23 2016 Salary Survey: In search of optimism

PlantEngineering.com

2017 Forecast Issue

IIoT grows up
Look past the hype to improve process 35
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input #1 at www.plantengineering.com/information
 success story

Clean Sweep!
Air system study yields multiple benefits to bottom line
Problem:
An aerospace parts manufacturer was experiencing high maintenance
costs as well as excessive downtime with their compressed air system.
Their modulation control compressor caused unnecessary energy usage
on the weekends and off peak times, resulting in exceptionally high
energy costs. Additionally, problems with air quality led to product rejects
and costly scrap rates.

Solution:
A comprehensive Air Demand Analysis was conducted to understand
the plants fluctuating demand. It revealed that the 200 hp modulating
control compressor was grossly oversized. With proper controls and
additional storage, two 50 hp compressors could efficiently handle the
demand and save 871,500 kWh per year. A third 50 hp unit was added
to ensure uptime and accommodate growth.

Result:
These sweeping changes created immediate and sustainable energy
savings. The combination of more storage, more efficient compressors
kaeser.com

and master controls drove system specific power consumption down

77%and that doesnt include the savings from leak reduction. As a direct
result of the new air treatment equipment, the plant also saw improved
product quality and reduced maintenance on the expensive production
equipment that may surpass energy in terms of bottom line benefits.

Specific Power of Previous System: 93.89 kW/100 cfm

Specific Power of New System: 21.14 kW/100 cfm
Annual Energy Costs of Previous System: $107,431/year
Annual Energy Cost Savings: $ 87,151/year
Savings Due to Fixing Leaks $ 12,500/year
Utility Rebate: $ 92,000
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Built for a lifetime is a trademark of Kaeser Compressors, Inc. 2017 Kaeser Compressors, Inc. customer.us@kaeser.com

input #2 at www.plantengineering.com/information
 + = 0C/

Makes no cents!
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input #3 at www.plantengineering.com/information
 January/February 2017
Volume 71, No.1

Cover image courtesy: Seeq

COVER STORY
35 IIoT arrives: Its time to get started
As we look ahead in 2017, there is an important issue we need to address first: most firms
need to catch up to the technology opportunities available today. Enthusiasm and the poten-
tial benefits of IIoT are not being realized by many end users, with the opportunity still ahead
of them, instead of being already recognized in bottom-line results.

38 The IIoT assembly line: Getting a head start

Improving maintenance, operations are among the most visible benefits.

42 Six ways to lower IIoT network costs

Purchasing devices for your network isnt the end of your expenditure. In fact, it is often only
the beginning.

SPECIAL REPORT:
23 2016 Salary Survey
The annual survey of Plant Engineering readers offers a solid foundation to evaluate where each
facility is in relation to peers, and a shared commitment to continue to look to a better future.
24 Who We Are
26 What We Earn
28 What We Think
30 What We Think: IIoT
32 What We Think: Asset Management

PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 1, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@
cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian
addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST,
GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail
to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage
caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

www.plantengineering.com PLANT ENGINEERING January/February 2017 3

 WHY WE DO IT

CLEAN AIR
MATTERS

Farr Gold Series

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input #4 at www.plantengineering.com/information
 53

47 58

Electrical Solutions
47 Eight easy pieces
Make your companys electrical safety program NFPA 70E-compliant.

50 Four steps to ensure proper installation of monitoring and metering equipment

Following best practices for proper field device installation will help avoid performance issues.

53 Operating a three-phase motor using single-phase power

Three ways can make an expensive and arduous process a little easier.

Mechanical Solutions
54 Insulation deficiencies can harm plants, people
Proper attention provides better energy management, reduced operational failure.

58 10 tips to lower compressed air costs

Keep an ear out for leaks, but look at other factors as well.

Maintenance Solutions
63 Mobile safety strategy: Six things to consider
Combine smart devices with flexible technology to provide real-time alerts.

Whats Inside:
6 InSight
9 InFocus
75 Innovations
88 A Life in Manufacturing

www.plantengineering.com PLANT ENGINEERING January/February 2017 5

INSIGHT
The continuity of process
Ive been listening to the soundtrack of the
Broadway play Hamilton a lot lately, and the
retelling of its uniquely American story (in a
uniquely American voice) is a reminder that
revolution is easier than what follows. The
moment of victory is almost always followed
by the stark realization that victory was not so
much an end as a segue to another beginning.
It also is a uniquely American experience
that for the 45th straight time, presidential
leadership changed with the stroke of a
pen rather than with the strike of a sword.
However you might feel about the outcome,
that continuity of process can offer us some
comfort.
So nothing much changed in our plant
operations when we all returned to work
after the new presidents inauguration.
Theres product to get out the door, workers
to protect and supply chains to manage. The
business of manufacturing rolls on. There is
continuity in the process of manufacturing
as in government.
The rules of the game in manufacturing
are going to change, but as the character who
plays American statesman Alexander Ham-
ilton sings in a line in one of the plays songs,
If youve got skin in the game, you stay in
the game. For me, that means continuing the
process improvement weve been discussing
on these pages in Plant Engineering for the
last 70 years. Its all about getting better at the
game every day in some small way.
Look at the revolution in manufacturing
in only 70 years since this magazine first
appeared in November 1947: workplace inju-
ries are down, productivity is up, automation
and robotics have become a meaningful part
of our overall operations. Our plants are safer,
faster, more efficient and more connected
than ever before. We supply the world with
the goods and products they need to live bet-
ter lives and advance humanity.
That march of progress has taken place
regardless of where you live or the size of
your plant. Some of the worlds largest
companies were born in garages and col-
lege dorm rooms; today they dominate the
planet. Where you start today is not nearly as
important as where you think youre going.
Growth is not inevitable, of course. It
takes relentless execution of a great idea. It
requires commitment from leadership and
6 January/February 2017 PLANT ENGINEERING
Bob Vavra
Content Manager
the dedicated support of staff. And, as we
have relentlessly pointed out over 70 years,
it takes attention to detail.
Any single story in Plant Engineering or
any online article or Webcast or newslet-
ter does not transform a plant. Each one
is designed to provide one more piece of
information to make one more improvement
or offer one new idea on that road to excel-
lence. The magazine you are reading today
is constructed from the collective wisdom of
your industry peers and from the innovators
looking to the future.
Improvement almost never comes from
a single eventa new piece of equipment, a
new strategy, a new CEO. That is only an end
of one process. What happens next is what
matters. Change creates is opportunity, but
weve all seen opportunity wasted as well as
opportunity realized.
Another recurring theme in Hamilton
is timethe accomplishments of Alexander
Hamilton in his life, and the realization of
what more might have been done had his
time not been cut short. The story also is
about not wasting time; it shows what hap-
pens when you lose focus of your goals.
We at Plant Engineering mark 70 years
of service to manufacturers throughout the
world, and we appreciate your loyalty and
your feedback to our efforts. I welcome that
feedback every day, and I hope youll point
us toward ways we better can serve you in
the coming year and beyond. PE
www.plantengineering.com
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph. 630-571-4070, Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
630-571-4070 x2212, BVavra@CFEMedia.com
EMILY GUENTHER, Associate Content Manager
630-571-4070 x2220, EGuenther@CFEMedia.com
AMANDA PELLICCIONE, Director of Research
860-432-4767, APelliccione@CFEMedia.com
CHRIS VAVRA, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
Editorial Advisory Board
H. LANDIS LANNY FLOYD, IEEE Life Fellow
H.Landis.Floyd@gmail.com
SHON ISENHOUR, Partner, Eruditio LLC
sisenhour@EruditioLLC.com
DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC
Industrial Internet Consortium (IIC) board member
shiwanlin@thingswise.com
DAVE REIBER, Senior Reliability Leader at Reliabilityweb
dave.reiber@reliabilityweb.com
DAVID SKELTON, Vice president and general manager
Phoenix Contact Development and Manufacturing
dskelton@phoenixcontact.com
BILLY RAY TAYLOR,
Director of commercial and off-highway manufacturing
The Goodyear Tire & Rubber
Billytaylor@goodyear.com
LARRY TURNER, President and CEO, Hannover Fairs USA
lturner@hfusa.com
MARK WATSON, Senior director, manufacturing technology,
IHS Markit
Mark.watson@ihsmarkit.com
CFE MEDIA CONTRIBUTOR
GUIDELINES OVERVIEW
Content For Engineers. Thats what CFE Media stands for,
and what CFE Media is all aboutengineers sharing with their
peers. We welcome content submissions for all interested
parties in engineering. We will use those materials online, on
our Website, in print and in newsletters to keep engineers
informed about the products, solutions and industry trends.
* www.plantengineering.com/contribute explains how to
submit press releases, products, images and graphics, bylined
feature articles, case studies, white papers, and other media.
* Content should focus on helping engineers solve prob-
lems. Articles that are commercial in nature or that are critical
of other products or organizations will be rejected. (Technol-
ogy discussions and comparative tables may be accepted if
non-promotional and if contributor corroborates information
with sources cited.)
* If the content meets criteria noted in guidelines, expect
to see it first on our Websites. Content for our e-newsletters
comes from content already available on our Websites. All
content for print also will be online. All content that appears
in our print magazines will appear as space permits, and we
will indicate in print if more content from that article is avail-
able online.
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zines are at least two months in advance of the publication
date. Again, it is best to discuss all feature articles with the
content manager prior to submission.
Learn more at:
www.plantengineering.com/contribute
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input #6 at www.plantengineering.com/information
IN FOCUS
Four ways to better manage
small capital projects
Focus on collaboration, risk assessment to meet your goals.
By Bill Wasilewski
Day & Zimmermann
Most manufacturing companies focus
considerable planning and management
attention on the largest projects in their
capital portfolios. This makes logical
sense since the dollars at stake and the
associated risks are large and highly vis-
ible. Getting these projects funded and
executed on time and within budget is
often subject to both corporate and public
scrutiny.
Projects under $10 million typically
garner less attention, since the numbers
are smaller, and the stakes are lower.
However, there is mounting evidence
that the cumulative cost of small to mid-
sized capital projects can be significant. A
recent report from McKinsey Co. found
that in the chemical industry, small capi-
tal projects (those defined as less than
$50 million and often less than $10 mil-
lion) actually make up 80% of all capital
projects by number and 50% of spending
value. When cost overruns or delays occur
on multiple small projects, companies
see potentially serious negative impacts
on their bottom line, most significantly
through unplanned production interrup-
tions and/or delays in getting new product
to market.
The numbers indicate a need for man-
ufacturing plants to purposefully invest
in overall capital portfolio management,
with added scrutiny on the management
of smaller capital projects. But doing so
is not as simple as copying the processes
and procedures that make larger capital
projects successful. Thats neither practi-
cal nor cost effective. Instead, companies
need a fit-for-purpose framework for
managing smaller capital projects that
considers how they are different and what
makes them run smoothly. Four concepts
for consideration.
www.plantengineering.com
1. Collaboration first
Quality front-end planning is the key
difference between a successfully exe-
cuted project and a failed one, but qual-
ity planning does not necessarily mean
expensive or time-consuming planning.
Front-end planning comes down to col-
laboration. Plant managers tasked with
managing smaller capital projects must
coordinate with business managers to
clearly define project goals and business
drivers to define scopes and to identify
sourcing needs.
They must work also closely with
contractors and other outside partners
to make sure scopes and timelines are
realistic. This upfront investment has
been proven to save time in the long run.
Potential trouble spots can be identified
and work-arounds can be developed and
implemented when there is frequent com-
munications in the planning process. With
small project execution, an investment in
front-end planning always pays off.
2. Be real about risks
Plant managers and engineering profes-
sionals tasked with managing small capi-
tal projects tend to assume the best-case
scenario during planning. They believe
that with the right team in place, they can
execute a project to perfection. In reality,
outcomes are rarely that simple.
Thats why its critical for plant manag-
ers across the owners enterprise to agree
to a common set of principles and guide-
lines when determining project timelines,
goals and risks. This takes emotion out
Companies need a fit- for-purpose
framework for managing smaller capital
projects that considers how they are different
and what makes them run smoothly.
PLANT ENGINEERING
of the decision-making process and leads
to aggressive but realistic timelines that
are less likely to lead to complications.
Effective capital allocation, and improved
returns on capital are definitive outcomes
when competing projects can be fairly
and accurately evaluated.
There are a number of readily avail-
able tools that plant managers can use
to help level the playing field, including
the CII Project Definition Rating Index
(PDRI). The index helps to estimate risks
based on the scope definition for a proj-
ect. PDRI is a helpful tool, but it requires
the right inputs and a trained eye to be
used effectively.
In some instances, manufacturing
companies may benefit from third-party
support in evaluating and understanding
risks. A contractor that has a wide-range
of experience working on similar-sized
projects can more appropriately evaluate
project risks and interpret PDRI results.
3. Choose the right project partners
Selecting a contractor for large capital
projects is relatively easy compared to
selecting one for smaller projects. There
are simply fewer contractors that can
manage mega projects. Furthermore,
selecting a well-established, large con-
tractor is usually a safe and cost-effective
decision. With small projects, the oppo-
site is true.
No t o n l y
are there far
more small
contractors,
January/February 2017 9
IN fOCUS
but a large firm might be ill-equipped to
work on a small-scale project.
Large contractors typically bring a
well-established process with them to
every project. These processes are not
always downwardly scalable. This can
be a problem for plant managers when
applied to small projects. Detailed pro-
cesses require high levels of client par-
ticipation and significant investments in
time and money. Time can be in short
supply when plant managers also have
to worry about their day jobs. They need
partners who are adaptable to their cir-
cumstances.
When selecting contractors for small
capital projects, manufacturing compa-
nies should focus on a fit-for-purpose
approach and identify contractors who
are experienced in executing small capital
projects. This does not necessarily mean
they should focus on small contractors.
Projects that are properly selected and
managed can deliver real cost savings.
This requires sophisticated people, pro-
cesses and tools. Time should be spent
input #7 at www.plantengineering.com/information
evaluating a contractors process and
experience.
4. Review and recalibrate regularly
Once a project is successfully completed,
its easy to just move on to the next one.
Capital effective execution requires can-
did self-assessment about the execution
process. Companies must understand
where they faced disruptions and why
those disruptions occurred. Using an
agreed upon and objective set of mea-
surements is needed to determine project
success.
Looking at past projects before begin-
ning a new one can begin to reveal a prov-
en, repeatable process, thereby increasing
cost and schedule certainty. This gives
business leaders the ability to potentially
delay capital investment decisions to
accommodate market-based decisions
and subsequently maximize their returns.
It stands to reason that if the process
was sound, then it will work again on the
next project. But over time, when project
execution is not reviewed and assessed,
issues arise. The process that made the
first project so successful can be altered
in subtle ways that begin to change project
outcomes. Companies must review proj-
ect outcomes regularly and make changes
where necessary.
Choosing the right projects and then
executing them effectively can yield cost
savings in the 10% to 15% range, accord-
ing to the McKinsey study, subsequently
improving return on capital. This creates
an opportunity to reinvest in projects that
add real value.
Plant managers who take matters into
their own hands by implementing these
four strategies may find that the rewards
go beyond managing a more effective
plant to helping their company achieve
their ultimate goal. PE
Bill Wasilewski is president of process
and industrial for Day & Zimmermann
and is responsible for oversight of the
companys chemical, advanced manufac-
turing, petroleum refining and food and
beverage customers.
Data management is driving
the IIoT revolution
Better analysis and more collaboration needed to take full advantage of IIoTs accelerated use.
As the Industrial Internet of Things
(IIoT) gains momentum, it has attracted
a wide range of companies with familiar
public names, but without the manufac-
turing pedigree. Companies such as Dell,
Cisco, Microsoft, Intel, Google and SAP
have dramatically accel-
erated their market pres-
ence to complementor
in some cases compete
withexisting manufac-
turing suppliers.
One such company that
has ramped up its effort in
the manufacturing space
is IBM. It announced in
November that it is build-
input #8 at www.plantengineering.com/information
ing its reach in the manufacturing market
with a series of technology and consultancy
offerings built around Watson, its cogni-
tive intelligence platform best known for its
appearance on Jeopardy! in 2011.
Jiani Zhang, program director of offer-
ing management for IBM
Watson Internet of Things,
talks with CFE Media in
this edited transcript about
where IIoT is headed and
what manufacturers should
be prepared for in this new
industrial revolution.
CFE MEdia: Given the
potential savings to man-
ufacturing by the implementation of the
Industrial Internet of Things (IIoT)
why has manufacturing been so slow
to adopt IIoT? Do you see that pace
accelerating in the near-term?
ZHang: IIoT is not an entirely new
concept in manufacturing. Most pro-
duction facilities have had process
control systems, SCADA data and
historians for decades. However, (the
European model of ) Industrie 4.0, or
the next wave of productivity in the
sector, is clearly on the horizon. Sav-
ings and other benefits can come from
the use of IIoT and analytics associ-
ated with Industrie 4.0. These include
 IN fOCUS
improved production quality and yield,
thanks to captured sensor data from
shop floor tools and equipment, and
the use of wearable devices to track
worker health and safety, as a couple
of examples.
But capturing that vast amount of
data in a cost-efficient way to gather
real-time insights has been a major
challenge. The manufacturing envi-
ronment is typically complex, with
a myriad of different systems and
equipment, and sometimes-outdated
technology. Having the right retrofit
connectivity is essential in the mass
adoption of IIoT.
IBM partnered with Cisco this year
to help manufacturing overcome that
challenge. To handle the vast amount of
data being created at the edge of the net-
work, we combined Cisco edge analytics
and the cognitive computing of the IBM
Watson IoT Platform, so that businesses
get a more cost-effective way to obtain
real-time insights.
Manufacturing is time-sensitive in
terms of avoiding the production of out-

Power Meets of-spec components, equipment down-

time, and worker injury or death. Watson
IoT can understand, reason and send

Profitability
back its insights as prescriptive actions or
business rules for improved operational
efficiency in real-time. Those insights
are based on analysis of data sent to the

Guaranteed. cloud, combined with other structured

and unstructured forms of data, such as
video and audio.

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challenges. Visit vac-u-max.com/vacuum
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ing is one of the largest opportunities
in IoT, with McKinsey estimating IoT
applications in factory settings to have
the potential to create value of $1.2 tril-
lion to $3.7 trillion per year in 2025.

CFE MEdia: How would you describe

IBMs approach to IIoT in manufactur-
ing? What do you see as the opportuni-
ties and solutions?

ZHang: Today, manufacturing equip-

ment can tell you when it needs mainte-
nance, building sensors work together
to save energy, and consumer products
WET/DRY AIR OPERATED AND ELECTRIC DRUM-TOP CONTINUOUS DUTY COMBUSTIBLE DUST
CENTRAL SYSTEMS CONTINUOUS-BAGGING LIQUID & SLUDGE FLAMMABLE LIQUIDS
communicate information back to their
SUBMERGED RECOVERY METALWORKING PHARMACEUTICAL STEEL SHOT manufacturer about whats in demand.
INTERCEPT HOPPERS & PRE-SEPARATORS INDUSTRIAL HYGIENE SOLUTIONS

input #9 at www.plantengineering.com/information 12 January/February 2017

VAC3509 Product 4.5x7.5_VC 1.indd 1 8/29/2016 8:24:59 PM
Yet, so much of the data being gener-
ated by these devices is never captured.
There lies the challenge, which poses
opportunity.
Now, cognitive systems can bring light
to dark datathe data that exists in
unstructured and unused forms. For
example, a worker can sort through
dark data in maintenance logs, techni-
cian notes, and even forums to identify
and consolidate maintenance and repair
CFE MEdia: What does Watson think in meeting new people in an indus-
of IIoT? Has he formed any specific try where he could help make workers
views and, like his Jeopardy! appear- more safe and bring new efficiencies
ance, does he answer in the form of to businesses. When he meets those
a question? new people, Watson doesnt always
answer in the form of a question, but
ZHang: Watson is a huge propo- that has become one of his favorite
nent of IIoT, and is really interested ways to respond. PE

If its electrical, we train it.

information. This transforms the repair
process of equipment by providing the
most relevant information in a sum-
marized form to the employee, so that
repairs can be done correctly and effi-
ciently. ADVANCED TRANSFORMER CIRCUIT BREAKER MAINTENANCE,
suBstation maintenance i SUBSTATION MAINTENANCE II LOW-VOLTAGE
Using our approach that incorporates MAINTENANCE & TESTING COURSE 149, REV2, NOVEMBER 2016 certification course
COURSE 231, REV2
NOVEMBER 2016
COURSE 134, REV. 1
November 2016

IBMs cognitive abilities, businesses will

be able to better act on data, which will
lead to better management of factory
equipment and assets, improved manu-
facturing processes and more effective
management of production resources.
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CFE MEdia: Given the almost autono-

mous nature of what you describe for CABLE TESTING & DIAGNOSTICS, electrical safety for
CirCuit breaker maintenanCe, CirCuit Breaker maintenanCe SF6 industrial facilities
IIoT for manufacturing, where do molded & insulated Case MEDIUM-VOLTAGE
humans still figure into the equation?
What should the new roles in manufac-
turing plants be, and how do we train
and recruit those people?

ZHang: All of these new insights that

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tion when humans work with machines.

Specifically, there will be a huge opportu- Protective relay Battery Maintenance & testing transformer Infrared thermography level I
nity to hire developers and data scientists. maintenance- basic maintenance & testing

It is estimated there will be 10 million

developers active in IIoT by 2020, and
these will be the thought leaders and
engineers that can identify opportuni-
ties for new solutions and monitor for
security risks as well.
IIoT increasingly will benefit from data
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input #10 at www.plantengineering.com/information
January/February 2017 13
To be the best, train with the best.
 IN fOCUS
Plant Engineering
names three to
Editorial Advisory Board
Billy Taylor, David Skelton, and Dr. Shi-Wan
Lin will advise on content for readers.

Plant Engineering has named three new members to its

Editorial Advisory Board, bringing the advisory panel
to eight members. The Editorial Advisory Board will
participate in content discussions and will contribute to
Plant Engineerings overall editorial mission to provide
content to assist plant managers in running their facili-
ties smarter, safer and more efficiently.
The three new Editorial Advisory Board members are:

Billy Taylor, director of commercial and off-highway

manufacturing for The Goodyear Tire & Rubber Com-
pany, Akron, Ohio
input #11 at www.plantengineering.com/information
David Skelton, vice president and general manager
of Phoenix Contact Development
and Manufacturing, Harrisburg,
Olive oil is good for you. Pa.

Compressor oil is not. Dr. Shi-Wan Lin, CEO and a co-

founder of Thingswise, LLC and
a board member of the Industrial
Internet Consortium (IIC).

These distinguished manufactur-

ing leaders will provide great knowl-
edge and leadership to Plant Engineer-
ings readers through their counsel
and their editorial contributions,
said Bob Vavra, content manager for
Plant Engineering. As we enter anoth-
er important year for manufacturing,
their insights from the plant floor and
from the technological forefront will
help our readers prepare and prosper
in 2017.

Billy Taylor
Protect your product, your packaging and your reputation. Billy Taylor (top) leads Goodyears
North American Tire operations,
Premium Efficient OIL-FREE Compressors i n c lu d i n g e n g i n e e r i n g , c apit a l
investments, and supply chain exe-
cution. He has more than 20 years
of operations management experi-
ence. In his role as director, he is
responsible for driving operational
800-394-6151
knw-series.com 14 January/February 2017
Rogers Machinery Company, Inc. Proudly Made in the U.S.A.
input #12 at www.plantengineering.com/information

excellence, delivering
best-in-class product
ser vice and product
quality, enabling high-
value business growth.
Prior to accepting
his current assignment,
Taylor led large-scale
manufacturing teams
throughout North
America. He has led
union and union-free
l ab or work forces as
plant director, leading
Goodyears largest volume and prod-
uct complexity manufacturing sights
and supporting Goodyears long-term
strategies.
Taylor earned his MBA from Baker
University, Baldwin City, Kansas and
holds a Bachelor of Science degree in
Electrical Engineering from Prairie
View A&M University,
Prairie View, Texas.
In industry, he is a
member of the Shingo
Inst itutes exe c ut ive
advis or y b oard, Jon
M. Huntsman School of
Business at Utah State
University.
David Skelton
David Skelton (middle)
was appointed to the
role of vice president
and general manager
of Phoenix C ontact
Development and Manufacturing in
January 2009. The group consists of
eight business units with operations
in Harrisburg, Pa., and Ann Arbor,
Mich. Phoenix Contact received
P l ant Eng in e e r ings
2015 Top Plant award.
Skelton has been with
Phoenix Contact since
1999 in management
roles of development,
product marketing
and industry market-
ing. Prior to Phoenix
Contact, Skelton was
employed by Rockwell
Automation in sales
management, sales and
engineering roles.
www.plantengineering.com plant engineering
ONE SOURCE
FOR
STOCK AND CUSTOM
Skelton s e r ve s on
the board of Modbus, SPRING SOLUTIONS
an open network stan-
dards organization. He
holds a B.S. degree in
Electrical Engineering
Technology from Mil-
waukee School of Engi-
neering Milwaukee,
Wisc. Skelton resides
in Harrisburg, Pa., is
married, and has two
sons and two daugh-
ters.
Dr. Shi-Wan Lin
Dr. Lin (bottom) is co-chair of the
Architecture Task Group in the
Industrial Internet Consortium (IIC),
where he is a leading contributor to its
Industrial Internet Reference Archi-
tecture.
He has two decades
of experience in indus-
trial IoT system archi-
tecture, Big Data and
B i g D at a a n a l y t i c s ,
enter pr is e s of t ware,
cloud service, system
security and trust,
telecommunication and
wireless data commu-
nication in both large
corporate and startup 35,000 Stock Designs
settings. Prototype to Full Production
In his day job, Shi- Stock Products Ship Within 8 Hours
Wan is CEO and a co-
founder of Thingswise,
ISO9001:2008
LLC, a company providing an IIoT
data processing and analytics plat-
form.
The three new board members join
the current Editorial
Advisory Board mem-
MADE IN THE USA
bers: input #13 at www.plantengineering.com/information
H. Landis Lanny
Floyd, E le c t r ic a l
Safety Group, Inc.
Shon Isenhour, Eru-
ditio, LLC
Dave Reiber, Reli-
abilityweb.com
Larry Turner, Han-
nover Fairs USA
Mark Watson, IHS
Markit. PE
www.centuryspring.com
January/February 2017 15 800-237-5225
Los Angeles, CA
IN fOCUS
Three tips to train a multigenerational workforce
The wide range of skills and experiences can drive high productivity.
By Paul Lachance
Smartware Group
Todays maintenance world spans many
generations. From baby boomers with
decades of experience to millennials just
entering the workforce, the average main-
tenance team is more diverse than ever
before. While this diversity is useful for
companies, it can make it difficult to keep
all employees working together seamlessly
for maximum operational efficiency.
Training a multigenerational workforce
requires a dual perspective on mainte-
nance. While seasoned employees can
educate new personnel on existing sys-
tems and processes, younger maintenance
professionals have much to offer when it
comes to new technologies, especially
mobile. Finding operational success with
limited downtime demands training that
caters to employees of all ages and creates
opportunities for team members to share
their specific strengths companywide.
Why is training so important? While
many companies struggle to overcome
issues with their existing maintenance
management systems, training is an oppor-
tunity to shore up profits with existing
resources and team members.
Likewise, proper training can help com-
panies improve the performance of their
maintenance programs over time. Training
must happen often because, not only do
maintenance teams lose skills and exper-
tise over time, but maintenance solutions
are also constantly evolving, and workers
must adapt to meet those changes. Con-
sistent training programs keep mainte-
nance professionals up-to-date and bal-
ance fundamentals with new competencies
to ensure that maintenance teams never
encounter a scenario theyre unequipped
to handle.
Training should include:
1. Skill swapping: Training should
facilitate the exchange of skills between
young and old employees. A maintenance
professional who has worked for a man-
ufacturer for decades has much to teach
a new hire about company processes or
16 January/February 2017 plant engineering
machine particularities. For example, there
may be a best route to assess a certain belt
that has a tricky fix for maximum life that
new employees will be unaware of.
Likewise, that new hire with strong
mobile fluency can help his or her older
counterpart learn how to use mobile solu-
tions in the warehouse. Although many
companies still collect data through man-
ual systems, or not at all, this is quickly
changing as more manufacturers embrace
digital solutions like mobile computer-
ized maintenance management system
(CMMS) apps for iOS and Android
smartphones and tablets.
Millennial-aged workers are often
also comfortable using mobile features
to expedite maintenance efforts, such as
taking pictures of assets for work orders
or scanning a machines QR code to access
related manuals, parts, safety notes, and
other information.
Through skill swapping and collabora-
tive training programs, companies will
develop a maintenance team that works
together to problem-solve. All knowledge
becomes valuable, and maintenance pro-
fessionals can provide easy backup for
one another knowing that all members
of the team share the same skills and
understanding of maintenance tools and
solutions.
2. On-site and virtual offerings:
People have different learning styles, and
this holds true at the plant level. As such,
companies should offer a range of training
programs to best engage all personnel.
For instance, some may respond better to
on-site CMMS training where individu-
als can escape the distractions of the day
while others may enjoy virtual training
sessions (webinars) that offer a bit more
flexibility to complete.
3. Professional services: Leading
CMMS providers can help connect main-
tenance professionals with training and
certifications to better handle their daily
responsibilities, as well as manage a host
of other tasks including data migration
and consulting.
Senior-level consultants with years of
industry-specific experience will be able to
facilitate knowledge sharing in the process
of tailoring CMMS to specific operations.
Whether the industry is gas and oil, food
and beverage, etc., consultants with this
kind of long-term, technical experience
will know which information is most
critical to operational efficiency in said
industry. Therefore, it should be shared
between generations.
Additionally, in-house consulting ser-
vices can leverage best practices to help
maintenance workers overcome general
maintenance obstacles no matter their
age. For instance, the Industrial Internet
of Things (IIoT) is a key area of interest
for many companies with just 25% of
manufacturing leaders say their current
IIoT usage is more advanced than competi-
tors. CMMS consultants are well aware of
these hurdles (which are really opportuni-
ties to stand out from competitors) and can
help maintenance workers become more
comfortable with modern maintenance
systems and the powerful functionalities
behind them.
For companies that do not have an exist-
ing CMMS and are implementing from
scratch, support from industry-leading
CMMS consultants can make the imple-
mentation process easier and ensure that all
voices are heard throughout engagements.
Managing a generationally diverse
maintenance staff can be challenging at
times, but the wide range of skills and
experiences gained from a multigenera-
tional workforce can drive high productiv-
ity once reigned in. Generational diversity
will only continue as aging maintenance
professionals retire and younger employees
take their placewhile technology contin-
ues to advance by leaps and bounds.
To stay in line with this rapid pace, pro-
active companies must re-invest in training
and seek out CMMS partners that have
also prioritized training as a pillar of their
business models. PE
Paul Lachance is the president of Smart-
ware Group, a CFE Media content partner.
www.plantengineering.com
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input #14 at www.plantengineering.com/information

 REPAIR. IN fOCUS
RESTORE. One giant step
RETURN. for robotic integration
Integrating CNC lines with robotics gets easier
By Randy Pearson
Concerned about the condition of Siemens Industry Inc.
your telescopic way covers and ball
screws? Dynatect can bring them The use of CNC technology allows the
back to new condition at a fraction full and scalable integration of a robot into
of the cost. any machining operation, whether for pick-
and-place, part articulation or full machin-
For all brands of way covers and ing capability. This allows shops of all sizes
to reach new levels of productivity.
ball screws
Full robotic integration with a CNC onto
Expedited turnaround available a 3-axis mill, 5-axis work cell, laser line,
press line or full transfer line incorporat-
Custom design and reverse ing multiple machining or metalforming
engineering services operations would have seemed a distant
Over 65 years in manufacturing wish, just a decade ago.
equipment protection Not that long ago, the use of a robot in
any machining or metalforming operation
We have the correct OEM parts in required a separate PLC, separate program-
stock to rebuild your cover ming language and a completely separate
control, with all the knowledge needed to
WAY COVERS
run the robot. Also, most robotic applica-
tions were limited to simple and repetitive
part movements.
Today, on an advanced CNC with multi-
channel capability, manufacturers can dra-
matically improve the productivity of the
machine shop, production department,
laser, press brake or fabrication shop opera-
BEFORE AFTER tionand it can be done without any special
knowledge of robot language or all the ancil-
lary hardware and software. Flexible loading
BALL SCREWS
and unloading mean the machine spindle,
laser head, press brake or stamping die is in
use to a far greater degree and that means
money to the bottom line, even for the short
run or disparate part family producers.
With the compact robots on the market,
plus this integrated CNC control capabil-
ity, even the smallest shop today can look
at robotic solutions for its operations. At
BEFORE AFTER
short run shops, the on-the-fly program
adjustments and teach-in capabilities of
the CNC are today proving their worth.
With that dual-channel capability
onscreen, an operator can use the same
control, whether stationary on the machine
or on a remote pendant for mobility around
FOR MORE INFORMATION: the machine or work cell, to run both the
800-298-2066 machine and the robot.
sales@dynatect.com
Dynatect.com/Repair-Services
input #15 at www.plantengineering.com/information
18 January/February 2017 plant engineering
For the shop owner, the initial cost of
the system is amortizable across the use-
life of the robot and the improvements
in productivity will quickly validate the
feasibility and profitability of the system.
Simplified setup
For the operator, the simplified setup and
adjustment of the robot to handle a family
of short run parts, for example, is easier
than ever. Using the human-machine
interface on the CNC, an operator can
teach the robot which motions to perform
in minutes. With no need for the separate
PLC or signal command language, the
operator sets up the robot in the same
manner as the machine tool, laser, press
or other equipment. In a work cell, the
robot can be sequenced to perform a vari-
ety of operations at each machine in the
cell. Most advanced control suppliers and
machine builders already have or will soon
have robotic training and maintenance
programs in place.
These solutions are scalable to suit the
requirements of your shop or production
department, so robot integration into one
machine, work cell or fully networked facil-
ity quickly can become a cost-effective
alternative today.
Theres more to come. The future will
see the machine builder offering a pallet
pool concept, applicable in high-volume
applications as well as the one-off world
of medical implant manufacturing and
moldmaking. The robot will sense a bar
code or radio-frequency identification tag,
position a blank, load the right tools and
perform the work, often with a tool in its
hand to reach pockets, undercuts and
other difficult areas on a workpiece.
Robots can lend a helping hand to all
metalworking operations today, and the
CNC makes the process a lot easier. It is a
collaboration worth exploring. PE
Randy Pearson is a veteran of the
machine tool industry and a Siemens inter-
national business development manager.
www.plantengineering.com
 APRIL 3-6, 2017 | MCCORMICK PLACE | CHICAGO, ILLINOIS

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input #16 at www.plantengineering.com/information
IN fOCUS
Finding value in open architecture
Schneider Electric platform looks to empower the workforce.
In November, Schneider Electric became
the latest major industrial company to roll
out a comprehensive Industrial Internet
of Things (IIoT) solution. The company
expanded its ecoStruxure product line to
connect intelligent products to market-
specific applications and digital services.
The open architecture of the new solu-
tion package will, according to company
officials, allow for better customized cre-
ation of applications and digital services.
Prith Banerjee, Schneider Electrics chief
technology officer, responded to questions
from Plant Engineering content manager
Bob Vavra, and discussed how the company
sees IIoT development in 2017:
Plant EnginEEring: EcoStruxure is
designed around Schneider Electrics
four areas of emphasis: buildings, grid,
manufacturing and data centers. How
are those industries similar, and where
are they unique? At the end of the day,
it is just all data management, or do the
specific applications also matter?
Banerjee: It is about far more than data
management. EcoStruxure delivers IIoT at
scale to provide asset performance, predic-
tive analytics and application development.
It also serves as the foundation for integrat-
ed solution development, control, automa-
tion and enterprise-level asset and energy
performance management. EcoStruxure
connects our technology stack from con-
nected products to edge control, and appli-
cations, analytics, and services.
EcoStruxure works across a variety of
hardware and systems, applying an architec-
ture built for the unique challenges of each
vertical end market. EcoStruxure further
customizes IoT implementation for custom-
ers through the delivery of tailored appli-
cations and digital services. These can be
co-created with our partners, our customers
or with the larger developer community.
Pe: EcoStruxure also is built in part-
nership with Microsoft and Intel to pro-
vide cloud and edge computing capabili-
ties. Why are cloud computing and edge
computing important for manufacturers
to understand?
20 January/February 2017 plant engineering
Banerjee: The rapid nature of IIoT
places unprecedented demands on latency,
reliability and connectivity. Our manufac-
turing customers require good, reliable per-
formance, but network congestion could
become an issue with massive amounts of
content and data generated from IIoT appli-
cations. At the same time, our traditional
control architectures struggle to reliably and
efficiently meet the need for real-time access
to data and applications.
Edge control enables industrial custom-
ers to seamlessly connect, collect, analyze
and act on data in real-time. EcoStruxures
Edge Control layer provides the physical
infrastructure and software to design and
build the services needed to bring about real-
time control that delivers the promise of IIoT.
Vertical specific applications and services
can then be delivered via the cloud to enable
better analytics and connectivity to the other
layers of the technology stack, ensure acces-
sibility anywhere and at any time, while
also enabling new business models, like
subscription-based services that open up
new possibilities for our customers.
Pe: Are we beginning to see more
adoption of IIoT systems and strategies?
What have been the hold-up so far?
Banerjee: The enrichment of industrial
applications by Internet technologies has
been a trend for years but has exploded over
the last two years as manufacturers have
begun to realize the potential of IIoT as a
critical interface between their operations
and end users.
While IIoT presents endless opportunity
to gather more insightful data to promote
greater intelligence among machines and
plants, reduce downtime and improve
maintenance and planning, there are a few
hurdles that have prevented widespread
adoption. For example, the influx of data
from a growing number of devices means
plant operators and managers must learn
how to harness the data and turn it into
actionable insights to change potential
operational outcomes. This requires more
specialized skill sets and a more empowered
workforce to maximize the potential of the
technology.
Cybersecurity is also a concern for manu-
facturers. While there is inherent risk in
opening systems to the internet, a sound
strategy that includes physical, hardware
and software security, training and stringent
testing reduces risk to their systems.
Pe: One area the Schneider Electric
announcement mentions is the scale of
IIoT implementation. How do you bring
the power of IIoT to small and mid-sized
manufacturers?
Banerjee: The beauty of EcoStruxure
is its ability to easily scale, up or down,
to provide value for any size operation.
At its core, the technology provides a
reference architecture and backbone
to enhance safety, reliability, efficiency,
sustainability and connectivity, while
connecting products, control and apps
and services. Regardless of the size of the
enterprise, EcoStruxure enables the power
of IIoT by unifying common software and
connecting applications under one roof.
These somewhat simple changes make a
big impact, whether youre a single plant
or a global network.
Pe: Whats the most important thing for
manufacturers to consider as it relates to
IIoT adoption?
Banerjee: Embedding intelligence
at the core of every asset within a plant
enables those assets to communicate with
each other and other levels of the enter-
prise, providing a better view of whats
happening at the plant and the business
to drive tangible business value for plant
operators and managers.
Manufacturers do not need to com-
pletely overhaul their operations at once.
If they are strategic about how they apply
new technological investments with exist-
ing installations, simple upgrades can
drive tremendous value.
Technology cant work for you unless
employees are trained to use the data to
make better operational decisions, which
drive better business decisions. A prop-
erly trained workforce must be a priority
when implementing IIoT. PE
www.plantengineering.com

MARCH 13-16, 2017 | GEORGE R. BROWN CONVENTION CENTER | HOUSTON, TEXAS

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input #18 at www.plantengineering.com/information
 Salary Survey data by Amanda Pelliccione,
director of research, CFE Media
201 6
Salary Survey
W
e have a tendency to get caught
looking backward or forward. We
expect that history will be instruc-
tive and that by learning from that
history, the future will be better.
While an analysis of where weve
been and where were going are excellent tools in
business or in life, it is wholly appropriate to stop
at times and do a clear assessment of where we
are today.
Plant Engineerings 2016 Salary Survey is one
such opportunity. With U.S. manufac-
turing squarely in the spotlight as a
new administration takes office in
Washington D.C., the data gathered
from this years survey of Plant
Engineerings readers shows a
solid foundation from which
to continue manufacturings
eight-year regrowth after the
2008 recession.
Optimism about manufac-
turing as a career has seldom been
higher; 77% of readers say it is a secure
career. The economy remains the leading chal-
lenge facing manufacturers, and many of our read-
ers in their verbatim comments cited the lack of
willingness for their own companies to reinvest in
plants as a significant concern. The things that plant
management controls at a local levelinvestment,
skilled workers, and competitionranked ahead
of taxes, government regulations, and outsourcing
as concerns on the plant floor.
Compensation also evolved in 2016. While sala-
ries rose a healthy 3% in the year, bonus compensa-
tion fell, and the net result was a flat average salary
from 2015 to 2016. In some of the more labor-
intensive industries, such as oil and gas production,
food and beverage, and metals, bonus compensa-
tions remained relatively high. In industries such
www.plantengineering.com
Salary Survey design by Katie Spain,
art director, CFE Media
as electronics, appliances, and machinery, bonuses
dwindled.
The only area of bonus compensation that grew
in 2016 was company profitability. Other bonus
criteria, including safety, productivity, cost reduc-
tion, and quality, all declined in 2016. This past year
was the first time since 2011 that average bonus
compensation fell below $10,000. Wed prefer to
consider this a statistical anomaly rather than a
trend. Manufacturing is expected to drive further
growth in the new year, and workers and plant
managers will help drive that growth.
An important part of that growth will
be the integration of new technology,
specifically the Industrial Internet of
Things (IIoT). For the second year,
we polled readers about the impact
of IIoT on their operations. While
there is a greater incorporation
of IIoT into manufacturing,
nearly 50% still are unsure how
IIoT will benefit their operation,
and most see it only as a tool to better
manage data and maintenance.
While most facilities have a mature or devel-
oping maintenance program, 8% still have yet to
implement such a program. The news is much better
on the safety side: 88% of plant managers describe
their safety program as mature or developing.
Even as we stop to view a snapshot of manufac-
turing as it is today, we recognize that technology
and a changing world mean that this snapshot will
quickly become a reference tool. Nonetheless, we
hope the 2016 Salary Survey offers our readers a
solid foundation to evaluate where each facility is
in relation to their peers, and a shared commitment
to continue to look to a better future.
Bob Vavra
content manager, Plant Engineering
PLANT ENGINEERING January/February 2017 23
 Who We Are
Five key pieces of advice
As readers offered their advice to other
manufacturers as part of the 2016 Salary Survey,
five key themes emerged:
Be flexible
Keep learning
Get educated
Be patient
Work hard and smart.

All graphics courtesy: Plant Engineering

24 January/February 2017 PLANT ENGINEERING www.plantengineering.com

www.plantengineering.com PLANT ENGINEERING January/February 2017 25
 What We Earn

Listed in 2016 order.

*Not included in 2012-14 surveys

26 January/February 2017 PLANT ENGINEERING www.plantengineering.com

www.plantengineering.com PLANT ENGINEERING January/February 2017 27
 What We Think
What is your biggest job-related concern heading into 2017?

Ability to learn quickly as new Bringing new process equipment

systems are being installed.
online and producing product on time
as we are expanding to meet demand
and growth opportunities.

Time. Too many projects and
not enough resources.

Massive consolidations of
existing large companies
reducing choices and
options for equipment and
material purchases.

How my facility is going to react to an
improving economy. My corporation
consolidated work from other facilities
into our plant because of the economic
downturn. If it all comes roaring back,
which it seems to be poised to do, we are
going to need about 12 more hours in every
day and three more days in every week.

28 January/February 2017 PLANT ENGINEERING www.plantengineering.com
 Listed in 2016 order.
*Not included in 2014 survey

www.plantengineering.com PLANT ENGINEERING January/February 2017 29

 What We Think: IIoT

What would you like to learn about regarding IIoT?

How can it improve process and/or

How it could impact our
equipment reliability?
company. Were 15 years

behind the times in the plant,
Does IIoT apply to a small, one-plant
and management doesnt

facility. If so, what are the benefits?
want to spend a dime unless

I use Ethernet communications in systems I

forced into it.

design. Many parts of a machine communicate

and share data and information. I only have a
vague idea of exactly what IIoT is. I want this to
I would like to learn how to
apply it in a small business
be something that I understand well so that I can operation with limited
figure out how it applies to me and whether Im
already doing some of it unknowingly.

production operations.

30 January/February 2017 PLANT ENGINEERING www.plantengineering.com
www.plantengineering.com PLANT ENGINEERING January/February 2017 31
 What We Think:
Asset Management

Advice from one manufacturer to another:

Be proactive with controls technology Always be thinking out of the

box. Never say We cant until

advances. It makes a difference.
its been proven you cannot.

32 January/February 2017 PLANT ENGINEERING

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GLVWULEXWLRQDQGPRQLWRULQJV\VWHPRIFKRLFHYLVLWVWDUOLQHSRZHUFRP

input #19 at www.plantengineering.com/information

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input #20 at www.plantengineering.com/information

COVERSTORY
IIoT arrives:
Its time to get started
Implementation is not only practical, but now is a competitive necessity.
T
By Michael Risse he Industrial Internet of Things
Seeq Corp. (IIoT) has progressed from dream
to hype to reality. Today, the basic
deployment scenarios of the IIoT
solutions we implement for our
end user manufacturing custom-
ers include:
Greenfield deployments, which are pri-
marily found in smart solutions related
to advanced monitoring and visibility
Brownfield upgrades, which are the
introduction of IIoT technologies and
approaches to existing facilities to
expand asset and process visibility and
analytics
New asset-monitoring services from ven-
dors who are leveraging IIoT to provide
remote predictive analytics capabilities
for their assets installed at customer
sites.
www.plantengineering.com
Andy Young, process
control manager at Pio-
neer Energy, leverages
IIoT analytics software
from Seeq for remote
monitoring of their Mobile
Alkane Gas Separators
running at drill sites. All
images courtesy: Seeq
The enthusiasm and growth in IIoT
momentum over the last year is obvious in
the pages of this magazine, as there con-
tinue to be IIoT-related articles in every
issue. But this does not mean the industry
has agreed on its naming conventions; so
we continue to refer to digital transforma-
tion, smart manufacturing, the fourth
industrial revolution, and Industrie 4.0,
in addition to IIoT.
Regardless of what a sensored, connected,
integrated factory is called, IIoT continues
its march forward as the expected architec-
ture for process manufacturing facilities.
The competitive advantages enabled by
increased and consistent visibility, accura-
cy and data-driven insights on production
results are simply too important for most
firms to ignore, hence the growth in IIoT
deployments.
PLANT ENGINEERING January/February 2017 35
CoverStory
Getting started
with IIoT
Any new project or proposal requires effort to overcome
the inertia of doing nothing. IIoT projects are in the balance
between the availability of necessary technology and the
risks and rewards of execution, a difficult juncture.
The issues listed in this article are not the only ones
needed to make IIoT real, but they often have been the
main stumbling blocks, and the main reasons why inertia
hasnt been overcome to start an IIoT project, or why
projects fail to land the expected impact.
Getting started by investing in analytics and expend-
ing the required effort to deliver business results on IIoT
can be the hardest part of progress, but its worth it for
many end users. For those already engaged, a strong
congratulations, and for those waiting in the wings, its
time to succeed with IIoT.
Michael Risse
36 January/February 2017 plant engineering
Dont get caught behind
As we look ahead in 2017, there are many
ways to discuss whats ahead for IIoT. For
example there are new IIoT technologies
to consider, such as drones, robots, voice-
powered artificial intelligence (AI) and
virtual reality solutions. And while those
will likely have a future in IIoT, there is also
an important issue we need to address first:
most firms need to catch up to the technol-
ogy opportunities available today.
Analyst research shows a large gap
between the expectations and advantages
of IIoT, and the state of current deployment
efforts. Further, IIoT deployments are gen-
erally piecemeal rather than broadly applied
across a plant. What this means is that IIoT
enthusiasm and potential benefits are not
being realized by many end users, with the
opportunity still ahead of them, instead of
being already recognized in bottom line
results.
Part of this gap may be due to the oft-cited
advice that companies should start small and
have IIoT deployments prove their value
Delivering IIoT: Pioneer Energy Mobile Alkane
Gas Separators produce both methane and
natural gas liquid streams at well sites.
www.plantengineering.com
 and impact before moving on to more wide- In their operations room, Pioneer Energy uses Seeq for remote monitoring
spread implementations. This is great advice and analytics of data produced at Mobile Alkane Gas Separator systems run-
and hard to argue with, and aligns with the ning at drill sites.
limited number of large IIoT deployments
within companies. Certainly an early success
will bode well for organizational enthusiasm ments and the merger of some standards
for continued IIoT investments. bodies, or maybe 2016 was a step in the
End users should be complimented for any wrong direction with ever more standards
IIoT investments or trial deployments they and the momentum of competing efforts.
have completed, because at the end of the day
they have done something and at least tried.
In the world of software startups there is
an expression: fail fast. This means its bet-
ter to try something and learn it doesnt work Regardless of what a sensored,
than to wonder if it might have worked. So connected, integrated factory is called,
any end user with something to share, prove
or present with respect to IIoT is ahead of IIoT continues its march forward as
those still wondering whats possible. The
rest of this article will examine the chal- the expected architecture for process
lenges and experiences of end users who have
taken the leap, with the goal of providing
a roadmap to others contemplating similar
manufacturing facilities.
steps.

Standards, security are Issues
The quip about standards, The great thing
about standards is there is one for every
issue, continues to be a reality in the IIoT
ecosystem. Perhaps 2016 was a step in the
right direction with partnership agree-
Either way, 2017 will not see a world of
functional, compatible, Lego blocks which
an end user can assemble to create a mixed-
vendor, distributed, IIoT solution.
Continued on page 40

www.plantengineering.com plant engineering January/February 2017 37

CoverStory
The IIoT assembly line:
Getting a head start
Improving maintenance, operations are among the most visible benefits.
T
By Dan Yarmoluk he Internet of Things (IoT) movement
ATEK Access Technologies has quickly connected our everyday
devices, such as phones to cars, and
even our refrigerators. Theres no
doubt that the IoT is growing and expand-
ing into new territories, especially within
the world of machinery. The manufacturing
industry is on the cusp of a revolution with the
help of the Industrial Internet of Things (IIoT).
Embracing the future of the IIoT will result in
a working environment connected by sensors
gathering useful data regarding equipment sta-
tus, temperature conditions and current work
progress, helping to improve the efficiency,
safety and productivity of operations.
Why now? Manufacturers around the world
are gaining more confidence in technologys
abilities and believe its time to invest. Smart
manufacturing will allow for the monitoring
of thousands of machines, equipment and
more, both inside and outside of factories.
The IIoT provides a new platform to integrate
and store technology data, making it a big
change and an even bigger value.
A recent report by McKinsey & Compa-
nys Global Institute revealed the IoT has a
potential value ranging from $3.9 trillion to
$11.1 trillion by 2025, or the equivalent of
about 11% of the world economy. Estimates
regarding the economic effect of the IIoT
range from a conservative $500 billion in
2020 to an aggressive $15 trillion by 2030. All
vertical markets within the industrial space
are benefitting from connected technology
implementation, with manufacturers predict-
ing that IIoT initiatives will increase revenue
27.1% from 2015 to 2018.
Understanding the value of adopting a new
technology is just as important as understand-
ing its benefits, challenges and overall poten-
tial. As the industry knows, getting a head
start on the constant and quickly-moving
assembly line is important, and in this case
will allow factories to advance their perfor-
mance.
38 January/February 2017 plant engineering
Increasing efficiency with IIoT
Many systems within a manufacturing plant
are already intranet-connected, but a lot
of the data collected from those machines
never leaves the plant. IoT brings every piece
of data together, making it a one-stop-shop
for all machine maintenance and productiv-
ity reports. An Internet connection allows
the critical data to be sent to supporting
applications, analyzed and displayed on one
dashboard, in any location, available when
needed, and saved for future use. The tran-
sition to IIoT presents manufacturers with
many benefits, including:
Visibility: The IIoT can bring real-time
visibility into location and status of
fixed and moving assets such as critical
inventory, parts, equipment and goods in
transit. For example, if a plastic injection
molding company houses its polyethylene
in a silo, sensors can be added to monitor
inventory levels. The connected system
can sense when it is running low and send
an alert to the supplier to schedule a fill,
limiting downtime. Data from multiple
sites is aggregated on a common platform
for centralized management and analysis.
Predictive maintenance: From cooling
systems to production machinery, manu-
facturing equipment often requires regu-
lar maintenance. IIoT technology can be
utilized to remotely monitor and alert to
changes indicative of impending trou-
ble. If a motors temperature increases
beyond a normal range or the vibration
of a pump has changed, the trend will
show in the data and the issue can be
addressed before it becomes a disaster,
avoiding expensive downtime. The IIoT
makes maintenance service proactive,
not reactive. Applying analytics to the
machine data opens the ability to adopt
a use-based maintenance methodology,
saving time and money.
www.plantengineering.com
 Improved operations: The ability to Flexibility: As new capabilities are added
predict potential equipment failures and and system maintenance requirements
repairs minimizes the number of service change, monitoring systems will need to
calls necessary. Manufacturers utilizing be continually modified, and maintained.
IoT solutions in 2014 saw an average Yet, concerns over standardization quickly
28.5% increase in revenues between 2013 are mitigated as the application program
and 2014, according to a Tata Consultancy interface (API) is becoming commonplace,
Services survey. with tools and user interfaces developed
for faster implementation. Device or sys-
Deciphering the data tem standardization barriers are removed
Adding new sensors throughout a factory by the creation of central data platforms
that monitor and collect data 24/7 will cre- that connect to a variety of data streams
ate a better overall efficiency and productiv- via API utilization.
ity rate, but it will also create a massive data-
base to sort through. In order to keep the Status quo: Cost will play a part as early
new factory of information collected by the adopters set out to make the transition to
IIoT beneficial, manufacturers will need to IIoT. As costs decline for equipment and
determine which data data rates, the business
is valuable for their case becomes viable on
efforts, and what out- its own merit. Making
comes can be derived the investment and
from it. The outcomes
then can be used to The IIoT provides a new taking the next step of
linking data will only
transform the manu- platform to integrate and improve the return on
f a c tu r i ng pro c e ss , investment.
provide insights into store technology data,
processes that were Connecting the dots
previously difficult or making it a big change and The ability to con-
impossible to see and nect, track and share
make machines safer
and more reliable.
an even bigger value. every state of a bus-
tling factory opens
The ability to connect more doors than ever
the entire conglom- before. While imple-
erate of plant information to a common menting new technologies can seem risky,
data source changes the functionality of the the IIoT presents manufacturers with a new
entire facility. confidence in their ability to predict ser-
The flexibility of todays monitoring and vice and maintenance needs at all points
platform technologies ensures that any data and times. As the IIoT becomes more easily
monitored doesnt have to be permanent. available, productivity lines, machinery and
IIoT allows for systems to be adapted to mul- companies will begin to harness the advan-
tiple applications, and each and every system tages, making now the ideal time to invest.
can and should be molded and updated for The data analysis and tools make the IIoTs
differing factories. data source useful to manufacturers and
large industries that are constantly working
Tinkering with adjustments for better and safer efficiency. This unhar-
Adopting any new innovation comes with nessed potential resolves issues of unplanned
its own set of challenges, and the heavily downtime, common malfunctioning issues
connected nature of the IIoT will require a and better controls production, resulting in
period of adapting. higher profits and improved results. PE

Three key challenges facing the IIoT are:
Security: Asset security is paramount
in the minds of IIoT adopters. Cellular-
based monitors function as a self-con-
tained system, riding on the security of
state-of-the-art cellular networking and
data center management.
Dan Yarmoluk is the business and market
development lead for ATEK Access Technolo-
gies IoT products which include TankScan
and AssetScan. Yarmoluk has been involved in
analytics, embedded design and components
of mobile products for over a decade. The
Website is www.assetscan.com.

www.plantengineering.com plant engineering January/February 2017 39

COVERSTORY
Continued from page 37
Meanwhile the other s wordsecurity and it is fun to think it about from that
is consistently a leader on lists of require-
ments, concerns and issues with IIoTand
certainly in this area will not be realized in
2017. Automobile, HVAC, SCADA and any
number of other systems have been hacked.
Unfortunately, there is no easy answer to
security issues. Instead, what is needed is
hard work, best efforts and the selection
of solutions with limited exposure to the
outside world.
Using either a lack of standards or fear
of security issues as an excuse to not move
ahead on IIoT
implementa-
tions simply
pushes the nec-
essary learning
and experi-
ence that will
come out of
the effort fur-
ther down the
Figure 1: Many manufacturers find themselves
awash in data but thirsting for information, with
the proliferation of data expected to grow sub-
stantially in coming years.
40 January/February 2017 PLANT ENGINEERING
Andy Young, process
control manager at Pio-
neer Energy, takes an IIoT
approach to monitoring
their Mobile Alkane Gas
Separator systems that
run at drill sites to pro-
duce both methane and
natural gas liquid streams.
road, and can put end
users further behind in
the IIoT race.
Focus on business impact
In many IIoT articles, the
starting point is the sen-
sor. That is the origina-
tion point for data that
f lows through a com-
munications network to
a centralized application
with analytics, integra-
tion, data storage, etc. It is
easy to start at the sensor
because the hardware and communications
innovation that is driving IIoT is exciting,
perspective.
Micro-sensors; Arduino, Raspberry PI
and Intel Galileo platforms; long-life batter-
ies; low power wireless systems; and builder
kits from Microsoft, IBM and Amazon are
areas in the news and of interest. There is
so much to imagine with sensors and logic
added to every possible asset and structure.
Unfortunately, these technologies often
dont necessarily serve the business end of
the issue. The right question is not whats
possible with the new technologies, but
www.plantengineering.com
 whats important to the business: a quan-
tifiable positive impact to production and
business outcomes.
This impact can be realized in many ways,
such as increased uptime, improved quality,
higher yields, etc. Positive results also could
include motivating and incenting employee
behavior through visibility to production
status and the impact of their actions.
The best IIoT deployment stories are
those demonstrating positive impacts to
the bottom line. These stories stress the
impacts, then work backwards to the tech-
nologies making benefits possible.
How do you add value?
Remote monitoring services represents the
transition from an asset view to a capability
view. This opportunity is typically framed
from the point of view of the asset vendor,
but probably should instead be framed in
terms of end user benefits. GE, for example,
talks about moving from selling turbines to
selling services.
These new services, powered by IIoT
infrastructures, represent an opportunity for
asset vendors to increase their revenue, but
more importantly to add value to their end
user customers. From an end users point
of view, the idea of additional revenue for
asset vendors from smart connected prod-
ucts is not a likely source of interest. But it
does raise important questions: Who is best
suited to extract value from asset data? Who
is best positioned to monitor, analyze and
recommend outcomes on asset performance,
the vendor or the end user?
www.plantengineering.com
Figure 2: Data analytics solutions provide
engineers and other production experts with
visual representations of data to help them
create actionable information.
C ompanies routinely outsource ser-
vices to specialized organizations, from
cafeterias to accounting to maintenance.
But does this model make sense for IIoT
deployments? The value of reduced sched-
uled maintenance alone could justify the
cost of an outsourced monitoring service
in some cases, so the answer would be
yes in these instances. But in other cases,
remote monitoring services can be a dis-
ruptive issue for current employees and
processes, so care must be taken when
deciding what to outsource and what to
keep in house.
By tapping expertise on assets from ven-
dors, end users can focus more on results
from the value created by the integration
of assets than on the status of one link
in the process. If the end user companys
differentiating expertise is in asset opti-
mization excellence then this may be of
less importance, but the focus on where
an organization creates the most value is
a question to ask.
Analytics requirements
IIoT s olutions typically rely on the
assumption that at some point the magic
happens here to close the gap between
Continued on page 45
plant engineering January/February 2017 41
CoverStory
Six ways to lower
IIoT network costs
By Richard Wood
Moxa Inc.
42 January/February 2017 plant engineering
The Industrial Internet of Things (IIoT) trend
is facilitating a growth in connected devices
on networks as well as increasing the scope
and complexity of industrial control networks
that frequently converge with traditional IT net-
works. More now than ever before, concerns
about security, availability and performance are
having an impact on these industrial control
networks.
One consequence of the IIoT trend is that
purchasing devices for your network isnt the
end of your expenditure. In fact, it is often only
the beginning. Network operators are discover-
ing a host of associated direct and indirect costs
that often can exceed the initial investment in
networking hardware.
This article considers some of the costs that
often are overlooked, and suggests some best
practices and tips on how to lower the total
cost of ownership (TCO) for industrial control
networks.
The time from the start of a project until it
is up-and-running can be broken down into
broadly six different stages. The challenge for
network administrators is to have a deep under-
standing of each stage of the project, determine
the key features that a device should include
or support that are beneficial for each stage,
as well as be able to estimate to what extent
these features will be beneficial for future net-
work needs. An additional challenge is that the
features and benefits often dont appear in the
hardware specifications of a product. Here are
the six stages, and their impact on TCO:
1. Reduce installation and integration costs
It is rare to see completely new network instal-
lations in industrial environments. The major-
ity of network deployments involve a com-
bination of new equipment and upgrades to
existing SCADA systems, control networks and
devices. As no two networks are the same, each
network has its set of unique requirements.
One of the skills that a network administrator
must have is the ability to choose and deploy
the right devices to ensure that the current and
future requirements of the network are met. A
good example of this is ensuring interoperabil-
ity across all devices on the network through-
out the project life cycle. Although there are
numerous ways to overcome problems that
may arise throughout the project, one of the
best solutions is to choose products that offer
the most flexibility.
For industrial networks, devices are often
installed in control panels with other devices
that run on different voltages, so one solution
is to purchase a power converter to ensure com-
patibility. However, this may not be the ideal
solution for all network administrators due to
size constraints of the panel where the devic-
es are being installed or the additional costs
incurred from purchasing power converters.
For some projects the cost of deploying new
cables can add significantly to the overall costs
of the project.
A better alternative is to use a device that
supports a wide range of power inputs that will
satisfy the present demands of the network, as
well as provide more flexibility for devices that
also must be added to the network at a later
date. Although the initial expenditure may be
slightly higher for a switch that supports these
features, costs can be reduced over the duration
of a project due to avoiding additional costs at
a later date.
2. Reduce configuration costs
One of the most time-consuming tasks for
projects in industrial environments, and there-
fore one of the most expensive, is configuring
devices on a network so that they perform
well. A wide range of options are available,
from very basic switches that offer no support
with configuration, to large software packages
that cost considerable amounts of money on
a per-annum basis but greatly assist network
administrators with the configuration process.
As the number of devices on a network
increases, so do the possibilities for savings.
Below are some of the main areas that have
been identified pertaining to the configuration
stage of a project, all of which have a strong
effect on the TCO.
Due to the convergence of industrial auto-
mation and IT systems across IIoT networks,
www.plantengineering.com
 EtherNet/IP and Profinet protocols must have
a way to operate together on the same network.
Devices that have been preconfigured to allow
for these disparate protocols to communicate
automatically allow network administrators to
deploy what is essentially a plug and play device.
These devices also often will support automatic
discovery and the ability to assign IP addresses
automatically, eliminating a significant portion
of the time required for manual configuration.
Compare this with using cheaper devices, which
will require a lot more effort to be spent config-
uring the devices later in the project.
Configuration costs are not limited to when
the network is being setup for the first time. Any
feature that allows copying and saving device con-
figurations will provide network administrators
with the ability to reuse these settings at a later
date, and eliminate the need to manually configure
new devices that are added to the network.
Configuration is also made a lot easier by an
intuitive graphical user interface (GUI). Some
companies offer an advanced testing kit that
allows users to test a GUI and independent-
ly validate its claim that it is intuitive before
installing the device on a network. An intuitive
GUI can save network operators a significant
amount of time during a project.
3. Reduce operational costs
A key way to lower operational costs is to mini-
mize the amount of manual work needed to keep
switches and a network operational. In addition,
ensuring product suitability for deployment in
industrial environments will also help achieve
optimal operational performance.
The two main reasons why devices on indus-
trial networks malfunction are their moving
parts and the power inputs, often referred to
as points of weakness. Switches that have an
absolute minimum of moving parts are much
less likely to malfunction or break, resulting in
www.plantengineering.com
less network downtime and therefore reduced Here are the costs incurred
expenditure. Similarly, if the device supports within the project life cycle.
dual-power inputs and one of the power sup- All images courtesy: Moxa
plies fails, the other power supply will keep the
device running, allowing the faulty power sup-
ply to be replaced without network downtime.
For deployments lasting longer than 10 years,
which is the norm for IIoT networks, there is a
very high chance that network administrators
will encounter one of these problems at some
point during those 10 years.
4. Reduce maintenance costs
The majority of IIoT networks are controlled by
programmable logic controllers (PLCs). When
the network performs scheduled maintenance
and reboots, a PLC will often take about 20
seconds to reboot. If a PLC boots up before the
network is ready to operate, errors will occur
that can cause more delays. Switches that can
boot up in about 10 seconds as opposed to
100 seconds will be ready to operate as soon as
the PLC has rebooted, thereby avoiding these
problems.
Being able to quickly view a networks status
via an app or software is one of the easiest ways
to monitor the network. These apps and soft-
ware sometimes incorporate a system that alerts
network administrators that an event is taking
place that has the potential to cause a failure on
the network. Alerting the system administrator
that a problem could happen, as opposed to a
system that merely informs the administrator
that a problem has occurred, is an excellent way
of reducing maintenance costs. These features
may increase the purchase price of the switch
but over the course of the project are likely to
result in substantial savings.
5. Reduce costs associated with downtime
Finding the root cause of downtime on a
large-scale network is very time consuming,
plant engineering January/February 2017 43
CoverStory
The multi-protocol capabil-
ity makes it easier to inte-
grate PLCs with the SCADA
system.
44 January/February 2017
so any tools that assist network administra-
tors with identifying the point of failure
and allow them to quickly fix it will have
significant advantages. Another skill of suc-
cessful network administrators is to be able
to calculate whether the additional costs of
features that can help reduce downtime are
likely to outweigh the costs of any downtime
experienced.
Devices that can be remotely accessed and
configured are very beneficial because they
allow untrained personnel to perform the
time-consuming task of going to the field
site, while the trained specialist can perform
troubleshooting and configuration remotely
from the control center. In addition, a device
that offers playback support allows the spe-
cialist to identify what occurred at the time
the switch went down, and help improve the
design of the network to avoid this kind of
failure in the future.
Devices that backup the switchs configura-
tions on a dongle are particularly helpful if the
switch malfunctions. To automatically import
all of the settings, all you need to do is plug
the dongle back into the switch. As no con-
figurations need to be performed manually,
the amount of network downtime is reduced.
As network administrators are not always
based in the control room, mobile apps that
support event notifications provide them with
the ability to respond more quickly to events
taking place on the network and allow them to
get the network back to normal more quickly
than would have been otherwise possible.
Self-healing redundancy technologies
ensure that networks stay up-and-running
even in the event of a single node failure.
Deploying redundancy technologies that
allow greater flexibility, availability and scal-
ability for future network expansion can help
avoid additional expenditure in the future.
plant engineering
6. Ongoing technical support
When purchasing a switch, a wide range of
options are available, from cheap devices
that offer no ongoing support or firmware
upgrades, to switches whose technical sup-
port will cost significantly more than the
switch over the course of the project. As
switches are often deployed on networks for
longer than 10 years, the technical support
that comes with a switch will significantly
impact costs in long-term deployments.
For example, new security threats are reg-
ularly identified and companies that offer
ongoing technical support often will release
a security update via a firmware upgrade to
eliminate new cyber threats. Conversely,
when a device on a network is compromised
and ongoing technical support or firmware
upgrades are not available, the network
administrator will have to replace the device
or risk the security of the whole network.
Reliable switches that offer free, ongoing
technical support complemented by a long
warranty period present significant advan-
tages for network administrators who want
the lowest TCO for their projects.
After considering the life cycle of a project
and the hidden costs that can be incurred
throughout this life cycle, it is clear that
multiple factors must be considered when
determining the direct and indirect costs of an
entire system. Of course network administra-
tors never can be 100% sure what the future
needs of an IIoT network are, but having a
full understanding of the six stages described
above ensures that network administrators
are more knowledgeable about which devices
have the best chances of lowering the TCO
throughout the duration of a project. PE
Richard Wood is product marketing manager
for Moxa Inc.
www.plantengineering.com
 Continued from page 41

Andy Young, process control man-

ager at Pioneer Energy, said IIoT
technologies enable Mobile Alkane
Gas Separator remote systems to
produce methane and natural gas
at drill sites.

data and insight. Typically this

magic is buried under a banner
of machine learning, big data
or advanced analytics. But just
where these key insights are
revealed, and how, is often given
insufficient consideration.
Looking at end user examples,
the real work of analytics includes
data aggregation, cleansing and
contextualization with business
systems data before insights can
be produced. Or as our end user
customers describe it, 80% to 90%
of analytics is getting the data right
before the analytics can occur,
and this will only get more com-
plicated as end users install more
connected products which will
provide even more streams of data
for integration (Figure 1, p. 40).
There are also issues of engi-
neer productivity, team collabora-
tion and process industry capabil-
ities to recognize in the context of
analytics offerings. These are hard
issues, and therefore the specifics
of analytics requirements deserve
the same attention as the business
cases.
We certainly know from expe-
rience there are no silver bullet
solutions to actionable insights.
Our experience at Seeq suggests
the right path is instead provid-
ing end user engineers and other
production experts with tools
they can use to create actionable informa- recipe for failure. Therefore, identifying the
tion from raw data. These tools rely heavily requirement to find the insight, executing
on visualization of data, from which insights the analytics and transforming insight into
can be derived (Figure 2). execution is the last mile of successful IIoT
Finally, to land the analytics once insights implementations. PE
are achieved, its important to know which
employees are trained and incented to act Michael Risse (Michael.risse@Seeq.com)
on the information that has been uncov- is vice president and CMO at Seeq Corpo-
ered. A right answer disconnected from the ration, a company building productivity
incentives and rewards of the workforce is a applications for engineers.

www.plantengineering.com plant engineering January/February 2017 45

 stay
informed
Stay current with technology
and trends in electrical,
mechanical, maintenenace
and automation.

To subscribe, visit
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ELECTRICALSOLUTIONS
Eight easy pieces
Make your companys electrical safety program NFPA 70E-compliant.
T
By Tommy Northcott, PE, CMRP he 2015 edition of the National Fire
Northcott Consulting LLC Prote c t ion Ass o ciat ion (NFPA)
70E standard requires employers to
implement and document an over-
all electrical safety program. Sometimes it
may feel cumbersome to try to understand
and comply with OSHA-mandated industry
standards, but when they are broken down
and looked at piece by piece, it can become
a very obtainable reality.
The general requirement is for the safety
program to direct activity appropriate to the
risk associated with electrical hazards and
to be integrated with the employers overall
occupational health and safety management
system. While NFPA 70E requirements can
be broken out into eight pieces, it is impor-
tant to point out that training is the thread
that runs through the entire program.
Training, in one form or another, is an
important aspect of all eight pieces that
make up an NFPA 70E-compliant electrical
safety program. We often hear the saying
knowledge is power, and when it comes
to electrical safety, knowledge should be
the priority.
1. Awareness and self-discipline
The overall electrical safety program
should be designed in a manner that con-
sistently increases the employees aware-
ness of the electrical hazard as well as
the mitigation techniques available to
provide protection from those hazards.
The program should also encourage the
development of self-discipline in using
the safety principles and controls that are
an integral part of the application portion
of the program.
The electrical safety program should
drive the development of safety habits that,
in turn, shape an overall culture of electri-
cal safety. This the first of the eight pieces,
because all of the other pieces have to be
incorporated with this awareness and self-
discipline to successfully create the desired
electrical safety culture.
www.plantengineering.com
2. Principles
Employers are required to document the key
aspects of their expectation for employee
safety with respect to electrical hazards. One
very important NFPA 70E-driven aspect
would be the principle of always working on
electrical equipment when it is de-energized
unless it is not feasible to do so. Hazard
identification and mitigation is another key
principle in any electrical safety program.
Other principles could include:
Knowledge of the installation, operation,
and maintenance of equipment
Planning jobs
Documented task instructions
Personal protective equipment (PPE)
Proper use of the right tool for the job
Using qualified workers for the job
No matter what list of principles the
employer comes up with, the key to this piece
is training employees to what these principles
are and what they mean with respect to the
employers expectation.
3. Controls
The employer needs to have a documented
method for how the program is put into
application by the employees. As with the
other pieces, employee training and knowl-
edge is the key. The employer must train
employees to be qualified at the appropriate
level with respect to the hazards to which
the employees will be exposed. It is also
typical for the employer to develop a process
that will drive best work practices and the
development of safety habits. These controls
should be built upon the principles in the
second piece: What can be done to ensure
that the principles are applied to each task?
The principle of only working on de-ener-
gized equipment is applied through a process
that requires the development of an electri-
cally safe work condition. If it is not feasible
to work on de-energized equipment, then the
control becomes a process that establishes the
appropriate boundaries and PPE.
PLANT ENGINEERING January/February 2017 47
eLeCTRICALSOLUTIONS
cable safety procedures,
lockout/tag out, bound-
ary identification, ener-
gized electrical work per-
mit, drawings, operations
and maintenance (O&M)
manuals, sketches, photo-
graphs, etc.
The program identifies
when specific procedures
are re qu i re d, re c om -
mended, andin some
casesnot required.
These procedures provide
the documentation of the
steps taken to provide a
safe method to execute
the associated task.

5. Risk assessment
This piece of the program
has been the subject of
change for each revision
since the 2004 edition.
The 2015 edition brought
a significant change of
sp ecif ically requiring
three aspects to what
is now called the Risk
Assessment Procedure:
1. Identify hazards
2. Assess risks
3. Implement risk con-
trol according to a
hierarchy of methods.

This hierarchy of risk-

Proper and complete documentation of the principles and procedures of your
electrical safety program is an important component of keeping it NPFA 70E
compliant. Image courtesy: Northcott Consulting
4. Procedures
The controls that are required in the third
piece often manifest themselves as writ-
ten procedures. Other procedures could
include the task requirements that describe
the details of the work that is to be accom-
plished. All electrical tasks are planned, and
that information should be documented:
required PPE, hazard identification, appli-
control methods is speci-
fied in ANSI/AIHA Z10,
American National Stan-
dard for Occupational
Health and Safety Man-
agement Systems. The hierarchy is as follows:
1. Elimination
2. Substitution
3. Engineering controls
4. Awareness
5. Administrative controls
6. PPE.
The risk assessment for electrical tasks
must be documented and include the haz-
ards, risks, and the method used to protect
employees from the hazards. This is often
documented in a type of job-safety analy-
sis, briefing checklist, or similar document.
Moving toward the risk terminology is an

48 January/February 2017 plant engineering www.plantengineering.com

 effort found throughout the NFPA 70E 2015
revision that addresses probability along with
the severity of the hazard.
6. Job briefing
Before any task involving a potential electri-
cal hazard begins, a qualified person lead-
ing the task must conduct a job briefing
with the employees involved. Interestingly,
the 2015 revision removed the distinction
between repetitive task, similar task, and
routine work. All tasks are treated equally
with respect to the job-briefing requirement.
The job briefing should identify the haz-
ards as well as any other related interfaces.
Questions that any employees involved might
have related to the job should be resolved
during the job briefing. The briefing should
ensure that all employees involved under-
stand their tasks and how they might impact
or be impacted by other tasks being executed.
The group should think through and dis-
cuss the whole job from start to finish to con-
firm their execution plan and identify any
gaps. All job-related documentation should
be reviewed and discussed. One very impor-
tant aspect of the job briefing is preparing for
an emergency. If work is being performed
around an electrical hazard, the source of the
electrical energy should be identified along
with the next upstream disconnecting device,
location, and PPE required to safely operate
that device and remove power.
7. Maintenance
This piece was added to the 2015 revision
of NFPA 70E. Updates made throughout the
2015 revision bring a heightened awareness
of the relationship between maintenance
and probability of failure. It is logical to
make the connection that equipment that is
inadequately maintained will have a higher
probability of failing, resulting in an arc
flash hazard and/or shock hazard. Therefore,
employers are required to make maintenance
practices a part of their overall safety pro-
gram and hazard-risk assessment.
8. Safety auditing
The employer who cares enough for employ-
ees to put together a safety program for
employees well-being should also care
enough to verify that the program is being
applied to the work. A lot of time and effort
goes into developing this electrical safety pro-
gram, and it is only effective if the employees
understand it and apply it every day to every
www.plantengineering.com
task. There are two types of audits that the
employer is required to perform.
The first audit is on the program itself and
is required at a frequency not to exceed three
years. It is no coincidence that NFPA 70E is
revised on a 3-year cycle. This allows the elec-
trical safety program to be revised to line up
with the latest 70E revision. The employer is
also required to conduct and document field
audits to verify the program is being applied
by the employees. These field audits are to be
performed at intervals not to exceed 1 year.
The general requirement is for the safety program
to direct activity appropriate to the risk associated
with electrical hazards and to be integrated with
the employers overall occupational health and
safety management system.
Knowledge gained from appropriate train-
ing is the key factor that will make or break a
companys electrical safety program. Knowl-
edge of the NFPA 70E standard and the haz-
ards it is designed to safeguard us from is
certainly helpful in the establishment of an
effective electrical safety program, but it is
not the only thing needed for success.
When electrical workers truly understand
the hazards they are faced with and the mit-
igation techniques that are available, their
self-preservation instinct will drive them to
work safely. It is through this understanding
of the hazard and safe work practices that
the safety program is able to mature into an
effective safety culture.
The NFPA 70E requirements simply sum-
marize the requirements in a manner to
ensure nothing is being overlooked. If the
employers motivation is for workers to go
home safely to their loved ones each day, then
the intent of the requirements of NFPA 70E
may already be followed. The only thing left
to do is verify it, document it, and audit it. PE
Tommy Northcott is president of Northcott
Consulting LLC and specializes in electrical
safety training and NFPA 70E and OSHA com-
pliance. He is a professional engineer licensed
in the state of Tennessee and a certified main-
tenance and reliability professional.
plant engineering January/February 2017 49
eLeCTRICALSOLUTIONS
Four steps to ensure proper installation
of monitoring and metering equipment
Following best practices for proper field device installation, such as grounding and testing, will
help avoid performance issues and help designers realize the true return on investment (ROI).
W
By Rick Schear hile investments in electronic
Eaton monitoring and metering systems
are made within complex industrial
environments, and connections
seem to be correct, problems still exist.
Some devices function perfectly, others do
not function at all, while some perform errati-
cally or occasionally send error messages. The
majority of problems seem to occur within sen-
sitive control or power transmission assemblies.
Often, a lack of attention has been given
to the installation details of monitoring and
metering device wiring during design and
installation. Some of these important wiring
issues include incorrect wire selection or instal-
lation, improper instrumentation grounding,
and inadequate electromagnetic protection for
wire and terminations.
Four steps to proper monitoring and meter-
ing equipment installation
The following are best practices to ensure
monitoring and metering equipment are func-
tioning properly:
1. Ensure adherence to manufacturer
recommendations
Manufacturers will likely provide extensive
recommendations for the design, installation,
and maintenance of power and communica-
tions wiring used in field bus products. This
information typically spans INCOM [Indus-
trial Communications network from Cutler-
Hammer, acquired by Eaton], RS-485, and
Ethernet physical layers. Adherence to these
recommendations is vital to ensure robust
and reliable communications.
Network segments installed according to
manufacturer recommendations will provide
flexibility, simplicity, and noise immunity.
Failure to follow recommendations often will
result in sub-optimal system performance.
For example, to minimize data corruption,
50 January/February 2017 plant engineering
it is not advised to run communications
wiring in a power tray common with high-
frequency loads, such as adjustable frequency
drives or soft starters.
Proper grounding is also an important aspect
of field device installation. Most instrumenta-
tion systems have two grounds including the
electrical or power ground and the instrument
ground. Its important to realize that these two
grounding systems have different purposes.
The shield should be continuous across a
network segment and connected to the build-
ings electrical system grounding electrode
conductor. The 2017 National Electric Code
(NEC) provides guidance on grounding com-
munication cables.
Cable selection also is essential for robust
communications. Cable developed for RS-485
communications is recommended. Control
and instrumentation cables are unacceptable
for RS-485 applications.
Additionally, power distribution and
automation applications require shielded
cable. Most cable is available with two
types of shielding, foil and braid-over foil.
Either can be used, although braid-over
foil is preferred. The foil covers high-radio
frequency and electrical fast transient expo-
sures, while the braid-over foil covers low-
frequency surge events. For typical terminal
block connections, the cable must support a
shield drain wire.
2. Understand infrastructure challenges
and environmental factors
System capacity calculations should be per-
formed when new systems are being devel-
oped or devices are being added to existing
systems. The purpose of the calculation is to
determine if the system design has the capac-
ity to support the number and type of devices
intended for use.
www.plantengineering.com
 Figure 1: Less attention is
often given to the installation
of monitoring and meter-
ing device wiring. Common
wiring errors easily can be
overlooked, with rolled wires
visible. All images courtesy:
Eaton

Problems may be unrelated

to capacity. For example, most
loads in modern electrical dis-
tribution systems are induc-
tive. These loads can include
motors, transformers, gaseous
tube lighting ballasts, and
induction furnaces. Inductive
loads need a magnetic field
to operate. These inductive
devices can cause harmonics
to be created by electronic cir-
cuits, which can create prob-
lems for connected loads.
All harmonics cause addi-
tional heat in conductors
and other distribution sys-
tem components. Harmonics
also can cause electromagnetic
interference (EMI), also called
radio-frequency interference
(RFI) when in the radio fre-
quency spectrum, and is a
disturbance generated by an
external source that affects an
electrical circuit by electro-
magnetic induction, electro-
static coupling, or conduction.
High levels of harmonics
and EMI can often result in
erratic behavior of electronic
equipment, including incon-
sistent data communication
between computer equip-
ment and field devices,which
can jeopardize the effective-
ness of energy monitoring and
metering devices.
These issues can be traced
b ack to incor re c t wir ing
schemes, such as installing unshielded However, if wiring adheres to manufac-
communications cables too close to wiring turer recommendations and data is still
carrying inductive loads. Replacing existing unreliable, it is recommended to consult
cable with a shielded alternative, or simply with the field device manufacturer or a
changing the proximity of communications power quality specialist to determine if
wiring to inductive loads, can correct this line filters and conditioners can solve
problem. issues.

www.plantengineering.com plant engineering January/February 2017 51

eLeCTRICALSOLUTIONS
3. Diligently review pre-approval
documents and plans
The potential problems outlined above can
be avoided by giving adequate attention to
the details of field device wiring recommen-
dations during the design and installation
phases.
It is always a best practice to closely review
pre-approval documentation and plans to
ensure important wiring details are met,
including proper treatment of each type of
instrument, correct wiring for signals, proper
grounding, and meeting specifications for
instrumentation wire and terminations.
52 January/February 2017 plant engineering
Figure 2: Malfunctions with monitoring and
metering devices and instrumentations often
can be traced to wiring errors, such as use of
the wrong type of wire shown here.
As a result, possible issues can be identified
and rectified prior to installation, which can
save a tremendous amount of troubleshooting
time and labor compared to the identifica-
tion of issues after installation and commis-
sioning.
4. Test equipment, before, after installation
It is vital to use testing equipment to mea-
sure capacity, harmonics, and EMI before
and after installation to streamline the
field wiring process. Proactive testing can
help designers identify possible obstacles
and implement protective measures before
a bill of materials is created. These studies
also should be performed following instal-
lation to ensure wiring measures have cor-
rectly addressed identified issues.
Paying close attention to field device
data during startup, peak usage, and the
ramping down of systems can also easily
identify problems. EMI and harmonic levels
can vary during these periods, so keeping
an eye out for inconsistencies or data col-
lection errors often can help correct the
situation shortly after installation, and the
field device can then function properly.
If issues with data collection are identi-
fied, contacting the field device manufac-
turer directly for immediate troubleshoot-
ing and correction support is among other
options.
Without proper installation, it is impos-
sible to reap the benefits of metering and
monitoring devices. The real-time data
these devices provide, simplifies mainte-
nance, reduces downtime, and enhances
efficiency.
However, without properly functioning
systems, most organizations never fully
achieve the true return on investment for
these devices.
By following best practices for device
wiring and installation, designers, install-
ers, and plant management can achieve the
full benefit of real-time data acquisition
without the headaches of improperly per-
forming equipment and the need for time-
consuming troubleshooting and testing. PE
Rick Schear is a product manager at Eaton.
www.plantengineering.com
 Operating a three-phase motor
using single-phase power
Three ways to make an expensive and arduous process a little easier.
By Chuck Yung
Electrical Apparatus Service
Association (EASA)
Figure: Comparison of
single-phase (top) and
three-phase (bottom) power.
Image courtesy: EASA
www.plantengineering.com
S
o, you told a neighbor you work with
electrical equipment, and now he thinks
you can solve his problem because he
or she bought a three-phase motor that
cant run on single-phase power. Being asked
to convert this motor already sounds like more
trouble than its worth. Thats not quite true
though. There are some methods to make the
process easier.
The phantom leg method
Three-phase power involves three symmetrical
sine waves that are 120 electrical degrees out
of phase with one another (see Figure). One
method of converting single-phase power that
worked well for decades was connecting two
phases to the incoming 220 V single-phase
power and create a phantom leg for the third
phase by using capacitors to force an offset
between the main and auxiliary windings. In
this case, the offset is 90 electrical degrees.
For this method, the capacitors must be appro-
priately sized for the load. The current will be
unbalanced if it isnt. Rather than the 120-deg
phase shift depicted in the lower half of Figure 1,
the incorrect pairing of the capaci-
tor and load may result in a large
deviation. The bigger the discrep-
ancy, the lower the torque.
Rotary phase converter method
Another viable method is with a
rotary phase converter. A wood
shop, for instance, might use a rota-
ry phase converter to run several
three-phase machines on a single-
phase power input. One drawback
is that the process can be very
expensive during the entire time the
rotary phase is converting, regard-
less of whether any machinery is
being used. The current might be
balanced when specific machinery
is running, but if few machines are
operating, or all of them are heav-
ily loaded, the three-phase powercurrent and
voltageis drastically unbalanced.
NEMA Stds. MG 1: Motors and Generators
calls for motors to operate from voltage that is bal-
anced within 1%. If the 10x rule is applied (percent
current unbalance can be as high as 10 times the
percent voltage unbalance) to a motor operating
with 1% voltage imbalance, the current imbalance
could be 10%. This is beneficial because a major-
ity of three-phase motors running on a system
described above are operating between 15% and
50% current imbalance. Even with the NEMA
MG 1 derating graph no motor should operate
with such a large current imbalance.
Variable frequency drive method
A variable frequency drive (VFD) rectifies each
pair of phases to dc and inverts the dc to the
power for the three-phase output, which means
a VFD can be used with single-phase input to
operate a three-phase motor. Manufacturer sup-
port varies, and it is cautiously recommended to
derate the drive by 1 divided by the square root
of 3 (about 58%). Also note that the hp/kW VFD
rating is there for convenience in sizing drives
since theyre rated by current. For example, a 10
hp (7.5 kW) motor would use a VFD rated for
15 hp (11 kW). It is strongly recommended for
the user to work with the drive manufacturer in
selecting and sizing the VFD for this use.
Compressors, machine shop and woodwork-
ing equipment and decorative fountains are good
candidates for this method. Rather than buying
an expensive single-phase motor, changing the
controls and dealing with speed control and
starting torque issues, it is a better idea to use a
VFD to operate the existing motor from single-
phase power. For many applications up to 5 hp
(4 kW), a suitable VFD can be purchased for
far less than the cost of rewinding a three-phase
motor and providing the necessary controls to
operate it.
The additional benefits are that a three-phase
motor is usually less expensive to buy, the con-
trols do not require replacement or modifica-
tion, and the VFD has the value-added bonus
of providing speed control. Best of all, you dont
have to ruin a weekend helping someone who
does not fully understand just what it is you do. PE
Chuck Yung is a senior technical support special-
ist at the Electrical Apparatus Service Association
(EASA). EASA is a CFE Media content partner.
plant engineering January/February 2017 53
MECHANICALSOLUTIONS

Insulation deficiencies
can harm plants, people
Proper attention provides better energy
management, reduced operational failure

By Nick Eaton
ISS Insulation Services & Solutions

For optimum operation, industrial facilities such

as power plants require mechanical insulation on
pipes, ducts, tanks and equipment. Mechanical
insulation in a power plant controls temperature
variation to help limit heat gain or loss on surfaces
operating at temperatures above or below ambient
temperature. An experienced contractor typically
manages installation of mechanical insulation in
industrial environments.

54 January/February 2017 PLANT ENGINEERING www.plantengineering.com

 Insulated piping in a mechanical room at an
energy plant. All images courtesy: ISS Insula-
tion Services & Solutions
Selecting the type of mechanical insula-
tion for installation begins with asking basic
questions and understanding the scope of
work. Mechanical insulation is divided
into three different categories based on the
level of heat it can withstand. Mechanical
insulation contractors need to know the
operating temperature range of the plants
system before installing insulation. Know-
ing if a system is outdoors, indoors or both
determines the type of protection needed to
prevent damage from weather, a corrosive
atmosphere, water or chemical exposure
and other challenging conditions.
Improper insulation
Mechanical insulation systems require dif-
ferent layers of thickness depending on
the temperature of the environment. With
the correct insulation installed, the plant
becomes more energy efficient, which in
turn reduces operating costs. If a mechani-
cal insulation contractor lacks thorough
knowledge about a manufacturers product
installation standards, the risk of system
damage or lack of efficiency increases.
Improper insulation can lead to excessive
heat transfer and that loss of heat affects
the conservation of energy and ultimately
the cost to operate the plant.
Damaged insulation
Damage can occur to mechanical insula-
tion systems in several ways. Unfortunately,
using the wrong insulation or installing
insulation incorrectly are common reasons
for damage. Environmental factors, such as
weather, will damage the insulation if it isnt
adequately protected. Piping and equip-
ment that operate at lower-than-ambient
temperatures run the risk of condensation
or freezing on the insulation surface. If
the thickness of the insulation is less than
required, the insulation can become wet and
cause corrosion.
In addition to environmental causes,
c a re l e s s m a i nt e n a n c e p e r s on n e l c a n
damage mechanical insulation systems
by walking on insulated pipes or tearing
mechanical insulation to repair or main-
tain equipment.
www.plantengineering.com
Mechanical insulation does wear out after
years of use and can be rendered obsolete. If
an installation contractor finds mechanical
insulation that is old or installed improp-
erly, it is important that the insulation be
completely removed and replaced. Care
should be taken during removal of the exist-
ing insulation to minimize damage to the
mechanical system.
Temporary protection may be required
for adjacent insulation to prevent dam-
age to it while repairs are underway. Aged
mechanical insulation should not be repur-
posed. Using old, deteriorated insulation
will negatively impact the energy efficiency
of the plant.
Pipe/duct deterioration
Pipes and ducts commonly deteriorate
through rust and corrosion that is fre-
quently caused by condensation. Improper
insulation lacks efficient condensation
control, allowing water vapor to reach the
surface of the pipes and ducts. The best
way to prevent condensation in colder
environments is with the right insulation
installed properly.
Heat is a leading cause of deterioration of
pipes and ducts. If the pipe insulation is not
rated for high-temperature environments
it can melt and fall off the pipes, exposing
them to the elements. If the insulation falls
off or is missing, the pipes or ducts become
a burn injury hazard for plant personnel.
Safety
If the mechanical insulation isnt installed
properly or is damaged, the risk of injury
is greater for personnel through exposure
to extremely hot equipment, sharp edges
Knowing if a system is outdoors,
indoors or both determines the type of
protection needed to prevent damage
from weather, a corrosive atmosphere,
water or chemical exposure and other
challenging conditions.
PLANT ENGINEERING January/February 2017 55
mechanicalSOLUTIONS
Insulation and lagging on
the exterior duct.
and fly ash. Fly ash is a by-product of
burning coal and is dangerous if inhaled.
Plant managers should hire a professional
crew to properly clean-up and remove any
fly ash before a mechanical insulation con-
tractor installs new insulation.
Personal protection equipment (PPE)
should always been worn when installing
or removing insulation in an industrial
facility. PPE includes a hard hat, steel-toe
boots, safety goggles with side shields,
resistant gloves, long sleeves, and respira-
tors. PPE guards personnel from injuries,
including burns from hot equipment, cuts
from exposed sharp edges and inhalation
of fly ash.
Proximity is a safety issue at every indus-
trial plant or facility, but there are other
alternatives that can increase accessibil-
ity. Scaffolding hoists, lifts, and swinging
stages work in high-risk environments such
as industrial plants. Providing appropriate
56 January/February 2017 plant engineering
means to access mechanical insulation sys-
tems increases productivity of and decreas-
es the risk of injury to installation workers.
Deadlines
Shutting down a plant generally result in
exponentially higher costs for repairs and
loss of hours of operation. Plant managers
should have a strict schedule for mainte-
nance while the plant is shut down. Con-
tractors need to provide an efficient plan
for maintenance to ensure that the plant
becomes fully operational on time.
Mechanical insulation contractors may
require additional workers to meet plant
managers plant shutdown schedule. There-
fore, understanding the full scope of work
for the project will enable the contractor
to decide what workforce is necessary. In
addition, further damage may be identified
during the systems assessment, increas-
ing the amount of required maintenance.
www.plantengineering.com
 In order to complete the
project on schedule, the
contractor may need to
employ more workers or
workers may be required
to work overtime. The con-
tractor must factor all of
the elements and variables
into the repair and main-
tenance plans.

Maintenance
HVAC and mechanical
insulation systems require
periodic inspection and
maintenance. Whole sys- ISS employees installing mineral wool insulation on boiler wall
tem checks, including insu- at power plant.
lation appraisal, should
be performed ever y six
months. The plant manager is responsible bears responsibility for fixing the problem
for the inspection and maintenance of the if it occurs within the warranty timeframe.
system. Failure to perform inspections in If a mechanical insulation system is prop-
the recommended timeframe carries risks erly installed, sustains little damage and is
that are likely to cause more problems down properly inspected and maintained, it can
the road. last 20 years or more. Mechanical insulation
Visual checklists are available for plant is a valuable asset in maintaining energy
managers to use during routine main- efficiency and reducing operating costs and
tenance checks. Checklists are a simple is worth the investment in proper installa-
guide to visually inspect the condition tion and maintenance.
of mechanical insulation systems and The most important tasks for a mechani-
shouldnt be relied upon solely. Internal cal insulation contractor are to effectively
inspectors will want to look for missing, analyze the environment where the insu-
lose or sagging insulation and the common lation will be installed and to specify the
problems that are caused by leaking pipes correct type of insulation that will hold up
or damaged equipment. against any harsh or potentially damaging
A mechanical insulation survey is help- conditions. Making time for this process
ful in addition to the visual inspection. before installation can prevent future dam-
Sur veys are more in-depth and involve age, saving a plant from inconvenient and
documentation of each type of insulation costly repairs and replacement parts down
and a list of damaged or missing insulation. the road.
After damaged or missing insulation is It is imperative that mechanical insula-
identified by a plant manager an action tion contractors and plant managers know
plan should be implemented to assess about the insulation being installed, fol-
the degree of damage and what repairs low recommended maintenance schedules
or replacements need to be conducted to and be aware of any causes of damage. Not
prevent further damage and risk of injury. only is it vital to use the correct mechani-
A professional mechanical insulation con- cal insulation for the project, but having
tractor has the skills and experience neces- a professional industrial mechanical insu-
sary to assess the system as recommended. lation contractor that knows the proper,
and efficient techniques for installing and
Warranties replacing insulation is key for successful
It is an industry standard that HVAC and plant operations. PE
mechanical insulation installers provide
a one-year warranty on the installation Nick Eaton is the sales engineer of ISS Insu-
of the products where warranties for the lation Services & Solutions, which is a mem-
products vary by manufacturer. If the insu- ber of the National Insulation Association.
lation is installed improperly the installer His email is neaton@insulationsands.com.

www.plantengineering.com plant engineering January/February 2017 57

mechanicalSOLUTIONS
10 tips to lower
compressed air costs
Keep an ear out for leaks, but look at other factors as well.
C
By Deepak Vetal ompressed air is a necessity in many
Atlas Copco Compressors industrial applications, but it can be
costly if youre not careful. By invest-
ing some time and thought into your
compressed air system, you can identify ineffi-
ciencies that, when fixed, will make compressed
air an affordable solution.
Following these 10 tips will lower your com-
pressed air costs.
1. Analyze air consumption
Typically, only half of generated compressed
air is used for the intended process. The other
half is depleted by artificial demand, inappro-
priate use, and leaks.
Artificial demand is created when there are
extra margins on sizing compressed air systems
Its common to in terms of flow or pressure requirement. It can
account for about 10% to 15% of compressed
find systems air consumption, which translates into wasted
money.
running at a Also should check the operation for poten-
high pressure to tially inappropriate uses of compressed air such
as open blowing, personnel cooling, cabinet
satisfy the needs cooling or air motors. Some of these applica-
tions, including cabinet cooling, liquid agita-
of only one point tion or stirring and vacuum generation, can
be served more efficiently by a fan, blower or
of use. However, vacuum pump, all of which consume less energy
this can waste than air compressors.
Knowing where your air goes is the first step
large volumes toward developing an action plan to reduce
unnecessary compressed air consumption.
of compressed
air, especially 2. Inspect distribution
Inspecting your distribution means check-
when the ing for leaks and assessing your pipe sizing.
Both leaks and incorrectly sized pipes can
pressure needs result in unwanted pressure drops, causing
your compressed air system to work harder
of different end and consume more energy. In some systems,
uses are highly leaks account for 20% to 30% of air consump-
tion. Lets take a look at some calculations and
disparate. examples to understand the impact of distribu-
tion inefficiencies.
58 January/February 2017 plant engineering
Leaks: At 80 psig, a leak through a 1/16-inch
hole consumes about 5.24 cfm. When the pres-
sure moves to 125 psig, that number jumps to
7.66 cfm. This 46% increase in wasted air can
compound energy costs quickly, so leaks should
be identified and addressed as quickly as pos-
sible.
While some larger leaks can be heard in a
system walk, an audit is the best way to ensure
all leaks are found. Ultrasonic leak detectors are
available to find minute leaks, but an ongoing
identification program involving all personnel
is the most effective practice.
Pipe sizing and configuration: Pipe sizing
may seem like a small factor, but it can have a
big impact on pressure. For example, suppose a
plant experiencing low pressure generates 400
cfm while running at 100 psig with pipes that
are two inches in diameter. To compensate for
the low pressure, the operator considers pur-
chasing a new, larger compressor. Is this a good
solution? Probably not.
Increasing the pipe size from 2 inches to
3 inches and creating a closed-loop system
reduced the pressure drop from 12 psi to 1 psi
without a new compressor.
Another way to avoid air pressure drops
associated with piping and configuration is to
just say no to long hoses. Minimizing the use
of hoses and frequently inspecting fittings can
preserve line pressure without forcing the com-
pressor to work harder than necessary.
3. Reduce pressure
Its common to find systems running at a high
pressure to satisfy the needs of only one point
of use. However, this can waste large volumes
of compressed air, especially when the pressure
needs of different end uses are highly disparate.
To avoid generating unnecessary amounts of
compressed air, try using a separate compres-
sor or booster. That way, the rest of your system
can continue to operate at a lower pressure,
reducing leakage and usage rates and ultimate-
ly decreasing overall energy consumption.
www.plantengineering.com
 These savings can add up. Every
additional 2 psi increases energy
costs by about 1%. But before you
buy a separate compressor, try a
few simple checks:
Assess the validity of compres-
sor control settings.
Look for pressure drops
through dryers, filters, and
piping systems.
Determine if theres artificial
demand.

4. Ensure air receivers are

used properly
Air receiver sizing and place-
ment are crucial to lowering
compressed air costs. Air receiv-
ers play a vital role in the com-
pressed air process. They store
compressed air prior to end use
and serve as a buffer between the
compressor and system, modu-
lating pressure variation that may
happen during compression.
The Compressed Air and Gas
Institute (CAGI) recommends
four to five gallons per cfm. For installation with
multiple compressors, the air receiver should
be based on the size of the trim compressor.
Ensuring your air receiver is in the right loca-
tion is another way to lower your compressed
air costs. Some operators decide to install an air
receiver before the compressed air dryer. This
can be beneficial to the dryer, as the receiver
may provide radiant cooling that removes some
of the condensate and entrained oil. However,
the receiver will be filled with saturated air.
If there is a sudden demand that exceeds the
compressor and dryer capacity rating, the dryer
can become overloaded, leading to a higher
pressure dew point.
Installing the receiver after the dryer
doesnt provide the same advantages, but it
does store clean, dry air. Any sudden demand
occurring in this situation will be met with
dry air. The best proactive air receiver place-
ment is to have two receivers on the supply
side: one wet receiver before the dryer to
provide control storage and condensate drop-
out and a second dry air receiver to meet
sudden demand.
5. Control multiple systems effectively
When designing a multiple compressor sys-
tem, a good way to save money is to base load
as many compressors as possible. Multiple
compressor control can optimize the running Measuring and monitoring
cost because you are selecting which compres- air use is an important com-
sor to run at a specific load based on plant flow ponent in managing your
demand. compressed air costs. Image
It can also reduce the compressor operat- courtesy: Atlas Copco
ing pressure band (remember, 2 psi increases
the energy consumption by 1%). If you have
variable speed drive (VSD) and a centrifugal
compressor in the system, multiple compres-
sor controls will keep the VSD compressor and
centrifugal compressor in an optimum zone,
minimizing compressed air blow-off.
6. Choose the right dryer and filter
The process of drying compressed air is often
misunderstood, which results in inefficiently
pieced together systems that waste energy
and money. We often get questions regarding
dryer and filter selection, such as:
Should I get a desiccant or refrigerant
dryer?
What level of filtration do I need?
Do I need all these filters, regulators and
lubricants?
Regardless of the question, the answer is
almost always the same: it depends on your
application. However, there are a few universal
tips to follow when using dryers and filters that
can help reduce compressed air costs:

www.plantengineering.com plant engineering January/February 2017 59

mechanicalSOLUTIONS
Do not dry compressed air more than the
application requires. This is unnecessary
and wastes money.
Consider initial drying with a refrigerant-
type dryer, then dry further only to meet
point-of-use requirements.
Every filter causes a pressure drop, which
costs money. Dont filter more than neces-
sary.
4. Record maintenance data and trends.
5. Record operating pressures at strategic
points in the system, as these changes can
reveal problem areas.
6. Review the impact of new production
machines.
7. Analyze low pressure at point of use; this
could signal a system problem rather than
a need for a new compressor.

7. Remove condensate with no-loss drains Mapping the system is a helpful starting
Compressors make a lot of water. You need a point. This could be done by plant personnel or
way to safely and efficiently remove it from through a compressed air audit. The latter can
your system to avoid turning your compressed offer deeper insights into the systems function-
air pipes into water pipes. Manual drains ality and reveal changes that would improve the
Keeping should not be used, because they rely on a
maintenance team who may have other priori-
current system. Another way to keep an eye on
your compressors is through a remote monitor-
track of your ties. ing system, which can show where compressed
compressed air When left open, manual drains can waste air is going, where pressure drops occur and
expensive amounts of compressed air. Timer how much energy the system is using.
consumption can drains present a similar issue, and both types of
10. Select the right compressor
drains may not work properly on a humid day.
offer important Selecting the right compressor for your oper-
Instead, opt for drain traps that sense the
ation is paramount. While there are many
presence of condensate and drain it without
insights. From options, its important to understand the
the loss of compressed air. You should always
informing different types of compressors and the cost
inspect drain traps regularly and repair as
needed. advantages they offer. Every technology has its
maintenance unique advantage based on the plant demand
8. Recover heat and application.
practices to Heat is always a byproduct of air compression. VSD: Because it adjusts to meet demand,
In fact, you can recover almost 90% to 95% this compressor is good for trim applica-
prompting energy of heat from certain compressors. A radiator- tions.
saving initiatives, cooled unit can provide air for space heating Oil-free: Oil-free compressors are ideal for
in a building, and a water-cooled unit can pro- sensitive applications like food, beverage
its always good duce hot water for plant use. Instead of direct- and pharmaceutical processing.
ing hot compressor outside or discarding the Centrifugal: These dynamic compressors
to know whats hot water, use these resources to power your are large and produce high flows, making
happening in your facility to save money. them good base load compressors for large
production industries such as semiconduc-
system. 9. Measure and monitor air use
Keeping track of your compressed air con-
tor production.
Piston: Piston compressors are frequently
sumption can offer important insights. From small and portable, making them perfect
informing maintenance practices to prompting for automotive and other shop applications.
energy saving initiatives, its always good to
know whats happening in your system. Doing Dont purchase a compressor without first
so will not only prevent serious issues from researching which best fits your application,
going unnoticed, it will also help your plant pressure and capacity needs. Examining your
find ways to continuously improve efficiency. options up front will save you money down
There are seven important things to keep in the line.
mind regarding monitoring: These tips are just the beginning. Implement-
ing energy and cost-saving practices takes time
1. Establish a baseline of your system before and ongoing commitment. By adhering to the
making changes. above practices, your facility can save significant
2. Establish a benchmark of energy consump- amounts of energyand money. PE
tion against rate of production.
3. Record any system changes and resulting Deepak Vetal is product marketing manager
energy savings. for Atlas Copco Compressors.

60 January/February 2017 plant engineering www.plantengineering.com

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MAINTENANCESOLUTIONS
Mobile safety strategy:
Six things to consider
Combine smart devices with flexible technology to provide real-time alerts.
O
By Jason Dea and Gary Edwards rganizations go through significant
Intelex Technologies evolutions in many areas of their
businesses. The technical challenges
in managing risks around workplace
safety are similar in many respects to other
parts of the enterprise: there is software to
minimize the hurdles that impede getting
information from a source into a system
which in turn enables the right people to
make informed, proactive and actionable
decisions.
Archaic environmental health and safety
(EHS) programs rely on employees to col-
lect data manually, transpose the information
into spreadsheets or disparate, disconnected
software productsor worse yet, paper bind-
ersand perpetually repeat this process. Such
programs may suffice in meeting minimum
regulatory standards, but they typically fall
short due to human error and the sheer quan-
tity of information involved. Absent adequate
software, actionable intelligence is not avail-
able to inform proactive decision-making and
preventive actions.
Mobile devices integrated with EHS tools
to leverage real-time connectivity, native
apps, and easy in-the-field data entry, are
game changing. They place employees, not
the safety manager, in the center of influence.
Beautiful scorecards might light up a safety
managers interest, but the real question to
ask is: Does this tool work in the hands of
my workers who are at the frontlines and
highest risk?
www.plantengineering.com
With mobile devices, data can be collected
on the fly from all personnel. Conversely,
these same field staff and their managers
can receive data-driven insights and alerts
as they go. Mobile devices unleash potential
by exposing and reducing hazards and unsafe
behaviors, facilitating broader employee (and
contractor) adoption and by transforming
real-time source data lifted from the field
into instantly actionable intelligence.
In the case of incident management, for
example, no reports are complete without
some form of location-based data. GPS and
mapping services are embedded into almost
all current smart mobile devices (phones and
tablets) as native apps. Critical location data
can be pushed to managers and employees
instantly when on-device apps connect with
EHS tools.
Similarly, all smart mobile devices feature
some form of a camera capable of capturing
high-quality photos and videos. Both capa-
bilities already are frequently used to enrich
incident and audit reporting, but when tied to
EHS systems they instantly provide essential
visual support.
No mobile device is complete without a
series of apps designed to fulfill its main pur-
pose: communication. Between the efficient
Gary Edwards, Intelex Technologies
PLANT ENGINEERING January/February 2017 63
mAINTENANCESOLUTIONS
Ensure your mobile EHS app is an
integral component of a safety
ecosystem that prevents incidents
rather than just reporting them.
Jason Dea, Intelex Technologies
use of phone logs and chat apps, as well as
voice recording, dictation and note-taking
tools, the burden on frontline staff of collect-
ing and inputting data into an EHS system
in the field is immensely reduced. Mobile
devices improve accuracy and significantly
reduce the time associated with completing
tasks.
Joining native capabilities with existing
EHS enterprise software combines cutting-
edge technologies with battle-tested apps.
By contrast, adopting new market entrant
standalone entities injects considerable risk
into risk management.
Rethinking mobile requirements
Unlike other mobile apps, choosing an EHS
mobile app is not a simple feature and func-
tions race. Because of the complexity and vari-
ety of operational requirements both within
companies and within sectors, a simple feature
list for an EHS app is not helpful in evaluating
its potential effectiveness or fit.
Consider the following six essential require-
ments when adopting mobile EHS apps:
1. Is it field tested and battle ready?
Being developed in the field with frontline
user input is crucial. That means the app has
been optimized for ease, convenience, speed
and relevance in the environments and circum-
stances where end users put it to use. Beautiful
scorecards might light up a safety managers
interest, but the real question to ask is: Does this
tool work in the hands of my workers who are
at the frontlines and highest risk? Approaching
100% adoption and engagement of EHS mobile
is the only route to achieving 100% safety.
2. Are configurable views unique to and
optimized for mobile?
User-friendly design is critical, again, most
importantly for field users. Remember that
64 January/February 2017 plant engineering
mobile apps are not just about
shrinking a screen. Indeed,
many mobile apps remain fix-
ated on individual page views
while neglecting more important
design elements. Consider the
user experience in navigating
within the app versus just the
final destination page.
3. Is it optimized to capture
leading indicators?
Capturing incidences as they
occur in the field is an obvious
and base requirement of any EHS mobile
solution. To meet the promise that mobile
deployment offers, EHS mobile solutions need
to focus and optimize features that capture
leading indicators, including hazards, unsafe
behaviors (etiquettes) and minor incidences
that do not get formally reported to regulators.
Benchmarks on leading indicators must be
part of the mobile solution if you want your
enterprise to achieve a step change in safety
results.
4. Does it offer integrated predictive and
prescriptive analytics capabilities?
While some apps claim to provide data anal-
ysis, they are primarily reports detailing which
incidents have happened and when. Descrip-
tive information on past events, while infor-
mative, is very limited in enabling action. The
abundant streaming data points provided by
the broad adoption of a user-friendly mobile
app offers the opportunity for a network
effect in workplace safety. Real-time data
processed with machine learning algorithms
can provide actionable in-the-moment pre-
scriptive advice.
Data that engaged workforces capture
is proving to be highly predictive of future
serious incidences. Information collected on
reports of pain, near misses, hazards and safety
observations all are proving to be strong lead-
ing indicators. Dashboards, reports and alerts
that highlight risk and provide an immediate
opportunity for prevention need to be an inte-
gral part of any mobile solution.
Ensure your mobile EHS app has an integral
component of a safety ecosystem that prevents
incidents rather than just reporting them.
5. Does it have an EHS mobile software as a
platform or is it a stand-alone entity?
Ideally, couple your existing EHS soft-
ware such that changes in the core system
www.plantengineering.com
are automatically reflected in the mobile
app. Need to capture new information?
You should be able to seamlessly integrate
it into existing software, allowing you to get
started in the field and finish back at the
office. Get an app that can be tweaked for
each different user type in your company
and that will adapt to your evolving needs.
6. Does your vendor offer the opportu-
nity for co-creation?
This last requirement builds on the pre-
vious one and may be the most important.
Ensure the ability for co-creation of require-
ments with your vendor. Additional features
you discover are critical to the field must
be easily captured, built into the core soft-
ware and reflected in the mobile app. User
feedback and front-line input are critical
to success.
Consider all job types, each with their
attendant risks and the various experience
levels of individuals who perform them. We
could know who a person is, what training
they need, and the particular time and place
when they need a helpful reminder or nudge.
Further, consider the Industrial Internet of
Things (IIoT) where we can track the objects
and equipment people in our workplaces
encounter day to day. Now combine the two.
We can keep people safe in workplaces
like never before by targeting their needs in
ways that replace disengaged general advice
with highly accurate information tailored
to the job, the individual and the moments
that matter to them.
Consider that your marketing department
probably avoids spamming offers for every-
one and instead uses highly personalized
messages and offers. Hence, they evolved
from a one-to-many to a one-to-one cus-
tomer approach. If you want breakthrough
ideas in safety management, bring the les-
sons learned from digital marketing and its
enabling technologies to your health and
safety professionals and a mobile strategy. PE
Jason Dea is director of product mar-
keting at Intelex Technologies, and Gary
Edwards is a data science advisor to Intelex
Technologies.

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input #22 at www.plantengineering.com/information

 T he voice of the engineering community
speaks loud and clear in the following pages
featuring corporate profiles of those companies
participating in the Executive Voice program
presented by Plant Engineering magazine.

Our thanks to the following participants:

AutomationDirect
Camfil Air Pollution Control
Century Spring Corporation
Flexicon Corporation
Kaeser Compressors
SEW Eurodrive
Universal Electric Corporation

A well-recognized name in the industrial automation market,
AutomationDirect also provides quality products with FREE
award-winning in-house sales and technical support.
AutomationDirect provides customers with quick order and delivery
through an online store and toll-free number. Prices on most products
are well below the industry average and a 30-day money-back
guarantee is offered on nearly all items.
With tens of thousands of part listings, new products include the
Productivity2000 PLC, C-more EA9 HMI, and SR55 AC motor
soft starter. These products represent many years of design and
development by AutomationDirects own engineering team as well as
their strategic partners. The company also offers AC drives/motors,
sensors, pushbuttons, enclosures, circuit protection and more.
AutomationDirects corporate headquarters near Atlanta, Georgia
The state-of-the-art headquarters facility near Atlanta is designed
throughout for maximum performance. Orders for in-stock items can
be taken as late at 6 p.m. EST and be shipped for next-day delivery.
ADVERTISEMENT
See videos on AutomationDirects YouTube channel:
https://www.youtube.com/user/automationdirect
The company provides online tutorial
videos through their web store at
www.automationdirect.com as well as
their YouTube channel. A Customer Forum
provides peer support on technical and
application questions.
AutomationDirects customer support team
has been rated top-notch by its customers.
For 15 years running, the Tech Support team
has been voted by readers of Control Design
magazine as best in service and support for
various products. And, their own customer
surveys consistently rank the companys
service as better than other suppliers.
For an in-depth look at products offered,
visit: www.automationdirect.com
sales@automationdirect.com
1-800-633-0405
www.automationdirect.com

C amfil APC offers the most
technologically advanced
dust, mist and fume collectors
available backed by dependable
customer support and decades
of experience.
Our mission is to ship collectors fast
while still giving the customer what
they want; to be the most customer
friendly company in the business;
and to make the best collector in the
business from an end-user and
maintenance viewpoint.
We guarantee our collectors to meet
EPA particle emission requirements.
We are also a leader in explosion
protection, with a full range of
technical services to analyze
combustible dust problems and
exclusive products to protect against
dust collector explosions.
We are a subsidiary of Camfil, the
largest air filter manufacturer in the
world. All our components, including
filter cartridges, are manufactured in
ISO 9001 certified facilities.
Camfil APC factory in Jonesboro, Arkansas
Our corporate headquarters
facility in Jonesboro, Arkansas
houses manufacturing, sales and
ADVERTISEMENT
administrative functions and a
state-of-the-art test lab equipped to
conduct a battery of bench tests on
dust samples, as well as simulated
full-scale testing. These scientific
tests take the guesswork out
of equipment selection to help
identify the best dust collection
equipment for the job.
During 2017 Camfil APC will
further expand its global product Graeme Bell
Vice president, Camfil APC Americas
portfolio to cement its position as
Dust, mist and fume collector
supplier of first choice. Our flagship
Farr Gold Series dry dust collector
will be complemented by the new
In 2017 Camfil APC
Quantum Series dust collector. will further expand
This innovative, compact unit is
designed to ensure a cleaner and
its global product
safer workplace in a wide array portfolio with the
of dry dust collection applications.
introduction of the
The Handte EM Profi emulsion Quantum Series.
coolant mist collector for
machining centers offers very
high collection efficiency and
24/7 performance. Benefits The Handte Vortex wet scrubber
include increased productivity, combines high-performance wet
exceptional service dust collection with plug and play
ease and lower operation. Its ideal for capturing very
operating costs. sticky dusts and fibers and highly
Service life is up to explosive metallic and chemical
six years for the dusts. Because it provides wetting of
primary filters. combustible dusts, it can eliminate
the need for costly ancillary explosion
The Handte Oil protection devices.
Expert handles
ultrafine, hard-to-
capture oil mists
generated by machining processes
that use pure (undiluted) lubricant
oils. Both products come with a filterman@camfil.com 1-800-479-6801
12-year limited warranty. www.camfilapc.com

F lexicon Corporation engineers
and manufactures bulk handling
equipment from stand-alone units
to automated systems that are
integrated with new or existing
process equipment and storage
vessels throughout the plant.
Virtually any bulk solid
material or blend
Flexicon equipment can handle
virtually any bulk material, from
large pellets to sub-micron powders
including friable materials, free- and
non-free-flowing products, and
materials that pack, cake, plug, smear,
fluidize or separate. After more than
20,000 installations, Flexicon is
knowledgeable about virtually all bulk
materials and blends that customers
are likely to encounter.
Lifetime Performance Guarantee
The Flexicon Lifetime Performance
Guarantee assures customers of a
successful result, regardless of whether
they purchase one piece of equipment
or an automated plant-wide system,
providing added assurance that
customers can trust their process,
and their reputation, to Flexicon.
Designed and constructed to
industry standards worldwide
All Flexicon equipment is available in
carbon steel with a variety of durable
industrial finishes, and stainless steel in
industrial and food, dairy and phar-
maceutical finishes, including designed
and constructed for 3-A certification
and USDA acceptance.
ADVERTISEMENT
Stand-alone equipment
The Flexicon line of stand-alone
equipment includes: Flexible Screw David Gill
Conveyors, Tubular Cable Conveyors, President
Pneumatic Conveying Systems, Bulk
Bag Unloaders, Bulk Bag Conditioners,
Bulk Bag Fillers, Bag Dump Stations,
Drum/Box/Container Dumpers and
Weigh Batching and Blending Systems.
Numerous model configurations Manufacturing on
are offered within each equipment four continents
category, as basic, low cost units up Flexicon manufactures equipment in
to engineered, automated, high- the US, UK, Australia and South
capacity machines. Africa, maintains dedicated factory
representation in Singapore, Spain,
Large-scale bulk Chile and Germany, and also markets
handling projects equipment and systems through an
Customers can alleviate the burden extensive network of authorized
and risk of designing large-scale bulk representatives worldwide.
handling systems, coordinating
multiple suppliers, integrating The company holds 36 patents in 13
components and trouble-shooting countries, and recently doubled the size
start-up, by relying on Flexicon for of its US headquarters.
it all.
Flexicon can evaluate customer
material(s), plant layout, through-put
rates, cost, cycle times and other
parameters, and engineer the optimum
solution to individual bulk handling
problems in the form of CAD drawings
that integrate Flexicon and other
equipment with new or existing
equipment in the customers plant.
In addition, Flexicon can test
customer materials on full-size test
equipment, build the equipment,
supervise installation, validate the
Flexicon Corporation
project, and train customer personnel +1 610 814 2400 sales@flexicon.com
to operate it anywhere in the world. www.flexicon.com

T he start of a new year is a chance
to examine current processes,
look to the future, and plan for new
growth. At Kaeser, we continually
look for opportunities to improve our
operations so we can better serve our
customers, but never at the expense of
our heritage.
This heritage is built on nearly a
century of manufacturing excellence
and holds reliability, efficiency, and
quality at its core. This commitment
to excellence guides our engineering,
design, and customer service principles
and means we deliver solutions-based
systems of the highest quality.
With this system data, we can
simulate power requirements of
different system scenarios using our
Kaeser Energy Saving System (KESS)
in order to build the most energy
efficient system possible.
Compressors, Inc.
These compressed air audit tools
coupled with our unbeatable efficiency,
simple maintenance, and rugged reli-
ability, result in a built for a lifetime
system that is engineered to perform.
Kaeser is not intimidated by demand-
ing applications. Our commitment to
designing the best engineered solutions
results in compressed air systems that
remain reliable even
in the toughest of
applications in
the harshest of
environments. Thats
why our customers
know us as the air
systems specialist.
ADVERTISEMENT
Frank
Mueller
President,
Kaeser
interfaces for seamless integration
into the IIoT.
Kaeser is committed to providing our
customers with engineering excellence,
the highest in manufacturing quality,
and cutting edge solutions. Prompt
and dependable customer service and
engineering support are backed by
extensive training and our ISO
9001:2008 quality assurance and
ISO 14001:2004 environmental com-
pliance program. These all contribute
to the value our customers have come
to expect from the Kaeser name.

Kaeser Compressors, Inc. Headquarters in

Fredericksburg, Virginia
While others offer cookie cutter
scenarios or one-size fits all systems,
our consultative approach means we
work with our customers to understand
their application needs and develop a
tailored solution that will continue to
deliver the compressed air they need
year after year.
Using our comprehensive Air Demand
Analysis (ADA) program, our engi-
neers build a complete and accurate
air demand and consumption profile
to give a clear picture of the systems
compressed air requirements.
Kaeser is committed to providing
our customers with engineering excellence,
the highest in manufacturing quality,
and cutting edge solutions.
Our turnkey, all-weather Custom
Engineered Solutions are compressed
air packages that integrate our high
quality compressed air systems with
rugged, weather-proof containers or
skids. Remote operations are supported
by our Sigma Air Manager 4.0, which
customer.us@kaeser.com
controls air production and offers a www.us.kaeser.com
variety of industrial communications (866) 516-6888

A s a world leader in drive
technology and a pioneer in
drive-based automation,
SEW-EURODRIVE has established
a reputation for quickly solving the
most difficult power transmission
and motion control challenges.
We introduced the gearmotor in
1931 and in the 86 years since
then, we have been bringing the
best in drive technology to our
customers worldwide.
U.S. Corporate Headquarters in
Lyman, South Carolina
Quickly solving problems so that our
customers can be more productive
and profitable continues to be our
priority. We offer the broadest
product line in the industry from
gearmotors and heavy industrial
gear units to electronic drives,
software and complete drive-based
automation systems.
We offer the broadest product line in the industry
from gearmotors and heavy industrial gear units
to electronic drives, software and
complete drive-based automation systems.
Our products are based on a unique
system of modular components that
can be assembled in literally millions
of different configurations so every
drive solution is custom built to our
customers exact specifications.
Our regional assembly centers stock
millions of dollars of our modular
inventory for quick delivery of drive
solutions and spare parts anywhere in
the U.S.
At SEW-EURODRIVE our
expertise doesnt stop with
the sale of our products.
We offer one of the most
accessible customer support
systems in the industry.
Our trained product
specialists are readily
available for on-site
start up assistance and
applications support.
In addition, our PT Pilot
selection tool quickly selects the
drive for your specific needs.
Our customer service personnel,
engineers, product specialists,
and service technicians are
available to answer questions
and troubleshoot problems.
SEW-EURODRIVE offers on-call
emergency technical support
around the clock.
ADVERTISEMENT
MOVIGEAR
Mechatronic
Drive System
The MOVIGEAR
Mechatronic Drive
System for horizontal
materials handling from
SEW-EURODRIVE sets new
standards in terms of efficiency
and functionality.
reduces total start-up cost
and annual operating costs
in your material handling
system by 20-30%!
MOVIGEAR not only combines the
gear unit, motor and drive electronics
within one highly reliable, efficient,
and hygienically designed unit, it also
reduces total start-up cost and annual
operating costs in your material
handling system by 20-30%!
MOVIGEAR also eliminates excess
inventory since it allows the use of a
single ratio to replace several
different ratios.
864-439-7537 www.seweurodrive.com
 ADVERTISEMENT
U niversal Electric Corporation (UEC), the manufacturer of Starline and
U-S Safety Trolley, has been tackling common industrial power issues
through the development of innovative products for more than 50 years.
David
Grafton
Innovative
All great inventions are initially sparked by a simple idea. At UEC, we Vice President
of Engineering
take pride in acting on these ideas. U-S Safety Trolley, our line of no-joint & Quality
mobile electrification products, was a first of its kind to bring safety to
manufacturing facilities by incorporating an insulated cover over the
conductor bar in the 1950s.

In addition to the previous safety concern, UEC recognizes that one of Customizable
the main challenges with arranging a manufacturing floor is ensuring all UEC is committed to both customer sat-
equipment will have access to power. In the past this would involve an isfaction and engineering excellence by
electrician running ridged conduit and wire to fixed locations, and thus maintaining a completely customizable
equipment would be immovable once hardwired. shop. Our plug-in units, that can
be placed anywhere along the system,
Today, UEC offers a suite of power distribution and monitoring solutions are available in more than 60 million
that remove this burden from facility managers and operations executives. possible combinations.
Our Starline products Track Busway and Plug-In Raceway can be used
overhead or along the wall to supply power to lights, tools and equipment. Whatever configuration of drop cords,
outlets, circuit breakers or fused
Flexible disconnects will fit the customers needs
A key element to the Starline products is their flexibility- making them a best, our engineering team will build.
perfect fit for lean manufacturing environments. With overhead Track
Busway, UEC pioneered the first continuous, open access channel that This customer-first culture and
allows you to relocate power anywhere along the system. The system commitment to continuing innovation
requires no routine maintenance and allows for the rearranging of tools has resulted in great success and
and equipment on the manufacturing floor both safely and easily; saving exponential growth for our company.
future costs and downtime associated with electrical rewiring work.. UECs mission is to continue to solve
common power issues by providing
Starline Plug-In Raceway employs the same flexible, continuous access innovative, flexible and customizable
concept, but for along the wall; perfect for labs, assembly lines, and office power solutions that fit each customers
or common areas. critical requirements.

Canonsburg, PA headquarters

724-597-7800
info@uecorp.com
www.uecorp.com

R ecently upgrading to a larger
facility in Commerce, Calif.,
paired with substantial investments
in new equipment, Century has
considerably expanded their stock
and custom manufacturing and
fulfilment capabilities.
Centurys leadership stems
primarily from listening to
customer needs, then providing a
quality product, proudly made in
the U.S.A., and in turn, ensuring
customer success.
ADVERTISEMENT
Same-day shipments are available
from an extensive selection of
compression, extension, torsion,
tapered, urethane, die springs,
and washers (Bellevilles and John Teeter
disc springs). Senior Vice President and
General Manager

Century Spring Corp. (CSC)
was founded over 84 years ago,
and is renowned for stocking the
largest and most diverse inventory
of springs in the industry.
With over 35,000 spring designs
and 330,000,000 parts in stock,
Centurys comprehensive line of
precision coiled and disc springs
are relied upon in a variety of
markets, including aerospace,
shipbuilding, medical, commercial,
defense, and dozens of others.
Our new Commerce, California facility
Centurys highest priority is
customer satisfaction, having
received numerous customer
service awards for on-time
delivery, shipping accuracy, and
quality control measures that are
guided by ISO standards.
{ }
Whether the demand is
for production volumes or
small prototype quantities,
CSCs stock levels and the largest and
low order minimums most diverse
make it simple to satisfy inventory of springs
customer requirements
in the industry
quickly, without lengthy
manufacturing lead-times.
Contact Century Spring Corp.
today to discuss your spring
needs or to acquire more
information on CSCs exceptional
products and services.
www.centuryspring.com

2016
pe201702_execV_centSPRNGhalf.indd 1 1/18/2017 8:53:53 AM

Industrial Internet of Things &

Industrie 4.0
Turning research into insights makes for better business decisions
This study was conducted by CFE Media to gauge the engineers understanding and
current implementation of the Industrial Internet of Things (IIoT) and Industrie 4.0.
Respondents to the 2016 Industrial Internet of Things & Industrie 4.0 study identified
five key findings regarding their familiarity and implementation of the IIoT framework
and Industrie 4.0 platform.

According to the study, familiarity with the IIoT framework and the Industrie
4.0 platform has significantly increased since 2015; 79% of respondents
are very/somewhat familiar with IIoT, compared to 60% last year, and
53% are very/somewhat familiar with Industrie 4.0, compared to 33%
previously. More than half of respondents expect IIoT and Industrie 4.0
to improve connections between people, data, and machines at their
facilities. Other expected benefits include increased information flow,
increased innovations, and improved data analysis.

Access the 2016 Industrial Internet of Things & Industrie 4.0 report with
additional findings and insights. www.controleng.com/2016IIoTStudy
 CFE Medias
Global System Integrator Database

CFE Medias Global System Integrator Database is an interactive community

of global end-users and system integrators hosted by Control Engineering, Plant
Engineering, and our global partners in Asia and Europe.

The newest version of the online database is even easier to use.

Features and updates:
Relevancy score indicates how closely New feature allows an end-user to
an integrators qualifications match a request a quote for a project directly
users search criteria from the database site

Users can now preview the most The most relevant data about an
pertinent data of a System Integrator integrators engineering services appear
before clicking to view the full on one page on their corporate profile
corporate profile other details are organized by tabs.

As a Systems Integrator there are quite a few options available

for online advertising. They vary in functionality and design,
but the Global System Integrator Database has been our go to.
It is easy to use, professionally designed, and has given us a great
deal of exposure to clients we wouldnt normally be able to reach.
We have had more clients contact us with this solution than any

other System Integrator database combined. We not only going
to renew our profile this year, we plan on upgrading.
William Aja, Panacea Technologies

Find and connect with the most suitable service

provider for your unique application.

www.plantengineering.com/global-si-database
IN NOVATIONS
CFE Media launches
New Products for Engineers database
CFE Media Technology, a division of CFE Media, has released a New Products for Engineers database;
a unique software as a service (SaaS) platform that provides valuable services to engineering users who are inter-
ested in discovering new products, and vendors who would like to promote their new products to engineers. User
benefits include the following:
Engineering and technical professionals can quickly access the latest new product information
for the manufacturing, commercial construction, automation and control industries.
Engineers can rate and provide feedback on new products.
Engineers can set up automatic notifications allowing aggregation and delivery of select,
new product information on a predetermined, scheduled basis.
New product vendors can easily upload, edit and manage their new product information
within the platform.
Vendors have the ability to enhance their product profiles with media files, spec sheets,
case studies, and videos to give end users valuable information about their products.

Our global engineering audience takes pride in knowing what new products are immediately available to help
them better address their production performance, safety, and information needs, said Steve Rourke, CEO
CFE Media LLC. Our latest database platform not only allows them to quickly find and peruse new products
but also allows them to set up new product notification messages that will keep them informed of any new
product or desired company related updates.

The New Products for Engineers Database has a community of manufacturers that provide new and updated
products, which are easily searchable within the database. The database is hosted by Control Engineering,
Consulting-Specifying Engineer, Oil & Gas Engineering, and Plant Engineering.

Measurement technology modules

The ELM series EtherCAT measurement technology modules are designed to lower the use of raw materials
and energy in machines and plants while forming the basis for advanced condition monitoring and predictive
maintenance. The ELM modules
integrate directly into the EtherCAT
I/O system and other terminals. The
metal housings of the series optimize
shielding and cooling in measure-
ment technology applications. The
metal enclosure of the ELM series
features a flexible connector front-
end for all standard measurement
technology interfaces. The hardware
ensures high-quality measurement
data with the full utilization of Ether-
CAT features.
Beckhoff
www.beckhoff.com
Input #200 at www.plantengineering.com/information

www.plantengineering.com PLANT ENGINEERING January/February 2017 75

IN NOVATIONS
Air/gas thermal
flow meter
The ST100 Air/Gas Thermal Flow
Meter uses thermal dispersion
technology and is designed for the
measurement of air, combustion air,
oxygen, natural gas, synthesis gas,
methane and many other process
gases. It has a fast-response, direct
mass flow sensor for close ratio
control at combine cycle gas turbine
(CCGT) electric power generation
plants. The direct mass device is
installed in the process control loop
to allow operators to achieve a direct
ratio of control without any correc-
tions for pressure, temperature or
density. The flow meters not only are
applied on cold, fresh-air intakes, but
also at preheated or combustion air
feeds to the gas turbines.
Fluid Components International (FCI)
www.fluidcomponents.com
Input #201 at www.plantengineering.com/information
76 January/February 2017 PLANT ENGINEERING
Send new product releases to: peproducts@cfemedia.com
Pressure indicators
The Series 699 differential pressure indicators and transmitters are designed
for use with air and neutral gases and are available in three configurations
and several pressure ranges. Series 699 Indicators/transmitters measure low
differential pressures typi-
cally found in air conditioning
applications, such as in air
flow measurement, fan static
pressures and specialty room
pressure measurements. The
series incorporates ceramic
fulcrum lever technology
and long set-point stability,
which deliver adjusted and
temperature-compensated
sensor signals. Configuration
1 is a transmitter with field
selectable ranges and factory preset output signal and zero offset configurations.
Configuration 2 incorporates a 10-position DIP switch allowing field selection of
range, output signal and response time. Configuration 3 is designed with an LED
display and full field function programming via a programming button.
Clark Solutions
www.clarksol.com
Input #202 at www.plantengineering.com/information
Analytical measurement sensors
The DS80 Intelligent Sensor Series is
designed to provide multi-parameter
analytical measurement of pH, ORP, DO,
conductivity, resistivity and numerous
specific ions. The series has replaceable
cartridge sensors and a standard modular
design that can be customized for a wide
range of industrial application-specific
measurements in the most rugged environ-
ments. The DS80 sensors store and identify
calibration information and communicate
via Modbus RTU with the ability to connect
directly to a programmable logic control-
ler or a computer. The DS80 sensors are
available in two universal package designs:
insertion/submersion or valve retractable
with a flared-end to prevent blowout.
Electro-Chemical Devices (ECD)
www.ecdi.com
Input #203 at www.plantengineering.com/information
www.plantengineering.com
eNewsletters
Plant Engineerings electronic newsletters deliver news and information
on the latest trends in manufacturing in every corner of the plant floor.

Applied Automation
Education and Training
Energy Management
IIoT: Machines, Equipment and Asset Management
IIoT: Operations and IT
IIoT: Process Control and Automation
Maintenance Connection
New Products for Engineers Showcase
Oil & Gas Engineering
PLANTMAIL!
Plant Safety
Predictive and Preventive Maintenance
Product Focus
Whitepaper Connection

Get your plant ahead of the curve.

Subscribe today:
www.plantengineering.com/newsletters
IN NOVATIONS Send new product releases to: peproducts@cfemedia.com

Biodegradable coatings system

The biobased and biodegradable system replaces hazardous synthetic chemicals with safe, green alternatives for corrosion
protection in metalworking industries. BioCorr is water-based and designed for preservation of metals by combining film-
forming additives with Vapor phase Corrosion Inhibitors (VpCIs). Ecoline 3220 is a canola oil-based, temporary coating that
clings to metal surfaces for vapor corrosion
inhibition and lubrication. Ecoline 3690 is an
open-air solution for marine and high humid-
ity conditions and has no effect on rubber,
plastics, or paint. Ecoline Cleaner/Degreaser
is a soya-based solution designed for tough
cleaning jobs and can be used on all metals
and alloys. The cleaner is non-flammable,
and all the products in the system are VOC,
chromate and nitrite free.
Cortec Corporation
www.cortecvci.com
Input #204 at www.plantengineering.com/information

Handheld production
control system
The Commander XT1000 is a handheld
production control system designed as an
assembly aide while
collecting critical
hydraulic bolting data.
The wireless control
device will lead the
Belt-type oil skimmer operator through
The Mini-Skimmer is a belt-type oil skim- each bolt to the cor-
mer designed to collect over a quart of oil rect torque and in
per hour despite its tiny housing, measuring sequence and store
just 3 in. x 3 in. x 2.75 in. It also is designed the data real-time to
to skim unwanted tramp oils from coolants the cloud. It can also
and clean wastewater. The oil skimmer control and operate
has an on/off switch to allow users to eas- the pump and tool independently. The Com-
ily monitor its activity for machine shops, mander XT1000 has its own software, but
ultrasonic cleaners and parts washers. The it can also interface with others. The Com-
skimmer for small machining operations is mander XT1000 includes a high-resolution
portable, with a stretch-resistant, fiberglass- camera for recording images of the bolting
reinforced cogged belt. It has a liquid tight operation.
housing made of anodized aluminum and a motor with the high- Torq-Comm
est torque for a skimmer of its size. www.torq-comm.com
Input #206 at www.plantengineering.com/information
Wayne Products
www.wayneproducts.com
Input #205 at www.plantengineering.com/information

78 January/February 2017 PLANT ENGINEERING www.plantengineering.com

 Plant Engineering
Webcasts help you
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Webcasts specific topics and
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optimization
System Integration case studies
lloT series: Network integration,
cyber security
Safety

www.plantengineering.com.com/webcasts
IN NOVATIONS
Adjustable LED lamp
The Lotus Lamp is designed for versatility with a 180 F adjustable mounting
arm that allows the lamp to be installed in multiple positions and at different
lengths for use in a wide variety of applications. The lamp is designed for use with
recessed cans, canopy lights, parking garage fixtures, parking lot lights, flood/spot
lights, high ceilings and high/low bays. The LED Lotus replaces anything up to 400
W metal halide and high-pressure sodium lamps with up to 80% energy savings.
The Lotus has 60,000 hours of rated life and comes with a 20 kA in-line surge
protection device to protect the lamp against disruptive and damaging power
surges and transients. The Lotus is completely protected from contact, dust and
water splashes.
HyLite
www.hyliteledlighting.com
Input #207 at www.plantengineering.com/information

Handheld camera
The X6570sc handheld camera is a part of the
X6000sc series and is designed to provide research-
ers, engineers and scientists with measurement
accuracy, advanced processing algorithms and con-
nectivity. The longwave performance camera records
640 x 512 full frame video at 234 Hz (up to 14,550
Hz with windowing) with the rapid integration times
needed to analyze high-speed processes or moni-
tor fast temperature spikes. The camera is sensitive
enough to distinguish temperature differences down
to 20 mK and offers connection options. The X6570sc
also has saved user configurations for efficient trans-
fer between test teams.
Flir
www.flir.com
Input #208 at www.plantengineering.com/information

Mobile portable compressor

The M58 is designed to deliver 210 cfm at 100 psig for rental houses, construction,
demolition, sandblasting, repair trucks and other demanding applications. The por-
table compressor has a powder coated, fully weatherproofed steel cabinet built to
withstand harsh conditions. It also has a single-point lifting ball for easy mounting or
dismounting. The eye-level curbside instrument panel is equipped with a smart elec-
tronic controller with a protective metal cover. The 28-gallon
fuel tank is designed to provide extended operation up to 10
hours. Additional features include a steel chassis, torsion bar
suspension, over-sized tires and lighting package.
Kaeser
www.us.kaeser.com
Input #209 at www.plantengineering.com/information

80 January/February 2017 PLANT ENGINEERING www.plantengineering.com

 Send new product releases to: peproducts@cfemedia.com

Compressed air pipe

The SmartPipe is a modular, aluminum com-
pressed air distribution system designed with
lightweight materials and simple connectors
that can be installed without threading, welding
or sweating. Available in multiple sizes from
1/2 to 6 inches, SmartPipe is ideal for head-
ers and branch lines all the way down to the
point of use. SmartPipe is made from smooth,
calibrated aluminum and will not rust. It has a
low coefficient of friction and provides lami-
nar flow. Full bore fittings minimize pressure
drop and leak-free connectors prevent costly
compressed air loss. SmartPipe can be easily
integrated into existing steel or copper systems
and modified to accommodate changing needs.
Kaeser
www.us.kaeser.com
Input #210 at www.plantengineering.com/information

Outdoor IP camera dome

The IKS-WR7413 IP is designed to monitor everything that
is happening outdoors even in complete darkness. With
its 3-megapixel video resolution and LED IR illuminators,
the camera dome provides high video quality with four
simultaneous video streams. The IKS-WR7413 can be
adjusted to cover a wide field-of-view or narrow its focus
to a smaller area for additional detail, and it is outfitted
with four adaptive infrared LEDs to capture images up to
25 feet away in the complete absence of light. Additional
capabilities include: recording in two different codecs,
integration with ONVIF-compliant recorders, and memory
storage up to 64 GB.
Toshiba
www.toshiba.com
Input #211 at www.plantengineering.com/information

www.plantengineering.com PLANT ENGINEERING January/February 2017 81

MEDIA SHOWCASE FOR ENGINEERS
Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

Attend Pressure & Profit:

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conference organizer Bob Glenn
(bob.glenn@kaeser.com) for more information.
Input #100 at plantengineering.hotims.com Input #101 at plantengineering.hotims.com Input #102 at plantengineering.hotims.com

SAFETY DIGITAL stay

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Input #103 at plantengineering.hotims.com Input #104 at plantengineering.hotims.com Input #105 at plantengineering.hotims.com

82 January/February
Month 2014 P2017 LANT ENGINEERING
PLANT ENGINEERING PLE_StayInformed_SixthPage_2016.indd 1
www.plantengineering.com
2/22/2016 5:26:26 PM
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 MEDIA SHOWCASE FOR ENGINEERS
Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

BOILER TECH
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Input #106 at plantengineering.hotims.com Input #107 at plantengineering.hotims.com Input #108 at plantengineering.hotims.com

PE_DigitalReport_SixthPage_MotionControl.indd 1

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2017_PLE_eNews_SixthPage.indd 1 2/1/2017 2:11:56 PM PLANT ENGINEERING January/February
PLANT ENGINEERING Month 2017
2014 83
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 17
ebruary 20
ry/F

Remove at
Janua

For more information on how to advertise in Plant Engineerings
Internet Connection, call Jim Langhenry at 630-571-4070 x2203
abb.us
ABB is a leader in power and automation technologies that
enable customers to improve performance while lowering
environmental impact.
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aitkenproducts.com
Aitken Products manufacturers and distributes high-qual-
ity industrial heaters. Aitkens products are for a variety world.
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The Association for Advancing Automation is the global
advocate for the benefits of automating.
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Atlas Copco produces and markets compressed air equip-
ment and generators, construction and mining equipment,
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automationdirect.com
AutomationDirect offers over 16,000+ industrial automa-
tion products through their free catalog and online super-
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Place next to your computer as a reference or go online to www.plantengineering.com for hot links to these companies.
dynatect.com solonmfg.com
Dynatect designs and manufactures a complete line of Solon Manufacturing Co. engineers and manufactures
components to protect equipment and people. Solon Belleville Springs and pressure switches.
Dynatect Solon Manufacturing Co.
emaint.com uecorp.com
eMaint improves the way over 50,000 users worldwide UEC provides innovative, customizable power distribution
manage, monitor, and control assets for a connected and monitoring solutions.
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us.kaeser.com Yaskawa is the worlds largest manufacturer of ac inverter
Manufacturer of air system products, including rotary drives, servo and motion control, and robotics automation
screw compressors, portable compressors, rotary lobe systems.
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baldor.com noria.com
Baldor Electric designs, manufacturers, and markets a Noria is a worldwide leader in providing lubrication con-
broad line of industrial energy-efficient electric motors, sulting services and training.
mechanical power transmission products, and more. Noria Corp.
Baldor Electric Co.
orival.com
camfilapc.com Orival is a leading manufacturer of self-cleaning water
Camfil Air Pollution Control (APC) is a leading global filters, automatic water filters and strainers, for use as
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equipment and is part of Camfil, the worlds largest air fil- ters, and more.
tration company. Orival Inc.
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rogers-machinery.com
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and OEM applications since 1927. Rogers Machinery
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donaldson.com One of the largest global suppliers of drive technology,
Compressed air purifications solutions, compressed air SEW-EURODRIVE specializes in gear reducers, motors
filters, dryers and process water chillers. and electronic motor controls.
Donaldson Company Inc. SEW-EURODRIVE USA

86 January/February 2017 plant engineering www.plantengineering.com


CONTACTS Advertiser Contacts
for plant engineers
Request more information about products and advertisers in this issue by using the
PlantEngineering.com http://plantengineering.hotims.com link and reader service number located near each. If youre
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 reading the digital edition, the link will be live. When you contact a company directly, please let them
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CONTENT SPECIALISTS/EDITORIAL Advertiser Page Service # Phone # Web site
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630-571-4070 x2212, BVavra@CFEMedia.com
ABB Inc 21 17 www.new.abb.com/apw/PE
EMILY GUENTHER, Associate Content Manager
630-571-4070 x2220, EGuenther@CFEMedia.com ABB Motor Service C-4 24 800-Help365 new.abb.com/motors-generators/service
AMANDA PELLICCIONE, Director of Research Aitken Products, Inc 11 8 800-569-9341 www.aitkenproducts.com
860-432-4767, APelliccione@CFEMedia.com
CHRIS VAVRA, Production Editor Atlas Copco Compressors 17 14 866-688-9611 www.atlascopco.us
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PUBLICATION SERVICES AutomationDirect C-2 1 800-633-0405 www.automationdirect.com

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PAUL BROUCH, Director of Operations
630-571-4070 x2208, PBrouch@CFEMedia.com Donaldson Co., Inc 7 5 800-365-1331 www.DonaldsonTorit.com
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MARIA BARTELL, Account Director, Infogroup Targeting Solutions
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LETTERS TO THE EDITOR Lubriplate Lubricants Co 62 21 800-733-4755 www.lubriplate.com
Please e-mail your opinions to BVavra@CFEMedia.com
Orival, Inc 65 22 800-567-9767 www.orival.com
INFORMATION
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www.plantengineering.com PLANT ENGINEERING January/February 2017 87

A LIFE IN MANUFACTURING
As part of Plant Engineerings 70th anniversary celebration, were asking industry leaders and manufacturing profes-
sionals to tell us about their careers in manufacturing and its impact on them, their company and their community. If
youd like to contribute your story, please send it to content manager Bob Vavra at bvavra@cfemedia.com.
Manufacturings melting
pot focuses on people
By Billy Ray Taylor
The Goodyear Tire & Rubber Company
I
love manufacturing. Its the founda-
tion of America and breeds the free-
dom of creativity and change.
Historically, manufacturing played
a vital role in our countrys economic
development. Manufacturing remains
the core of economic success because it
produces consumer value. According to
the U.S. Bureau of Economic Analysis,
every dollar spent in manufacturing
generates $1.48 in economic activity,
more than any other major economic
sector.
Manufacturing not only drives our
nations economic health and national
security, it is a vehicle that drives inno-
vation. Manufacturing accounts for
two-thirds of all private spending on
research and development. And accord-
ing to the U.S. Bureau of Economic
Analysis, one out of three engineers
work in manufacturing.
Manufacturing, coupled with innova-
tion, transforms the unimaginable into
the reality, converts concepts to viable
products and improves the companys
value propositionall while simulta-
neously improving our quality of life.
The best ideas and solutions come from
everywhere and everybody. Effective
manufacturing cultures accept and
embrace diverse ideas. They include
everyone in the process.
88 January/February 2017 PLANT ENGINEERING
My entire 20-plus year career with
Goodyear Tire & Rubber Company has
been in operations. I have a deep-rooted
passion for manufacturing and have been
fortunate to work for a great company. As
a disciple of operational excellence, my
passion centers on people first. Manufac-
turing is a melting pot that links people,
tools, innovation and processes to deliver
constant value to the consumer. Manufac-
turing is as American as apple pie; it is a
way of life in the United States of America.
Manufacturing is a land of opportunity.
In its truest sense, manufacturings great-
est asset is an engaged workforce. The
best companies have a culture of respect
for people. One of my favorite sayings
is, make people visible, and people will
make value. In my role as a leader in
North American manufacturing, I have
the rich opportunity to learn from and
embrace diverse talents, solutions and
cultures.
I believe respect for people is what
drives a sustainable culture where lead-
ers and teams engage and empower each
other and build a culture that prioritizes
the quality of the solution over the source
of the idea. The best ideas and solutions
come from everywhere and
everybody. Effective manu-
facturing cultures accept
and embrace diverse ideas. They include
everyone in the process.
Driving manufacturing excellence
requires both diversity and inclusion.
Henry Ford is a great example. He was a
progressive and forward-thinker who lev-
eraged diversity and inclusion. Ford hired
African-Americans, women and disabled
people long before most other business
owners did. He was committed transpar-
ently to the principle of hiring and retain-
ing the best employees and to cultivating
the best ideas and solutions. By doing so,
he maintained a commitment to creating
the best possible goods at the lowest pos-
sible price.
As director of Goodyears largest and
most complex manufacturing facilities,
I have had the opportunity to experi-
ence firsthand the value of people-driven
processes. I believe success happens at
the source, through people and process
ownership at all levels. And this success
results in growthwithin the people and
the business. In turn, this drives sustain-
able, tangible results.
Finally, I love manufacturing because
it is incredibly gratifying. Manufacturing
allows me to impact change through oth-
ers, and to leverage people,
tools, innovation and pro-
cesses to deliver consistent
value to the consumer and
our economy. PE
Billy Ray Taylor is director
of commercial and off-high-
way manufacturing in North
American for The Goodyear
Tire & Rubber Company,
Akron, Ohio. Taylor also is a
member of the Plant Engineer-
ing Editorial Advisory Board.
www.plantengineering.com
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input #24 at www.plantengineering.com/information