2012 - 11 - Plant Engineering

71 Remote monitoring

81 Rugged flexible enclosures

89 Oil contamination

Remote Monitoring ®

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Compact Infrared Cameras with On-Board Visual Camera, Wi-Fi Connectivity, P-i-P and Bright LED Light • Superior Thermal Imaging—Up to 76,800 Pixels (320 x 240) • Improved Digital Camera—3.1 Mega Pixel Resolution • Wi-Fi Connectivity • Scalable P-i-P and Thermal Fusion

OSXL-E Series Starts at $ 2995

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Duct-Pipe Leakage

Electrical

Energy Loss

Mechanical & Industrial

iPad not included ®

Not for Export: USA and Canada only

Digital Infrared Video Thermometer

Thermal Imager

Compact Non-Contact Infrared Temperature Transmitter

OSXL-101 Series $ 1990

OS151-USB Series Starts at $ 593

OS-VIR50 $ 500

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Because of transmission frequency regulations, these wireless products may only be used in the United States, Canada and Europe.

Visit omega.com/osxl-101

omega.com ®

© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

input #2 at www.plantengineering.com/information

Ensure that your equipment is safeguarded at every point in the power distribution network with high-quality, cost-effective circuit protection and disconnection devices that meet UL standards. They’ll pay for themselves in no time!

UL 98 Disconnect Switches starting at $83 • Non-fusible and fusible rotary disconnect switches • Make/break loads up to 800 amps

Motor feeder short circuit and ground fault protection

UL 248 Current Limiting Fuses

Motor disconnecting means (NEC 430.101-430.113)

starting at $36 (10-pack)

UL 489 MCCBs

Motor branchcircuit short circuit protection (NEC 430.51430.58)

UL 489 Miniature Circuit Breakers, up to 40A

Class T, RK5, RK1 and Class J current limiting short circuit protection up to 600A

starting at $179

starting at $17.50 • • • •

• Rated current up to 800A, max 600V • Standard and high-interrupting capacity types

Bryant Manual Motor Controllers

Motor controller (NEC 430.81-430.91)

starting at $23.50 Motor overload protection (NEC 430.21-430.44)

DIN-rail mounted Up to 40 amps 1, 2, or 3-pole available 10kAIC @ 277/480VAC

UL 98 and UL 508 Compact Fusible Disconnect Switches

UL 508 Load Switches starting at $25.50

starting at $18.00

OSHA Lockout/ tagout disconnect (NEC 430.81-430.91) • • • • •

Control Transformer

Lockout / Tagout capability 30, 40 and 60A up to 600 VAC 2-pole and 3-pole switches Quick make, slow break design UL Listed as “Suitable as Motor Disconnect” under UL 508

• 35mm DIN rail mountable or direct mountable • Loads from 16 to 125 amps • IP20 degree of protection

UL 1077 Supplementary Protectors

• Up to 30A, utilizing Class CC or Midget fuses • 1, 2 and 3-pole models • Open fuse indication • Lockout/Tagout capability

UL 248 General Fuses

starting at $8.75

starting at $1.75 (5-pack) • Class CC, general purpose class M (Midget) and small dimension glass and ceramic fuses • Ideal supplementary protection up to 30 amps for branch circuits and end of line equipment

PLC I/O

Contactor Coils

Relays

• DIN rail mountable • Full line of auxiliary switches, alarm switches and padlock lockout accessories • B trip curve 6 to 60 amps • C trip curve 0.5 to 60 amps • D trip curve 0.5 to 40 amps

www.automationdirect.com Go online or call to get complete information, request your free catalog, or place an order.

1-800-633-0405

input #1 at www.plantengineering.com/information

NEVER SETTLE FOR

GOOD ENOUGH. Clean air is essential for keeping your employees and your equipment productive. Don’t risk downtime and damage to your most important assets with a sub-optimal dust collector or filters. Our broadest-in-theindustry product selection, unmatched customer support and a history of industry-leading innovation assures Donaldson Torit always delivers EXACTLY WHAT YOU NEED.™

Learn more about Donaldson Torit solutions DonaldsonTorit.com 800.365.1331 input #3 at www.plantengineering.com/information

© 2012 Donaldson Company, Inc.

November 2012

What’s INside

Volume 66, No. 9

6 Interactive 9 In Focus 23 In Practice 93 Product Mart 94 Internet Connection 95 Advertiser Contacts 96 In Conclusion

76 Enhancing systems PLANT ENGINEERING (ISSN 0032-082X, Vol. 66, No. 9, 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 2012 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. Telephone: 630-571-4070 x2220. 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 $20.00 US and $25.00 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

2012 Product of the Year Finalists

The next wave of innovation There are more than 100 finalists in 15 categories vying for your approval in this year’s Product of the Year voting. 30 Automation & Controls 36 Apps for Engineers

44 HVAC 45 Lighting

37 38 40 41 42 43

47 49 51 53 54

Compressed Air Electric Motors & Drives Electrical Controls Energy Management Environmental Health Fluid Handling

Maintenance Tools & Equipment Material Handling Systems Power Transmission Productivity Training Software Safety

PLANT ENGINEERING

November 2012 • 3

Analyze power quality and calculate energy loss. Poor power quality. It affects how your facility operates. It affects your bottom line. Fortunately, there’s the new Fluke 435 Series II Power Quality and Energy Analyzer. It features the most advanced waveform and power efficiency functions available and calculates the cost of wasted energy. So don’t settle for half the job–do the whole job with Fluke.

Learn more: fluke.com/pqandenergy.

input #4 at www.plantengineering.com/information

Automation Solutions PlantEngineering.com 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph 630-571-4070, Fax 630-214-4504

CONTENT CONTENT SPECIALISTS/EDITORIAL SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager BOB VAVRA, Content Manager 630-571-4070, x2212, [email protected] 630-571-4070 x2212, [email protected] AMANDA MCLEMAN, Project Manager AMANDA MCLEMAN, Project Manager 630-571-4070, x2209, [email protected] 630-571-4070 x2209, [email protected] MARK HOSKE,Content ContentManager Manager MARK HOSKE, 630-571-4070, x2214, [email protected] 630-571-4070 x2214, [email protected] PETER WELANDER,Content Content Manager PETER WELANDER, Manager 630-571-4070, x2213, [email protected] 630-571-4070 x2213, [email protected] AMARA ROZGUS,Content ContentManager Manager AMARA ROZGUS, 630-571-4070, x2211, [email protected] 630-571-4070 x2211, [email protected] CHRIS VAVRA,Content ContentSpecialist Specialist CHRIS VAVRA, 630-571-4070, x2219, [email protected] [email protected] BRITTANY MERCHUT,Content Content Specialist BRITTANY MERCHUT, Specialist 630-571-4070, x2220, [email protected] 630-571-4070 x2220, [email protected]

BEN TAYLOR, ContentSERVICES Specialist PUBLICATION

630-571-4070 x2219, [email protected]

JIM LANGHENRY, Co-Founder and Publisher, CFE Media 630-571-4070, x2203; [email protected] PUBLICATION SERVICES STEVE ROURKE, Co-Founder, CFE Media JIM LANGHENRY, Co-Founder & Publisher, CFE Media 630-571-4070, x2204, [email protected] 630-571-4070 x2203, [email protected] TRUDY KELLY, Executive Assistant STEVE ROURKE,x2205, Co-Founder, CFE Media 630-571-4070, [email protected] 630-571-4070 x2204, [email protected] ELENA MOELLER-YOUNGER, Marketing Manager TRUDY KELLY, Executive Assistant 630-571-4070, x2215; [email protected] 630-571-4070 x2205, [email protected] MICHAEL SMITH, Creative ELENA MOELLER-YOUNGER,Director Marketing Manager 630-779-8910, [email protected] 630-571-4070 x2215, [email protected] PAUL BROUCH, Production MICHAEL SMITH,Web Creative Director Manager 630-571-4070, x2208, [email protected] 630-779-8910, [email protected] MICHAEL ROTZ,Web Print Production Manager PAUL BROUCH, Production Manager 630-571-4070 x2208, [email protected] 717-766-0211, Fax: 717-506-7238 [email protected] MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 KARIE BURT, Account Director, mardevdm2 [email protected] 212-584-9374; [email protected] MARIAELLIS, BARTELL, Account Director, Infogroup Targeting Solutions nagement Director RICK Audience Management 847-378-2275, [email protected] Phone: 303-246-1250; [email protected] RICK ELLIS, Management Director LETTERS TOAudience THE EDITOR 303-246-1250, [email protected] Please e-mail your opinions to LETTERS TO THE EDITORor fax us at 630-214-4504. [email protected] Please e-mail opinions to company, and address, Letters shouldyour include name, [email protected] or fax us at 630-214-4504. and may be edited spacecompany, and clarity. Letters should includeforname, and address, and may be edited for space and clarity. INFORMATION For a 2012 Media Kit or Editorial Calendar, INFORMATION e-mail TrudyKitKelly at [email protected]. For a Media or Editorial Calendar, e-mail Trudy Kelly at [email protected]. REPRINTS REPRINTS For custom reprints or electronic usage, contact: For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco Wright’s877-652-5295 Media – Nick Iademarco Phone: ext. 102 Phone: [email protected] 877-652-5295 x102 Email:

71 Remote monitoring

technologies lower costs, improve operations The latest remote communication technologies allow experts to monitor and control multiple plants from any location.

76 Using sensors to enhance systems Recognize the limitations, then plan for redundancy.

Maintenance Solutions

81 Smaller, more flexible

enclosures still need to be rugged

Cabinets allow for safe and accesible storage, but can generate dangerous heat.

Mechanical Solutions

89 Particulates, liquids,

oxidation contribute to oil contamination

Oil discoloration should be addressed with high importance for optimal operation performance.

Email: [email protected]

PUBLICATION SALES PUBLICATION SALES Tom Corcoran, West, TX, OK [email protected] Tom Corcoran, West, TX,250, OK [email protected] 1111 W. 22nd St. Suite Tel. 215-275-6420 1111Brook, W. 22nd Suite 250, Tel.484-631-0598 215-275-6420 Fax. Oak IL St., 60523 Oak Brook, IL 60523 Fax 484-631-0598 [email protected] Karen Cira, Southeast Karen Cira, Southeast [email protected] 879 Autumn Rain Lane Tel. 704-523-5466 879 Autumn Rain Ln. Tel. 704-523-5466 Charlotte, NC 28209 Fax Charlotte, NC 28209 Fax630-214-4504 630-214-4504 Patrick Lynch,AL, AL,FLFL [email protected] Patrick Lynch, [email protected] 1111 W.22nd 22ndSt., St.Suite Suite250, 250, Tel. 1111 W. Tel.630-571-4070 630-571-4070 x2210 x2210 Fax. Oak Brook,ILIL60523 60523 Oak Brook, Fax630-214-4504 630-214-4504 Kerry Gottlieb,N.N.Central Central [email protected] Kerry Gottlieb, [email protected] 1111 W. Tel.312-965-8954 312-965-8954 1111 W.22nd 22ndSt., ST.Suite Suite250, 250, Tel. Oak Brook, Fax630-214-4504 630-214-4504 Oak Brook,ILIL60523 60523 Fax Richard A. PAPA [email protected] [email protected] Richard A.Groth GrothJr.Jr.NJ/ NJ/E. E. 12 Pine Tel.774-277-7266 774-277-7266 12 PineSt. Street Tel. Franklin, MA Fax508-590-0432 508-590-0432 Franklin, MA02038 02038 Fax Stuart Smith, Stuart Smith,International [email protected] SSM International [email protected] Global Media Ltd. Tel. +44 208 464 5577 Tel. Global Media Ltd. Fax+44 +44208 208464 464 5577 5588 Fax +44 208 464 5588 fax

9 In Focus  Get Skills to Work formed to address skills gap, veterans training  Georgia Tech study: Sales, Lean, skilled worker help needed  Data center management more than cooling  Hope is not an effective safety strategy  Measuring quality through software  Fine turning your preventative maintenance schedule

PLANT ENGINEERING

November 2012 • 5

INTERACTIVE www.PlantEngineering.com

WHAT 2 CLICK 2 Here are this month’s online highlights at www.plantengineering.com. Type the keyword into our exclusive search engine and find full details on each article:  Keyword: SME student assessment: The Society of Manufacturing Engineers (SME) has been granted $292,000 from the U.S. Dept. of Energy to partner SME Student Chapters with existing Industrial Assessment Centers at universities nationwide.  Keyword: Compressed dew points: Sampling is needed when direct measurement of the air is undesirable or is simply

VIDEO

Energy management trends in manufacturing CFE Media content manager Amara Rozgus sat down for an exclusive one-on-one interview with Jeff Drees, North American president for Schneider Electric, to discuss trends in manufacturing, including the increasing use of energy management and energy audits to identify and reduce the cost of energy to a plant. Scan the QR code above with your Smartphone or visit www.plantengineering.com/videos

not feasible. This may be due to a high process temperature, the need to protect the sensor from water spikes, the added convenience of installing and removing the instrument from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location. This paper shares tips on how to get a representative sample of the process gas and avoid potential sources of error caused by incorrect sampling practices.  Keyword: Industrial wireless market: New research study from Frost & Sullivan projects massive growth for the wireless industrial automation market. While revenues are expected to more than double over the next four years, implementation of wireless technology still is lagging. Analysts attribute this to a lack of understanding about the full potential of wireless.  Keyword: AME Hall of Fame: The Association of Manufacturing Excellence named four 2012 Hall of Fame inductees at its annual conference. The honor recognizes individuals who have distinguished themselves in the manufacturing community in a manner that is consistent with AME’s mission to inspire a commitment to enterprise excellence through shared learning and access to best practices.

6 • November 2012

PLANT ENGINEERING

WHITE PAPER

Effectively manage your fleet system A new white paper from Hyster talks about the most effective ways to manage your lift truck fleet systems. When lift truck fleets are not properly maintained or utilized efficiently, downtime increases, productivity is reduced and you may end up spending money when you should be making money. The challenge of properly maintaining your fleet can be resolved through an effective fleet management program. Fleet management programs help navigate hidden opportunities to reduce your materials handling spending. As you are confronted with difficult economic hurdles, the need to shed cost for sustainability is a must if you are to emerge from these economic times leaner, stronger and poised to take advantage of economic recovery. Visit www.plantengineering.com/media-library/white-papers to view the white paper.

PRODUCT OF THE YEAR

Cast your vote As a qualified subscriber to Plant Engineering, you are eligible to vote for the best products in this year’s Product of the Year program. Voting is open until Jan. 15, 2013, and the winners will be announced at the 2013 Awards in Manufacturing Event on March 18, as well as in the April 2013 issue of Plant Engineering.

2012

Turn to page 29 or visit www.plantengineering.com/POY to read about this year’s finalists and cast your vote. www.plantengineering.com

Machining without Coolant!

Watch The Video!

www.exair.com/79/49979.htm

Replace messy mist systems & improve dry machining with clean, cold air! Extend CNC Tool Life The Model 5315 Cold Gun cools a two flute 3/8" carbide cutter on a CNC, increasing tool life by 50%. Ideal for diamond tooling.

Milling & Drilling Fly cutters up to 460mm in diameter have been cooled with the Cold Gun. Dissipating heat with cold air extends tool life, increases speeds and feeds, and improves finishes. Chill Roll Cooling a roll with 20°F (-7°C) air keeps the material on the surface from bunching up, jamming or tearing. The metal surface transfers the cold temperature to the product.

Increase tool life and machining rates! The Cold Gun increases tool life, tolerances and production rates by eliminating heat build up. It produces 20°F air from ordinary compressed air. The Cold Gun is ideal for dry machining or to replace messy mist systems. It eliminates the costly coolant purchase and disposal. • Low cost, portable, quiet • Won't freeze up during continuous use • No health problems from airborne coolant • Improves surface finish • No moving parts - maintenance free

High Power Cold Gun

Twice the cooling power of standard Cold Guns.

Tool Grinding Cold air eliminates heat cracking of carbide and tool Manufacturing Intelligent Compressed Air® Products Since 1983 edge burning during grinding and sharpening operations. 11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 • (800) 903-9247 fax: (513) 671-3363 • E-mail: [email protected] • www.exair.com Increased tool life between regrinds is the result.

www.exair.com/79/499.htm

input #5 at www.plantengineering.com/information

@EXAIR

Fill one bulk bag per week or 20 per hour at the lowest cost per bag Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements FILLER FOR PALLET JACK BAG REMOVAL Low profile version of patented TWIN-CENTERPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options.

BULK BAG FILLER USES PLANT SCALE Full length forklifting tubes allow positioning of this TWINCENTERPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls.

FILLERS WITH AUTOMATED FEEDING SYSTEMS Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters to interface with optional overhead storage vessels.

COMBINATION BULK BAG/DRUM FILLER Patented SWING-DOWN® filler features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums.

PATENTED SWING-DOWN® FILLER Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations.

CANTILEVERED REAR-POST FILLER Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system.

BASIC FILLER FOR TIGHTEST BUDGETS A lighter-duty version of the economical TWIN-CENTERPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options.

PATENTED TWIN-CENTERPOST™ FILLER Two heavy-gauge, on-center posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust. Numerous performance options. First filler to receive USDA acceptance.

.com

See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

USA [email protected] 1 888 FLEXICON

+56 +44 +61 +27

2 415 1286 (0)1227 374710 (0)7 3879 4180 (0)41 453 1871

©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

input #6 at www.plantengineering.com/information

Z-1227

CHILE UK AUSTRALIA SOUTH AFRICA

IN FOCUS Get Skills to Work formed to address skills gap, veterans training Four major American manufacturers recently announced the creation of a coalition to fund and encourage military veterans to get the training needed to fill the manufacturing jobs shortage. The Get Skills to Work coalition will focus on accelerating skills training for U.S. veterans; helping veterans and employers translate military skills to advanced manufacturing jobs; and empowering employers with tools to recruit, onboard, and mentor veterans. It will be managed by the Manufacturing Institute and supported through financial and in-kind commitments from GE, Alcoa Inc., Boeing, and Lockheed Martin. “These initial investments will help 15,000 veterans translate military experience to corresponding advanced manufacturing opportunities and gain the

technical skills needed to qualify for careers in this growing sector,” the group said. “A strong manufacturing industry is central to the longterm health and success of our economy,” said Jeff Immelt, chairman and CEO of GE. “But as technology advances, skill sets must be upgraded to ensure companies have the talent to continue to fuel innovation. Today, many veterans are out of work, despite the nation’s growing industrial sector and increased demand for skilled workers. Through this initiative, we have an opportunity to help veterans with extraordinary leadership capabilities better compete for good paying jobs with a long-term future.”

Reportedly 600,000 high-tech manufacturing jobs remain open in the U.S., and more than 82% of manufacturers report they cannot find people to fill their skilled production jobs. Meanwhile, one million veterans are expected to exit the armed forces over the next four years and will be transitioning to civilian careers. The coalition commissioned an online survey of more than 1,000 veterans and active duty military members preparing to transition to the private sector. The survey found that while 76% of respondents are confident they will be as successful in their careers as they were in the military, one-third do not feel equipped to

Study: Returning vets say they have the skills to help manufacturing

A

new survey finds that veterans returning from military service believe their skills will translate well into the private sector, but don’t believe the private sector feels the same way. GE and the Institute for Veterans and Military Families at Syracuse University released the results of their “Voice of Veterans” survey to coincide with the announcement of the coalition between GE, Alcoa, Boeing, and Lockheed Martin. The four companies, working with the Manufacturing Institute, have developed the Get Skills to Work program to help train and deploy returning veterans for manufacturing jobs. The survey found that 76% of U.S. veterans and active duty military preparing to transition to civilian life are confident they can be successful in their private-sector careers. But 66% said they believe the skills they gained in military service are undervalued by private sector employers. More than 1,000 veterans and active duty personnel under the age of 45 took part in the survey. They said they want the same kind of training they received in the military, and believe their background and existing skills will translate well into private sector employment. “What stands out in this data is that veterans are motivated to make a difference beyond their military careers. Given their contributions, we must pay attention to the www.plantengineering.com

unique challenges and opportunities they face as they navigate the transition to civilian life,” said Mike Haynie, founder and executive director, IVMF. “There is a lot we can do to match the desire to work in dynamic, rewarding industries with training that creates a pathway for success.” “The U.S. manufacturing industry is growing, and we stand ready to provide our military veterans with the training, education, and mentorship they are seeking to build long-term, well-paying careers that make a positive difference in the world,” said Frank Taylor, chief security officer of GE. “The skills earned in the U.S. armed forces translate to today’s sophisticated, highly technical manufacturing industry, and we are confident that working together with America’s heroes, we are poised to drive American competitiveness.” The Get Skills to Work coalition’s goal is to bolster the talent pipeline, enhance American competitiveness, and give our nation’s veterans the skills and tools they need to compete for the jobs of the future. Coalition partners include The Manufacturing Institute, GE, Boeing, Lockheed Martin, Alcoa Inc., LinkedIn, Futures Inc., Atlantic Council, the Gary Sinise Foundation and Techshop. For more information about the Get Skills to Work coalition, visit www.getskillstowork.org. PLANT ENGINEERING

November 2012 • 9

IN fOCUS

Mark Huber (from left) of Alcoa Inc., Gabriele P.M. Tyler, Deputy Director of Transition Strategic Outreach for the U.S. Army, and actor and veterans activist Gary Sinese discuss the formation of the Get Skills to Work coalition. Courtesy: GE

overcome the challenges of the transition to civilian life; the percentage rises to nearly 48% when surveying active duty military who are scheduled to transition in two years or less. “Veterans offer the technical, leadership, and critical thinking skills that advanced manufacturing demands,” said Paula Davis, president of the Alcoa Foundation. “Forming the Get Skills to Work coalition and coordinating with nonprofits to train, recruit, and develop veterans is an exciting model that has the potential to change lives and produce a significant competitive advantage for U.S. manufacturers.” “We believe the Get Skills to Work initiative could have a major impact on the hiring of veterans nationwide,” said Rick Stephens, Boeing’s senior vice president of human resources and administration, and a U.S. Marine Corps veteran. “Using many of the same tactics and tools, such as a website for transitioning veterans that includes a military-to-civilian skills translator, we have hired and trained nearly 3,000 veterans in the past 21 months for jobs at Boeing. It’s a proven approach for matching the skills of those who have served our country to the hiring needs of American businesses. We’re honored to be part of Get Skills to Work, and look forward to integrating our efforts with the coalition.”

10 • November 2012

plant engineering

“America’s veterans want and deserve the opportunity to contribute to our society and provide for their families,” said Bob Stevens, Lockheed Martin Chairman and CEO. The program will consist of three elements: n Accelerating skills training To help prepare veterans whose military service experience doesn’t immediately qualify them for available manufacturing jobs, coalition partners will work with local community and technical colleges to establish the Manufacturing Institute’s Right Skills Now program, which fast-tracks industry-recognized certifications and offers training in core manufacturing technical skill areas. Partners will engage their regional supply base to ensure the certifications being offered meet the immediate skill needs of local employers, and will work with the U.S. Depts. of Defense and Veterans Affairs, as well as local military transition offices and bases, to recruit veteran participants. n Translating military experience into civilian opportunities Many veterans and employers have difficulty recognizing and translating the skills gained through military training and experience into civilian workforce skill sets. The Manufacturing Institute, working with Futures Inc., has created a digital badge system to help translate

Among the findings of the “Voice of Veterans” study conducted by GE and the Institute for Veterans and Military Families at Syracuse University: n 76% of young veterans are confident they can be successful in their careers, despite the many challenges faced when transitioning to civilian life, and this confidence level increases with age. n 66% feel their skills are undervalued. Unparalleled work ethic, leadership, teamwork, discipline, and dedication are translatable skills they have to offer the civilian workforce. n 70% believe the skills they earned in the military align with a job in the manufacturing industry. n 79% are motivated to find educational opportunities to help them find and advance their civilian career. n Work/school balance (48%) and financial burdens (35%) pose barriers to their pursuit of education. n 76% want a civilian career that makes a positive difference in the world. n 78% seek a career that fills them with a sense of pride. n 62% believe companies have a responsibility to provide veterans with opportunities to enter and succeed in the civilian job market.

applicable Military Occupational Specialty (MOS) codes, the U.S. military’s system for identifying jobs, to civilian positions in advanced manufacturing. n Empowering employers GE and the Institute for Veterans and Military Families at Syracuse University (IVMF) will develop and deploy a toolkit for employers focused on creating meaningful, lasting career opportunities for veterans in the advanced manufacturing sector. The toolkit will be available to employers participating in the U.S. Chamber of Commerce’s Hiring Our Heroes initiative and the 100,000 Jobs Mission, as well as the broader business community. PE For more information visit www. getskillstowork.org. www.plantengineering.com

You Have Big Ideas We Have a Big Catalog

2013 Allied Catalog Over 110,000 products | Over 10,000 new products | Over 300 world-class suppliers New suppliers include Siemens Corporation and FLIR Commercial Systems

1.800.433.5700 © Allied Electronics, Inc 2012. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.

input #7 at www.plantengineering.com/information

An Electrocomponents Company.

IN fOCUS Georgia Tech study: Sales, Lean, skilled worker help needed The 2012 edition of the Georgia Manufacturing Survey, conducted by Georgia Tech University, points to four areas of concern for manufacturers in that state. Topping the list is a need for more help in sales and marketing, with 36% of manufacturers citing this as a significant need. Manufacturers also want more help with the Lean manufacturing operation, cited by 32% of manufacturers, and worker skills, with 24% needing more technical workers and 16% needing more workers with basic skills. Energy cost management is cited by 21% of manufacturers as an area of concern. That percentage has doubled since 1999. The study also noted a significant increase in re-shoring of jobs to the state. According to a press release issued by Georgia Tech, nearly 16% of the companies responding to the survey said work had been transferred to them from outside Georgia, compared to slightly more than 14% that lost work to out-of-state facilities. “We have finally seen a crossing of the lines so that more companies are benefiting from in-sourcing than are losing to outsourcing,” said Jan Youtie, director of policy research services in the Enterprise Innovation Institute at

Manufacturing Problems/Needs Problems/needs

2012

2010

Change

Marketing and sales

36.0%

39.1%

-3.1%

Manufacturing process/Lean

31.6%

31.6%

0%

Technical skills

23.5%

18.8%

4.7%

Energy costs management

21.4%

18.9%

2.5%

Basic skills

16.4%

13.9%

2.5%

While Georgia manufacturers still cite marketing and sales their biggest area that they need help with, the need for more technical skills, energy management and basic worker skills all rose in 2012 from 2010, the last time the study was conducted. Source: Georgia Manufacturing Study, Georgia Tech

Georgia Tech. “It’s not a huge difference at this point, but it is a positive and consistent trend for the manufacturing community.” Plant Engineering spoke with Youtie about the implications for manufacturers in Georgia and elsewhere. PE: What are Georgia manufacturers able to offer right now that seems to be attracting manufacturing investment? Is this occurring in specific sectors or across the board? Youtie: Science-based manufacturers (those in medical device, chemicals, and petroleum industries) and large manufacturers are more apt to be engaged in in-sourcing.

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PE: The study also focuses on the relationship between technology and employment. Has the skills gap emerged as a problem for Georgia manufacturers, and how are they addressing the issue? Youtie: This survey highlighted a reemergence of manufacturers’ concerns about technical skills, but we continue to see that investment in training is relatively low ($100 per respondent on average). PE: What are the barriers to sustainability? Is it more profitable today to run a sustainable plant? Youtie: Although we do not ask about the barriers to sustainable manufacturing, we do see that the vast majority of manufacturers are engaged in some aspects of sustainable manufacturing, such as eliminating waste materials sent to landfills, and more than half have a goal to eliminate air or water pollution. Both of those areas appear to have their 2010 plans implemented by 2012. Other areas such as using renewable energy to run the plant still are not very common at all (set by only 7% of manufacturers in 2012), however, although the percentage with this goal has risen slightly from 2010 to 2012. PE

12 • November 2012

plant engineering

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IN FOCUS INDUSTRIAL EFFICIENCY: DEBUNKING THE MYTHS

Data center management more than cooling By Kevin Brown, Schneider Electric

technologies to manage a data center’s energy supply and demand, businesses of Myth: Building my own data center all sizes can meet and exceed green and is expensive, inefficient, and time- sustainability goals—without breaking consuming—but worth it to meet my the bank. Below are a few examples. specific IT needs.  Energy procurement: To ensure Due to advances in data center technol- the most reliable and affordable clean ogy, modular and containerized data cen- energy is being sourced, data centers ters are now often a better alternative to now have the option to work with outside customized data centers. For data center sustainability service providers. These managers looking to increase their ROI, providers can help data centers with the modular or containerized data full-time job of energy planning, centers are not only faster to monitoring, and reporting. These deploy, but they’re also signifipartners can also help reduce cantly more affordable and can complexities involving price offer better operational, effivolatility, and control costs. ciency, and processing benefits.  Energy use: Just as we’re in a series The most obvious benefit to reminded to consume energy modular data centers is a drastic reduc- intelligently in our homes, data centers tion in installation time. Traditional data also need to be mindful of how and when centers take months or even years for they’re consuming energy. Some methods construction, compared to just 10 to 16 to reduce energy usage include: weeks for a modular data center. This is in  Natural cooling: Instead of an part because they’re already verified for expensive HVAC system, use a free compliance in safety, energy efficiency, resource to cool your racks: outside air. compatibility, and security. While this is clearly best for data centers Cost savings is another major benefit. located in colder climates, it’s an ideal Not only will the upfront cost of instal- way to slash cooling costs and reduce lation be drastically lower than that for energy use. a traditional data center, but mainte Air containment strategies: Data nance and operating expenses are also centers routinely mix hot and cold air, reduced over time. A modular approach limiting how effectively a system opercan deliver capital expenditure cost sav- ates, as well as its overall capacity. An ings anywhere from 10% to 20%, and air containment system can be impleoperating expenditure cost savings from mented by placing air tiles in the cold 20% to 35%. aisle, installing supply vents in the cold Because of their manufacturing process aisle and return vents in the hot aisle, and and predictability, modular facilities also physically dividing the hot and cold aisles have a lower risk of operational human with a curtain or hard enclosure. This can error. Systems have factory-verified return up to 25% in savings. operation and are tuned for maximum And as the connecting element in a energy efficiency. Product defects are smart data center equation, demand limited and software is preprogrammed, response helps data centers get the most allowing technicians to spend less time value out of their utility budget. By taktroubleshooting and more time devoted ing advantage of their utility’s demand to other critical IT issues. response programs, businesses have the ability to determine when to best conMyth: Sustainability in my data cen- sume electricity, in conjunction with low ter is unattainable within my budget rates. Plus, companies can also sell back constraints. unused energy (gleaned from efficiency Sustainability isn’t just for big bud- and smart sourcing) to their utility at peak gets. Using the right equation of afford- times, generating entirely new streams able, widely available services and of revenue.

5

Fifth

14 • November 2012

PLANT ENGINEERING

Myth: Updating cooling is the only way to lower data center energy costs. There are many other tactics to be considered for lowering data center energy costs. Though cooling is a tremendous energy consumer, there are equally important areas you should be paying attention to if you want to slash your energy bills as much as possible, including air containment, higher voltage power distribution, more efficient UPS, redundancy requirements, and power architecture. Also consider:  Power equipment efficiency: Data centers often fail to account for the heat produced by critical devices within a data center, such as UPS, transformers, transfer switches, and wiring. By cooling the heat generated by these devices, data centers maintain optimal conditions but also consume far more energy. Data centers should consider switching to more energy-efficient equipment, such as high-efficiency UPS, which have up to 70% less loss than legacy UPS at typical loads, servers, and CRAC/CRAH units, which can be programmed to reduce or cease demand fighting entirely.  Centralized management system: Advancements in data center infrastructure management (DCIM) software now allow data center managers to easily integrate and prioritize all IT equipment and functions into one application. This centralized point of control allows data center managers to holistically monitor temperatures, operations, security, and power utilization. While cooling should not be overlooked, data centers would do well to look at energy usage holistically. By implementing a variety of tactics, data centers can slash energy bills in a way that works best for the organization. PE Kevin Brown is Vice President, Data Center Global Solution Offer for Schneider Electric’s IT Business.

GO TO: www.PlantEngineering.com Keywords: “Dubunking the Myths” to find Parts 1 through 4 of this series.

www.plantengineering.com

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Answers for industry. input #10 at www.plantengineering.com/information

IN FOCUS Hope is not an effective safety strategy By J.B. Titus

It basic nature that businesses don’t want incidents to occur. And, at the same time employees don’t want to be hurt. Businesses generally, some only when confronted, don’t wish for exposure to unneeded regulation, unscheduled machine downtime, employee injuries, costly liabilities or the cost burdens associated with these issues. Yet, these are some of the negative results a business can expect as consequences of avoiding the required risk assessments for their machinery operations. Some of the potential liabilities of exposure (avoidable consequences) might be:  Timing: Too many businesses still avoid the issue of compliance to the risk assessment requirement which extends to existing, new or modified equipment. The sooner the better to meet compli-

ance requirements and avoid citations.  Misapplied devices: Quite often safety devices are provided but are miss-applied because a hazard level was not properly assessed. For example, a Cat 4 hazard could require a control reliable solution involving a Cat 4 safety rated switch with redundant contacts. A miss-applied device in this example could include; a single standard interlock switch, safety rated devices below Cat 4, or an application which is not control reliable.  Foreseeable misuse: A properly conducted machine guarding risk assessment will typically uncover misuse situations like; equipment malfunction, unauthorized process material, operating tooling beyond its useful life, unexpected loss of power, and reach over, under, around, or through guarding.  Misapplied procedure: Lockout/

Tagout (LOTO) is frequently misunderstood and/or not always followed as prescribed by OSHA. LOTO incidents are preventable via frequent training, documenting procedures, not permitting shortcuts, and by establishing employee penalties for non compliance.  Unidentified modes: All modes of operation and their related tasks need to be identified in order to reveal their related hazards. Unidentified modes include; setup, cleanup and preventive maintenance. The advice of industry experts is to not become aware of the importance of risk assessments only after a serious incident and the resulting OSHA citation, or the legal engagement, or the sever financial expenses which fall directly to your bottom line. “Hope” is not an effective strategy – proactive engaged machine safety leadership is! PE Read J.B. Titus’ blog, Machine Safety, at www.plantengineering.com/blogs.

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input #12 at www.plantengineering.com/information © 2012 Hyster Company. Hyster,

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IN FOCUS Measuring quality through software

Matthew Littlefield LNS Research

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Plant Engineering: In evaluating the top vendors for Enterprise Quality Management Software, what criteria would you say is most critical for an effective system for end users? Littlefield: There are a number of factors that determine how well suited a particular vendor is for a particular client. First and foremost I think comes industry experience, some vendors have experience in life sciences, others have experience in discrete manufacturing like automotive or aerospace and defense, still others have started to develop experience in consumer products or food and beverage. The drivers and needs are very different in all these industries and very few vendors have expertise across all these industries. Second, I would say existing IT infrastructure, some companies are heavily invested in ERP, others have a large PLM footprint, still others have disparate systems at the enterprise level, again different vendors have different strengths in this regard. Finally I would recommend looking at the technology itself. Originally EQMS vendors were very form based, over time many have updated their technology to be work-flow based that has a more solid data model and ability to interoperate with other systems through web-services. Finally, is the vendor continuing to invest in areas like BI, Mobility, and an enhanced user-experience. Some companies are and others are still behind the curve. PE: Why is software the best measuring tool for quality? What industries might benefit the most from such a system? Conversely, which industries are not a good fit for EQMS? Littlefield: Software is an important tool for a number of reasons but I think one that stands out the most is our changing business environment. Companies are continuing to expand globally, products are continuing to increase in complexity, regulations continue to expand, and consumer demands continue to increase. Companies that don’t specifically invest in a platform to manage how quality impacts the entire value chain and how

18 • November 2012 input #13 at www.plantengineering.com/information

LNS Research has released its Enterprise Quality Management Software Selection Guide, which looks at 18 major vendors in the spaces and offers comparisons on performance and applicability to individual industries. Matthew Littlefield, president and principle analyst at LNS Research, discussed with CFE Media the value of measuring quality with software, and how the acceptance of such tools is growing throughout the plant.

PLANT ENGINEERING

2012 quality addresses all these market drivers will be at a distinct competitive disadvantage. From an industry perspective, industries that have high risk products, high risk processes, a deep impact on consumers, or a restrictive regulatory environment are all candidates for EQMS, including life sciences, consumer products, discrete manufacturing, and process manufacturing. PE: You mentioned the education process is critical in a successful deployment of EQMS. How far into the organization does this training need to go? Littlefield: For a quality culture to take hold, it truly has to go to the operator level. Continuous improvement, nonconformance management, compliance, and more all have to be managed at the most granular level possible. We are now seeing some companies that have 10,000-plus users on EQMS systems.

For a quality culture to take hold, it truly has “ to go to the operator level. Continuous improvement, non-conformance management, compliance, and more all have to be managed at the most granular level possible.

”

PE: What are the leading causes of failure for EQMS, or any operating system for that matter? Littlefield: Very rarely is the technology to blame itself, although that could be the case with some vendors that have not kept based with investments in their products. Most likely that failure comes from executive leadership not promoting and believing in a quality culture. If executives do not walk the walk it can be very challenging to have the right culture and technology adoption flow through the organizations PE: What’s the potential ROI for a successful implementation? Littlefield: ROI is tough to measure in the EQMS world and many companies don’t. Although there are two ways we are starting to see companies measure ROI. First is around the Cost of Quality and second is around risk reduction. Both are viable ways for measuring business success and companies that invest in EQMS can often see major improvements in these metrics, often providing an ROI in less than 1 year. PE: Why might this be a good time for manufacturers looking to upgrade their quality management process? Littlefield: We have seen companies be most successful with EQMS in two major ways. One if there is a major quality issue or compliance issue at your company, adopting software maybe a very prudent step for correction. Second, if your company is focused on a new (or improving an old) operational excellence initiative, EQMS can help in the success of these initiatives and building quality into operational excellence. PE plant engineering

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November 2012 • 19 input #14 at www.plantengineering.com/information

IN fOCUS Fine tuning your preventive maintenance schedule By Paul Lachance, Smartware Group

What comes first: corrective or preventive maintenance? Well, the industrial engineers would say “PM,” of course. But the reality of busy schedules and a

reduced labor force often set in and best laid plans slip. Example: Company X has older, inefficient ventilation in one of its production facilities. The HVAC breaks down frequently, is expensive to run, and finally

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management agrees to replace it with a brand new, more energy efficient system. Since the conversion, air quality and temperature have never been better, and the cost savings is tangible. During installation, the manufacturer strongly advises Company X to follow a recommended maintenance plan. The maintenance supervisor asks her administrator to make sure the PM calendar is set up in the CMMS. The team is so happy to not be dealing with the older, often malfunctioning system they wonder, “Why bother doing anything; the system is brand new!” PMs are dutifully set up and the automated reminders/PM work orders churn out every month. The challenge begins when the technician assigned tries to balance PM work orders on a combination of assets, including a shiny, new ventilation system and other antiquated, poorly-running systems that should be replaced. The reality is that technicians will likely continue to “MacGyver” older systems to keep them running and the new system will be ignored since it is humming along nicely. There are just not enough hours in the day. Reality forces us to make compromises. Sometimes these choices have to be made. If all of a sudden the CMMS issues an actual corrective maintenance work order for this system, it indicates that the team has to get back to a more frequent schedule, but it may not need to be as frequent as the manufacturer’s recommendations. A good CMMS system can deliver the information users need to better fine-tune their PM schedules. If a less-rigorous PM schedule gets the maintenance team slapped with a corrective work order, it’s time to adjust. Sometimes it is the other way around. If the CMMS system tells the maintenance manager ‘all is well’ with an asset, that may be a signal to shift resources to other equipment in greater need. PE Paul Lachance is president and chief technology officer for Smartware Group, which produces Bigfoot CMMS. Contact Paul at paul.lachance@bigfootcmms. com.

input #15 at www.plantengineering.com/information

20 • November 2012 12-375 Shaft Volt Test Kit IsleHalf (PE-NOV2012).indd 1

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Driven by Efficiency Setting New Milestones in Performance

Hey, I'm Trey, Product Marketing Manager at Atlas Copco Compressors. It's my great pleasure to introduce the next generation of the GA oil-injected screw compressor range. The GA 40-125 horsepower range has been redesigned in line with Atlas Copco's commitment to continuous innovation. Featuring new and improved components that provide unparalleled performance, sustainability, efficiency and reliability, the VSD models deliver up to 35% energy savings, while the premium efficiency fixed speed models offer industry leading Free Air Delivery (FAD). Visit our dedicated website to learn how this new compressor range can boost your productivity www.atlascopco.com/drivenbyefficiency or call 866-688-9611 to learn more about us, our products, and how we have earned and will continue to earn our reputation.

input #17 at www.plantengineering.com/information © Copyright 2012 Atlas Copco Compressors LLC. All rights reserved.

IN PRACTICE Make your plant floor time productive By Kimo Oberloh, Life Cycle Engineering

I

frequently pose this question to managers: “How much time controls are what will allow you to see what is happening on do you spend on the floor?” I get responses that run the the shop floor. It is how the operator communicates to the gamut from “I don’t need to go to the floor” to “I’m on the management team what is happening in their process. Things floor all the time.” Of course, the amount of time that you like progress control boards, color coding, and having spespend on the floor is directly proportional to where you sit in cific locations for tools, work in process, raw materials, and your organization’s hierarchy. finished goods will help you to identify the current condition You’ve probably heard the phrase “Go to the gemba.” From of satisfying customer demand for that particular day. Even what I can ascertain, this means go to where the work is being if you are producing an item that gets completed only once done. I absolutely, wholeheartedly, agree with this concept. every 45 days, it can still be broken down into weekly, daily, However, the amount of time you spend there and what you and even hourly targets. get accomplished are not always proOne of the foundational visuals is portional to each other. As the operators understand what is the progress control board. It can disSo, how do you make your time in causing the line to be unstable, they play everything about an area that is the work area more productive? First, required to understand what is being will take action to constantly reduce done to satisfy customer demand. It let’s talk about the inverted pyramid. This is not a new concept, and it can the variation. This could be problem will always contain a temperature be used in a myriad of ways. The pyrof where the area stands in meeting solving and implementing the amid that I am talking about stands customer demand. Some will call solutions themselves, thus the 5% to it an hour-by-hour chart; I call it a on its point, and like the traditional pyramid, the head of the organization 10% dedicated to improving the line. feeling. When you look at it, you get resides at the point. The difference a feeling for whether the process is here is that now the point supports the entire organization performing well or not. instead of the rest of the organization supporting the point. Another integral part of the progress control board is the Ask yourself a question, no matter where you sit on the Pareto of reasons for missing target (or capacity). As the operapyramid. How much time do you spend making sure that daily tors understand what is causing the line to be unstable, they will customer demand is met? And how do you know that it is being take action to constantly reduce the variation. This could be met? Can you walk into the workplace and understand where problem solving and implementing the solutions themselves, you stand in meeting daily customer demand? In most places thus the 5% to 10% dedicated to improving the line, or it could that I have worked, it is not easy to determine. That information be listing items on an action item log for someone else to handle. is usually communicated at the morning production meeting. This brings us to the final mandatory item on the progress And where do these meetings usually take place? If you said control board—the action log. When the operators run into “the floor,” you are in a small minority. an item that they themselves cannot solve, they will put it on the action log. It is then the responsibility of the people that Meeting customer demand are lower on the pyramid to review these action items and act Whose job is it to meet daily customer demand? The opera- on them. tors who are in the trenches every day making the equipment/ processes operate. About 90% to 95% of the time, they need Allocating time How much time should you spend on the floor? If you can to be focused on meeting daily customer demand. And what should they do with the other 5% to 10%? Teach them to solve adhere to the 90%-95% rule for the operators, the team leads (or problems in order to create greater stability and increase effi- supervisors, or assistant general foreman) will spend 70%-80% ciency. With the operators taking on the biggest burden in on daily demand and 20%-30% looking ahead. They will look order to meet customer demand, what does everyone else do? one week to a month out and see what is coming up. What do Everyone else supports the operator; thus the inverted pyramid. they have to do with manpower? Are temps required? Are there A typical structure could include operators, team leaders, any tests that will need to be run that require special attention? group leaders, assistant managers, and managers, with each What is required of the team lead to support the operator in lower level of the pyramid supporting the level above it. Visual making the line more stable and efficient?

www.plantengineering.com

PLANT ENGINEERING

November 2012 • 23

IN PrACTICE The next level down (group leader, assistant manager, foreThe content on the rest of the progress control board is up man) should spend 50%-60% of their time satisfying customer to you. Remember, you have the daily progress sheet, Pareto demand and the remainder of the time looking ahead at what is of reasons for not meeting plan (or capacity), and the action happening this month or this quarter. Each level needs to ask list of what is being done to solve the issues. Be careful that what it can do to support the operator. the action log does not become a whine sheet. There should As we progress another level down, managers should allocate only be about two to three actions on the list. This is because 25% of their time to meeting daily demand, and 75% to plan- in large plants with a lot of progress control boards you need ning for the year. Are you starting a the ability to make sure that the new line? What needs to be done in actions identified are being solved. How much time do you spend making the holiday shutdown? How are we Other items that you could sure that daily customer demand is met? place on the board are items that going to staff for the summer peak, And how do you know that it is being what do I need to do to satisfy the will roll up to the overall metrics targets and objectives for the year of the company. These usually fall met? Can you walk into the workplace and, of course, what can I do to into the categories of quality, cost, and understand where you stand in support the operator? At the bottom safety, and, of course, delivery. All of the pyramid (CEO, COO, plant metrics should roll up and down to meeting daily customer demand? director), leaders focus 5% to 10% support policy deployment. on daily demand and 90% to 95% on looking ahead. So while the question, “How much time do you spend When we look at these percentages more closely, if the bot- on the floor?” is very relevant, because no one is excused tom of the organization were to spend 10% of their day making from spending time on the floor, maybe the real quessure that customer demand is met, that would be one hour per tion should be, “How productive is the time that you day (assuming that most management teams usually work a spend on the floor?” PE 10-hour day). This would entail walking the floor, observing Kimo Oberloh is a Lean manufacturing subject matter expert the progress control boards, and seeing what items on the action list require their attention. This would also include walking the at Life Cycle Engineering (www.lce.com). Kimo can be contacted at [email protected]. floor with the team members that report to you.

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Visit us at www.rosler.us or call us at 269-441-3000. input #18 at www.plantengineering.com/information

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input #19 at www.plantengineering.com/information

Energy Consumption: How it Relates to Performance in Refrigerated Compressed Air Dryers Timothy J. Fox | Research and Development, SPX Those in charge of specifying and purchasing equipment for industrial compressed air systems have many decisions to make. The design of a proper compressed air system does not end after determining the quantity of air required (i.e., the air compressor and receiver tank); the user must also pay particular attention to the quality of the air that his or her process needs. Today’s optimal air systems demand less moisture, less particulates, less oil aerosols, and less oil vapor than ever before.

requirements for moisture removal. With so many manufacturers offering “equivalent products”, each with promises of delivered pressure dew point, pressure drop and consumed electrical power, how does one make an intelligent selection? This paper will address power consumption, and how it relates to a refrigerated dryer’s ability to remove moisture. It will explain how a potential buyer can determine if the stated performance is possible with the power consumption that is published in the manufacturer’s literature.

For most users, a refrigerated-type compressed air dryer will satisfy their ple201211_SPX_whitePprHLF.indd 1

input #20 at www.plantengineering.com/information

an SPX Brand For more information please contact: [email protected] or visit our website at www.hankisonintl.com

10/29/2012 3:22:28 PM

Four Things You Need to Know About Compressed Air Dew Point Sampling Sampling is needed when direct measurement of the air is undesirable or is simply not feasible. This may be due to a high process temperature, the need to protect the sensor from water spikes, the added convenience of installing and removing the instrument from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location.

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To get a representative sample of the process gas and avoid potential sources of errorcaused by incorrect sampling practices, the following aspects should be considered.

• Changing the pressure of the gas changes the dew point

Download the White Paper at knowledge.vaisala.com/SampleCell

• To avoid condensation the dew point • •

must be below the ambient temperature in the sampling line A leak-tight sampling system construction is essential Sampling in still air should be avoided, however low air flow is okay

input #21 at www.plantengineering.com/information

www.vaisala.com/compressedair [email protected]

10/12/2012 10:17:06 AM

Maximize Uptime and Profits Through Effective Fleet Management Practices Pat DeSutter | Director NMHG Fleet Management

This paper from Hyster Company discusses lift truck fleet management. From planning and use strategy to understanding total cost of ownership, this white paper helps any operation with a fleet of lift truck equipment to understand how to effectively and efficiently manage that fleet. Topics included in this paper are challenges to fleet management, key elements of fleet management, total cost of ownership, replacement planning, telemetry and outsourcing.

One central challenge presented to lift truck fleets is hidden cost. Multiple service providers can add an unexpected financial and administrative burden to the fleet’s operation. With only an estimated 20 percent of an operation’s materials handling costs going to the initial purchase of the lift truck, the remaining 80 percent is composed of maintenance, operator and fuel costs. A proper understanding of total fleet management from purchase to operation helps a company to review all associated costs and asset utilization. Several key element of true fleet management are also outlined, including proper planning, which is essential as lift trucks have an economic life of approximately 10,000 to 12,000 hours as a general rule.

While that life varies depending on maintenance practices and operational conditions, it is a reminder to plan not only the usage of the trucks, but also their replacement, to avoid costly downtime or increased maintenance expenses. Hyster’s FleetSmart web-based reporting system allows managers to monitor and measure the fleet’s utilization, specific truck cost per hour and overall operating expenses. After reviewing many of the factors necessary to effectively manage and maintain their fleet, some operations choose to sign agreements with lift truck manufacturers or dealers to provide expertise and management assistance. Capitalizing on years of experience, a strong dealer network and utilization of latest technology, Hyster Fleet Services can deliver unmatched results in reducing costs and maximizing productivity. Download the paper at: http://www.hyster.com/AMERICAS/EN-US/FLEET SERVICES/FleetManagementWhitePaper.htmx

1-888-FLT-SVCS www.hyster.com/Americas/en-US/FleetServices

input #22 at www.plantengineering.com/information

input #23 at www.plantengineering.com/information

2012 Finalists

I

f innovation is one of the best indications of a strong manufacturing economy, the finalists for the Plant Engineering 2012 Product of the Year awards are pointing the way to a bright future. Entries in this year’s contest were up by more than 35%. This year’s crop of finalists covers 15 categories, including our newest category—Apps for Engineers. This points toward a greater use of handheld and Smartphone devices on the plant floor, and we expect this to be a very large category in future years as more widespread adoption of apps and mobile devices continues. Just as exciting this year are the two categories with the most entries. Automation & Controls is a category that highlights the desire of manufacturers to measure and manage their manufacturing process in the most efficient fashion possible. The Safety category highlights that the most important asset on the plant floor is still the human one. This year’s 116 finalists stretch across all areas where a plant manager’s influence is felt and his knowledge is required. From

motors and drives to maintenance and lighting, the things a plant manager must specify and purchase perform very different functions. They all have one common element: they must help him or her do the job better, smarter, safely and more efficiently. That has been the hallmark of Plant Engineering’s Product of the Year program for the past 25 years. It might have been tempting to make a bigger deal out of the 25th anniversary of Product of the Year. People tend to like anniversaries and birthdays, especially a silver anniversary year. But Product of the Year is important each year, on its own merits. We certainly hope the cumulative effect of Product of the Year has helped improve your operation each year. But each year, our task is simple: We showcase the best in innovation each year, and then put it in the hands of our readers to determine the best of that best. In 2012, for the 25th time, we again give the decision of this year’s Product of the Year winners to you. We hope you vote, and we hope you make use of this year’s outstanding innovations in manufacturing products. –Bob Vavra, Content Manager

By Brittany Merchut, Content Specialist

www.plantengineering.com www.plantengineering.com

PLANT PLANT ENGINEERING ENGINEERING November November2012 2012 • • 2929

2012

Product of the Year

Automation & Controls Wireless sensor network

Wireless network access point The 802.11 WiFi Access Point for Industrial M2M Applications provides users with wireless networking capabilities. The access point appears as an embeddable module, which allows original equipment manufacturers to Wi-Fienable their products. The access point also appears as an external Ethernet access point, which provides the same functions as a stand-alone box. The access point technology allows the access point device to become its own Wi-Fi network communicating with other devices. The 802.11 WiFi Access Point contains an Ethernet port with two serial ports, providing more port configuration and connectivity tools.

The SureCross Q45 is a wireless photoelectric sensor solution developed for industrial automation applications. The SureCross Q45 improves efficiency in control and monitoring applications through the integration of a scalable, wireless sensor network infrastructure. The SureCross Q45 can be used for applications such as cable replacement, moving applications, remote applications, and productivity solutions. Banner Engineering Corp. www.bannerengineering.com

B&B Electronics Mfg. www.bb-elec.com

Communication cards BAFWorks is a fan application that allows users to control an unlimited number of Big Ass Fans products from a particular location. This application eliminates individual controls in large facilities by providing access to real-time fan speed and status of all fans. The BAFWorks application is available for all industrial overhead Big Ass Fans products. The application was designed specifically for the new industrial line of fans but is also compatible with previous generations.

The C441 Ethernet series of communication cards allows customers to select Ethernet/IP, HTTP web services, Modbus RTU communication protocols, and Modbus in a single card. The series contains added communications including options to configure, control, and monitor systems. Users have the ability to use one network for control and another for monitoring. The available Web services provide a Webbased graphical user interface. The series is compatible with Eaton C440, XTOE, and C441 electron motor protection relays, and S611 soft starters.

Big Ass Fan Co. www.bigassfans.com

Eaton Corporation www.eaton.com

Fan control

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Panel wiring system solution The SmartWire-DT System replaces multiple wires used to connect motor control components with a single cable. The system allows users to easily integrate with the original equipment manufacturer’s preferred industrial network. The SmartWire-DT system uses an eight-conductor, flat cable located in the control cabinet to connect motor starters, pushbutton actuators, and indicator lights. Eaton Corporation www.eaton.com

I/O expansion series The I/O Expansion Module is a new set of products to help customers achieve optimal performance, faster ROI, and customization for communication networks. The I/O Expansion Module offers an increased degree of monitoring, control and optimization, and flexible wired and wireless I/O. The I/O Expansion Module provides faster access time for up to 192 I/O points. The new module’s products carry the same measurement accuracy of analog inputs and can snap directly onto FreeWave radios or connect to other serial communication devices. With the I/O Expansion’s flexibility, the module can be used for a range of applications. FreeWave Technologies www.freewave.com www.plantengineering.com

Operator interface and controller The XV Series HMI-PLC incorporates programmable logic controller functionality and integrates with the Eaton SmartWire-DT system. The XV Series HMI-PLC combines control, visualization, and data management tasks in one device. The design of the XV Series removes the physical PLC, incorporates logic into the operator interface, and provides a single software package. The series has an optional integrated SmartWire-DT master, eliminating the need for a gateway. The SmartWire-DT device connects directly into the back of the panels. Eaton Corporation www.eaton.com

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2012

Product of the Year

Automation & Controls Lighting control panels

Wall switch sensors

The 16- and 24-relay CX Commercial Lighting Control Panels can be ordered as Master and Secondary Panels enabling two panels to be connected together on one project. There is an LCD user interface located in the door with scrolling menus to program, check status, or update the pane. The CX Commercial Lighting Control Panels are available in relay sizes of 4, 8, 16, and 24 with four types of relays. The programming capabilities of the panel include 365day programming with astronomical and real-time clock.

The LightHAWK Wall Switch Occupancy Sensor line has expanded to include a suite of wall switch occupancy sensors with neutral connections. The line has sensors available in passive infrared, ultrasonic, and dual-tech models with single or dual relays, several override options, and a complete palette of architectural finishes. All of the sensors come with a built-in photocell with SuperSaver mode. Hubbell Building Automation Inc. www.hubbell-automation.com

Hubbell Building Automation Inc. www.hubbell-automation.com

Recorder/ controller

Control and simulation software

Eurotherm Nanodac recorder/ controller’s latest edition includes greater storage flexibility for longer local data archiving, store and forward data retrieval, and connectivity to Invensys’ Wonderware Historian. The nanodac record/controller is best used as a local historian to third-party equipment, but it can be used as a stand-alone device. The nanodac recorder/controller has 50 MB of flash memory for data storage, an on-screen help system, and remote viewing functionality. The device also offers the option to provide two high-stability PID looks with the unique Eurotherm Autotune facility.

The I/A Series is a control system with an Intelligent Marshalling solution and highperformance Foxboro Control Software and Simulation Software. The I/A Series features a Universal Fieldbus Module that eliminates the need for marshalling. Designed to improve user experience, the software embeds Invensys’ ArchestrA System Platform and Wonderware InTouch HMI in the system. This allows for integration of plant devices, systems, databases, and software applications. The software has the ability to simulate, including dynamic control of time, alarms, and trends using the same configuration files used in a live I/A Series DCS. Invensys Operations Management iom.invensys.com

Invensys Operations Management iom.invensys.com

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Compact gearhead The Nexen Harmonic Gearhead has a short and rigid design combined with a large, rugged, crossed-roller output bearing that can handle all combinations of radial, axial, and overturning moment loads in a compact envelope. The Harmonic Gearhead is available with Nexen’s Roller Pinion System through the integration of the gearhead into the pinion without any added length. This allows for the maintenance of zero backlash from the driving motor shaft through to the driven load. The RPS has a unique roller pinion/rack combination that can be adapted to any application. Nexen Group Inc. www.nexengroup.com

Modular HMI The GP-4000M Series Modular HMI allows users to easily monitor conditions and the operating environment in real time. The series offers a full graphics touchscreen with a selection of serial or Ethernet connections. The series design is energy saving with its on-board LED backlight, and a dimmer setting used to stand-by the display after being idle. The GP-Viewer EX software provides remote monitoring functions such as checking the screen from a remote office. Pro-face www.pro-face.com

Automation communications platform The KEPServerEX 5.9 industrial automation communications platform has new electronic flow measurement capabilities and Wellsite Information Transfer Specification Level 0 drivers. The new solutions ensure that systems and devices supporting pipelines, wells, and drilling rigs can gather and share vital operational information. The new drivers with EFM capabilities have the potential to tap into stored data to manage, collect, monitor, and distribute information. The WITS Level 0 drivers provide quick and easy access to real-time drilling and mud logging data to offshore drilling platforms, onshore rigs, well sites, and other geographic sites. Kepware Technologies Inc. www.kepware.com

www.plantengineering.com

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2012

Product of the Year

Automation & Controls Wireless monitoring system VIBCONNECT RF is a wireless condition monitoring system for machine components. The system monitors the condition of roller bearings and other rotating components, and detects damage caused by cavitation. The VIBVONNECT bridge acts as the central receiver as it processes the data from the sensor units, transmitting it through the operator’s network. Operators can assess machine vibration, bearing condition, and temperature through the variety of analytical functions available. Prüftechnik Group www.prueftechnik.com

Programmable automation controllers The Allen-Bradley CompactLogix 5370 programmable automation controllers include 5370 L1, L2, and L3 controllers. These controllers have enhanced performance and motion capabilities while leveraging the common design and networking environment of Rockwell Automation’s Integrated Architecture system. The CompactLogix 5370 offers performance and cost competitiveness for machine builders requiring up to 16 axes of complex motion on EtherNet/IP. The series offers the same processing speed upgrades as the ControlLogix 5570 series, but with more than twice the processing speeds. Rockwell Automation Inc. www.rockwellautomation.com

Virtual image templates

Power monitoring software StruxureWare Power Monitoring 7.0 Software is a software application that tracks real-time power conditions to improve efficiency, availability, and reliability. The software has a Web-based interface allowing users to monitor, analyze, and report on energy usage and power quality information. The software includes several new libraries for common real-time values, alarm views, and reports. StruxureWare Power Monitoring can function as a standalone software application and can connect easily to other StruxureWare software within suites, developed to address the unique needs of key market segements. suites. Schneider Electric www.schneider-electric.com

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The PlantPAx Virtual Image Templates deliver the core system elements as preconfigured, drop-in templates on a USB hard drive. Delivered in an open, virtualformat file, and supported and tested for use with VMWare vSphere, the Engineering Workstation, Operator Workstation, and Process Automation System Server templates are provided. The pre-installed and preconfigured Virtual Image Templates help reduce validation costs and initial engineering time, simplify upgrades, and patch management and enhance scalability. Rockwell Automation Inc. www.rockwellautomation.com

www.plantengineering.com

Comfort panels The SIMATIC HMI Comfort Panels feature the same functionality and performance across the entire product range. The panels come in different size of displays, including high-resolution, brilliant, and widescreen, and can be adapted for any application. The SIMATIC HMI Comfort Panels can switch off the displays of the units in break times. The panels are configured using TIA Portal based SIMATIC Step 7 and SIMATIC WinCC engineering software. Siemens www.siemens.com

Compact CPU The SIMATIC S7-1215C is equipped with 100 kb of user memory, a second PROFINET interface, two analog outputs, and fast outputs for controlling as many as four stepper motors. The controller offers 14 digital inputs, 10 digital outputs, two analog inputs, and two analog outputs. The SIMATIC S7-1215C can replace relays and contactors, convey systems, and pump control and energy management through to distributed tasks in a complex automation network. Siemens www.siemens.com

Sales resource planning software Atlatl-Sales Resource Planning Software is designed to support manufacturing and industrial sales and streamlines the engineer-toorder sales process. The software merges all elements of manufacturing sales processes including client data input, product demonstration, and configuration, as well as specification gathering engineering, and drafting. SixAxis LLC www.sixaxisllc.com

www.plantengineering.com

Now the vote is yours…

2012

Plant Engineering subscribers with a valid e-mail address will receive the 2012 Product of the Year ballot. Simply fill it out, click ‘Submit,’ and let your vote for this year’s best products be counted. Then, in the April 2013 issue of Plant Engineering, meet the 2012 Product of the Year award winners honored at our 2013 Awards in Manufacturing Event in Chicago.

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2012

Product of the Year

Apps for Engineers

Product and technical information application

Software platform application aPriori 2011r2 is a software platform that offers functionality and enhancements that expand a platform’s cost-optimization capabilities for companies with hightolerance machining requirements. The software platform has upgraded its abilities to create detailed tooling cost estimates for components. A flexible and powerful costing engine allows for instant and precise determination of the cost of a part or product from a CAD model. aPriori 2011r2 has the capability to reassess and provide updated product costs as design changes are made or new product specs are introduced. With the software platform, companies are able to make better design and production decisions while reducing costs.

The POWEREDGE mobile application provides real-time access to Eaton’s electrical catalogs, videos, and training. Electrical products can now be searched, selected, and located from an Apple device. The application is created to engage, educate, and enable users to find the product and technical information. Through the POWEREDGE mobile application, users can learn more about Eaton’s products with direct access to the electrical product catalog. The design of the application helps users find information on solutions to improve reliability, efficiency, and safety of systems they manage. Eaton Corporation www.eaton.com

aPriori Inc. www.apriori.com

HMI software application

Data processing application

The Wonderware InTouch 2012 software is the primary application of the company’s InFusion Enterprise Control System. The software offers users the ability to quickly and easily create standardized, reusable HMI and real-time decision support applications. The application’s graphics, ease of use, efficiency, and support allow users to help drive business optimization.

The iQagent is an application that enables users to display live process data, documents, and resources about a given point of interest (POI) while connected to the plant wireless network. POIs are configured on the plant floor and then are tagged using a QR Code. POIs contain a Data View showing live process values and Info View containing links to documents and resources. On the plant floor, users can scan the QR Code and view data or other resources.

Invensys Operations Management www.invensys.com

iQuest www.iquest.net

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Compressed Air HOC dryers

Air nozzle EXAIR’s Stainless Steel Super Air Nozzle offers 6.6 lbs of blowing force for blow-off, cooling, and drying applications in corrosive, high-temperature, food and pharmaceutical environments. The air nozzle has an aerodynamic design that directs compressed air to a single point of convergence, allowing a concentrated stream of high-velocity airflow. The nozzle contains applications including ejection of heavy parts, drying, part and machinery cleaning, chip removal, liquid blow-off, and cooling hot parts.

Ingersoll Rand’s new line of heat-ofcompression (HOC) dryers provides flexibility, reliability, and energy efficiency in a low-profile package. The dryers use heat produced during the compression process, which allows for instrument-quality air to be delivered using virtually no energy. The dryers contain Smart Control technology, which adjusts dryer operation to minimize dew point and temperature spikes. To prevent wasting compressing air, the dryers feature no-loss drains. The HOC dryers by Ingersoll Rand can be used with multiple compressors, reducing footprint requirements. Ingersoll-Rand plc www.ingersollrand.com

EXAIR Corporation www.exair.com

Rotary screw air compressors Ingersoll Rand’s R-Series range of rotary screw air compressors is available in fixed speed and Nirvana variable speed drive. The new range of compressors comes with the Xe-Series controller, featuring a high-resolution LCD color display. The controller provides access and remote control of the compressor from any tablet, smartphone, or PC. The compressors have an integrated Total Air System dryer and filtration option that provides clean, dry air in a single package. The new design of the compressors reduces maintenance and allows for easy service with the swing-out separator covers, longer life consumables, and easy-access hinged doors. Ingersoll-Rand plc www.ingersollrand.com

www.plantengineering.com

Portable air compressor Sullair Corporation’s E900H Portable Air Compressor is designed to combine the clean, quiet efficiency of electric drive technology with the Sullair legacy of rugged air ends and portable compressor designs. The compressor delivers 900 cfm at operating pressures up to 150 psig. The E900H portable compressor features the Sullair AF System that allows the compressor to process equipment and other industrial applications. The compressor comes equipped with a built-in high-capacity after-cooler and efficient filtration. The E900H portable compressor is powered by a 214 hp premium efficiency TEFC electric drive motor with Wye-Delta starter. Sullair Corporation www.sullair.com

plant engineering

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2012

Product of the Year

Electric Motors & Drives Tapered roller bearings

Adjustable frequency drives

Baldor’s Dodge Type EXL tapered roller bearings provide misalignment and expansion capability, while maintaining industry standard Type E mounting dimensions. The design of the Dodge Type EXL incorporates a cartridge-style inner unit into a split ductile iron housing, which allows the inner unit to swivel freely in the hosing. The Dodge Type EXL offers a new bearing design with a 13% to 14% increase in load ratings. The roller bearings come in twoand four-bolt pillow blocks and utilize the same inner unit for expansion and non-expansion housings.

Eaton’s H-Max Series of adjustable frequency drives are equipped with HVAC software and hardware features, including an industryleading energy control algorithm. The H-Max Series has new technologies such as advanced dc capacitors and latest generation insulated gate bipolar transistors, with real-time clock and calendar. This gives customers the ability to design and operate efficient HVAC systems. The drives are available in 1.5 hp to 250 hp at 480 V and ¾ hp to 125 hp at 230 V. The H-Max Series comes with Ethernet, Modbus, N2, and BACnet built-ins. Eaton Corporation www.eaton.com

Baldor Electric Co. www.baldor.com

Split universal mounting kit The S811+/S801+ Soft Starters provide smooth acceleration and deceleration of the load with advanced monitoring, protection, and communication. The soft starters are designed for constant torque and variable torque applications. The soft starters come equipped with power and power factor monitoring capabilities, analog input, fault warnings, and integrated Modbus RTU communication. With the digital interface, users can configure, monitor, and enable protection. The soft starters are available in open and packaged control configurations with five frame sizes for currents ranging from 11 A to 1,000 A.

The Split uKIT version of the AEGIS SGR Bearing Protection Ring protects the bearings of VFD-driven motors from electrical damage, and allows quick and easy retrofitting of the ring on virtually any ac motor shaft without decoupling attached equipment. The AEGIS Split uKIT is ideal for HVAC service contractors and plant maintenance departments. Designed to accommodate slingers, shaft shoulders, and other end bell protrusions, the kit comes with a split AEGIS ring, the halves of which are held together with a unique hinge. This hinge design allows the split AEGIS ring to be opened on one side, then closed and fastened together with built-in adhesive-backed aluminum tabs, providing rigidity to the assembled ring.

Eaton Corporation www.eaton.com

Electro Static Technology Inc. www.est-aegis.com

Soft starter solutions

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Line of actuators The Tritex II dc powered line of actuators integrates power and control electronics with brushless servo motors and actuators in one package. The actuators combine electric power with advanced thermal management modeling and maximize power in smaller packages without sacrificing performance. The Tritex II dc offers continuous forces of 1,000 lbs and 1,300 lbs peak and speeds reaching 33 in./sec. The actuators have a wide range of I/O capabilities including digital I/O, analog I/O, and communication buses including Ethernet/IP, Modbus TCP, and PROFINET IO. With a wide range of applications including demanding environments, the actuators provide motion control in linear and rotary applications. Exlar www.exlar.com

3 hp and 5 hp motors NovaTorque’s Gen2.0 PremiumPlus+ Electronically Commutated Permanent Magnet (ECPM) Motors are packaged in standard NEMA frame sizes and mounting dimensions for easy substitution. The motors are driven by variable frequency drives and boast motor-only rated point efficiencies of 93% and 92% for 3 hp and 5 hp versions. NovaTorque motors are available in the mounting frame size typical for induction motors in addition to one frame size smaller. The motors are compatible with readily available frequency drives from many leading manufacturers. NovaTorque www.novatorque.com

EtherNet/IP enabled servo drive

Base drive solution

The Allen-Bradley Kinetix 350 single-axis EtherNet/IP servo drive offers a cost-effective entry in the Rockwell Automation Integrated Architecture system. This system scales from 200 to 10,000 I/Os, allowing machine builders portability to migrate existing machine designs into new, higherend machine designs. The drive comes equipped with safe, torqueoff functionality allowing for tasks such as machine setup, cleaning, removal of jams, and other maintenance tasks. The Kinetix 350 servo drive has 400 W to 3 kW of power range to meet global machine requirements. Rockwell Automation Inc. www.rockwellautomation.com

www.plantengineering.com

The SINAMICS DC Master Base Drive is a prewired solution that comes with all the necessary components mounted onto a back panel. The drives are designed for end users and third parties such as system integrators and Siemens solution partners. Features of the SINAMICS DC Base Master Drive include input fuses, output dc fuses, a control transformer, ac line contractors, PROFIBUS, BOP20, UL508A certifications, and 65 kA SCCR rating. The new drives offer more power per panel in the same footprint compared to the previous two generations. Siemens www.siemens.com

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2012

Product of the Year

Electric Motors & Drives

Electrical Controls

Base drive panels expansion The SINAMICS S120 drive system’s expansion includes PROFINET, Ethernet TCP/IP, and EtherNet/IP connectivity allowing for industrial Ethernet communication while offering innovative concepts for users wanting a single network for an entire plant. PROFIBUS DP and PROFINET are supported by the SINAMICS S120 drives to ensure seamless communications between all the components involved in an automation solution. The drives are designed to handle any drive requirement and facilitate vector, serve, and variable-frequency drive application with single or multiaxis offerings. Siemens www.siemens.com

Cabinet cooler system The Dual High Temperature Cabinet Cooler Systems purge and cool overheated electrical control panels in harsh environments. The cabinet coolers eliminate hightemperature malfunctions and protect sensitive electronics from hot, dirty locations by keeping electrical enclosures cool with air as cold as 20 F. With high cooling capacity of up to 5,600 Btu/hr, the cabinet coolers are designed for large electrical enclosures and high heat loads. The cabinet cooler applications include variable frequency drives, programmable controllers, industrial computers, motor controls, microprocessors, and robotics. EXAIR Corporation www.exair.com

CNC operator panel

Sensing switch and transducer

The SINUMERIK OP 019 is a CNC operator panel with advanced technology that enables seamless design integration to the SINUMERIK Operate graphical user interface. The design features a touchscreen operation including the new Power Control Unit 50.5 allowing high-speed key actuation. The OP 019 also features wide LEDs, which allow the user to clearly visualize every key actuation. The OP 019 panels provide basic machine display with three or four channels showing up to 13 axes.

The ATS Current Sensing Switch and Transducer is a one-piece solution combing a limit alarm with an analog output signal transducer to monitor produced and consumed ac current up to 1,200 A while isolating outputs and input to maximize safety. The rotary switch makes it easy for operators to set the trip point. With an analog signal available at all times, increases or decreases in current can be detected. The switch also provides limit alarm contacts for over- or under-current conditions.

Siemens www.siemens.com

NK Technologies www.nktechnologies.com

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Energy Management

Gateway solution Device and data management The Foreseer X-Class software is designed to monitor, track, and analyze data from more than 100,000 devices at the same time across an enterprise. The software collects data and status information from power, environmental, safety, and security systems to help companies reduce energy consumption. The Foreseer X-Class software has a customized executive dashboard to help track and predict power usage trends and events, and improve energy efficiency. The software is designed for companies with global operations and a vast array of devices.

The Power Xpert 200E gateway is a solution that collects energy usage data from meters, allowing customers to benchmark energy usage, set energy management goals, determine the effectiveness of energy management initiatives, and reduce energy costs. The Power Xpert 200E gateway is designed to be used as a data acquisition tool for serially communicating energy meters via an embedded Web server or connecting to Ethernet-based applications. Eaton’s gateways can be used with the Power Xpert Energy Viewer, which provides a simple way to gather key energy parameters and display them in reports. Eaton Corporation www.eaton.com

Eaton Corporation www.eaton.com

Consolidated complex data Power Xpert Reporting 3.0 enables users to make sense of exhaustive power monitoring data and identify important statistics to improve efficiency and reliability. This software was designed for energy, healthcare, information technology, and facility managers to track and compare systems within facilities and across the enterprise. Power Xpert Reporting is equipped with 13 ready-to-go report templates with graphics and charts to help users understand and control critical power systems and energy flow. The new version of Power Xpert Reporting allows users to create custom reports with user-selectable or virtual attributes and complex formulas for custom data. Eaton Corporation www.eaton.com

www.plantengineering.com

Data logger EXAIR’s Digital Flowmeter is designed to monitor compressed air consumption and waste. With EXAIR’s newly added USB Data Logger, users can maintain a history of the Digital Flowmeter’s measurements for analysis. The information from the data logger can be removed from the Digital Flowmeter and plugged into a computer where the data can be viewed. The Digital Flowmeter comes with an optional Summing Remote Display to allow for easy monitoring of compressed air consumption in any location. EXAIR Corporation www.exair.com

PLANT ENGINEERING

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2012

Product of the Year

Energy Management

Dock seal The Insulator Dock Seal with Light-Blocking Header is a durable dock seal that closes small light gaps caused by trailer protrusions. The design of the Insulator Dock Seal features rows of layered, horizontal pleats that conform to the protrusions as a trailer backs in. All of Frommelt’s dock seals are reinforced with high-strength Durathon fabric over a flexible vinyl base fabric to protect against wear and tear. The corners of the Insulator Dock Seal are also reinforced with layers of Durathon fabric and flexible high-molecular weight polyethylene sheeting to prevent damage and are attached with industrial Velcro for quick replacement.

Environmental Health

Ultra-fine atomized misting system The AirGo Misting System fan is available with highfiltered misting, producing a cooling effect equivalent to 22 tons of air conditioning. The system’s design features an ultra-fine atomized mist that absorbs heat in the air and allows for a safe cooling zone in hot outdoor settings. The fan produces the cooling power of air conditioning in any setting. The AirGo Misting System provides a cooling breeze measured at 140 ft and about 6,000 sq ft of floor coverage area. Big Ass Fan Co. www.bigassfans.com

Frommelt Products Corporation www.frommeltsafety.com

Power protector The 300 kW VDC-XE with High Current (HC) option is a solution for protecting powerdependent applications in facilities that do not have the floor space for multiple backup units. Compatible with all major brands of 3-phase UPSs, the VDC-XE with HC option connects to the dc bus of a UPS. The system includes patented technology consisting of a flywheel hub formed from aerospace-grade steel, a high-speed permanent magnet motor generator, a contact-free magnetic levitation system, and a touchscreen graphical display. VYCON’s flywheels incorporate a host of advanced features that make the systems easy to use, maintain, and monitor. VYCON Inc. www.vyconenergy.com

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Mercury adsorbent The VaporLokCapture is a breakthrough technology that adsorbs mercury vapors from broken lamps within lamp storage, shipping, or recycling containers. The VaporLokCapture is featured in VaporLok’s fluorescent lamp shipping and recycling system. The design minimizes the risk of exposure to mercury by reducing 95% of the vapor within a container. The VaporLokCapture is manufactured with powdered activated carbon and inert chemicals, which immediately capture mercury vapor when lamps or compact fluorescent lamps (CFL) break. The product will be incorporated into industrial products of VaporLok and consumer CFL packaging solutions. VaporLok Products www.vaporlokproducts.com www.plantengineering.com

Fluid Handling Fluid recycling solution

Siphon fed spray nozzles

The mobile SumpDoc by Eriez provides complete, inline fluid recycling for machine tools operating in three simple steps. The operator selects each mode starting with Sump Vac mode, moving to Filtration Mode and then to Coolant Makeup Mode. When the sump tank reaches the desired concentration level, the process is complete. The SumpDoc is completely portable, allowing operators to drop in the hoses, complete a full cycle, and move on to the next machine tool sump or parts washer to be cleaned.

EXAIR’s Atomizing Spray Nozzles atomize fluids in a range of spray patterns by combining liquid and compressed air to create a mist of atomized liquid that can be easily adjusted to various applications. The siphon fed nozzles require no liquid pressure and can be used with gravity fed liquids or lift liquids from a siphon height as much as 36 in. Siphon fed nozzles can be used on liquids with a viscosity up to 200 cp. The nozzles are fully adjustable with a stainless steel construction for durability and corrosion resistance.

Eriez www.eriez.com

EXAIR Corporation www.exair.com

Threaded port connectors

Inline vortex flowmeter The VLM10 combines an inline vortex meter, a built-in flow computer, and an integral temperature sensor giving users an elegant all-inone solution for their metering needs. The VLM10 is precise and reliable with a steam or gas mass flow accuracy of ± 1.5% over a wide 20:1 flow range. The fully welded, no-gasket design ensures safe measurement of steam and allows the sensors and RTD to be removed without having to shut down the line first. The built-in Web server allows customers to monitor flow and monitor meter health through the Internet.

FasMate FN Series connectors allow for quick, easy connections to threaded ports, delivering results in many applications. The connectors feature easy actuation and a split collet design. The versatile connectors have the capacity to perform three styles of actuation: squeeze level, pneumatic pilot, and pneumatic thumb valve. The new series offers additional features and benefits for better performance and durability. The FasMate FN Series provides increased application compatibility through the connectors that offer an extensive threaded port sealing range of 1/8 in. to 1/2 in. NPT. The connectors are equipped with pressure-assisted sealing technology to eliminate the risk of separation. FastEST Inc. www.fastest-inc.com

Spirax-Sarco Inc. www.spiraxsarco.com

www.plantengineering.com

plant engineering

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2012

Product of the Year

HVAC

Airfoil fan system Big Ass Fans’ Powerfoil X2.0 system combines patented airfoils and winglets with AirFence technology to increase the overall coverage. The winglet improves airfoil effectiveness through the elimination of turbulence at the tip, while the AirFence is able to capture air that would have slipped off the end of the airfoil. The Powerfoil X2.0 offering a 28% increase in coverage area is available in 8 ft to 24 ft diameters. Big Ass Fan Co. www.bigassfans.com

Modulation infrared heater The MP Series of modulation infrared heaters allow users to select a desired operation for their specific needs through the incorporation of three performance curves, as well as a Blast Mode. The Blast Mode allows users to temporarily lock the heater into its highest input with an extra 5,000 BTU for extreme environmental demands. The models available in the MP Series range from 80,000 BTU to 200,000 BTU. The MP Series features full gas modulation with corresponding airflow modulation to allow for optimal fuel utilization. Detroit Radiant Products Co. www.re-verber-ray.com

Portable and adjustable fan The Renegade Series of HVLS fans are designed for improving air circulation in areas with overhead obstructions or limited ceiling access with a floormounted configuration. The HVLS fans are portable and can be moved when necessary and are also adjustable from 10 ft to 15 ft in height. The Renegade fans are designed with RiteHite’s Propell-Aire custom aluminum blades with a single unit circulating air covering up to 7,850 sq ft. The fans are available in 8 ft, 12 ft, and 16 ft diameters with optional SureStop Safety Barriers to protect against accidental contact. Rite Hite Holding Corp. www.ritehite.com

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Steam system software Steam DesignPro 6.1 was designed to meet the demands of mechanical engineers, designers, and contractors in the HVAC market. The software was created as a visual design tool through an easy, drag-and-drop method for designing and modeling HVAC steam systems. The Windows-based software allows for easy modeling of steam generation, steam distribution, steam utilization, and condensatehandling systems. Steam DesignPro supports compiling of equipment schedules based on the Spirax Sarco catalog. Additional features include the ability to select relief valves, flowmeters for steam and hydronic applications, and control valves. Spirax-Sarco Inc. www.spiraxsarco.com www.plantengineering.com

Lighting

Architectural luminaire Color-consistent LED

Columbia Lighting’s e•poc LED uses precise standards to maintain superior color consistency within each fixture throughout its lifetime. The luminaires are passed through a test booth where each receives a QR code capturing the exact initial color, lumen rating, and module serial number creating the best quality and the most traceability of LED lighting. The e•poc LED is constructed from 70% recycled steel and has a 50,000-hr, mercury-free lamp life. The e•poc LED provides reduced energy consumption when higher light levels are not necessary through the two lumen output configurations available.

As part of Columbia Lighting’s createchange series, the Serrano Architectural Luminaire is a three-element diffuser combining a performance-optimized center optic with two high-transmission, lenticular side lenses to provide efficiency. Serrano delivers energy savings of up to 40% while maintaining lighting quality and light levels. The Serrano is compatible with a variety of controls and has a wiHUBB-enabled option to integrate with Hubbell Building Automation’s wireless mesh network. Columbia Lighting www.columbialighting.com

Columbia Lighting www.columbialighting.com

Architectural LED The Serrano LED delivers high efficacies up to 101 lumens per watt and a fixture life of up to 50,000 hours at 80% lumen maintenance. Serrano LED is compatible with a variety of controls and can be ordered with wiHUBB capability to easily integrate with Hubbell Building Automation’s wireless mesh network. The modular plug-and-play design allows for components to be easily swapped out as technology advances. To ensure color consistency, each Serrano LED is tested to maintain a three-step MacAdam ellipse. Columbia Lighting www.columbialighting.com

www.plantengineering.com

Emergency LED lighting

The EV Series LED emergency light utilizes two highpowered long-life LEDs to produce superior light output with optimized fixture spacing of 27 ft. The EV Series emergency lights require less than 2 W to power and utilize an environmentally friendly nickel metal hydride (NiMH) battery. The EV Series measures only 8.5 in. wide by 5 in. high with fast wall mount installation. The LEDs are mounted inside a die-cast housing, utilizing precious components to offer adjustability and thermal stability. Dual-Lite www.dual-lite.com

plant engineering

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2012

Product of the Year

Lighting Heavy industrial LED Hubbell Industrial’s LED Highbay is engineered for tough industrial environments, offering a customized solution in an eco-smart and retrofit-ready package. The design features a rugged cast aluminum housing design with a hinge and latch-mounting system. The LED Highbay’s design also features custom engineered LED optics for evenly distributed 5,000 K light in aisle, narrow, and wide distributions for use in up to 45 C ambient temperature environments. The LED Highbay comes standard with 0 V to 10 V dimmable drivers and can produce up to 100 lumens per watt with a life span of 100,000 hours. Hubbell Industrial Lighting www.hubbellindustrial.com

Surface mount luminaire Hubbell Industrial’s Sedona LED Surface Mount luminaire is designed to provide a unique, high-performance illumination solution for surface ceiling mount and parking garage applications. The Sedona LED features a hexagonal LED cluster design that provides optical flexibility and light level scalability. The packages available in this luminaire provide 92 to 100 lumens per watt with an ambient temperature of 40 C. The Sedona LED is wet-location listed and offers complete on/off dimming operation. Hubbell Industrial Lighting www.hubbellindustrial.com

Commercial, industrial LED luminaires The AccuLite Highbay and Lowbay LED Luminaires are low-profile industrial LED luminaires ideal for large commercial and industrial spaces. The fixtures are equipped with several innovative features including the large-format LED chip technology, hybrid TIR/reflector optics, and an ultra-thin efficient housing design. These features offer higher efficacy with improved thermal performance and ability to drive the LED more efficiently at higher currents. The LED luminaires produce up to 34,000 lumens of uniform area illumination and efficacies approaching 100 lumens per watt. The fixtures provide 57% energy reduction with a 100,000-hr lamp life. Juno Lighting Group www.junolightinggroup.com

46 • November 2012

PLANT ENGINEERING

www.plantengineering.com

Maintenance Tools & Equipment Heavy-duty gear oils

Power quality analyzers

The Mobil SHC Gear Oil Series are heavy-duty gear oils designed for enclosed gearing, as well as plain and rolling element bearings. The series is designed to provide service in equipment protection, oil life, and problem-free operation, enabling increased customer productivity. The lubricants are formulated from synthetic base fluids with exceptional oxidation and thermal properties. The Mobil SHC Gear Series covers a viscosity range from ISO VG 150 to 6800, which allows the series to meet the lubrication needs of very slow speed and high-load/hightemperature gears and bearings.

The Fluke 430 Series II three-phase power quality analyzers use patented algorithms to measure energy waste and quantify costs. By providing the ROI justification to mitigate power quality distortion, the 430 Series II helps reduce electrical power consumption and improve the performance and lifespan of electromechanical equipment. With the Unified Power function of the 430 Series II, electricians, utility technicians, electrical engineers, field service technicians, and energy consultants can determine how much power is being wasted and calculate the extra consumption costs. The improved screen quality and battery life on the 430 Series II gives users more options to analyze power quality and power consumption.

Exxon Mobil Corp. www.exxonmobil.com

Vibration screening tool

Fluke Corp. www.fluke.com

Infrared cameras

The Fluke 805 Vibration Meter is a portable multifunction vibration screening tool, providing quantifiable information on the bearing and health of motors and other rotating equipment. The Fluke 805 has the ability to measure overall vibration, bearing condition, and surface temperature. The design of the Fluke 805 features a unique sensor tip that minimizes measurement variations caused by device angle or contact pressure, reducing operator error and improving accuracy. The vibration meter also has a severity scale for overall vibration and bearing condition.

Fluke’s Ti Series of infrared cameras or thermal imagers offer a broad range of easyto-use capabilities, capturing images of infrared energy or temperature. Fluke infrared cameras combine the power of infrared images with visible light images on the same display. The thermal imaging detects heat patterns or temperature changes in objects, allowing users to discover problems or monitor developing problems. Common applications of the Ti Series include electrical, mechanical, process, and building inspection. Fluke Corp. www.fluke.com

Fluke Corp. www.fluke.com

www.plantengineering.com

plant engineering

November 2012 • 47

2012

Product of the Year

Maintenance Tools & Equipment Machinery alignment ROTALIGN Ultra iS is a system designed by Prüftechnik for machinery alignment, combining sensALIGN intelligent sensor technology with ROTALIGN Ultra computer for fast acquisition and real-time results display. sensALIGN calculates misalignment from collected measurement points while monitoring the rotating angle, speed, acceleration, and environmental vibration. This eliminates external influences and coupling backlash, ending in accurate readings in harsh conditions. With ROTALIGN Ultra iS, users can accomplish alignment in three steps: enter dimension, measure, and view results. Prüftechnik Group www.prueftechnik.com

Inspection system The SeeSnake MAX rM200 Camera System combines portability and versatility to provide plumbing professionals with a solution for inspecting longer and tighter lines up to 200 in. in length and 1-1/2 in. to 6 in. in diameter. The camera system features improved reel mechanics for easier passage through tight turns, an ultracompact camera capable of providing optimal lighting through narrow spaces, and an upgraded cable. This provides greater abrasion resistance and allows users to push further with less effort. The system comes equipped with a built-in docking system for attaching viewing monitors and is compatible with RIDGID SeeSnake CS10 and CS1000 digital recording monitors. RIDGID www.ridgid.com

Warning beacon The wireless aisle-way beacon is a pushbutton and motion sensing technology providing users with the flexibility to position aisle-way beacons when and where they are needed. This allows plant operators to signal for parts, material refills, or machine maintenance in a timely manner. The design of the beacon allows for one, two, or four wireless pushbuttons to be linked. The motion sensor can be linked to the beacon for visible warning of approaching industrial vehicles, and the ultrasonic sensor can be linked for blind doorway applications. Schneider Electric www.schneider-electric.com

48 • November 2012

PLANT ENGINEERING

www.plantengineering.com

Materials Handling Systems

Tire lift trucks The LoadRunner makes it safe for one operator to easily move loads up to 2,500 lbs on air by utilizing an on-board compressed air caster to float a load across the floor. The self-contained unit features a low-profile deck with a 2–in. insertion height and throttle-style fingertip controls. The LoadRunner can assist or replace traditional equipment such as hand trucks, pallet jacks, and forklifts. The LoadRunner unit is emission free and designed for manufacturing, cleanrooms, assembly, testing, and warehouse applications requiring load movement.

Cat Lift Truck’s 2EPC5000-2EP6500 Series is equipped with powerful ac technology, featuring improved energy efficiency, performance levels, and premium operator ergonomics. The model gives users the ability to run up to two shifts on one battery charge in most applications. The 2EPC5000-2EP6500 Series is equipped with sealed wet-disc brakes, electrical components, and connectors, providing added protection for harsh environments. The enhanced operator control features an adjustable compartment and standard fingertip hydraulic control with an optional enclosed cabin for protection in cold or wet environments.

AeroGo Inc. www.aerogo.com

Cat Lift Trucks www.cat-lift.com

Air caster

Chain hoist The Lodestar Electric Chain Hoist incorporates features that provide steady lifts for a variety of applications. The hoist is designed with a lightweight, durable cast aluminum housing and a powder-coasted finish for high visibility. The Lodestar Electric Chain Hoist has a capacity range of 1/8 to 3 tons and a wide range of speeds creating versatility. The control panel of the hoist allows for quick voltage change, access to terminal strips, and simple fuse installation. The adjustable limit switch prevents the load from over-travel and built-in overload protection helps prevent lifting of dangerous overloads. Columbus McKinnon Corporation www.cmworks.com www.plantengineering.com

Electric end rider The Jungheinrich ECR 327/336 Series of electric end rider pallet trucks, available in 6,000 lbs and 8,000 lbs, incorporate a variety of applications including order picking, long distance transporting, and loading/unloading trailers. Designed for durability, the ECR Series features thick forks with a cast steel frame and sealed electrical components. The riders come equipped with standard features such as an electromagnetic brake, advanced regenerative braking, and adjustable casters. An optional corrosion protection package provides a galvanized coating on key components, resulting in durability in wet and corrosive environments. Jungheinrich www.jungheinrich-lift.com

plant engineering

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2012

Product of the Year

Materials Handling Systems Eco-performance truck series The 7000 Series Reach-Fork Trucks feature economic and ecological benefits, maximizing the number of pallets that can be moved per hour. This includes regenerative lowering that produces energy when the forks are lowered to increase battery shift life. The trucks were designed with an A-frame suspension with strong steel springs to provide a strong connection between the wheels and frame. They also feature an exclusive steered idler wheel, eliminating caster snap, and full-time traction and steering. The Raymond Corp. www.raymondcorp.com

Material handling workhorses

Galvanized pallet trucks Toyota’s three models of ac electric pallet trucks and walkie riders feature a Galvanized Chassis option to protect the vehicles while operating in wet environments. The three models include the 8-Series ac electric walkie pallet truck, 8-Series end-control walkie rider, and 7-Series electric walkie pallet truck. The chassis is designed for users who move materials in and out of cold storage facilities, the chemical, salt and brine industries, or in areas where frequent wash-down is required. Other features include heavy-duty Teflon coated Polytube bushings; galvanized metal frames; corrosion-resistant linkage pins; and galvanized lower linkages, pull rods, and connecting links.

The 8000 Series pallet trucks are material handling workhorses that stand up to tough applications while maximizing productivity and contributing to sustainable operations. The design of the pallet trucks features increases in material strength, enabling them to meet heavy-duty application needs. With PowerSteer, the trucks reduce steering efforts by up to 90% and provide speed-sensitive steering for smooth control at all speeds. The trucks offer a number of user-friendly features including roomy operator compartments, accessory bars, large storage totes, and additional caster options. The Raymond Corp. www.raymondcorp.com

Toyota Industrial Equipment www.toyotaforklift.com

50 • November 2012

PLANT ENGINEERING

www.plantengineering.com

Power Transmission Operator safety switchgear Eaton Corporation’s ArcResistant Front-Accessible Switchgear provides centralized control and protection for low-voltage power distribution equipment and is engineered to enhance operator safety. The front accessible design minimizes equipment footprint for utility, industrial, data center, institutional, hospital, and water facilities. The design also allows the equipment to be installed against the wall and eliminates the need to meet the National Electrical Code requirement of 36 in. of rear clearance. With an optional ANSI Type 2B rating for the front-accessible arcresistant switchgear, the operator can be protected while the low voltage control or instrumentation compartment doors are open. Eaton Corporation www.eaton.com

Drawout switchboard, panelboard Eaton Corporation’s 2- and 3-pole molded case circuit breakers (MCCB) provide front-accessible and frontconnected equipment with ease of maintenance. Drawout feeder MCCBs are available in 20 A to 600 A. The drawout MCCB switchboard and drawout MCCB panelboard may be submitted for almost any application. Breakers on the drawout MCCB units are inserted and removed through a mechanical removal system similar to other drawout designs associated with switchgear. For greater density and reduced space, the breaks are horizontally mounted in a traditional panelboard group mounted way. Eaton Corporation www.eaton.com

Grid-connect inverters

The Power Xpert Solar 1,500 kW Inverter is designed to improve plant levelized cost of energy, maximize energy harvest, operate in harsh environments, and adhere to safety standards. The inverter for utility-scale, solar applications converts dc power into clean ac. Eaton created the inverter to use an MV pad-mount transformer, which is connected to the inverter via a direct-coupled throat connection, reducing cable requirements, pad size, and commissioning time. The Power Xpert Solar 1,500 kW features a wide Maximum Power Point Tracking voltage range, which maximizes inverter operation time to boost energy harvest.

Eaton Corporation’s Series 6001 Energy Storage Grid-Connect Inverter features proprietary electronics and provides i mproved stability for wind and solar energy customers. The inverter is designed to allow users to achieve full battery storage potential because of a large dc operating voltage window. With a 20-year life for utility applications, the Series has rated magnetic, liquid-cooled power modules with over seven million hours mean time between failure and a rugged enclosure for harsh environments. The Series inverter provides the required grid support, including low-, zero-, and high-voltage range, stand-alone/black start operation, islanding detection, utility communication, and full four quadrant operation.

Eaton Corporation www.eaton.com

Eaton Corporation www.eaton.com

Utility-scale inverter

www.plantengineering.com

plant engineering

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2012

Product of the Year

Power Transmission

Mid-size bevel speed reducers

Bevel speed reducers

The new upgraded series is a mid-sized family of right angle spiral bevel speed reducers and gearmotors. The Cyclo BBB4 has a combination of features that results in a highly reliable, efficient, and durable gearbox. The allsteel internal construction, featuring Cyclo or planetary inputs and the ductile iron housing, provides unmatched ruggedness. Interchangeable with the Cyclo BBB3 series, the redesigned Cyclo BBB4 series has been optimized for increased power ratings. A new F size yields higher torque and accommodates larger shaft diameters. Sumitomo also introduces 46 new standard ratios, along with 87 optional ratios with this generation of Cyclo BBB4.

The new Cyclo BBB5 series is a compact, energy-efficient family of right angle spiral bevel speed reducers and gearmotors. This series has been optimized for direct shaftmounted applications. Similar to the Cyclo BBB4 Series, the Cyclo BBB5 has a combination of features that results in a very reliable gearbox. The all-steel rotating components, featuring Cyclo or planetary, exclusive bevel outputs, and compact housing design provide top performance without thermal limitations. To enable customers to precisely define operating speeds, Sumitomo introduces more than 100 ratios with this new 5 series of Cyclo BBB.

Sumitomo Machinery Corp. of America www.smcyclo.com

Sumitomo Machinery Corp. of America www.smcyclo.com

Electric linear actuator Thomson WhisperTrak Electric Linear Actuators maximize design flexibility and improve performance and user comfort in personal mobility, rehabilitation, and medical equipment applications where reliability, small size, and low noise are design considerations. The actuators comply with all relevant certificates and are built in accordance with ISO 9000. A sealed, IP67 enclosure allows the electric linear actuator to provide maintenance-free operation throughout its lifetime. The actuators are rated to provide at least 10,000 cycles at maximum load. The actuators operate at 12 Vdc or 24 Vdc and can handle static and dynamic loads up to 2,000 N at speeds up to 5.8 mm/sec. Thomson Industries Inc. www.thomsonindustriesinc.com

52 • November 2012

PLANT ENGINEERING

www.plantengineering.com

Productivity Training Software Blended learning solutions

Test question scrambler

G PA l l i e d ’ s inspired Blended Learning is d e s i g n e d to allow participants to take control of their learning experience through instructor ledclasses, online curriculum, and skill applications within their facility or industrial environment. The training is a three-step process including a learning project kickoff, eLearning, and practical application. GPAllied inspired Blended Learning enables organizations to expand the capabilities of existing maintenance and reliability engineers and develop new maintenance and reliability engineers to meet growing needs. GPAllied employs its Rapid Improvement Process throughout the blended learning experience to ensure retention, alignment, and lasting change. GPAllied www.gpallied.com

The newly developed Scramblizer by Ramsay Corporation allows online administration of test questions in a randomized order, so each test taker sees a different arrangement of test questions. The scrambling of test questions discourages cheating while allowing the use of computers in close proximity. With each test showing the questions in a different sequence, memorization of answers is discouraged in order to avoid communicating those answers to others. The tests are machine-scored without the possibility of hand-scoring errors. With the answers on each item reported in their original order, test administrators can easily compare test-takers’ results. Ramsay Corporation www.ramsaycorp.com

System monitoring mobile application

FactoryTalk VantagePoint 4.0 Software is designed to simplify the end-user experience, include connectivity to additional Rockwell Automation products, and provide native integration to Microsoft SharePoint 2010. The software lets users expose plant floor data to the enterprise and provides capabilities like business intelligence, collaboration, and communications. The software connects real-time, historical, relational, and transactional data sources to create a single resource that can access, aggregate, and correlate information into a common, unified model. The Web-based dashboards and reports monitor key performance indicators and help empower users at every level of an enterprise to better manage their operation in real time.

Ta n g o M o b i l e Rounds Logging software designed for a smartphone or tablet allows reliability information management to take place in real time and in process. Tango Mobile Rounds Logging is an economical way to involve operators and mechanics in a plant’s reliability program. Numeric readings can be set for low and high alarm levels. Tango QR codes can be installed on equipment by plant personnel, contractors, or repair vendors. Users can quickly scan a QR code with Tango Mobile and instantly view condition monitoring history, equipment repair history, equipment design details, and linked documents.

Rockwell Automation Inc. www.rockwellautomation.com

24/7 Systems Inc. www.tf7.com

Performance and visibility software

www.plantengineering.com

plant engineering

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2012

Product of the Year

Safety Square D VR remote racking system

GE AK-1/2-50 remote racking system CBS ArcSafe offers a single application Remote Racking System for GE AK-1/2-50 extraction-style power circuit breakers. The RRS-3 AK-1/2-50 system enables operators to install and remove GE AK-1/2-50 equipment from up to 150 ft away with the wireless remote control. Installation of the RRS-3 AK-1/2-50 requires no modifications to the breaker or switchgear. This lightweight and portable system is ideal for hard-to-access areas including mezzanines, basements, and other areas with space restrictions.

CBS ArcSafe has developed a single application Remote Racking System for Square D VR-style power circuit breakers. The RRS-3 VR system allows operators to install and remove this style of circuit breaker from up to 150 ft away using a wireless remote control. The user-friendly RRS-3 VR requires no modifications to the breaker or switchgear and may be installed by one person in a matter of seconds. This lightweight and portable system is ideal for mezzanines, basements. and other locations with space restrictions. CBS ArcSafe www.cbsarcsafe.com

CBS ArcSafe www.cbsarcsafe.com

Rotary remote racking system The CBS ArcSafe RRS-4 Remote Racking System is an upgraded version of the RRS-1 for rotary-style power circuit breakers. The RRS-4 boasts many of the same components as the RRS-1 unit, making it portable, adjustable, and user-friendly. The RRS-4 is operated using a dual mode, source programmable, PLC-based control system. This PLCbased control system offers two operating modes: CCM Mode, allowing users to monitor the drive motor running current, and SEK Mode, allowing users to monitor the drive motor revolution count. Users have an option of which control mode to choose and can switch between the two. CBS ArcSafe www.cbsarcsafe.com

54 • November 2012

PLANT ENGINEERING

DHP remote switch actuator The RSA-11A is a remote switch actuator for Westinghouse DHP power circuit breakers. This product allows operators to remotely close and/or trip the circuit breaker. Installation of the lightweight and portable RSA-11A may be performed by one person in a matter of seconds and requires no modification to breaker or switchgear. CBS ArcSafe www.cbsarcsafe.com www.plantengineering.com

DS remote switch actuator

GE AK-1/2-25 remote switch actuator

The RSA-12A is a remote switch actuator that remotely operates all styles of DS power circuit breakers. The RSA12A is designed to operate on equipment with either manual or electric charging mechanisms and is compatible with all manufacturers and sizes of DS breakers. This product enables operators to charge, close, and/or trip the circuit breaker. Installation of the lightweight and portable RSA-12A requires no modification to existing breaker or switchgear.

The RSA-29 is a remote switch actuator for GE AK-1/225 power circuit breakers. This product allows operators to remotely charge, close, and/or trip the circuit breaker from up to 150 ft away when using a wireless remote control. Installation of the lightweight and portable RSA-29 may be performed by one person in a matter of seconds and requires no modification to breaker or switchgear. The RSA-29 is powered and operated by a CBS ArcSafe Remote Switch Operator (RSO-IIID).

CBS ArcSafe www.cbsarcsafe.com

CBS ArcSafe www.cbsarcsafe.com

Bidirectional disconnect switches

Medium-voltage vacuum circuit breaker

Eaton’s bidirectional disconnect switches incorporate the latest switching technology to enhance operator safety, extend equipment life, and reduce installation costs in grounded and ungrounded systems. The bidirectional disconnect switches can switch one circuit per pole and remove polarity limitations. The switches are available at 30, 90, and 100 A, with either 600 Vdc or 1,000 Vdc configurations. These new switches are available for either grounded or ungrounded PV systems and are capable of breaking up to six circuits with one switch. Grounded system switches include individual, isolate terminals for landing the grounded conductors.

T h e W - VA C i M B medium-voltage vacuum circuit breaker is designed for mining applications and engineered to provide reliable and robust circuit protection in a compact and reliable package. The breakers are also designed to protect transformers, capacitor banks, motors, busbar sections, and cable. To protect from demanding environmental conditions, the breakers are sealed from dust and contaminants prevalent in the mining industry and are suitable for high altitude, shock, vibration, and high temperatures. The 17.5 kV circuit breakers make and break power in a sealed environment with no external arcing. Eaton Corporation www.eaton.com

Eaton Corporation www.eaton.com www.plantengineering.com

plant engineering

November 2012 • 55

2012

Product of the Year

Safety Dock warning signal alarm The Safety Sentry Warning Signal Alarm improves loading dock safety by alerting those nearby a vehicle backing into the dock position. The Safety Sentry utilizes a 105 dB siren and strobe light combination system with industrial motion sensing technology. The patent-pending design is rated NEMA 4 and constructed with UVresistant polycarbonate using liquid tight strain relief connections.

Automated barrier door

Erich Industries Inc. www.erichindustries.com

The Guardian Defender combines safety interlock switches/controls capable of achieving up to PLe, Category 4 level safety with a movable physical barrier restricting access to dangerous machine movement. At the same time, process driven hazards such as weld flash, sparks, flying debris, mist, spray, and smoke are contained. The Guardian Defender’s switches/controls provide clear visual communications with two signals, green for safe and red for unsafe. The machine is designed with a 9-in. foam soft bottom edge and Armorplex curtain material. Frommelt Safety www.frommeltsafety.com

Swing arm system The Tether Track Swing Arm Fall Arrest System protects workers from injures due to falls. The system provides workers with a high degree of mobility and freedom, while preventing falls to lower levels. The Swing Arm System provides circular or semicircular fall protection with a compact footprint. The swing arm can be positioned over the workspace when needed and moved out of the way when not in use. The track can be wall mounted, column mounted, or stand alone and is available in standard arm lengths from 8 ft to 30 ft. Gorbel Inc. www.gorbel.com

56 • November 2012

PLANT ENGINEERING

Safety valve Cormack Propane Safety Valve helps prevent LPG escaping when changing forklift cylinders. When the Cormack valve is closed, it shuts off LP Gas next to the coupler to prevent it from coming through if the seal fails. If the Cormack valve is open, the foolproof handle design covers the coupler so the operator cannot disconnect it in the open position. The Cormack valve fits almost all forklifts and increases LPG cylinder exchange safety. With installation only taking minutes, LPG cylinder changes are quicker. Liftow Limited www.liftow.com www.plantengineering.com

Metal detectable components

Versatile lubricant DETEX Clear Penetrating Grease is a high-performance, versatile lubricant fortified with PTFE additives for enhanced lubrication. Clear Penetrating Grease is NSF Registered H1 No. 143804 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities.

DETEX Belt Dressing is a metal detectable plastic aerosol component for the food industry, designed to assist food processing plants in meeting strict HACCP requirements. Blue colored caps, actuators, and extension tubes signify the components, which are metal detectable and can help prevent food from being contaminated. All metal detectable plastic component ingredients are GRAS listed, meeting the FDA requirements as an acceptable material for use in food processing plants. The aerosol can is in compliance with the Food Safety Net Services and contains lithographed labels.

LPS Laboratories www.lpslabs.com

LPS Laboratories www.lpslabs.com

Water-resistant lubricant

Lubricant and penetrant DETEX Food Grade Machine Oil is a lubricant and penetrant that minimizes friction, extends equipment life, and penetrates to provide complete surface coverage protection against wear and corrosion. Food Grade Machine Oil is NSF Registered H1 No. 129000 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities.

DETEX Food Grade Chain Lubricant is a water-resistant lubricant designed primarily for the effective lubrication of all types of chains and conveyors operating in food environments. Food Grade Chain Lubricant is NSF Registered H1 No. 132899 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities.

LPS Laboratories www.lpslabs.com

LPS Laboratories www.lpslabs.com www.plantengineering.com

plant engineering

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2012

Product of the Year

Safety Anti-stick agent

Water-based lubricant

DETEX Food Grade Silicone Lubricant is a nonstaining, highquality lubricant designed especially for the food industry for use as an anti-stick agent for chutes and slides. Food Grade Silicone Lubricant is NSF Registered H1 No. 113815 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities.

DETEX Heavy-Duty Silicone Lubricant is a unique waterbased formulation that contains a high percentage of silicone for better and longer lubrication. Heavy-Duty Silicone Lubricant is NSF Registered H1 No. 01519 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities. LPS Laboratories www.lpslabs.com

LPS Laboratories www.lpslabs.com

Nonchlorinated electric cleaner

Nonflammable electronic cleaner

K2 Electronic Cleaner is a nonchlorinated, plastic-safe cleaner that is engineered to rapidly clean and restore electronic components. K2 Electronic Cleaner is NSF Registered K2 No. 146516 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities.

K2 NF Electronic Cleaner is a nonflammable, heavy-duty electronic cleaner that is engineered to rapidly clean and restore electronic components. K2 NF Electronic Cleaner is NSF Registered K2 No. 146517 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as protect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufacturing, processing, and packaging facilities. LPS Laboratories www.lpslabs.com

58 • November 2012

PLANT ENGINEERING

LPS Laboratories www.lpslabs.com

www.plantengineering.com

Rescue kit

Safety gate

The Miller QuickPick Rescue Kit delivers peace-of-mind during unexpected, peer-rescue situations involving those working at height. The rescuer can attach the system to the suspended worker while remaining securely anchored on the working surface. All rescue components are included in an easy-to-store kit with no required assembly. The kit is available in two configurations: the Premium Miller QuickPick Kit designed for workers whose job is not normally rescue, and the Standard Miller QuickPick Kit designed for those experienced in rescue situations. The kits are a professional solution that enhance worker safety and comply with corporate fall protection plans.

The GateKeeper Mezzanine Safety Gate is a reciprocating barrier that creates a controlled access area where workers can safely load and unload from the edge of a mezzanine, pick module, or other elevated platforms. The barrier designed with the GateKeeper is interconnected and cannot be open at the same time. When the outer gate opens to allow pallets to enter the mezzanine level, the inner gate automatically closes, keeping workers out. The exclusive link bar design ensures that both gates always work in unison, without relying on the chains or cables. Also featured with the GateKeeper is a Saf-T-Latch, preventing workers from raising the outer gate while inside the work zone.

Miller Fall Protection www.millerfallprotection.com

Rite Hite Holding Corp. www.ritehite.com

Vehicle restraint

Virtual main system

The RHR-4000 DokLok Vehicle Restraint adds another layer of safety by securing overseas container chassis, which can have a plate of obstruction above the rear impact guard. The RHR-4000 offers a water- and dust-resistant IP66 rated motor and a longer lasting, corrosive-resistant finish that meets the ASTM B117 testing standard. Like previous Dok-Loks, the RHR-4000 helps prevent all types of trailer separation accidents, including early departure and landing gear collapse, as well as trailer creep, popup, upending, and tip over. The Dok-Lok rotating hook restraints are designed for impact and to withstand the loading dock environment.

Schneider Electric offers an arc flash mitigation solution to upgrade Unit Substation equipment with the addition of a virtual main system. The system reduces arc flash energy on low-voltage switchgear, including the main incoming section. The virtual main system features a switching device with fault interruption capability on the high-voltage side of the service transformer. The system provides maintenance mode for arc flash reduction, improving the overcurrent protection of unit substation. The virtual main system is equipped with a built-in fault recording and event reconstruction technology in the digital relay.

Rite Hite Holding Corp. www.ritehite.com

www.plantengineering.com

Schneider Electric www.schneider-electric.com

plant engineering

November 2012 • 59

2012

Product of the Year

Safety

Fail-safe program

Braided hose

Siemens introduced the SIMATIC STEP 7 Safety Advanced V11 option as a part of its Totally Integrated Automation (TIA) Portal, providing end users with all configuration and programming tools required for generating a fail-safe program. The TIA Portal integrates product and production engineering via one interface, linking all of Siemens automation software packages and platforms. The framework of the TIA Portal enables all Siemens Programmable Controllers, HMI operator panel, and drives to be configured in the same development environment. The new Safety Advanced feature allows for intuitive operation and quick entry into the generation of fail-safe programs.

The Series AH2 Braided Hose is an extension of the VicFlex Sprinkler Fitting System. The hose is 100% kink resistant, offering a tight bend radius at 2 in., as well as a new level of installation ease and advantage. The VicFlex hose also offers an improved hydraulic performance with a 50% lower friction loss over corrugated systems. The improved corrugation and braided technology reduce the effort needed to bend the hose, allowing for better shape retention. The Series AH2 Braided Hose is cULus Listed and FM Approved in combination with the Style AB1 Bracket. Victaulic www.victaulic.com

Siemens www.siemens.com

Fire suppression system The Victaulic Vortex 500 Fire Suppression System is designed specifically for information technology spaces such as data rooms and server spaces. This technology utilizes both water and nitrogen in a combined suspension to both cool the hazard area and remove oxygen that sustains the fire using high velocity and low pressure. The swirling distribution fills the hazard space at 40 mph and extinguishes the fire with little to no water. The Victaulic Vortex 500 system provides supreme protection and fire suppression with limited residual moisture, no toxic chemicals, and full design flexibility. Victaulic www.victaulic.com

60 • November 2012

PLANT ENGINEERING

Now the vote is yours…

2012

Plant Engineering subscribers with a valid e-mail address will receive the 2012 Product of the Year ballot. Simply fill it out, click ‘Submit,’ and let your vote for this year’s best products be counted. Then, in the April 2013 issue of Plant Engineering, meet the 2012 Product of the Year award winners honored at our 2013 Awards in Manufacturing Event in Chicago. www.plantengineering.com

Product Index Company

Product

Category

Page

24/7 Systems Inc.

Tango Mobile Rounds Logging

Productivity Training Software

53

AeroGo Inc.

LoadRunner

Material Handling Systems

49

aPriori Inc.

aPriori 2011r2

Apps For Engineers

36

B&B Electronics Mfg.

802.11 WiFi Access Point for Industrial M2M Applications

Automation & Controls

30

Baldor Electric Co.

Dodge Type EXL

Electric Motors & Drives

38

Banner Engineering Corp.

SureCross Q45 Wireless Photoelectric Sensor

Automation & Controls

30

Big Ass Fan Co.

AirGo Misting System

Environmental Health

42

Big Ass Fan Co.

BAFWorks

Automation & Controls

30

Big Ass Fan Co.

Powerfoil X2.0

HVAC

44

Cat Lift Trucks

2EP5000-2EP6500 Electric Pneumatic Tire Lift Trucks

Material Handling Systems

49

CBS ArcSafe

RRS-3 AK-1/2-50

Safety

54

CBS ArcSafe

RRS-3 VR

Safety

54

CBS ArcSafe

RRS-4

Safety

54

CBS ArcSafe

RSA-11A

Safety

54

CBS ArcSafe

RSA-12A

Safety

55

CBS ArcSafe

RSA-29

Safety

55

Columbia Lighting

e•poc LED Full Distribution Luminaire

Lighting

45

Columbia Lighting

Serrano Architectural Luminaire

Lighting

45

Columbia Lighting

Serrano LED Architecturally Styled Luminaire

Lighting

45

Columbus McKinnon Corp.

Lodestar Electric Chain Hoist

Material Handling Systems

49

Detroit Radiant Products Co.

MP Series ‘Modulating Plus’ Overhead Infrared Heaters

HVAC

44

Dual-Lite

EV Series LED

Lighting

45

Eaton Corporation

Arc-Resistant Front-Accessible Switchgear

Power Transmission

51

Eaton Corporation

C441 Ethernet Series of Communications Cards

Automation & Controls

30 55

Eaton Corporation

DC Disconnects

Safety

Eaton Corporation

Drawout MCCB Pow-R-Line Panelboard and Switchboard

Power Transmission

51

Eaton Corporation

Foreseer X-Class Software

Energy Management

41

Eaton Corporation

H-Max Series Adjustable Frequency Drives

Electric Motors & Drives

38

Eaton Corporation

Power Xpert 200E Gateway

Energy Management

41

Eaton Corporation

Power Xpert Reporting v3.0

Energy Management

41

Eaton Corporation

Power Xpert Solar 1,500 kW Inverter

Power Transmission

51

Eaton Corporation

POWEREDGE Mobile Application

Apps For Engineers

36

Eaton Corporation

S811+/S801+ Soft Starters

Electric Motors & Drives

38

Eaton Corporation

Series 6001 Energy Storage Grid-Connect Inverter

Power Transmission

51

Eaton Corporation

SmartWire-DT System

Automation & Controls

31

Eaton Corporation

W-VACiMB Medium-Voltage Vacuum Circuit Breaker

Safety

55

Eaton Corporation

XV Series HMI-PLC

Automation & Controls

31

Electro Static Technology Inc.

AEGIS Split uKIT

Electric Motors & Drives

38

Erich Industries Inc.

Safety Sentry Warning Signal Alarm

Safety

56

Eriez

SumpDoc

Fluid Handling

43

EXAIR Corporation

Dual High Temperature Cabinet Cooler System

Electrical Controls

40

EXAIR Corporation

Siphon Fed Atomizing Nozzles

Fluid Handling

43

EXAIR Corporation

Super Air Nozzles

Compressed Air

37

EXAIR Corporation

USB Data Logger for Digital Flowmeter

Energy Management

41

Exlar

Tritex II DC Powered Actuators

Electric Motors & Drives

39

Exxon Mobil Corp.

Mobil SHC Gear Oil Series

Maintenance Tools & Equipment

47

FastEST Inc.

FasMate FN Series

Fluid Handling

43

Fluke Corp.

Fluke 430 Series II Three-Phase Power Quality and Energy Analyzers

Fluke Corp.

Fluke 805 Vibration Meter

Maintenance Tools & Equipment

47

Fluke Corp.

Fluke Ti Series Thermal Imagers

Maintenance Tools & Equipment

47

Maintenance Tools & Equipment47

FreeWave Technologies

I/O Expansion Module

Automation & Controls

31

Frommelt Safety

Guardian Defender Automated Barrier Door

Safety

56

Frommelt Safety

Insulator Dock Seal

Energy Management

42

Gorbel Inc.

Tether Track Swing Arm Fall Arrest System

Safety

56

GPAllied

inspired Blended Learning

Productivity Training Software

53

Hubbell Building Automation Inc.

CX Commercial Lighting Control Panels

Automation & Controls

32

Hubbell Building Automation Inc.

LightHAWK Neutral Wall Switch Occupancy Sensors

Automation & Controls

32

Hubbell Industrial Lighting

HBL LED Highbay

Lighting

46

www.plantengineering.com

PLANT ENGINEERING

November 2012 • 61

Product Index Company

Product

Category

Page

Hubbell Outdoor Lighting

Sedona LED

Lighting

46

Ingersoll-Rand plc

Heat of Compression Dryers

Compressed Air

37

Ingersoll-Rand plc

R-Series Rotary Screw Air Compressors

Compressed Air

37

Invensys Operations Management

Eurotherm Nanodac Recorder/Controller Historian

Automation & Controls

32

Invensys Operations Management

Intelligent Marshalling for Foxboro I/A Series DCS

Automation & Controls

32

Invensys Operations Management

Wonderware InTouch 2012

Apps For Engineers

36

iQuest

iQagent

Apps For Engineers

36

Jungheinrich Warehouse Products

ECR 327/336 Electric End-Rider Pallet Trucks

Material Handling Systems

49

Juno Lighting Group

AccuLite Highbay and Lowbay LED Luminaires

Lighting

46

Kepware Technologies Inc.

KEPServerEX 5.9

Automation & Controls

33

Liftow Limited

Cormack Propane Safety Valve

Safety

56

LPS Laboratories

LPS DETEX Belt Dressing (2216)

Safety

57

LPS Laboratories

LPS DETEX Clear Penetrating Grease (6716)

Safety

57

LPS Laboratories

LPS DETEX Food Grade Chain Lubricant (6016)

Safety

57

LPS Laboratories

LPS DETEX Food Grade Machine Oil (1316)

Safety

57

LPS Laboratories

LPS DETEX Food Grade Silicone (1716)

Safety

58

LPS Laboratories

LPS DETEX Heavy-Duty Silicone Lubricant (51516)

Safety

58

LPS Laboratories

LPS DETEX K2 Electronic Cleaner (57116)

Safety

58

LPS Laboratories

LPS DETEX K2 NF Electronic Cleaner (57016)

Safety

58

Miller Fall Protection

Miller QuickPick Rescue Kit

Safety

59

Nexen Group Inc.

Harmonic Gearhead

Automation & Controls

33

NK Technologies

ATS Current Sensing Switch and Transducer

Electrical Controls

40

NovaTorque

Gen2.0 PremiumPlus+, ECPM Motors

Electric Motors & Drives

39

Pro-face

GP4000 Series Modular HMI

Automation & Controls

33

Prüftechnik Group

ROTALIGN Ultra iS with sensALIGN

Maintenance Tools & Equipment

48

Prüftechnik Group

VIBCONNECT RF

Automation & Controls

34

Ramsay Corp.

Test Scramblizer

Productivity Training Software

53

RIDGID

SeeSnake MAX rM200 Camera System

Maintenance Tools & Equipment

48

Rite Hite Holding Corp.

GateKeeper Mezzanine Safety Gate

Safety

59

Rite Hite Holding Corp.

Renegade Series HVLS Fans

HVAC

44

Rite Hite Holding Corp.

RHR-4000 Dok-Lok Vehicle Restraint

Safety

59

Rockwell Automation Inc.

Allen-Bradley CompactLogix 5370 PACs

Automation & Controls

34

Rockwell Automation Inc.

Allen-Bradley Kinetix 350 Single-Axis EtherNet/IP Servo Drive

Electric Motors & Drives

39

Rockwell Automation Inc.

FactoryTalk VantagePoint 4.0

Productivity Training Software

53

Rockwell Automation Inc.

PlantPAx Virtual Image Templates

Automation & Controls

34

Schneider Electric

Aisle-way Beacon

Maintenance Tools & Equipment

48

Schneider Electric

StruxureWare Power Monitoring 7.0 Software

Automation & Controls

34

Schneider Electric

Unit Substation “Virtual” Main Circuit Breaker Solution

Safety

59

Siemens

SIMATIC HMI Comfort Panels

Automation & Controls

35

Siemens

SIMATIC S7-1215C

Automation & Controls

35

Siemens

SIMATIC STEP 7 Safety Advanced V11

Safety

60

Siemens

SINAMICS DC Master Base Drive

Electric Motors & Drives

39

Siemens

SINAMICS S120 Drive w/ Industrial Ethernet

Electric Motors & Drives

40

Siemens

SINUMERIK OP 019 CNC Operator Panel

Electric Motors & Drives

40

SixAxis LLC

Atlatl-Sales Resource Planning Software

Automation & Controls

35

Spirax-Sarco Inc.

Steam DesignPro 6.1

HVAC

44

Spirax-Sarco Inc.

VLM10 Inline Vortex Mass Flowmeter

Fluid Handling

43

Sullair Corp.

E900H Portable Air Compressor

Compressed Air

37

Sumitomo Machinery Corp. of America

Cyclo Bevel Buddybox 4 (BBB4)

Power Transmission

52

Sumitomo Machinery Corp. of America

Cyclo Bevel Buddybox 5 (BBB5)

Power Transmission

52

The Raymond Corp.

Raymond 7000 Series Reach-Fork Trucks

Material Handling Systems

50

The Raymond Corp.

Raymond 8000 Series Pallet Trucks

Material Handling Systems

50

Thomson Industries Inc.

WhisperTrak Electric Linear Actuators

Power Transmission

52

Toyota Industrial Equipment

Galvanized Chassis

Material Handling Systems

50

VaporLok Products

VaporLokCapture

Environmental Health

42

Victaulic

Series AH2 Braided Hose

Safety

60

Victaulic

Victaulic Vortex 500 Fire Suppression System

Safety

60

VYCON Inc.

VDC-XE with HC Option

Energy Management

42

62 • November 2012

PLANT ENGINEERING

www.plantengineering.com

SPECIAL ADVERTISING SECTION

2012

You’ve meet the finalists for Product of the Year. After you’ve completed the electronic ballot, you can learn more about the finalists and the products they offer. Our special Product of the Year advertising section provides a way to make plants run more efficiently, safely and productively.

   Companies interested in entering the 2013 Product of the Year competition may do so before the Sept. 2 7, 2013 deadline. Details and entry forms will be available Apr. 15, 2013, at www.plantengineering.com/POY www.plantengineering.com

PLANT ENGINEERING

November 2012 • 63

★

A VOTE FOR RAYMOND IS A VOTE FOR

PRODUCTIVITY. Vote for the 7000 series Reach-Fork® trucks and the 8000 series pallet trucks as your Plant Engineering Product of the Year, in the Material Handling category. They both represent great thinking. As all leaders should.

input #24 at www.plantengineering.com/information

7000 SERIES LIFT TRUCK 2012

Raymond 7000 Series Reach-Fork® trucks leverage Eco-Performance to deliver reduced energy consumption and increased productivity. In fact, they use up to 21% less energy and produce cycle times up to 9% faster than the competition. With faster lift speeds, quicker acceleration and longer battery life, you can move more pallets per hour and minimize maintenance and labor costs. Bottom line, it’s performance without compromise.

8000 SERIES PALLET TRUCK 2012

Raymond® 8000 Series pallet trucks perform without compromise–engineered with Eco-Performance, our design philosophy that reduces energy consumption and increases productivity. That means longer battery life with up to 33% less energy used and a 6% increase in productivity over the competition. Plus dramatically lower maintenance costs and zero compromise on reliability and durability. Add it up, and you’ll move more product per shift. And, achieve a lower total cost of ownership.

For any questions or to learn more, please call 1-800-235-7200 or visit raymondcorp.com.

View Live Plant Data on Your iPad®! What if you could use your iPhone® or iPad® to scan a QR Code on any piece of production equipment within your plant to: •View Live KPIs, Process Values, Trends, Charts and Graphs? •Review Maintenance Procedures, Drawings, or Parts Lists? •Call or e-mail the Equipment Support line, Sales Rep or Vendor? •Enter a work order, PM Action, or Trouble Report? •Record MP4 movies with video, live data and annotations to send to offsite support personnel for quick analysis?

With iQagent, You Can! (Try it Now with your IOS Device.)

Step 1: Download the Free iQagent App from the Apple App Store. Step 2: Launch iQagent on your iPad or iPhone Step 3: Scan the Sample QR Codes below using iQagent. Step 4: Visit www.iQagent.com to watch our Product Video and learn more about the first true Process App for IOS Devices! Production QR Codes (Scan with iQagent)

Line 1 Production

Plant Environment

Thermal Former 3

uest,Inc. www.iQuestcorp.com input #25 at www.plantengineering.com/information

Ingersoll Rand has unleashed two products, nominated for Product of the Year, that optimize the efficiency and productivity of your compressed air system: Long-Life, Contact-Cooled R-Series Rotary Compressors (55-160 kW) • Leak free, reliable components lower cost of ownership • Integrated intelligent controls optimize airflow • Flexible options such as fixed- and variable-speed motors, single- and two-stage airends and integrated Total Air Systems Cost-Saving HOC Dryers • Uses heat generated by compression process to lower energy cost • Low pressure drop design conserves energy • Patented stainless steel heat exchangers provide optimal performance

Ingersoll Rand Efficiency... input #26 at www.plantengineering.com/information

ingersollrandproducts.com

Hubbell Building Automation input #27 at www.plantengineering.com/information

The new Fluke 805 Vibration Meter is more than a pen. It’s a Fluke meter that gives you results you can trust, time after time. • Checks overall vibration, bearings and temperature • Ability to export and trend data • Four-leve l scale quickly assesses problem severity • Unique sensor design ensures accurate and repeatable measurements

Forget the pens. Think METER: fluke.com/VibrationMeter

input #28 at www.plantengineering.com/information

input #29 at www.plantengineering.com/information

Courtesy: AutomationDirect

AUTOMATIONSOLUTIONS

Remote monitoring technologies lower costs, improve operations The latest remote communication technologies allow experts to monitor and control multiple plants from any location. By Greg Philbrook AutomationDirect

www.plantengineering.com

R

emote monitoring isn’t new to the industrial automation world as over 25 years ago the first remote monitoring systems were installed using dial-up phone connections. In the 1990s, these early systems advanced to hardwired Ethernet/Internet connections that offered greater speed and reliability. Today, many plants are benefiting from technologies in which wireless networks and devices are used for easier and more economical remote monitoring and control. The advent of cellular technology has significantly expanded the ability to monitor plant operations from just about anywhere, while lowering costs and simplifying imple-

mentation. 4G technologies have made cellular connections much faster, often matching the speed of hardwired Ethernet/Internet connections.

Benefits of remote monitoring Once only found in significant numbers in industrial applications that covered widely dispersed areas, remote monitoring is becoming a more integral part of daily operations in many manufacturing facilities, thanks to the lower costs and simpler implementation associated with the newest technologies. Some of the factors driving remote monitoring proliferation have to do with lower upfront investment costs needed for implementation; PLANT ENGINEERING

November 2012 • 71

aUTOMaTIONSOLUTIONS

Remote monitoring is becoming a more integral part of daily operations in many manufacturing facilities, thanks to the lower costs and simpler implementation associated with the newest technologies.

others are the result of leaner operations and fewer operators on the plant floor. Not only does remote monitoring enable operators to monitor conditions from just about anywhere, it also facilitates more effective monitoring by fewer personnel, a real differentiator in today’s tough economic climate. The potential benefits of remote monitoring are significant: minimizing labor costs, filling the knowledge gap resulting from experienced operators retiring, prolonging equipment life, preventing unplanned downtime, and more. However, there’s no easy answer as to what type of remote monitoring is best. While remote monitoring can greatly contribute to cost savings and improved operations, there are considerations that must be addressed to ensure the security and practicality of implementing a remote monitoring system. Also required are definitions of what data can be accessed and by whom, and, most critically, what remote control options will be allowed.

Wireless advantages and challenges Installing wireless networks for remote monitoring systems is becoming a common way to reduce costs associated with installing and maintaining a network. Wireless networks offer significantly more flexibility than wired remote monitoring networks that have a fixed topology. The ability to mix and match equipment from different suppliers is also much easier with wireless. Eliminating the need to purchase and install wires and cables is the most immediate cost savings associated with implementing a wireless network. Another area for savings is the

Some advantages, disadvantages of wireless networks Advantages: n Flexibility for different hardware and software types n No cables or wiring n Faster and easier installation n Can provide greater visibility into operations.

Challenges: n Not a closed system as with wired networks n Early security standards not robust n Implementation of new security technologies can be challenging.

72 • November 2012

plant engineering

ability to add sensors much faster and for very little cost versus the high price of adding a hardwired device. Adding sensors improves visibility into a machine’s overall function, or to the overall performance of a batch or continuous process. The additional data gathered from new sensors enables operators to diagnose potential problems faster and with better accuracy, which leads to improved efficiency and reduced maintenance costs. While providing much lower installation costs, wireless networks aren’t a panacea for every situation or plant. The biggest concern with using wireless networks is security. Early wireless standards, such as wired equivalent privacy (WEP), were not as robust as they should have been, which has led to continuing concerns about data security over wireless networks. Although security measures are vastly better today, it is still important to remember that wireless networks can be more vulnerable than their wired counterparts. However, wireless networks have become far more secure through the use of encryption, and through standards such as the IEEE.802.11X-based Extensible Authentication Protocol, which requires clients to be identified in order to gain access to the network. But implementing and maintaining wireless network security requires certain IT knowledge, and smaller operations may not know how to implement these new security measures. Although wireless networks may pose a challenge for some users, wirelesses networking protocols and security features have advanced considerably, and wireless networks are definitely a viable option for reducing remote monitoring installation and maintenance costs.

Remote data access Regardless of the type of remote monitoring system, great strides have been made in terms of how and where the data from these systems can be accessed. In the late 1990s, PC-based access became the norm, later followed by Web-based access. These developments not only lowered costs, but also improved efficiency and productivity because plant operators could more easily and frequently access data. In addition to easier data access, PC-based monitoring brought about significant improvements in alarming and alarm response times. Now, many plants are taking advantage of the www.plantengineering.com

[ MOTOR TRUTH #13 ]

Are you into belts and chains? If not, then you need SEW’s patented TorqLOC®. Its keyless hollow shaft and taper bushings eliminate inefficient belts, chains, and sprockets thus reducing maintenance and energy costs while enhancing system safety. Mounting

Its spacious air gap provides easy mounting. Its tightening bolts provide easy dismounting. No more tight tolerances! No more keys! Need retrofit? No problem. TorqLOC even mounts onto an existing shaft that has a keyway. Visit sewmotortruth.com/truth13 for other ways to save energy.

Dismounting

sewmotortruth.com/truth13 864-439-7537 input #30 at www.plantengineering.com/information

aUTOMaTIONSOLUTIONS ability to use mobile devices such be compared and analyzed, often Remote monitoring as Smartphones to reduce costs and leading to early problem detection. gain greater visibility into plant Remote personnel can troublevia Smartphones operations. shoot issues, change an operatWhether as a result of the recesing parameter, and shut down a Web browser/VPN for remote monitoring: sion or experienced operators retirmachine or process to avoid possi n May provide snapshot, not real-time data ing, most manufacturing plants ble problems. They can also advise n May be read-only have fewer operators to monitor on-site engineers and operators as n Often not designed for small displays plant conditions. Process monitorto how best remedy a problem or n Security challenges. ing requires extensive oversight, improve performance. yet plant managers can no longer This type of expertise combined Smartphone app for remote monitoring: afford to operate isolated diagwith real-time visibility into daily n Very low cost nostics stations or assign certain operating conditions can extend n Wide range of functionality operators to specific areas of the the lifetime of machinery and n Fast loading of app plant. process equipment. Maintenance n High-speed access In today’s plants, many operaschedules and historical data can n Seamless upgrades from the supplier tors must simultaneously monitor more easily be used to determine n Designed for small displays multiple machines or processes maintenance and replacement n Security challenges. in various locations throughout intervals, all without having to a facility. Without remote monibe physically at the plant. toring, potential problems may not be cover multiple plants. With these moddetected, quality can suffer, equipment els, highly experienced operators and Cellular technology use Smartphones have replaced individucan be damaged, and unscheduled engineers can access detailed, realdowntime can occur. time information from each plant, as al devices that once seemed absolutely More manufacturers are moving to well as detailed historical information. necessary. Watches, alarm clocks, camconsolidated monitoring models that Information from different plants can eras, maps, video recorders, calculators,

Your operation is only Trust T&B Engineered ™ components to keep your operation running.

Wire & Cable Management • Cable Protection Systems

INTERACT recording devices, and much more now fit into a typical user’s pocket. It’s no wonder that the advances in cellular technology are being taken advantage of in manufacturing environments. Everyday more companies are using mobile devices such as Smartphones, tablets, and other handheld devices to cut costs, and to communicate information economically and quickly. While many manufacturers are enabling remote access via Smartphones and other handheld devices, implementation isn’t quite as simple as checking e-mail online. One of the main decisions to be made is how and when to implement browserand app-based remote monitoring.

Web browsers: Pros and cons The logical progression for accessing data remotely via a Smartphone is to use a browser to access plant automation systems via a company’s virtual private network (VPN). Many companies today offer remote connectivity via a VPN,

with users simply connecting to the company’s network and then interacting with the automation systems via a Web browser interface. This access is generally to a human machine interface (HMI) or a controller, although browser-based access can be used with any automation component equipped with Web-served capability. This type of access can be very good and relatively quick when the browser is running on a PC, but can raise issues with Smartphone browsers. In many cases, the Web server screens don’t scale well to the smaller displays found in handheld devices, and screens often take too long to load. Another consideration is that often remote browser-based access provides only a snapshot of the HMI screens, which can cause problems when monitoring large amounts of data in operating conditions that change frequently. Some Web servers and VPNs enable two-way access for remote control, but many just offer read-only access.

www.plantengineering.com/interact

Q: Does your plant implement browseror app-based remote monitoring? What applications do you use? Therefore, care must be taken when selecting a supplier or implementing a VPN solution to make sure users can perform remote actions as necessary. While Web browser access is essentially free, the costs of designing, deploying, and maintaining the VPN and the Web servers can be considerable and must be factored in when determining overall ROI.

Continued on pg. 86

as strong as your electrical system.

Corrosion Resistance T&B Superior PVC-coated Conduit Systems fight corrosion and help to avoid downtime

Ingress Protection

Extreme Temperatures

T&B Sealed Power Connectors T&B Extra High Temperature Cable Ties with stainless steel locking prevent washdown shorts device withstand temperatures and shutdowns from -40° to 150° C

Continuous Operation T&B Motor Lead Disconnects allow faster replacement of electrical motors

You may not think of electrical components as a means to better productivity, but we have ways to help prevent costly downtime due to electrical system malfunction or failure, and ways to help extend the working life of electrical equipment. Our portfolio includes a vast array of power and low-voltage electrical products, T&B Engineered™ to optimize performance, reliability and safety in even the most challenging manufacturing and processing environments. To learn how our products can help you keep your operation running strong, visit www.tnb.com

input #31 at www.plantengineering.com/information

Power Connection & Control • Safety Technology • HVAC Building Solutions • Engineered Transmission Structures

aUTOMaTIONSOLUTIONS Solar kits allow accurate monitoring and control of processes or equiment without a power infrastructure. Courtesy: B&B Electronics

like local decision-making and controls, and redundant backhaul paths.

The myth of 100% uptime

Using sensors to enhance systems Recognize the limitations, then plan for redundancy. By Mike Fahrion B&B Electronics

76 • November 2012

T

he network edge is continually expanding into new applications and new industries, and network-enabled sensors are leading the way. Metcalfe’s Law tells us that every time you add another device to a network, whatever that device’s function may be, you increase the value of the network. Sensors demonstrate that point every day. Whether they’re measuring deformation errors in a tire plant, geo-fencing an oil pipeline, or monitoring well water quality for the U.S. Geological Survey, sensors lower costs and enhance productivity. Each new application presents its own set of new problems. Sensors must function in a wide array of environments, and they must be able to report their data. This article will describe system design techniques that anticipate issues like brownouts and equipment failure, and prepare for them by employing solutions

plant engineering

All data communications installations have vulnerabilities. Fiber optic cable, for example, the option with by far the greatest range and bandwidth, is used by the telecommunications companies to move data across entire continents. Uptime is excellent, but the system isn’t perfect. The cables are either run through sewers, where backhoes break them with annoying regularity, or they’re strung along telephone poles, where they’re knocked down by everything from windstorms to sleepy truck drivers. Indoor fiber optic connections have problems of their own. Transceivers and receivers eventually fail. Cables can be bent or broken by anything from careless forklift drivers to the cousins of the raccoons that get into power substations and shut down the grid. Copper cable adds additional weaknesses. Any strong magnetic field can induce current on a copper cable, which will lead to power surges that can burn out sensors, integrated circuits, and connectors. Industrial machinery isn’t the only thing that can generate those strong magnetic fields. For example, a 1989 solar flare famously produced a magnetic storm that took out the power grid for all of Quebec. Lightning strikes will also produce damaging electrical events, as will the ground loops that occur when connected devices have different ground potentials. Wireless connections are subject to failure, too. Interference from other devices on the same frequencies can lead to data loss. And radio signals attenuate with the square of distance. Merely doubling the range would require a four-fold increase in power. No system is perfect. And the harder you try to achieve perfection, the faster your costs will rise. It’s cheaper and easier to eliminate the need for 100% uptime from the very beginning.

Rugged devices and isolation While 100% uptime is a mirage, at least for a price that any reasonable person would be willing to pay, that doesn’t mean you shouldn’t try to do your best. Industry-hardened network devices that will stand up to off-the-desktop, www.plantengineering.com

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input #32 at www.plantengineering.com/information

aUTOMaTIONSOLUTIONS real-world conditions can minimize many potential problems. Their copper connecting cables can be equipped with isolators. Unlike surge suppressors, which only try to limit spikes between the signal and ground line, isolators allow the lines to float while keeping the local side at the proper ground and signal level. USB connections, which are becoming ubiquitous because of their usefulness, also have an unfortunate proclivity for permitting ground loops. They should be isolated as a matter of course.

Planning for downtime

Monitoring remote assets via discrete analog and digital sensors and controlling remote control equipment from a central SCADA/PLC can both be accomplished with a single compact, rugged unit. Courtesy: B&B Electronics

Each new application presents its own set of new problems. Sensors must function in a wide array of environments, and they must be able to report their data.

78 • November 2012

Occasional glitches and communications failures are a fact of life. After you’ve done your best to eliminate the potential problems caused by equipment failure, human error, solar flares, and pesky raccoons, it’s time to start planning for what will happen when communications fail anyway. You can solve many problems by placing enhanced intelligence and local decision making at the end point, rather than calling for unbroken connectivity with the central controller. Autonomy at the sensor’s end is a great way to get around connection glitches and variations in bandwidth. Monitoring can be done in a “store and forward” scheme where the local sensor has the ability to store data and send/ resend it as needed. That is becoming easier and easier to implement. Processors keep growing more powerful, yet their power requirements keep dropping. Sensors can now be equipped with powerful internal processors as well as significant quantities of internal memory. That’s a great substitute for perfect uptime. One good example would be the U.S. Geological Survey (USGS) mentioned earlier. The USGS monitors well and surface water conditions at sites all over the country and uses the data to make ongoing updates to its website. As you might expect, many of its sensors are deployed in very remote locations, and in places where there is no access to the power grid and no Internet infrastructure. Data communications are handled by low-power radio transmitters. Because the transmitters have low power but must broadcast across large distances and overcome interference, there will be ongoing fluctuations in bandwidth and link quality. Trying to achieve 100% uptime in such circumstances would be absurd. Instead, the sensors use localized intelligence to record and store data, and they send/resend until they are satisfied that the information has been passed along.

plant engineering

Redundant backhaul Cable of one kind or another, with its built-in security, bandwidth, and reliability, normally forms the basic infrastructure of an industrial LAN. But what happens if you’d like to establish redundant backhaul and nudge your uptime rate that much closer to 100%? Cable installations involve a lot of labor and materials; they aren’t cheap. If the main infrastructure is already wired, you might consider using wireless as the backup. (It’s what the telecoms did while they were rebuilding their fiber optic networks in the aftermath of Hurricane Katrina.) There are a number of ways to go about it, depending on what you need to accomplish. With advances in multiple-in, multiple out (MIMO) technology and associated developments, Wi-Fi now has very serviceable range and bandwidth capabilities. It uses licensefree frequencies, which presents a financial advantage, and it is inherently interoperable with off-the-shelf wireless network adapters, laptops, tablets, and even Smartphones. For many applications Wi-Fi would be a very costeffective and uncomplicated way to establish redundant backhaul. Wi-Fi does have range limitations. You’ll need another wireless option if you need to establish M2M communication over long distances and the connections must be under your own control. Companies like Conel, in the Czech Republic, specialize in enabling users to maintain data communications over the cellular telephone network. The packet transfer system lets users employ any station in the network as an end station or as a retranslation station, allowing for networks with complex topology and vast size. Data transfer can be encrypted, and the system will support your choice of protocols. The technology is mature enough that 3G often serves as the backhaul for telecommunications and broadband services in countries like Belize, where a fiber build-out in difficult terrain like jungles and mountains would be far too expensive. The goal of 100% connectivity remains elusive. But industrial-grade installations, alternative power, and redundant backhaul combined with smart sensors can get you very, very close. PE Mike Fahrion, the director of product management at B&B Electronics, is an expert in data communications with 20 years of design and application experience. www.plantengineering.com

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input #33 at www.plantengineering.com/information

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input #34 at www.plantengineering.com/information

MAINTENANCESOLUTIONS

Courtesy: Hoffman

Smaller, more flexible enclosures still need to be rugged Cabinets allow for safe and accessible storage, but can generate dangerous heat. By Brian Mordick Hoffman

www.plantengineering.com

T

echnology advancements are resulting in electronics playing a greater role in the daily activities of business and manufacturing plants than ever before. A direct effect of the additional network and electronics is the growing demand for connectivity and network equipment to be relocated from centralized data centers—where conditions can be carefully monitored and controlled—to localized network and wireless applications, placing them at the point of control or activity. This increases the potential for exposure to the often harsh manufacturing conditions or environmental elements. To accommodate these changing needs, enclosure solutions have had to adapt to provide more flexible and controlled access, enhanced protection, durability, and performance versatility.

As component size decreases, PCB density increases, allowing more electronics and networking equipment to fit into smaller spaces. Now, control, networking, and security monitoring equipment that once filled full-size electronic enclosures easily fit into a smaller enclosure that can be affixed to a wall or mounted directly onto a machine—freeing up valuable floor space. Wall-mount cabinets allow manufacturers to safely store electronics where they are needed most, without exposing them to industrial conditions. However, these small, highly dense electronics generate a significant amount of heat. Therefore, the ideal wall-mount enclosure will offer thermal management capabilities, adapt to changing networking requirements, and accommodate a wide variety of applications. PLANT ENGINEERING

November 2012 • 81

mAINTENANCESOLUTIONS

Ideal wall-mount enclosures will offer thermal management capabilities and accommodate a wide variety of applications. Courtesy: Hoffman

Along with selecting enclosures to complement equipment size and location, cabinet specifiers must also consider the application challenges and environmental conditions that can compromise an enclosure’s integrity. Exposure to extreme temperatures, corrosive agents, or impact can damage enclosures.

Wall-mount enclosures Within industrial facilities, floor space is valuable, and many companies measure productivity and efficiency by dividing the amount of floor space by dollars generated. Consequently, installing a full-size electronics enclosure can take up valuable floor space that could otherwise be designated for equipment or machines and becomes detrimental to plant productivity. Wall-mount cabinets house and protect a variety of electronics and networking devices, conveniently mounting on walls or machines. To accommodate the demand for networking flexibility, wall-mount enclosures can be used to extend the data center via intermediate distribution frame (IDF), which further supports remote access points (AP) for wireless applications. An IDF is a free-standing or wall-mounted rack used to manage and interconnect cables between end-user devices and a main distribution frame (MDF). AP applications utilize dedicated hardware devices that act as a central transmitter and receiver for wireless signals. By supporting both IDF and AP networking applications, wall-mount input #35 at www.plantengineering.com/information

82 • November 2012

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enclosures aid in extending networks to remote locations to handle a broad scope of activities, such as industrial controls, access control, HVAC, monitoring, security/cameras, communications, building automation systems, and more. When selecting the ideal wall-mount solution, users should take multiple factors into consideration, such as space limitations, enclosure size, cable management, and any thermal issues. Wall-mount cabinets should provide easy access to equipment. For instance, single-door cabinets offer a cost-effective solution for protecting, securing, and cooling a host of equipment, while double-hinged door cabinets facilitate easy front and rear equipment access, enhancing access to cabling and reducing time to install and connect system components. Wall-mount cabinets are available in standard sizes and with custom options to support all types of networking and industrial electronics—both 19-in. rackmounted and traditional back panel mounted. In addition to the enclosure size, users must also consider how far the cabinet will extend from the wall or machine on which they intend to mount the unit. To avoid collisions in public aisle ways, cabinets should typically extend less than 12 in., but requirements can vary depending on application.

Cable management Cable management is a crucial aspect in cabinet selection. Proper, efficient cable management provides organization and support. For applications requiring www.plantengineering.com

INTERACT a simple solution, cable knock-outs allow cables to easily enter and exit the cabinet. Alternatively, in demanding applications where the enclosure’s rating integrity must be maintained, gland plates, which are removable sections of the enclosure, offer an outlet for cable egress. Gland plates not only provide cable management without compromising the enclosure, but they also accommodate evolving network needs by allowing cables to be frequently changed or added. Along with providing environment protection and management for cables entering or exiting a cabinet, internal cable organization minimizes stress points while still supporting frequent cable moves, additions, and changes (MACs). To accommodate these needs, wall-mount enclosures contain vertical and horizontal cable managers. This allows the cabinet to support all categories of networking cables, providing flexible cable management capabilities. Thermal management is another critical factor when selecting enclosure solutions. Electronics and networking equipment generate heat, requiring thermal management to protect components from overheating. Ranging from simple, passive cooling to complex solutions, thermal management capacities should correspond to the amount of heat generated by equipment being housed. The most advanced wall-mount cabinets combine protection, support, and access with integrated thermal management for a comprehensive enclosure solution.

Enclosure materials Protecting electronics and equipment from harsh industrial conditions requires enclosure and cabinet solutions that isolate and secure devices and connections from the surrounding environment. Non-metallic enclosure solutions provide rugged durability and enhanced longevity for applications repeatedly exposed to caustic chemicals or temperature changes, offering an alternative to traditional steel enclosures. Two prevalent non-metallic options include fiberglass and polyester. Also, non-metallic cabinets allow Wi-Fi signals to freely exit, protecting the equipment without impeding signals. www.plantengineering.com

www.plantengineering.com/interact

hang

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Q: How does your plant maintain continual network function, improve overall efficiency, and increase productivity?

Fiberglass Fiberglass is a common non-metallic material used in networking applications, due to its capacity to resist chemical exposure and extreme temperature changes—providing a costeffective alternative to stainless steel for corrosive environments. Composed of a high-performing, engineered composite resin, fiberglass enclosures are typically formed in one of two ways: compression molding or spray-up process. Compression molding incorporates precision-designed molds to deliver superior part uniformity and material consistency, and utilizes a material known as SMC, which is a long-glassfiber pigmented polyester resin. These long fibers provide superior strength and, when formulated with UV inhibitors and aluminum trihydrate, they resist material degradation. Further, this combination enables the enclosure to achieve the UL 94 5V flammability rating, which classifies the rate of burning, time to extinguish, ability to resist dripping, and whether or not the drips are burning. This rating is the highest performance requirement for a UL 508 enclosure. The second method of fiberglass enclosure forming, the hand lay-up or spray-up process, also delivers similar advantages. The molding used in this process also ensures part uniformity and material consistency, as well as achieves the UL 94 5V flame-resistance rating. Plus, its heavy, unfilled pigmented outer gel coat layer provides rugged protection against environmental contaminates or exposure. PLANT ENGINEERING

November 2012 • 83

Epoxy EP30D-7 • Abrasion resistant • Cures at room temperature • Outstanding chemical resistance • Excellent bond strength

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mAINTENANCESOLUTIONS

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Polyester

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input #37 at www.plantengineering.com/information

Pfannenberg_Plant_1_4.indd 3

Plant Engineering’s

The use of hybrid polycarbonate/polyester blends for nonmetallic enclosures is a relatively new development. Providing an alternative to traditional non-metallic enclosures, its thermoplastic material delivers high impact resistance, enhanced electrical properties, and superior chemical and moisture resistance. Unlike fiberglass enclosures, which eventually break under extreme pressure, polyester is engineered to absorb tremendous amounts of pressure without shattering. With its inherent durability, polyester is also less susceptible to scratches and abrasions. Featuring flame-retardant properties,

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polyester performs well in extreme temperatures and will not ignite when in contact with fire. Further, polyester’s corrosion and chemical resistance enables these units to withstand the highest range of solvents, alkalis, and acids without failure. Additionally, since polyester produces virtually no dust, it can be easily drilled and punched for holes and cutouts—even in the field—without contamination. By lacking glass particles, polyester is not susceptible to fiber bloom, minimizing the risk of product contamination and skin irritation, as well as reducing wear on tools. Plus, constructed of recyclable, thermal molded components, polyester is an eco-friendly enclosure material.

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Conclusion By understanding the available enclosure options, their advantages and performance capabilities, cabinet specifiers can select the ideal solution to perform in virtually any application, from limited spacing to damaging environments. Implementing the proper enclosure is instrumental in maintaining continual network function, which, in turn, improves overall efficiency and productivity. PE

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input #39 at www.plantengineering.com/information

aUTOMaTIONSOLUTIONS Continued from pg. 75 Using apps for monitoring and control

and wait for a screen to load. By contrast, app access is much quicker and requires fewer steps. Finally, app access typically requires much less IT support than VPN/Web browser remote access.

A different approach for using Smartphones and handheld devices to monitor and control operations remotely involves the use of apps specifically Security issues Just as with implementing a wireless designed for these devices. Extremely economical, with some costing as little remote monitoring system, new security as five dollars, Smartphone apps can be measures must be implemented when an optimal method for accessing data. accessing sensitive data via a SmartSome of these apps may offer the ability phone or handheld device. Regardless of to view and control operations as if the whether a Web browser or Smartphone user were in the control room in front of app is used, remote access must be prothe HMI screen. However, as with the tected from unauthorized personnel, and VPN/Web browser combination, care access levels must be controlled. Methods and technologies exist to must be taken. make remote wireTo create fully functioning remote Everyday, more companies less connections more secure. These security monitoring apps for are using mobile devices measures are similar Smartphones, develto those used for other opers must increase to cut costs and to comwireless communihardware, software, municate information cations: encryption, and protocol performance levels to economically and quickly. password authorization, and device idenreduce the latencies While many manufactur- tification. that can occur over The required securemote connections. ers are enabling remote rity settings and proIf not, users can access via Smartphones cedures can be too become frustrated by slow or poor perand other handheld devic- time-consuming or difficult for some formance. To opties, implementation isn’t plant managers and mize performance, engineers. developers must also quite as simple as check- control To a l l e v i a t e t h i s reduce the amount of situation, neophyte data transfer from the ing e-mail online. users should select automation components, typically HMIs and controllers. a company that provides a high level When done correctly, using an app of service, and has a deep underto access data via a Smartphone can standing of both the security requirebe very cost-effective and reliable. Joel ments and the technologies needed Froese, owner/operator of the Red Bank to make access via handheld devices Hydro Plant in Columbia, S.C., uses feasible and smart. Not every manufacturing plant will his Smartphone for remote access as depicted in Image 2. “I can access data employ the same remote monitoring anytime and anywhere to ensure I have systems, as each system has its own optimal operating conditions. I can start pros and cons, and as each plant has or stop the plant just as if I were stand- different needs. But regardless of the ing in front of the HMI. The screens type of access used, remote monitoring are scaled correctly, safety features are will become more the norm as techincluded, and I can quickly access the nologies advance and as the need to accomplish more with fewer resources data I need.” Not only is app access often supe- continues. PE rior in terms of performance, but it’s Greg Philbrook is HMI/Communicaalso easier to load. Browser access via a Smartphone requires a user to load tions product manager for Automationup the browser, then enter the address Direct.

input #40 at www.plantengineering.com/information

86 • November 2012

plant engineering

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input #42 at www.plantengineering.com/information

MECHANICALSOLUTIONS Three oil contamination examples: The left-most sample contains a new premium grade industrial mineral oil — no contamination. The center sample contains the same oil grade after five years of intermediate service in an oil film bearing with minimal external contamination. The oil is notably darker and has visible metallic particles suspended. The last sample contains the same oil grade with water contamination. Notice the cloudy appearance. Courtesy: Baldor

Particulates, liquids, oxidation contribute to oil contamination Oil discoloration should be addressed with high importance for optimal operation performance. By Andrew Myers Baldor

M

aintaining proper oil quality is essential for satisfactory operation and longevity of oil film bearings. Oil discoloration is a sign of potentially harmful contamination or degradation. There are three main causes of oil discoloration in oil film bearings: particulate contamination (external and internal), liquid contamination, and oxidation. Each cause has some unique characteristics, but discoloration is often a combination of the three.

Particulates, external and internal External particulate contamination refers to particles that are ingested from the surrounding environment. In an oil film bearing there is a radial clearance between the bearing liner and shaft to allow for shaft movement as the www.plantengineering.com

oil film develops. There are also axial shaft movements due to thrust loads and shaft expansions/contractions. These shaft movements, inherently, make completely sealing the bearing around the shaft a challenge. Without special sealing, small particulates in countless forms (lime and coal dust, sand/silicon, soot, metal chips, etc.) can work their way into the bearing and discolor/ darken the oil. During maintenance and installation, when the bearing housing is open, the bearing is exposed to large scale particulate contamination. For this reason it is recommended to thoroughly clean and flush the bearing with clean oil after it has been opened. In addition to particulate contamination coming from external sources, there are internal sources of particulate contamination that come from inside the bearing. To begin with, there will naturally be some wear particles generated each time a hydrodynamic bearing is started or stopped. These wear particles are created when the shaft is rotating below the minimum speed required to develop a full oil film. Without a full oil film, the shaft rubs against the white metal (babbitt) in the bearing liner. This is commonly referred to as boundary lubrication. The babbitt is a soft metal alloy designed to protect the shaft and will generate wear particles primarily in the form of tin, lead, and antimony. The babbitt also protects the shaft by embedding contaminates, but this has its limitations. If particulates are too large, they will not fully embed in the babbitt and will begin to score the shaft. A large concentration of small particles can also build up in the babbitt and lead to shaft scoring. Shaft wear particles (iron, chromium, etc.) will then further contaminate the oil and propagate the wear. Internal wear particles, just PLANT ENGINEERING

November 2012 • 89

mechanicalSOLUTIONS like external particulates, will particles. However, during generally cause the oil to darken. operation, oil rings are continuShaft surface finish plays a ously coated in oil and should critical role in controlling the not cause significant wear. Shaft amount of wear developed durseals come in many different ing starts and stops. Minor scorconfigurations and materials ing, pitting, or sharp edges on including aluminum and nitrile the shaft should be smoothed out elastomer. A well-designed shaft as much as possible. For most seal, if properly installed and applications, shafts should have maintained, should not genera surface finish of 32 micro in. ate significant amounts of wear or better. particles. Iron wear particles may also One last source of internal parbe generated in the contact areas ticulate contamination is actually between the bearing housing and Oil film bearings can be found in just about every type from new oil. Studies have been liner. A minor amount of con- of industrial environment and are therefore exposed to conducted to show that new oil structive wear in these areas can countless forms of contaminates. Courtesy: Baldor can contain a large quantity and be expected when a new housing wide variety of contaminates or liner is installed and the new surfaces for wear should be performed during rou- ranging from metallic wear particles to mate or “seat” together. tine maintenance to rule out this source large organic debris. It is a good practice However, if the liner is not clamped of contaminates. to filter the oil using a 10 µm, or finer, filsecurely in the housing, or if there is Oil rings and seals are other sources ter before ever pouring it into the bearing. vibration in the system, the contact of internally generated wear. Oil rings, If a circulating oil system is to be used, surfaces can begin to abnormally wear usually made of bronze, rest freely on then the standard practice is to filter the or fret and produce iron particulates. A the shaft and can rub against the oil ring new oil with a finer filter than the filter visual inspection of these contact areas grooves and produce copper and tin used in the circulating oil system.

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input #43 at www.plantengineering.com/information

Liquids Liquid contaminates are simply contaminates in the liquid state. The most common liquid contaminate in oil film bearings is water. Water or water vapor, just like external particulates, may enter the bearing through the clearances around the shaft seals and migrate into the oil. The presence of water in oil will make it appear cloudy or milky in appearance. Water has many harmful effects in bearings including rust/corrosion, accelerated oil oxidation, depletion of oil additives, and dilution of oil viscosity properties. Too much water can degrade the oil properties to a point to which the oil film will not develop at all. For these reasons, it is recommended to keep the water content less than 500 ppm (1,000 ppm maximum). Other forms of liquid contaminates can be cleaners, lubricants, assembly chemicals, assembly greases, process chemicals, and detergents. These can cause a wide range of oil discolorations and changes in chemical composition.

INTERACT Care should be taken to prevent these contaminates from entering the bearing, and extra precautions should be in place to ensure that oils are not mixed during installation or during routine oil checks/refills. The same oil used for lubrication (during operation) should also be used for cleaning and assembling. Simply knowing the color of the correct oil is an important step in preventing and identifying this type of contamination.

Oxidation Oil oxidation is one last source of oil discoloration. Oil oxidation is a process of chemical degradation that naturally occurs in oil over time when it is exposed to air. Some of its by-products are sludge, varnish, and acid, which cause the oil to thicken and darken. Higher temperatures (above 160 F for mineral oils) accelerate oxidation, as well as other contaminates such as water, iron, and copper. Synthetic oils are available which have better oxidation resistance than conventional

input #44 at www.plantengineering.com/information

www.plantengineering.com/interact

Q: How often are you checking on the oil quality for your systems? How often SHOULD you check it? oils and can be considered to extend oil change intervals.

Oil analysis There are many types of oil analysis tests available today. The most informative tests for oil film bearings show oil viscosity, water content, total acid number (oxidation indicator), and parts per million for each contaminate type. Due to reasons described previously, some

mechanicalSOLUTIONS small (less than 10µm) particulate is to be expected under normal operation; therefore, keeping a trend of particle count is more helpful than a single particle count for assessing bearing performance. A spike in particle count during steady operation (few starts and stops) is indicative of external contamination

or abnormal wear. Particles of 10µm or larger are on the same magnitude as the oil film thickness, and should be kept to a minimum in order to prevent abnormal wear. A very practical tool for analyzing oil samples in the field is an oil patch test kit. An oil patch test can be used to

get quick test results of the contamination level in the oil without waiting for results from a laboratory. In addition to oil sampling, monitoring the bearing operating temperature can detect changes in oil conditions. High levels of contamination and degradation result in increased friction and oil film breakdown, which will lead to a rise in operating temperature.

Oil type The recommended oil for oil film bearings is a premium grade, industrial mineral oil or turbine oil, with rust and oxidation inhibitors and anti-foaming agents. Extreme pressure (EP) additives are not recommended. Oil viscosity is determined individually for each application and is based on bearing clearances, loads, temperatures, and speeds. For units operating in hot or cold climates, synthetic oils can be considered which will not thicken as much at low temperatures and which will have better oxidation resistance at high temperatures.

Conclusion Oil discoloration in oil film bearings is a visible indication of oil contamination or degradation. Contamination comes in two main forms: particulates and liquids. Particulates can either be ingested from the environment or come from inside the bearing. Liquid contaminates can come from the environment, but they can also be inadvertently added to the bearing in the form of incompatible cleaners and lubricants. Oil degradation will naturally occur over time through oxidation. Regardless of the source, significant oil discoloration should be addressed with high importance. Slight discoloration does not necessarily indicate a problem. The lubricant supplier ultimately determines the acceptability. Oil is the lifeblood for oil film bearings, and maintaining proper quality through regular oil replacement and analysis will greatly increase the longevity and reliability of the bearings. PE

input #45 at www.plantengineering.com/information

Andrew Myers is a Baldor applications engineer for Dodge Sleeve Bearings.

92 • November 2012

plant engineering

Plant Engineering’s

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PL AN T EN G IN EER IN G E- N E W SL E T T ER S

PRODUCTMART Why Should You Filter Your Water?

Scale formation reduces the heat transfer rate and increases the water pressure drop through the heat exchanger and pipes. In fact, one study has shown that .002" fouling will increase pumping needs by 20%.

The Best Engineered Water Filtering Solution Always Costs Less 2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A ( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8 w w w. t e k l e e n . c o m [email protected] Input #100 at plantengineering.hotims.com

PORTABLE FALL PROTECTION

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Fall Protection from FabEnCo

3.5" – wide 4.5" high ThexSafety Gate Company American-made Pantone 382c Fa-

bEnCo XL Self Closing Safety Gates offer more vertical coverage wherever fall protection is needed. Gates are available in carbon steel, aluminum and stainless steel. FabEnCoat™ finishes include galvanized and safety yellow powder-coated. Custom gates are also available. www.safetygate.com/ple Input #103 at plantengineering.hotims.com

Reach your Audience! Place your Ad in PLANT ENGINEERINGS’ Product Mart or Classifieds section, call today and get results!

630-571-4070

Input #101 at plantengineering.hotims.com

PLANT ENGINEERING

November 2012 • 93

For more information on how to advertise in Plant EnginEEring’s Internet Connection, call Jim Langhenry at 630-571-4070 x2203 aggreko.com

gorbel.com

rosler.us

Aggreko is a global leader in generator rental, providing efficient and cost effective industrial generators and power distribution. Aggreko plc

Gorbel provides a wide variety of overhead handling solutions that handle loads from 50 lbs up to 40 tons. Gorbel Inc.

The Rosler group is the leading supplier of surface finishing equipment and consumables. Products include mass finishing and show blast equipment, wastewater treatment systems, and compounds for mass finishing. Rosler Metal Finishing USA

alliedelec.com Allied Electronics is a small order, high service level distributor of electronic components and electromechanical products. Allied Electronics

atlascopco.us Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco

automationdirect.com AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including PLCs, operator interfaces, sensors, and more. AutomationDirect

baldor.com Baldor Electric Co. designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.

donaldson.com Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.

exair.com Exair’s product line includes Vortex Tubes and products utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination. Exair Corp.

flexicon.com Flexicon Corp. designs and manufactures bulk handling equipment and custom-engineered and integrated plantwide systems. Flexicon Corp.

fluke.com Fluke Corp. is the world leader in the manufacture, distribution, and service of electronic test tools and software. Fluke Corp.

grainger.com Grainger is a leading distributor of industrial supplies, MRO equipment, tools, and materials. MRO, manufacturing, supply chain, tools, and more. Grainger Inc.

hamiltoncaster.com Casters at Hamilton Caster. Your source for heavy duty industrial casters, stainless steel casters, caster wheels and polyurethane wheels. Hamilton Caster

hyster.com Hyster offers a comprehensive range of warehousing equipment, industrial lift trucks, container handlers and reach stackers as well as quality material handling parts. Hyster Co.

lubriplate.com Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.

mhia.org MHIA is the leading non-profit trade association representing the U.S. material handling and logistics industry. Material Handling Industry of America

omega.com Omega offers more than 100,000 state-of-the-art products for measurement and control of temperature, humidity, pressure, strain, force, flow, level, pH, and more. Omega Engineering Inc.

pentair.com Pentair Ltd. delivers industry-leading products, services and solutions for needs in water and other fluids, thermal management and equipment protection. Pentair Ltd.

selinc.com SEL serves electric power utilities and industrial sites worldwide through the design, manufacture, and support of digital protective relays and automation products, plus services for power system protection, control, monitoring, integration, and automation. Schweitzer Engineering Labs

seweurodrive.com One of the largest global suppliers of drive technology, SEW-EURODRIVE specializes in gear reducers, motors and electronic motor controls. SEW-EURODRIVE USA

usa.siemens.com/drives One of the world’s leading motor manufacturers, Siemens offers NEMA, ANEMA, IEC, ac motors, dc motors, and Motors for motion control and machine tools. Siemens Motors & Drives

spiraxsarco.com Spirax Sarco applies world class knowledge, service and products to the efficient pressure and flow control of steam and other industrial fluids. Spirax Sarco Inc.

stanleyproto.com Pros who work the demanding jobs demand Stanley Proto. Our industrial hand tools are built to be precise, durable and make work easier. Stanley Proto

sullair.com AirMetrix is a total system management program designed to maximize the productivity of your compressed air system. AirTility delivers air as needed with no capital expenditures and no maintenance worries. Sullair Corp.

ridgid.com

tnb.com

Every tool that bears the RIDGID brand is engineered to the same high standards of quality, strength, and endurance as was the first heavy-duty pipe wrench. Ridge Tool Co.

Thomas & Betts supplies over 70% of the items used in a typical electrical application and provides market-leading commercial heating and ventilation products. Thomas & Betts Corp.

ge-energy.com

rigalite.com

yaskawa.com

GE Energy is one of the world’s leading suppliers of power generation and energy delivery technologies. GE Energy provides integrated products, services, and solutions in all areas of the energy industry. General Electric Co.

Rig-A-Lite leads the industry in innovative solutions and ruggedly designed products for marine lighting, industrial lighting, specialty lighting, petroleum lighting and food processing lighting. Rig-A-Lite Industrial Lighting

Yaskawa is the world’s largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.

94 • November 2012

plant engineering

www.plantengineering.com

Place next to your computer or go online to plantengineering.com for hot links to these companies.

Remove at Line

r 2012 e b m Nove

CONTACTS

Advertiser Contacts for plant engineers

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Plant Engineering. Page Number

Advertiser

RSC Number

Send Info

Aggreko LLC 866-215-7966

16

11

 www.aggreko.com

Allied Electronics 800-433-5700

11

7

 www.alliedelec.com

ALL-TEST Pro, LLC 860-399-4222

86

40  www.alltestpro.com/c/246

Atlas Copco Compressors 866-688-9611

22 17  www.atlascopco.com/drivenbyefficiency

AutomationDirect 800-633-0405

C-2

1

Baldor Electric Company 800-828-4920

C-4

47

 www.baldor.com

70

29

 www.reverberray.com

Detroit Radiant Products Company 800-222-1100 Donaldson Co., Inc 800-365-1331

2, 82

Electro Static Technology, Inc 866-738-1857

 www.automationdirect.com

3, 35

 www.donaldson.com

20

15

Exair Corp 800-903-9247

7

5

 www.exair.com

Flexicon Corp 888-353-9426

8

6

 www.flexicon.com

Fluke Corp 888-443-5853

4, 69

GE Energy 203-373-2211

 www.est-aegis.com

4, 28

 www.fluke.com

13 9  www.PeopleBehindThePromise.com/Vishal

Gorbel, Inc 585-924-6262

85

39

 www.gorbel.com

Grainger 847-535-1000

77

32

 www.grainger.com

Hamilton Caster & MFG. Co. 888-699-7164

92

45

 www.HamiltonCaster.com

Hankison 724-745-1555

26

20

 www.hankisonintl.com

Hubbell Building Automation, Inc. 888-698-3242

68

Hyster 800-HYSTER1

17, 27

27  www.hubbell-automation.com 12, 22

 www.hyster.com

Ingersoll-Rand 704-655-4000

67

26  www.ingersollrandproducts.com

iQuest, Inc. 813-909-1108

66

25

 www.iQuestcorp.com

Lubriplate Lubricants Co 800-733-4755

80

34

 www.lubriplate.com

Page Number

Advertiser Master Bond, Inc 201-343-8983

RSC Number

Send Info

83

36

 www.masterbond.com

Material Handling Industry of America 87 800-345-1815

41

 www.mhia.org

NuStar, Inc 800-800-9274

12

8

 www.powerpusher.com

1

2

 www.omega.com

Pentair 763-545-1730

25

19

 www.PENTAIR.COM

Pfannenberg USA 716-685-6866

84

37

 www.PfAdvantage.com

Omega Engineering, Inc 888-556-6342

Plant Engineering’s Electronic Newsletters 630-571-4070

84  www.plantengineering.com/newsletters

Ramsay Corporation 412-257-0734 Raymond Corporation 800-235-7200

85

38

64, 65

24

www.ramsaycorp.com  www.raymondcorp.com

RIDGID 800-769-7743

79

33  www.RIDGID.COM/PRESSING

RIG-A-LITE 713-943-0340

90

43

 www.rigalite.com

Rosler Metal Finishing USA 269-441-3000

24

18

 www.rosler.us

Schweitzer Engineering Labs 509-336-7946

91

44

 www.selinc.com

SEW-Eurodrive, Inc.

73

30

 www.seweurodrive.com

Siemens Industry, Inc. 800-241-4453

15

10  www.usa.siemens.com/ids-pe

18, 19

13, 14  www.spiraxsarco.com/us

Stanley Proto Industrial Tools 800-800-8665

28

23  www.PROTOINDUSTRIAL.COM/PE

Sullair Industrial Products 219-879-5451

88

Spirax Sarco Inc 800-883-4411

Thomas & Betts Corporation 901-252-8000 Vaisala, Inc. 888-824-7252 Yaskawa America, Inc 800-927-5292

21, 74, 75 26 C-3

42

 www.sullair.com

16, 31

 www.tnb.com

21  www.vaisala.com/compressedair 46

 www.yaskawa.com

Need More Info? FAX this page to: 630-214-4504

or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523

Name Company City Telephone

Fax

Title Address State e-mail

Zip

PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.

www.plantengineering.com

PLANT ENGINEERING

November 2012 • 95

INCONCLUSION Veterans can deliver skills to manufacturing

L

Bob Vavra Content Manager

Manufacturing leaders need to deliver the same level of service to our returning veterans that they have delivered to us during their time in the military. We would have this obligation even if there were not a skills gap.

96 • November 2012

ast month’s launch of the Get Skills to Work program by the Manufacturing Institute and four major American manufacturers is to date the highest profile attempt by American manufacturing to bridge its ever-widening skills gap. Its stated goal is to link the hundreds of thousands of existing and projected American manufacturing jobs to the tide of military personnel returning from wars in Asia or from the end of their tours of duty. The link between veterans and manufacturing is the key to the program, and so the first four companies to sign up—Alcoa, Boeing, GE and Lockheed Martin—fully understand the relationship between a strong military and a strong manufacturing environment. They also see the strong connection between the two, especially at this pivotal time in manufacturing. All have a long tradition in American manufacturing; all of them also are major defense contractors or suppliers. There is an unquestioned need for skilled manufacturing workers, and enlisting military personnel is both a strong political and strategic move. Reaching out to reemploy veterans in the private sector after their service to their country was completed has long been a patriotic concept. More than at any time since World War II, Americans value the service of our military personnel, and this program is yet another attempt to recognize and honor that service. American military personnel are trained on some of the world’s most sophisticated equipment. They understand discipline, commitment to hard work and an ability to apply critical thinking to solve problems. This skill set is exactly what many manufacturing employers want and need as they address a technological evolution in manufacturing. Plant managers need this kind of skill set to be able to remain competitive in a global manufacturing environment. “Veterans offer the technical, leadership and critical thinking skills that advanced manufacturing demands,” said Paula Davis, president

PLANT ENGINEERING

of the Alcoa Foundation, in a press release announcing the formation of the coalition. “Forming the Get Skills to Work coalition and coordinating with nonprofits to train, recruit and develop veterans is an exciting model that has the potential to change lives and produce a significant competitive advantage for U.S. manufacturers.” The timing of this announcement comes as wars are winding down in Afghanistan and Iraq and military personnel will be returning to civilian life. Get Skills to Work estimates that one million veterans will leave the Armed Forces over the next four years, while 600,000 high-tech manufacturing jobs remain unfilled. The return to civilian life from the military often is not easy. No one associated with the program underestimates that reality. We also can see the value of worker in our manufacturing ranks. For those who may struggle with what to do on their return from military service, Get Skills To Work offers a tangible direction and a clear path to the future. Manufacturing needs this influx of skilled talent. Manufacturing leaders need to deliver the same level of service to our returning veterans that they have delivered to us during their time in the military. We would have this obligation even if there were not a skills gap. The fact that one exists is all the more reason to get moving on this initiative today. The roster of manufacturers involved in Get Skills to Work current stands at four. I expect that roster to grow rapidly. But even without the formal involvement in this program, manufacturers around the country can and should tap into this resource without delay. Our soldiers are coming home, and a warm greeting and a parade is one way to welcome them home. But after the parade is over, let’s make sure we have a job training program and a job in manufacturing waiting for them. It’s good for manufacturing, it’s good for our veterans and that has to be good for America. PE www.plantengineering.com

WHAT YOU ALWAYS WANTED

Our customers tell us that quality means no product hardware failures. Now, that’s a gift that keeps on giving. When you take Yaskawa drives out of the box, you can count on them to work. In fact, Yaskawa products have a meantime-between-failure rate (MTBF) of up to 28 years. That means your engineers can spec Yaskawa and never have to worry. Just program, plug and play. Get what you want, every time. Call Yaskawa.

YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M

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©2012 Yaskawa America Inc.

DC On Demand

While other manufacturers have chosen to leave the DC motor market, ABB and Baldor continue to invest in product development and U.S. manufacturing in order to offer the widest variety of permanent magnet and wound field industrial DC motors in the world.

• The Most DC Choices

DC motors continue to provide the right solutions to many application requirements. We now can supply IEC or NEMA frame motors, stock motors from 1/50 to 500 Hp or custom-designed motors to 3000 Hp to meet your specific application. If you need a DC motor anywhere in the world, call Baldor!

• Superior Reliability

baldor.com

479-646-4711

• Unmatched Quality

• Quickest Delivery Available • American Made Since 1920

©2012 Baldor Electric Company

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