) with low

interpolation error (optical encoder); and B) with high interpolation
error (modular magnetic encoder).
Temperature variations of a direct drive with optical (A) and magnetic

(B) position encoder. Courtesy: Heidenhain Machine Tool Division
EN6
Nissan Plant Reduced Energy

Expenditure 30% with
Daily Power-Down Regimen
Accumulation chain conveyors, overhead lighting,
and compressed air among areas addressed
IN THE MANUFACTURING ENVIRONMENT, manual
processes used to stop and restart equipment can be costly due to manpower demands. The energy cost of keeping
equipment running continuously may be less than that of
paying employees for a daily power-down regimen. But
given rising energy costs, its hardly an ideal situation.
Depending on the amount and nature of the equipment installed in a facility, an automated solution may be
the most economically viable one. Fortunately, the modern
manufacturing environment has the luxury of using many
of the original smart home devices, with programmable
logic or automation controllers (PLC or PAC).
With some creativity and a slight change in a companys mindset, any manufacturing plant can become an
energy efficient facility using minimal resources to accomplish the task. Once an energy program begins, and
the benefits are realized, the savings can be used as investments to fund future projects.
PLCs are now standard on most major pieces of
equipment purchased for modern manufacturing, and
they provide almost infinite flexibility for modifying
equipment operations. These devices are instrumental as

a foundation for an automated energy reduction effort.
In fact, without purchasing a single additional component, PLCs in existing equipment panels can be used to
immediately generate cost savings. Using existing inputs
on machinery for monitoring the equipments primary
function, the absence of machine or operator movement
can also be monitored. If no movement is detected for a
predetermined amount of time, select processes can be
stopped in a controlled manner, and utility savings will
begin to accumulate.
Step by step
The first step in any plants energy-savings development
plan should be to identify the energy consumers that can
be idled during non-production times without causing
quality, production, or safety concerns. Many different
motors, heaters, lights, and compressed air lines are energized continuously in a typical plant. Each hour a component runs without producing product is money spent in
the form of utility usage that has no added value. Yearly
EN7
by Josh Hauskins
Nissan North America
The Nissan manufacturing plant in

Smyrna, Tenn., was named a 2010 and
2011 ENERGY STAR Partner of the Year
by the US Environmental Protection
Agency for its work aimed at industrial
energy efficiency.
Courtesy: Nissan
utility budgets can be adversely affected by this wasted

energy use.
Not long ago, the Nissan manufacturing plant in
Smyrna, Tennessee (NNA-S) was faced with the challenge
of reducing energy consumption without taking on additional resources. The 25-year old plant consumed virtually
the same amount of utilities during an idled state as it did
at full production. After implementing countermeasures,
the Smyrna plant was able to reduce energy consumption
by over 30 percent. The plant later was named a 2010 and
2011 ENERGY STAR Partner of the Year by the U.S Environmental Protection Agency. Although many opportunities for energy efficiency existed, the most conspicuous
areas of impact were the accumulation chain conveyors,
overhead lighting, and compressed air services.
Miles of conveyors ran day and night, regardless of
production hours. After some planning, key inputs were
identified to monitor movement throughout the chain
systems using a timer for each chain motor. If one of the
switches on the conveyor is made, the timer resets and
begins the timing process again. If the timer exceeds the
defined preset value, the conveyor motor is stopped.
Each of these conveyors supplies product to a production line. When the manufacturing line begins to run
production, and the supply conveyor is in a no-activity
shutdown state, an alarm sounds and the conveyor restarts. This practice was developed as a standard logic
routine and replicated throughout the plant. In fact, any
machine that was equipped with a PLC and inputs had a
version of the standard program implemented.
Looking at lighting
Automated lighting shutdown was the next step in
energy reduction strategy. Several products are currently
on the market that will work with an equipment PLC
to automatically turn off select lighting. Circuit breaker

manufacturers have lighting panel solutions that receive
inputs to monitor the running state of equipment. The
task-lighting panels in the plant were changed to the
smart panels, and the task lighting was automatically shut
down several minutes after production had stopped for
breaks and lunches. This alone produced an immediate
and dependable reduction in electrical consumption.
The Body Assembly department at NNA-S also implemented a very creative automatic light reduction program. The overhead lighting was automatically shut down
over robot cells when safety fences were active because
robots do not need light to work. The lights automatically turn on for operators when set-up or maintenance
is performed.
Although conveyors and lighting were the first areas
modified because of their visibility, compressed air is also
a large electrical consumer that is often overlooked.
Compressed air is one of the most inefficient energy
sources in any facility. Pneumatic devices need a constant supply of compressed air to maintain a load. Most
industrial compressors are very large and consume many
kilowatts, especially in large facilities that have expansive air line systems. The larger the system, the larger the
compressors electrical load. Larger systems also provide
more potential for air leaks that further compound the
problem.
Fortunately, automatically reducing pneumatic supply
is a very simple solution. An electrically actuated ball valve
can be placed in any pneumatic supply line. Using a version of the standard shutdown logic implemented on the
conveyors, inputs can be monitored, and the valve can be
turned off during non-production times. All compressed air
consumption is immediately stopped. When a pneumatic
supply is eliminated, compressor load is reduced, which
ultimately saves kilowatt hours and money.
Quantitative measures
To view the savings from all of the improvements, a measuring system was developed as well. Each utility meter
of every type was wired to a PLC, so usage could be monitored during idle times. Data from the meters is logged
to provide trending of the numbers independent of the
utility company reports. Web reports were created to display the usage data. Because the data provided visibility,
the budget responsibilities could be divided more equally
among consuming departments. Very similar screens were
used to set the timer presets for monitoring equipment as
well. This portion of the project was not essential, but
the interface did provide measurable data, operator status
indication, and configuration convenience.
As a precaution, cost savings should not be the
only consideration when stopping equipment, turning
off lights, or removing compressed air from machinery.
EN8
The Nissan manufacturing plant in Smyrna, Tenn., took advantage of PLC and HMI technologies already in place to improve
and quantify plant energy efficiency. Courtesy: Nissan
The safety of the operators in proximity of any automated

equipment should always be the top priority. No equipment can be de-energized, regardless of the savings, without considering the safety impact.
When lighting is turned off, the required amount
of lumens has to be provided with adequate safety
lighting.
Light curtains or safety scanners may be needed
to protect operators in areas that will experience
conveyor or machinery movement upon restart.
Controlled stops on equipment may mean that the
machinery has to be free of parts, so no damage
from binding or jamming will occur to them on
startup as well.
When compressed air is depleted from cylinders,
the retained load may fall. In cases such as this,
a holding fixture may need to be built to support
any load, tooling, or parts. The fixture can be
equipped with switches that are monitored in the
automatic shutdown logic.
Regardless of the situation, each circumstance will
have to be evaluated individually to assess the risk.
At first, the task of plant-wide energy reduction may
seem overwhelming and could meet much resistance.

However, using PLC, inputs and outputs already installed,
a viable energy reduction program can be implemented
without expending many additional resources.
Once the benefits become apparent, creativity and
imagination are the only limiting factors on how far an
automated utility conservation program can go. As long
as safety considerations are met, any machine can be
stopped in a controlled manner to provide long-term
maintenance benefits, create a quieter factory, produce
an environmental performance improvement, and ultimately, a significantly lower utility bill.
www.nissanusa.com/innovations
www.energystar.gov/industrial
Josh Hauskins is a senior engineer and new-model
controls-engineering project leader in the Trim and Chassis
department at Nissan North America in Smyrna, TN.
He has a diploma in electronics technology and a B.S.
in information technology. He was one of the Leaders
Under 40 named in the November 2010 issue of Control
Engineering magazine.
Rust Belt Plant Goes Green,

Saves $1.3 Million Annually
Keith Lang | Operations Manager
Continuous plant improvements should be

considered for almost any plant, despite the age.
Siemens Norwood, Ohio, motor manufacturing
plant, for example, was built in 1898 and is one of
the nations oldest continuously operating
manufacturing facilities.
As a leading industrial manufacturer, Siemens
understands the pressures of optimizing manufacturing processes and reducing energy consumption.
Against these pressures, some felt it might be better
to move the motor manufacturing lines to a low
cost country or invest in the plant and retain the
employees knowledge and experience. However an
analysis determined investment was the better path.
The upgrades are

dramatically impacting the bottom
line saving the
Norwood facility
$1,346,000 annually
in energy savings.
Additionally, the
plants carbon footprint
has been reduced
by 12,200 tons annually.
Today, the Norwood Motor
Manufacturing Facility is a
showcase for efficiency and environmental
stewardship. The employees at the plant continue
to look for other cost reductions and process
improvements. For example, the plant is currently
considering installing Siemens charging units for
hybrid and electric vehicles in the parking lot.
This kind of forward thinking has made the
Norwood plant a jewel in the community, and
demonstrated Siemens commitment to energy
efficient, responsible manufacturing. It has
also taken an outdated, underperforming plant to
an efficient and profitable operation.
Visit our website to download the complete white paper.
The decision to invest showed Siemens values the

knowledge of its employees -- all the way from
engineering to the shop floor -- and wanted to keep
knowledge and production capacity in the United
States. Improvements included replacing outdated
and energy-eating equipment, enhancing lighting
systems and optimizing processes.
Siemens
usa.siemens.com/energyefficiency
EN10
by Michael Grant
Yaskawa America Inc.
Cut Chiller Energy Costs by 30%

Prepackaged retrofit for centrifugal compressor chiller
also said to reduce required maintenance and extend
operating life
Building
maintenance
personnel
can easily
monitor and
control chiller
operation from
the touchscreen
using graphic
icons and simple
commands.
A CHILLER IS OFTEN the single largest consumer of

power in a building, so its a logical place to look for reduced energy costs. Chillers expend excess energy when
their compressors run at full-rated constant speed, a
wasteful and unnecessary operating condition. Most chillers operate at partial load or are off 99% of the time. A
chillers compressor motor is typically quite large, in the
range of 150 hp to 600 hp. Money saved by operating the
compressor motor more efficiently can add up quickly.
The best way to improve chiller compressor motor
efficiency is by upgrading motor control from constant- to
variable-speed using a variable frequency drive (VFD).
Rising energy costs and electric utility rebates for VFD upgrades, coupled with falling prices for large horsepower
VFDs, can reduce investment payback times to as little as
one year. However, chiller compressor motor VFD retroSUPPLEMENT TO PLANT ENGINEERING
fits can be complex. Many companies postpone retrofits

and forego savings.
Prepackaged solutions can be economical to purchase, easy to install, and simple to operate. Such a prepackaged retrofit can be optimized to existing chillers regardless of brand or size.
This type of package is most effective retrofitted to centrifugal compressor chillers, but can also be applied to other
chiller types, including those with reciprocating, rotaryscroll, or screw compressors. Centrifugal compressors make
up the bulk of the chiller market with about 70% market
share. To understand how the retrofit package works, its
important to first examine chiller operating details.
A chiller transfers heat from an area where it is unwanted to a place where it is unobjectionable. This is
accomplished using a refrigerant exchange medium and
EN11
a compressor to perform the required heat transfer. This
process is known as the refrigerant cycle, and is depicted
in the diagram.
The refrigerant cycle employs four main components: a liquid metering device, evaporator, compressor,
and condenser. The cycle begins with the refrigerant in
the condenser, in a liquid state and at high pressure. From
there, the liquid refrigerant flows to the evaporator. Flow
is regulated by a metering device. The evaporator is at a
lower pressure than the condenser, so flow is naturally
induced from the higher to the lower pressure area.
In the evaporator, the refrigerant changes state from
liquid to gas by absorbing heat from the area where it is
unwanted, typically called the load. The refrigerant gas is
then discharged from the evaporator to the compressor,
which raises its pressure.
Next, the high-pressure gas discharges the unwanted
heat to the unobjectionable place, typically the atmosphere, changing state from a gas back to a liquid in the
condenser. The refrigerant then flows from the condenser
to the evaporator, and the cycle begins again.
With a basic understanding of the refrigerant cycle in
hand, we can now look at how a retrofit improves refrigerant cycle and overall chiller efficiency.
Plant Engineerings
Table: Advantages of
Chiller Optimization
Cuts electrical energy use by 30%

Cuts peak power demand
May be eligible for electric utility rebate
Cuts required chiller maintenance
Extends chiller operating life
Solve the crime of wasted energy

To understand how a retrofitted chiller saves energy, consider the two factors that most affect chiller energy consumption. The first is the load, and the second is the temperature of water entering the condenser. A reduction in
either load or water temperature saves energy. However,
load is not a controlled parameter. Rather, it is a function
of building demand. So the chiller retrofit focuses on efficient reduction of entering condenser water temperature.
A chiller with a constant-speed compressor motor
reacts to a reduced load or lower entering condenser water temperature by closing its prerotational vanes, which
reduces refrigerant flow and saves some energy. However,
as the vanes close, they create frictional losses, reducing
chiller efficiency and limiting energy savings.
On the other hand, the chiller retrofit sequences the
vanes to a closed position before the compressor motor
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ple201109_enewslttrs_halfHZ.indd 1

9/6/2011 11:57:30 AM
EN12
COMPRESSOR
INLET
Diagram:
A chiller
uses a
SUCTION LINE
COMPRESSOR
OUTLET
COMPRESSOR
DISCHARGE LINE
CONDENSER
FAN
refrigerant
exchange
medium
able.
WARM
AIR OUT
AMBIENT (OUTSIDE) AIR IN
and a
compressor
to move heat
from where it
is unwanted
to where it is
unobjection-
2
CONDENSER
LIQUID LINE
WARM
RETURN AIR
IN
COOL
SUPPLY AIR
OUT
EVAPORATOR
BLOWER
REFRIGERANT FLOW
EVAPORATOR
METERING DEVICE
starts. The unloaded chiller is then given a command to

make a controlled acceleration to full speed, usually 60
Hz or about 3600 rpm. This control sequence keeps starting torque low by providing gradual and controlled compressor acceleration, thereby increasing mechanical drive
and chiller system longevity while cutting required maintenance. The compressor motor soft-start also reduces
instantaneous power draw from the electric utility, often
reducing demand charges.
The chiller retrofit controller measures the difference
between compressor suction and discharge pressure while
dialing the vanes open. The lift temperaturethat is, the
saturated compressor discharge temperature minus the saturated evaporator temperatureis measured as the vanes are
simultaneously controlled to maintain the required chilled
water setpoint for the condenser. A chiller has to maintain a
certain minimum required lift temperature at all times.
Chiller compressor motor speed is then regulated to
keep refrigerant velocity slightly higher than that needed
to maintain the required lift temperature. For example,
if the exiting condenser water temperature rises as load
increases, the required lift will go up, thereby increasing
chiller compressor motor drive speed.
Starting torque must be considered in selecting a
drive, as refrigerant density is often much higher at startup than at operating conditions. Typically, 160% of rated
starting torque is provided by a standard motor starter or
controller. The VFDs inherent soft start eliminates this
torque transient, so standard normal duty-rated ac drives
can be used with the centrifugal compressor motor in the
DRIER
chiller, reducing VFD initial investment.

A much more efficient way to adjust to changing
load characteristics or lower condenser water temperatures is to vary the speed of the chiller compressor motor,
as opposed to adjusting vanes or other mechanical flowcontrol devices.
The chiller retrofit is not only the most efficient way
to operate a chiller, its also simple to install. A retrofit
can consist of a VFD, sensors, controller, and touchscreen
operator-interface panel. Installation consists of supplying power to the VFD, connecting it to the compressor
motor, installing and connecting the sensors, and connecting the vanes to the retrofit package.
The retrofit front panel touchscreen shows relevant
operating parameters. Building maintenance personnel can monitor and control chiller operation from the
touchscreen using graphic icons and simple commands.
A solid-state design doesnt require maintenance and will
typically operate trouble-free, usually for a service life exceeding that of the associated chiller.
Retrofitting an existing chiller with a predesigned package
delivers many advantages, as summarized in the table.
Michael Grant is regional drive specialist with Yaskawa
America Inc., Waukegan, Ill. Edited by Kevin Parker, contributing content specialist, CFE Media.
ONLINE: Details about a retrofit solution
www.airmasters.com
www.yaskawa.com
EN13
by Kevin Totherow
Production Energy
Optimization Profile
We cant necessarily see energy being wasted, but

it can be identified and tracked on the road to lower
costs in manufacturing and process industries.
WHAT ARE THE MOST IMPORTANT FACTORS that
impact energy costs in a production facility? Some of these
conditions are permanent, while others change from day
to day based, for example, on the production schedule or
how hot or cold it is outside. Are costs high due to record
productivity or excessive due to such things as downtime
or steam leaks? Given the many factors involved, looking
at a facilitys overall energy cost by itself doesnt tell you
much. Even then, many companies cannot say how
given their energy-intensive operations and processes
the energy is used and if the cost is truly justified.
The concepts of sustainability and energy efficiency already are part of the lexicon for manufacturing and
process industries. Yet at many companies, energy is still
treated as an overhead cost, even though things like quality
quantified in scrap, rework, and similar work are well
recognized as variable costs to be tracked and managed.
Operators cannot see energy being wasted when
a kiln is kept heated for hours without product moving
through it. Manufacturers need tools to monitor energy
use to identify poorly run processes. One good first step
in this direction is to define a production energy optimization (PEO) solution as an enterprise management system empowering existing teams to reduce energy waste
through continuous improvement, as well as capture the
variable cost of energy per product produced.
Defining an energy solution

While vendors and users are developing, assembling and
implementing solutions for industrial energy management, the reality is that getting companies to invest in
and getting users to buy into these solutions is only possible if they deliver actionable information and empower
work teams.
A production energy optimization system should include the following capabilities:
Reads real-time energy consumption for water,
air, gas, electric and steam (WAGES) and process

information such as product ID/SKU, equipment,
rate, operator/team and machine state
Provides an energy-per-product base-line
Recognizes energy over-consumption events
(NVAW)
Alerts managers of energy events and other items
needing attention
Interfaces with the ERP or activity-based costing
model to pass energy costs per product
Creates virtual sub-metering by reading system
meters, splitting costs among the relevant process
areas based on business rules and in conjunction
with real-time equipment monitoring
On the one hand, PEO includes web dashboards of
metrics, goals and real-time performance indicators of a
business-level optimization system, scalable from single
production lines to multi-plant scenarios. On the other
hand, a PEO solution will include analytic tools to help
managers understand causal relationships and identify
procedure-change opportunities.
PEO is an operations-management decision-support
system focused on energy and its undesired by-product
CO2. Implementing the right solution requires an understanding of energy usage in relation to industrial processes, aimed at attaining maximum return to the business.
The system drives knowledge-based decisions.
PEO project management

The PEO project begins with defining its scope. The work
starts with a person, or team, responsible for facility energy management or accounting. Any goods producer
will want to have a team of people providing input and
oversight to a PEO project. In addition, the team needs an
executive-level sponsor. This sponsor will serve as champion, solve problems, and resolve conflicts.
Not all team members will have active roles, but, in
EN14
.. .. .. .. .. .. .. .. .. .. .. .. .............................. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
.. .. .. ..optimization
.. .. .. ...... ..empowers
. .. .. .. .. ..existing
.. .. .. .. .. .. ..
............... ... ... ... ... ... ...Production
... ... ... ... ... ... ...energy
.
......through
.. .. .. .. ..continuous
.. .. .. .. .. .. .. .. ..
.......... .. .. .. .. .. ..teams
.. .. .. ..to..reduce
.. .. ... ... ..energy
. ... ... ... ...waste
........ .. .. .. .. .. .. .. .. .. .. .. ..
.......... .. .. .. .. .. ..improvement
.. .. .. .. .. .. .. .and
. .. ..captures
. .. .. .. ...the
variable cost of
.
.. .. .. .. .. .. .. .. .. .. .. energy
.. .. .. .. per
.. .. ..product
.. .. .. ..produced.
.. .. .. .. ... ... ... ... ... ...... ... ... ... ... ... ... ... ... ...
.. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
.......
addition to the sustainability manager, the team should
include representatives from the following groups or departments:
Operations management uses the energy and the
PEO system
Facilities or maintenance owns most of the metering systems. Integration from PEO to the maintenance system could initiate service request in
the event of abnormal energy consumption
Engineering process automation owners
Information technology supports system, databases and network connections
Accounting needs the energy consumption per
grade for activity-based costing
Once the team participants are in clear view, the next
step is likely a discovery services study (DSS). This study
may have different names such as pre-engineering study,
scope development or project definition study. The important thing is that the team will either produce or
hire a company to produce a formal document that
includes the following:
Long-term system solution definition based on the
companys strategic goals
Proposed system architecture, including definition
of metering (including virtual meters), system integrations, and user interfaces
Data to be collected: key performance indicators
The ability to monitor energy use by machine state

is an important step in getting a handle on the
(KPIs), display information, alerts, notifications,

and reports
Estimated costs, implementation schedule, return
on investment projection and risk evaluation
Implementation challenges
The overall project includes three major elements: submetering installation; computers and networking; and
software configuration and roll-out. Sub-metering is the
only step that may require downtime and outages.
1. Sub-metering of WAGES The DSS should have
defined all of the metering necessary; if virtual meters
can be used in the application; and if the PEO will read
WAGES data directly from the meters, from a process historian, or from the energy management system (EMS).
PEO is concerned with monitoring energy usage. Power
quality, power factor, disturbances, and other tools are
typically associated with energy management systems.
Often both are needed and custom dashboards can display metrics from both systems.
2. IT: Computers, databases, and communications
A clear, written understanding of responsibility for
loading software, communications, troubleshooting and
security is very important. Security, IP Addresses, domain
authentication, user accounts, network configuration,
firewalls, COM problems and communication drivers can
all delay work. Whats worse, these nuisance delays can
kill team morale and lead to a poor initial user experience.
3. The PEO software solution The DSS should
have answered most of the questions about what is to be
implemented. Schedule a time for implementation engineers and the system owners to meet. A general discussion of the project and long-term goals helps everyone
to better understand the needs and fosters good working relationships. The configuration should have specific
milestone delivery dates that drive early configuration.
efficiency of its use.

The causes of energy consumption can be
technology- or management-based. Therefore,
monitoring is applied to both equipment and
crews.
A production energy dashboard is a convenient
means for keeping interested parties up to date
when it comes to energy-related key performance
indicators.
Courtesy: Schneider Electric
EN15
Integrating PEO with existing systems

Integration with other systems can be minimal, interfacing only with plant controllers and energy meters, or it
can be quite complex: including with enterprise, asset,
or energy management systems; information portals and
dashboards; and other possibilities. The number of interfaces will likely increase over time as more functionality
is added. Integration accomplishes the following:
ERP - to pass product and SKU information and
energy consumed per unit, per SKU to update the
activity-based costing model.
Automation to get process operations data, such
as rates, flows, machine state, and so on.
Metering/EMS to get the energy data
Maintenance system Send completed maintenance work request based on energy over consumption business rules
People systems - Operators acknowledge energy
over-consumption events and provide classification
End adverse energy events

A production energy optimization system is a manufacturing operations management tool that reads the realtime energy consumption in each process area along with
the production information (product SKU, machine state,
rate, shift, etc.). It is configured by means of business
rules to give the existing operational excellence team the
ability to eliminate adverse energy events and give companies the ability to execute activity-based costing for
better scheduling, accounting, and profitability.

www.schneider-electric.us
Kevin Totherow is the Schneider Electric business

development manager for the Ampla manufacturing
execution system and production energy optimization
solutions. Totherow has held a variety of executive
and operations management positions with major MES
and automation vendors and has been an automation
engineer.
Get the latest information on industrial energy

management my subscribing to Hot Wire. Go to www.
PlantEngineering.com/subscribe.
Sensors turn off equipment to

avoid demand peak pricing
NEW PRODUCT
Inspect the work at milestone dates. The configuration

engineers should understand procedures for getting technical assistance from technical support personnel and
escalating problems above technical support. Perform
a factory acceptance test (FAT) on the system. Keep a
punch-list of incomplete items. Perform a site acceptance
test (SAT) on the system.
The recently introduced OptoEMU Sensor

energy monitoring unit, with demand response,
monitors the electrical energy used in a facility
and then turns electrical equipment on or off
in response to demand-response events sent
from an electrical utility. To avoid reaching
energy use levels that trigger expensive demand
peak pricing, the device can also turn electrical
equipment on or off based on predefined
usage thresholds. Its maker, Opto 22, says the
sensor makes it easy to reduce energy costs
by managing consumption, taking advantage of
demand response programs, and gaining control
over dynamic pricing.
www.opto22.com
IANA
Global Automation
& Manufacturing
Summit
Discover strategies for plant improvement
that you can take back to your plant and
implement immediately.
September 12 - 13, 2012

Chicago, McCormick Place - East Building
CFE Media and Hannover Fairs International partner
to present a two-day senior-level conference program
at the inaugural Industrial Automation North America
expo, September 12-13 in Chicago.
WEDNESDAY, SEPT. 12
Goodyear Tire and Rubber Company
9:30 a.m.: Energy as a Raw Material,
Speakers: Bruce Lung, ASE; and Greg
Bodenhamer, Schneider Electric
11 a.m.: Integrating Operator Knowledge,
Speakers: Mary Bunzel, IBM; Beckhoff
Automation; and Grainger
12:30 p.m.: Luncheon keynote:
Karen Kurek, McGladrey
2 p.m.: Stay Ahead of the Technology
Curve, Speakers: Chuck Edwards,
Lenze Americas; and B&R Automation
3:30 p.m.: Gaining, Training, Retaining
the Next Generation of Workers,
Speakers: AMT; and Raj Batra, Siemens
THURSDAY, SEPT. 13
Key topics in global automation and manufacturing

will be highlighted including: enterprise asset
management, process optimization, energy
management and sustainability manufacturing.
8:30 a.m.: Keynote address:

Douglas Woods, AMT
9:30 a.m.: Empowering the Mobile
Worker, Speakers: Joe Granda, Syclo;
and June Ruby, Motorola
11 a.m.: Securing Your Data,
Speakers: Greg Hale, ISS Source; and
Peter Esparrago, MAVERICK Technologies
Case studies on how plants have automated for

profitability, improved performance of existing assets,
and reducing maintenance costs will also be presented
at the conference.
Register today at
IANA Global Automation & Manufacturing Summit: Early Bird Rate of $165
per person. Price will increase to $195 per person after August 10, 2012.
ENTER a drawing to
win a FREE iPad!
A drawing will be held for a
FREE iPad during the event on
Wednesday, September 12.
NOTEWORTHY
When our engineers work on a motion project with you, they share everything thats in their
heads. Sometimes that means turning over 100 pages of notes, formulas and drawings. Other
times, its simply having straight forward conversations.
At the same time, Yaskawa customers share their proprietary knowledge because they can trust
us. Because we give their challenges a lot of thought. Because when they talk to us, they know
we are on their side.
Trusting the guys across the table from you with your most important product secrets.
Thats noteworthy.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
Follow us:
For more info:
http://Ez.com/yai333
2012 Yaskawa America Inc.
Together
Well Do
BIG Things.
Baldor now offers the most complete line of large AC

motors in the world. BaldorReliance motors deliver
ratings to 1,500 Hp from stock and custom motors
available to 15,000 Hp, alongside ABB induction and
synchronous motors up to 100,000 Hp. Every large AC
motor is designed and built for superior reliability, energy
savings and rugged performance.
Plus, our large AC motor line includes both NEMA and
IEC configurations assuring you the motor you need
meets frame, enclosure and duty cycle standards for any
applicationanywhere in the world. One source for all
your global motor needs. Only from Baldor and ABB.
baldor.com
479-646-4711
NEMA and IEC Designs
Unmatched Quality
Superior Reliability
Global Sales and Support
2012 Baldor Electric Company
Download a QR reader app

and scan this code for
more information.
http://qr2.it/Go/1031261

2012 - 06 - Plant Engineering

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In-house integration?

Ignoring electrical myths

Financial asset planning

GS1 AC drives (1/4 to 2 hp) offer simple Volts/Hertz

GS2 AC drives (0.5 to 10 hp) feature built-in PID

DuraPULSE AC drives (1 to 100 hp) add sensorless

0.25 to 300 hp ratings, single

High-Speed Class J Fuses

Go online or call to get complete information,

1 to 600A, 600VAC / 450VDC

Test & Measurement Systems

Compact Thermal Imagers

Compact Size, Lightweight 368.5 g (13 oz)

4 DIN Ramp/Soak Advanced

Compact Non-Contact Temperature

OS210, OS150, OS300

COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

Our team has the experience and expertise needed

Put our experience to work for you.

Volume 66, No. 5

28 More than meets the eye

25 Take a step-by-step approach

Tom Corcoran, West, TX, OK

37 System integration services:

In-house or hired out?

Should automation and process control services

Debunking the myths

Where to begin? By ignoring these myths

47 Financial planning for

The world around us is changing and

IF WE DONT HAVE YOUR FILTER,

Learn more about

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Other tools tell you:

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