Professional Documents
Culture Documents
High-quality
AC drives pay
for themselves
in a hurry
Variable speed drives can improve
your bottom line by reducing your
applications energy consumption.
An investment of as little as $99
can start paying off immediately.
www.automationdirect.com/drives
www.automationdirect.com
LR Series Line Reactors
10-year warranty
input #1 at www.plantengineering.com/information
1-800-633-0405
Powered
By
OSXL-I Series
Starts at
$
1195
Visit omega.com/osxl-i_series
Visit omega.com/video
CN230 Series
Starts at
$
842
Visit omega.com/cn2300
STM Series
Starts at
$
298
Visit
omega.com/os210-150-300-800
Integrated Stepper
Drives/Motors
Visit omega.com/stm_series
omega.com
input #2 at www.plantengineering.com/information
GE Energy
Years of
experience,
customized for you.
Weve built our reputation by listening and providing
customized industrial maintenance and repair solutions.
Our employees are experts in their field, educated
through years of practice and driven by the discipline
to deliver results.
We offer complete industrial maintenance and repair
services for both existing equipment and new
infrastructure installations, extending the life of your
equipment and lowering your total cost of ownership.
input #3 at www.plantengineering.com/information
June 2012
Whats INside
7 Interactive
9 In Focus
25 In Practice
53 Innovations
58 Product Mart
59 Internet Connection
60 Advertiser Contacts
61 In Conclusion
62 Featured Innovations
PLANT ENGINEERING (ISSN 0032-082X, Vol.
66, No. 5, GST #123397457) is published 10x
per year, monthly except in January and July,
by CFE Media, LLC, 1111 W. 22nd Street, Suite
#250, Oak Brook, IL 60523. Jim Langhenry,
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
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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.
2012
Synthetic
Lubrication Guide
30 Lubrication Guide
A sound lubrication strategy is essential to keep all the gears in your
operation running at their best.
In Practice
June 2012 3
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 SPECIALISTS/EDITORIAL
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For custom reprints or electronic usage, contact:
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PUBLICATION SALES
Electrical Solutions
43 Industrial efficiency:
Maintenance Solutions
asset management
9 In Focus
Manufacturing experts to address summit
Manufacturings steak rolled at a slower pace in May
ISM forecast: Spending, revenues both expected to keep climbing
Siemens teams with community college to develop workforce
Strength in U.S., China drives growth in industrial automation
CMMS takes the guesswork out of safety inspections
Sweatman: Let manufacturers adapt without policy changes
Raymond Corp. celebrates youth apprenticeships
PLANT ENGINEERING
June 2012 5
NOBODY DOES
One call to Donaldson Torit is all it takes to fulfill all your
filtration needs. Your call will be answered quickly by a live
filtration expert with vast product knowledge and access to filters
of all styles and sizes. And, thanks to our massive warehouse and
Ready 2 Ship program, your order will be out the door in less than
24 hours. Even if your dust collector is from another manufacturer,
the filter performance and quality service of Donaldson Torit is only
a phone call away. Youre sure to get Exactly What You Need.
input #5 at www.plantengineering.com/information
INTERACTIVE
www.PlantEngineering.com
VIDEO:
WEBCAST:
In your opinion...
Which metric do you give the most weight to when evaluating your lift truck operations?
Your responses at www.PlantEngineering.com:
74%
Cost of operations
13%
Dependability
5%
Productivity
4%
Serviceability
4%
Ergonomics
June 2012 7
.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
CHILE
UK
AUSTRALIA
SOUTH AFRICA
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-1164
USA
sales@flexicon.com
1 888 FLEXICON
IN FOCUS
GLOBAL AUTOMATION AND MANUFACTURING SUMMIT
June 2012 9
IN FOCUS
Manufacturings streak rolls
at a slower pace in May
SAVE ENERGY.
REDUCE DOWNTIME.
EXTEND COMPONENT LIFE.
anufacturings three-year growth streak continued in May, albeit at a slower pace than in April,
according to the latest Institute for Supply Management manufacturing report.
The manufacturing sector expanded for the 34th
straight month and the nations overall economy hit the
three-year mark in growth, according to the report, issued
by the ISMs Manufacturing Business Survey Committee.
The PMI registered 53.5% a modest decrease of 1.3
percentage points from
IMS Report: The last 12 months
Aprils reading of 54.8%
indicating expansion in
Month
PMI
Month
PMI
the manufacturing sector
May 2012
53.5
Nov 2011
52.2
for the 34th consecutive
Apr 2012
54.8
Oct 2011
51.8
month, said committee
Mar 2012
53.4
Sep 2011
52.5
chair Bradley J. HolFeb 2012
52.4
Aug 2011
52.5
comb, CPSM, CPSD.
Jan 2012
54.1
Jul 2011
51.4
The New Orders Index
Dec 2011
53.1
Jun 2011
55.8
continued its growth
trend for the 37th conAverage for 12 months 53.1
High 55.8
secutive month, registerLow 51.4
P
ing 60.1% in May. E
PfAdvantage.com
input #7 at www.plantengineering.com/information
Pfannenberg_Plant_1_4.indd 1
3/1/12 8:03 PM
NE
XCESX
ENCLOSURES
BUILT TO LAST
IN HIGHLY
CORROSIVE AREAS
input #8 at www.plantengineering.com/information
TM
and resilience in the midst of global economic uncertainty and volatility. Capacity utilization is at historically typical
levels and manufacturers are continuing
to invest in their businesses. The positive
forecast for revenue growth and modest
price increases will drive a continuation
of the recovery in the manufacturing sector, said Holcomb.
Purchasing and supply managers report
that their companies are currently operating at 81.6% of normal capacity, representing an increase from the 79.2% reported in December 2011, and a decrease from
the 83.2% reported in April 2011.
Production capacity in manufacturing
is expected to increase 5.2% in 2012.
This increase is slightly less than the
5.6% increase predicted in December
2011 for 2012, but greater than the 4.6%
increase reported in December for 2011.
Survey respondents expect a 6.2%
increase in capital expenditures in
2012. This is considerably greater than
the December 2011 forecast when members predicted an increase of only 1.9%
for 2012. Currently, 42% of respondents
predict increased capital expenditures
in 2012, with an average increase of
23.4%, while the 13% who said their
capital spending would decrease expect
an average decrease of 25.8%, and 45%
say they will spend the same in 2012 as
they did in 2011. PE
June 2012 11
input #9 at www.plantengineering.com/information
IN FOCUS
Strength in U.S., China drives
industrial automation growth
ns
o
i
t
lu
o
S
l
a
Rent
tors
Genera
Rental ry HVAC
Air
ra
Tempo Oil-free Compressed
100% Solutions
Cooling 365 Service
/
800.AGGREKO
| aggreko.com/northamerica
24/7
For more information,
call 866.215.7966 or visit us
online at aggreko.com/northamerica
Theres a vibration
What it is
Where it is
How severe it is
Put a good vibration expert on staff. Like the Fluke 810 Vibration Tester.
Unique in its design, the 810 identifies four common equipment faults:
misalignment, unbalance, looseness and bearing condition. You learn exactly
what the problem is, where it is, and how to fi x it. Prioritize maintenance,
prevent unplanned downtime and manage cash flow. All for a fraction of the
cost of a full predictive maintenance program. So go with the vibration expert.
Go with Fluke. www.fluke.com/answersnow
2011 Fluke Corporation.
AD 4114910A
Stainless
Steel
Filled
Epoxy
Steelmaster 43HT
For repairing and
rebuilding worn
or damaged metallic
components
High compressive
strength
Corrosion resistant
IN FOCUS
SPECIAL REPORT: THE AGE OF INDUSTRIAL SECURITY
First
www.masterbond.com
14 June 2012
PLANT ENGINEERING
Thermal
Imaging
Made Easy.
Get focus-free
imaging with
IR-OptiFlex
One-touch
manual focus
for close
spaces
AutoBlend
identifies
problem areas
faster
Point-and-shoot easy
New from Fluke: Our easiest-to-use thermal imagers ever. With simple,
Electrical Safety,
Evolved.
THINK DONALDSON
Cost effective
High performance
Greater efficiency
Ease of use
Versatile
Registered
Registered:
System
nt
ageme
an
ality M
Qu
Member of
9001:2008
ISO
IN fOCUS
controllers were used in production 50 years ago, they had
one objective: to provide an electronic and freely programmable alternative to the failure-prone relay. Up until this
point, relays had controlled all the automatic processes of
a production line, in a similar way to their function in the
Konrad Zuses first binary computer, the Z1. What followed
were durable, compact units that could be distributed around
the plant and linked by means of networks.
Initially, these were proprietary networks that afforded little
compatibility to the devices supplied by other manufacturers.
But still, the use of distributed intelligence represented an
16 June 2012
plant engineering
June 2012 17
IN fOCUS
CMMS takes the guesswork
out of safety inspections
By Paul Lachance,Smartware Group
PowerPusher
h
Watc O
E
D
I
V ne
Onli
3/13/12
18 June 2012
plant engineering
12HST5231
hyster.com
IN fOCUS
Sweatman: Manufacturing needs a clear path
Roy Sweatman, President of Southern Manufacturing Technologies in
Tampa, Fla., and a member and former
Chairman of the National Tooling and
Machining Association (NTMA), joins
24 other U.S. manufacturing leaders
as new members of the Manufacturing
Council. The Council provides advice to
U.S. Commerce Secretary John Bryson
on issues related to manufacturing sector competitiveness, as well as government policies and programs that affect
the industry. Sweatman is vice chairman
of the National Institute for Metalworking Skills, an organization founded by
metalworking trade associations to
maintain a globally competitive workforce. He discussed his appointment and
the manufacturing issues that should be
communicated to the administration with
Plant Engineering:
Plant Engineering: There are two
issues that seem to be running neckand-neck among manufacturers: the
need for more skilled workers and the
need for tax reform. Which one in your
view is more crucial, and how do we
address it effectively?
Sweatman: Its simply not possible
to prioritize one of these issues over
another since both are essential to the
long-term future of manufacturing in
America.
Roy Sweatman
On the issue of skilled workers, manufacturing has been tainted by an outdated perception of dark and dangerous
plants of yesteryear; todays facilities
are efficient, high-tech environments
where we make sophisticated products
ranging from satellite parts to cuttingedge medical devices. We need to do a
better job of marketing manufacturing
and attracting workers to our industry
in order to have a viable employee base
in years to comeand were working
on it now.
For example, my company, Southern
Manufacturing Technologies, gives tours
to high school and even middle school
groups, works with various groups advocating STEM education, supports robotics competitions such as the National
Thousands of enclosures
Hundreds of options
Designed and delivered in 10 days
ENCLOSURES
POWER DISTRIBUTION
CLIMATE CONTROL
IT INFRASTRUCTURE
IN fOCUS
Continued from p. 18
With a CMMS, the maintenance team
sets up PMs to check all bacteria lab testing equipment, including water filtration
systems, air quality systems, and metal
detectors that look out for foreign objects.
There are numerous opportunities
to gain a positive return on investment
using a CMMS: improved operations,
asset preservation, etc. Another is fine
avoidance. Many companies decide to
purchase a CMMS package only after
theyve suffered the consequences of
fines levied for lack of proof or some
other failure during a regulatory audit.
While the initial appeal of a CMMS is
to automate and schedule routine maintenance tasks, why not add the tasks on
your regulatory checklist to your PM
schedule and avoid noncompliance penalties before they happen? PE
Lachance is president and chief technology officer for Smartware Group,
which produces Bigfoot CMMS. Contact
him at paul.lachance@bigfootcmms.com.
PERMANENT BEARING
PROTECTION
FROM YOUR RELIABILITY EXPERTS
The original, non-contacting Inpro/Seal Bearing Isolator
is custom engineered to permanently protect your rotating
equipment from lubrication loss and contamination
ingress increasing plant reliability. At Inpro/Seal, we
recognize the high cost of downtime, thats why were able
to ship same day on most products, including new designs.
The right technology, right when you need it.
Find out more at www.inpro-seal.com.
www.inpro-seal.com | 800-447-0524
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.
IN PRACTICE
Take a step-by-step approach
to system troubleshooting
First
PLANT ENGINEERING
June 2012 25
Lubriplate
WHEN IT COMES
TO PLANT
LUBRICATION...
YOU HAVE A
FRIEND IN
THE BUSINESS!
Have a
Lubrication
Question?
Newark, NJ 07105 / Toledo, OH 43605 / 1-800-733-4755
www.lubriplate.com / LubeXpert@lubriplate.com
E-mail
LubeXpert@lubriplate.com
Synthetic
2012
Lubrication Guide
PLANT ENGINEERING
June 2012 27
More
eye
than
meets the
28 June 2012
PLANT ENGINEERING
Synthetic technology
Through extensive and ongoing testing,
scientists are building a more detailed understanding of the physical characteristics and
demands placed on modern-day oils. Alongside this, advancements in synthetic technologyparticularly over the last 10 yearshave
June 2012 29
Lubrication Guide
LUBRIPLATE
Lubricants Company
Newark, N.J.
www.lubriplate.com
Schaeffer Manufacturing
St. Louis
www.schafferoil.com
Viscosity,
SUS at 100 F
32
135-165
46
194-236
68
284-346
100
420-520
150
630-770
220
900-1100
320
1350-1650
460
1935-2365
420-520
150
630-770
220
900-1100
320
1350-1650
460
1935-2365
135-165
46
194-236
68
284-346
100
420-520
Compressor lubricant
32
136-165
46
194-236
68
284-346
100
420-520
150
630-770
NLGI2
NLGI2
30 June 2012
NLGI2
PLANT ENGINEERING
AMSOIL
Superior, Wis.
www.amsoil.com
Sentinel Lubricants
Miami, Fla.
www.sentinelsynthetic.com
Compressorgard PAO 32
S MPO 32
Compressorgard PAO 46
S MPO 46
CITGEAR Synthetic HT 68
S MPO 68
S MPO 100
Alphasyn T 150
Alphasyn T 220
Alphasyn T 320
Alphasyn T 460
PolySi Technologies,
Inc.
Sanford, N.C.
www.polysci.com
Dimension 46
Dimension 68
CITGO FR-40 XD
Compressorgard PAO 32
Aircol SR 32
Compressorgard PAO 46
Aircol SR 46
Compressorgard PAO 68
Aircol SR 68
Aircol SR 100
Tribol 4541
PST-4700
Tribol 4541
PST-433
PLANT ENGINEERING
June 2012 31
Application
Lubrication
servicing should
be considered a
standard procedure
in the ongoing care
of an oil and the
machine components
it is protecting.
32 June 2012
plant engineering
How do you improve the best fan in the world? You upgrade everything
from the ceiling down. You boost performance by more than 28%,
improve durability and back it all up with a 15-year warranty*.
Introducing the Powerfoil X2.0: The only fan in the world
with its own patented airfoil system that combines a
patented airfoil design and winglets with patent-pending
AirFences to increase overall coverage area by 28%.
Not only does the Powerfoil X2.0 provide the best
*15 year parts, 1 year labor warranty; certain exclusions apply. See complete warranty for details.
An ISO 9001:2008 certified company. Covered by one or more of the following U.S. Patents: 6,244,821; 6,589,016; 6,817,835; 6,939,108; 7,252,478; 7,284,960; 7,654,798; D587,799;
D607,988 and other patents pending. 2012 Delta T Corporation dba The Big Ass Fan Company. All rights reserved.
IANA
Global Automation
& Manufacturing
Summit
Discover strategies for plant improvement
that you can take back to your plant and
implement immediately.
WEDNESDAY, SEPT. 12
8:30 a.m.: Keynote address: Billy Taylor,
Goodyear Tire and Rubber Company
9:30 a.m.: Energy as a Raw Material,
Speakers: Bruce Lung, ASE; and Greg
Bodenhamer, Schneider Electric
11 a.m.: Integrating Operator Knowledge,
Speakers: Mary Bunzel, IBM; Beckhoff
Automation; and Grainger
12:30 p.m.: Luncheon keynote:
Karen Kurek, McGladrey
2 p.m.: Stay Ahead of the Technology
Curve, Speakers: Chuck Edwards,
Lenze Americas; and B&R Automation
3:30 p.m.: Gaining, Training, Retaining
the Next Generation of Workers,
Speakers: AMT; and Raj Batra, Siemens
THURSDAY, SEPT. 13
www.imts.com/education/ianaSummit.html
IANA Global Automation & Manufacturing Summit: Early Bird Rate of $165
per person. Price will increase to $195 per person after August 10, 2012.
ENTER a drawing to
win a FREE iPad!
A drawing will be held for a
FREE iPad during the event on
Wednesday, September 12.
www.sullair.com
www.facebook.com/SullairCorporation
input #26 at www.plantengineering.com/information
E-Z-Ground
Grounding Connectors
Eliminates need for exothermic
welding; reduces risk of poor
connections caused by moisture
Can be installed in any weather
conditions
No special training required
Trap-Eze
Connector
MaxGard
Interconnection System
High-Temperature
Wire Joints
Easier insulation
simply slide on
reusable
insulation boot.
Extra High-Temp
Cable Ties
Looking for more uptime and lower installed costs? Look to Thomas & Betts. Our portfolio
of electrical products includes the industrys most trusted brands, and breakthough
innovation that helps you work safer and smarter. For more information about the
Blackburn line or the other proven products shown here, contact your Thomas & Betts
representative or visit www.tnb.com
Wire & Cable Management Cable Protection Systems Power Connection & Control Safety Technology
2012 Thomas & Betts Corporation. All rights reserved.
AUTOMATIONSOLUTIONS
June 2012 37
AUTOMATIONSOLUTIONS
Considerations checklist for services: In-house or hired out?
Use this checklist to help decide if automation engineering services should be in-house or hired out.
Yes
No Consideration questions
Are automation and operational engineering services a core competency for your company?
Do automation and operational engineering services make up the majority of your business?
By taking on this project in-house, will there be missed opportunities to take on more profitable projects?
Considering your current workload and staff size, can your in-house staff support this project?
Does the one-time cost of a hired-out consultant outweigh the cost of hiring additional inhouse staff?
Does your in-house staff have the ability to meet the critical deadlines dictated by the project
schedule?
Is the project schedule flexible enough for the work to be forecasted to help fill in gaps in your
in-house workload?
Does your in-house staff have the special expertise or specific project experience necessary
to complete the project?
Will you receive the same quality of work in-house as you would by hiring out the engineering
services?
Are you willing to take on the risk and potential liability associated with this project?
TOTAL
If the majority of answers are yes, then you may consider keeping the service in-house. If the majority of answers are
no, then consider hiring out your engineering services, suggests ProcessPlus, www.processplus.com.
38 June 2012
PLANT ENGINEERING
aUTOMaTIONSOLUTIONS
services for process control systems
and IT infrastructure extend through
the full lifecycle of a project. When
deciding between in-house or hiredout integrator, consider the quality
and type of services available, and ask
the following questions, according to
Vladimir Morenko, director-general,
Industrial Automation Systems LLC
(Insist Avtomatika), Russia.
What does the customer receive if he
gets an engineering company involved
in service maintenance at all stages of
a control system lifecycle? What essential components determine the quality of
services? What criteria should be used
to choose service contractor? What to
choose: services of an automation vendor or services of an independent system integrator? How can one reconcile
While oil-field storage tanks provide a repository for products, system integrators
can provide steady stream of process control, services, and project management
talent. Courtesy: Industrial Automation Systems LLC (Insist Avtomatika), Russia
40 June 2012
plant engineering
know their way around it all. But your automation needs will
ebb and flow. You may hire up for a major implementation
project, but then after thats complete, then what?
Cumming cautioned that internal staff may not be able to
keep up with the latest technologies as easily as an outside
firm.
Even with an in-house team, consider schedule and
project complexity, the two biggest reasons to hire out,
said Purvis. And when the new project needs outpace the
capacity of internal resources, the choice is to hire more
staff, delay projects, or contract services.
Therefore, the outsourced team selection process should
include a review of project methodologies and evidence of
adherence to best practices, such as those advocated by
the Control System Integrators Association (CSIA). They
will often leverage proven efficiency techniques, such as
requirements traceability and risk mitigation documentation,
conferencing capabilities for design and system reviews,
and remote webcam witnessing of factory acceptance tests.
In the end, Cummings, Gacioch, Purvis, and Triassi concede that even the best outsourced team with the greatest
skills is still going to have a learning curve when it comes to
understanding your business, over and above the in-house
staff. The key to a successful project with an outside firm
is to play an active role every step of the way, with all team
members focused on clearly defined project results.
Online, see how to use the expertise of an outside firm,
benefit from best practices, and take the right approach to
outsourcing: http://bit.ly/IfvSuH.
Written by Jennifer Palumbo, a marketing communications specialist at Optimation Technology Inc.
INTERACT
June 2012 41
PLANT ENGINEERING
VFD-Induced Bearing
Currents Kill Motors!
Save your
motors with
SGR
BEARING PROTECTION RING
Mounting
sewmotortruth.com
input #30 at www.plantengineering.com/information
Dismounting
ELECTRICALSOLUTIONS
INTERACT
Industrial Efficiency: Debunking the myths
Where to begin?
By ignoring the myths
Myth No. 1: Energy is just another component of my overhead.
By Greg Bodenhamer
Schneider Electric
First
PLANT ENGINEERING
June 2012 43
eLeCTRICALSOLUTIONS
as motors, drives, pumps, etc.
The energy management process really
comes to life with Senior Management,
even C-level sponsorship and involvement the effort to reduce energy use
needs sponsorship and reinforcement and
it needs to be the responsibility of the
entire organization. Having a plan and
When
Member
www.martinsprocket.com 817-258-3000
The ONE You Rely On
Implementing a comprehensive
energy management plan
would not only help avoid
energy waste, but also improve
equipment efficiency. But
where does an industrial
manufacturer begin?
payback periods of only 1-2 years. When
you look at it this way, energy efficiency
programs can be highly valuable even
during times of economic uncertainty or
downturn the opportunities are there,
you just have to take advantage of them.
Energy efficiency is one of the easiest ways for companies to maximize
short and long-term cost savings. The
technologies exist today to make energy
visible and manageable driving not
only efficiency in your process but also
efficiency of your assets and your workforce, optimizing production across the
board.
The companies that are using energy
management and sustainability as a
strategic advantage are differentiating
themselves from their competitors, not
only saving money but attracting a more
talented and engaged workforce, increasing their brand value and, potentially,
enhancing the market valuation of their
business. PE
Bodenhamer is the vice president of
Industry End User Marketing, Solutions
& Services, Industry Business, at Schneider Electric.
44 June 2012
plant engineering
IDENTITY THEFT.
DuPont
Teflon
MAINTENANCESOLUTIONS
Source: CMRP
receive capital investment from the corporation, or additional market share as a result of
their demonstrated efficiency.
RONA is a very dynamic metric and works
like a pendulum swinging from a fixed point
based on fluctuations in net income or net
assets. The idea is to create a balance by
increasing revenue to offset the cost of consuming fixed assets, or reducing costs to
improve margins per unit produced while
reducing your net asset value through depreciations. This brings us to the point of this
article. When developing your improvement
strategy, it is important to begin with a clear
understanding of the Financial Plan for Asset
Management. Here are a few questions to get
you started:
At what point will improvements to
PLANT ENGINEERING
June 2012 47
mAINTENANCESOLUTIONS
only drive greater increases your net asset base and makes
downturns in opera- your RONA weaker if revenue remains
tional performance. constant, or worse, Cost of Goods Sold
I look at it this way: (COGS) increases. Ideally, the invested
If we dont focus capital should increase the capacity of
on removing the the plant to further offset the current
volume of work, COGS. What about the cost to mainbe that operational tain the new or upgraded assets? It has
workloads or main- been my unfortunate experience to have
tenance workloads, witnessed the best-laid plans for capithen how can we tal improvement go unrecognized as a
expect to reduce result of unforeseen costs to operate and
the labor that has maintain the new or refurbished assets
been mediocre at after commissioning. In some extreme
c o m p l e t i n g t h e cases, the plant was worse off financially
workload within after a significant capital expansion due
the current business to the fact that engineering and plant
system?
management failed to consider the susC o s t c u t t i n g taining costs associated with the new
also refers to the assets relative to the marginal increase
Source: CMRP
rapid reduction of in capacity.
reserve inventorieswork-in-process inventories or Defining the financial strategy
There are two main strategies you and
maintenance supplies that are required
within the existing business systems due your organizational leaders must conto the lack of process control and insta- sider before embarking on your asset
bility. These reserve inventories are in management journey. The first is the
place today because our current asset Asset Strategy.
The Asset Strategy is a balancing
management practices require them.
Without these inventories, the operat- act between short-term and long-term
ing process would suffer from extended financial objectives. The task of reducdowntime periods or, at minimum, fre- ing capital requirements is contingent on
quent interruptions
in flow or service.
Figure 3: Asset Strategy model
If financially we can
justify removing the
reserve inventories,
then financially we
can justify improving how we manage
assets so we dont
need the reserves.
Buying your
way to success is
an equally ineffective strategy for
long-term growth
and performance
improvement.
Although capital
investments can
improve existing
technologies, which
in turn improves
your ability to maintain a reliable plant
Source: CMRP
short-term, it also
48 June 2012
plant engineering
MAINTENANCESOLUTIONS
your organizations ability to minimize
working capital by increasing inventory turns and systematically eliminating reserves based on varying product
demand and material availability. The
short-term goal of the Asset Strategy is
to compress the overall cash conversion
cycle, and in effect turn inventory into
revenue faster.
On the other hand, the long-term view
of the Asset Strategy should consider
how your organization will effectively
reduce fixed capital by eliminating
redundant equipment trains, innovating equipment configurations in order
to improve your organizations ability to
meet several product specifications with
fewer fixed equipment requirements, or
consolidating non-physical assets, such
as information management systems.
The second strategy that must be considered is the Expense Strategy. This
is a given.
point is this: Turn your attention, relative to cost reduction, on those aspects
of your business that are within your
control and will have a positive, longterm effect. If supply chain expenses
are not within your control, then focus
your attention on extending the performance life of your fixed assets and
lowering your lifecycle expenses. If
you feel lifecycle costs are already
optimum, then focus the asset management improvement strategy on energy
reduction to gain control of overhead
expenses.
Lifecycle costing
50 June 2012
PLANT ENGINEERING
INTERACT
How?
) ) ) )
) ) ) ) ) )
) ) ) ) ) )
Heres how.
Right Instrument.
Right Expertise.
Delivered Right Now.
800-732-3457
www.testequity.com/agilent
Agilent Technologies 2012. Bluetooth and the Bluetooth logo are registered trademarks owned by Bluetooth SIG, Inc., U.S.A. and licensed to Agilent Technologies, Inc.
*Monthly drawing. Purchase of HH-DMM not required to enter drawing.
IN NOVATIONS
EDM line
The wire EDM MV Series features allencompassing, game-changing engineering
improvements, many of which are industry
firsts, and none as poignant as the Cylindrical
Drive Technology. The round magnetic shaft
of the linear motor creates a 360-degree
magnetic flux for a revolutionary, no-contact
design. The drive also prevents friction, wear
and tear, and reversal error and does not
need lubrication. The system also works with
servo drivers and is not affected by shop
or metal grinding dust. The MV machines
offer a hardened stainless steel table and
larger travel size without leaving a significant
impact on machine footprint.
MC Machinery Systems, Inc.
www.mitsubishi-world.com
Input #201 at www.plantengineering.com/information
Zero-configuration
Android app
Opto aPAC is an application for monitoring and
managing the companys SNAP PAC System using
mobile devices running the popular Android operating system. It provides real-time control system
access and information to authorized automation
professionals equipped with wireless, Android-based
smartphones or tablets. Opto aPAC allows users
to discover SNAP PAC controllers and I/O systems
and then view, debug, and fine-tune them, saving
time and money during commissioning and ongoing
maintenance. Authorized users with proper security credentials
can monitor values in a SNAP PAC control system such as temperatures, pressures, machine status, voltage, and PIDs. Opto
aPAC users can also perform control functions such as changing
setpoints, turning lighting on and off, and controlling motors.
Opto 22
www.opto22.com
Input #202 at www.plantengineering.com/information
Polycarbonate enclosures
The EK series of NEMA 4X polycarbonate enclosures are designed to
house and protect DIN rail-mount IEC components, such as DIN rail-mount
circuit breakers, timers, switches, meters, and other control devices. This
CE-compliant product features a shrouded cutout and tinted transparent
hinged door with push release door latches for quick access and visibility. The
EK series enclosures are high in mechanical strength as well as corrosion- and
maintenance-free. They are ideal for chemical, plastic, and water industries.
Omega Engineering
www.omega.com
Input #203 at www.plantengineering.com/information
PLANT ENGINEERING
June 2012 53
IN NOVATIONS
Wall-mounted
power supply
Transducer series
The ITZ Transducer Series provide galvanically isolated measurement of ac, dc, and
pulsed currents. The high-accuracy product
range, which employs advanced closed-loop
Fluxgate technology, comprises 14 models
for nominal current measurements from 600
A to 24 kA with apertures from 25.4 mm up
to 150.3 mm diameter. Overall accuracies at
ambient temperature (25 C) are a few ppm.
The initial offset error is under 2 ppm. The
transducers are configured as measurement
head plus rack-mounted electronics. They
deliver measurements as an output current
or voltage. In addition to these normal signal
outputs, the transducers also provide outputs
indicating the transducer state.
LEM
www.lem.com
Input #204 at www.plantengineering.com/information
The screw-mounted
PSU100D eliminates the need
for traditional rail mounting
while affordably meeting the
basic power supply requirements. Ideally suited for wall
mounting in apparatuses and machines, the PSU100D features a
rugged, low-profile aluminum casing with IP20 degree of protection
that requires little space while enhancing mounting flexibility. A wide
temperature range from -10 to 70 C accommodates a broad range
of applications in harsh environmental conditions. Electronic shortcircuit, overload, and overvoltage protection features ensure safety
in the event of a fault.
Siemens Industry, Inc., www.siemens.com
Input #205 at www.plantengineering.com/information
Retractable belt
The 2-Axis retractor series permits
360-degree rotation on the belt as well as
180-degree swing-away from the body
for a full range of motion accessibility. In
addition, because of the universal movement of the dual action mechanism, resistance
and line wear are minimized and the life of the tether
is extended. Once mounted on the belt, the retractor can be easily
moved to different positions but remains impossible to dislodge.
Optionally, the retractor/belt combination can be user-converted to a
slide on/off unit for any belt while still maintaining the same security
that prevents unwanted dislodging.
Hammerhead Industries, www.hammerheadindustries.com
Input #206 at www.plantengineering.com/information
54 June 2012
PLANT ENGINEERING
Differential
pressure
transmitters
The ProSense SPT25
pressure transmitter
series is engineered to
meet many industrial,
commercial, and OEM pressure measurement applications. Compatible with many different media sensing
applications, the all stainless steel welded thin-film sensing element provides very fast response time. With a pressure sensing range from vacuum to 5,000 psi, transmitters
are designed to resist vibration, shock, and EMI/RFI while
providing high accuracy.
AutomationDirect, www.automationdirect.com
Input #208 at www.plantengineering.com/information
Bionic gripper
NanoForceGrippers cling reliably
and permanently to the surfaces
of the object to be gripped, thanks to
tiny, intermolecular forces of attraction
called van der Waals forces. A key component
of the gripper is the Gecko Nanoplast tape on its
underside with 29,000 gripping elements per cm. Once
a part is gripped, it is permanently held by the gripper.
A counteracting force is only needed when it is time to
release the bond and set down the gripped object.
Festo, www.festo.com
Input #209 at www.plantengineering.com/information
PLANT ENGINEERING
June 2012 55
IN NOVATIONS
Polycarbonate
shields
Chip Shields on Safety Air Guns
are used to protect workers and
to help businesses comply with
OSHA safety standards. They can
be used on Safety Air Guns with
or without an extension pipe. Chip
Shields are polycarbonate shields that protect operators from flying debris off machine parts. Chip Shields
are great for keeping coolant from splashing everywhere
during drying operations and Chip are available to fit the
Safety Air Guns you currently have in use. Safety Air Guns
use engineered air nozzles for high performance and
safetythey are designed to maximize entrainment of
room air while minimizing compressed air consumption.
The Precision Safety Air Gun is extremely lightweight and
comfortable to operate during periods of extended use.
Exair Corporation
www.exair.com
Input #211 at www.plantengineering.com/information
Contamination
magnet, separator
Magnetic Humps and Round Pipe Separators provide a simple and effective way
to remove tramp iron contamination from
gravity or pneumatically conveyed dry, freeflowing products such as feed, grain, wood chips,
food stuffs, sand, or plastic. Materials entering
the Magnetic Hump are abruptly forced to change
direction against the face of the powerful series
SD Plate Magnet. As the materials tumble
in the housing, they change direction once
more against the face of a second plate
magnet. The Magnetic Hump design takes
advantage of the ferrous material density.
Magnetic Humps are simple to operate and
maintain. The ferrous contamination remains on the face
of the magnet until the operator swings the magnet out of
the product flow and physically removes the metal.
Eriez, www.eriez.com
Input #212 at www.plantengineering.com/information
Large
ac motors
EtherCAT box
Reliance stock
and custom motors
are available up to
15,000 hp, while induction and synchronous
motors are available
up to 100,000 hp.
This large ac motor
offering includes both
NEMA and IEC configurations, assuring customers
they will get the motor that meets frame, enclosure,
and duty cycle standards for any application, anywhere in the world. Every large ac motor is designed
and built for superior reliability, energy savings, and
rugged performance.
Baldor
www.baldor.com
Leaves
Beckhoff Automation
www.beckhoffautomation.com
Input #214 at www.plantengineering.com/information
Algae
Insects
Airborne
Particles
Protect:
Pollen
Heat
Exchanger
Cooling
Tower
Spray
Nozzles
Instrumentation
Rust
Water
Filter
Applications:
O
L
A
IV
R
Users:
Automatic Self-Cleaning
WATER FILTERS
PRODUCTMART
LUBE-IT Users Say It Best
TM
The RX Series
Safety Gate:
Replaces Old
Plastic Gates
Made in America, FabEnCos RX Gate is a rugged, spring-loaded metal
safety gate designed to
replace aging and/or deteriorating plastic gates
with solid, weather-resistant metal gates, conveniently bolting into the same mounting holes
used to secure old plastic gates. These gates
are competitively priced and easy to install on
all types of handrails (angle and pipe).
www.safetygate.com/ple
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in every corner of the plant floor.
Plant engineers and managers refer
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PlantMail:
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Keeps NFPA 70E risk category =
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58 June 2012
PLANT ENGINEERING
ple1003jh_enewslttrs.indd 1
3/1/2010 2:56:53 PM
Place next to your computer or go online to plantengineering.com for hot links to these companies.
Remove at
Line
2012
June
flexicon.com
omega.com
Manufacturing explosion proof enclosures, ATEX enclosures and electrical enclosures for over 80 years.
Adalet
aggreko.com
fluke.com
orival.com
Fluke Corp. is the world leader in the manufacture, distribution, and service of electronic test tools and software.
Fluke Corp.
agilent.com
gardnerdenver.com
seweurodrive.com
Agilent offers the broadest range of innovative measurement solutions in the industry.
Agilent Technologies Inc.
atlascopco.us
geindustrial.com
usa.siemens.com
The reliable parts and services you need. GE has thousands of quality electrical parts that you can count on.
GE Energy Industrial Solutions
ame.org
grainger.com
stanleyproto.com
automationdirect.com
hyster.com
sullair.com
baldor.com
inpro-seal.com
tapeswitch.com
The inventor and original patent holder of the Bearing Isolator, a compound labyrinth oil seal.
Inpro/Seal
bigassfans.com
goulds.com
tnb.com
camfilfarr.com
lubriplate.com
ustsubaki.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants.
Lubriplate Lubricants Co.
donaldson.com
martinsprocket.com
dupont.com
motionindustries.com
est-static.com
movincool.com
EST specializes in mitigating static charges, moving surfaces, and all types of manufacturing equipment.
Electro Static Technology
Responsible for pioneering the use of portable air conditioning solutions for a wide variety of markets since 1982.
MovinCool
yaskawa.com
Yaskawa manufactures ac inverter drives, servo and
motion control, and robotics automation systems.
Yaskawa America Inc.
plant engineering
June 2012 59
CONTACTS
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
Page
Number
Advertiser
Adalet Wireless
216-267-9000
10
Aggreko LLC
866-215-7966
Agilent Technologies, Inc.
866-436-0887
12
51
11
49
Flexicon Corp
888-353-9426
Fluke Corp
888-443-5853
Fry Communications, Inc
800-334-1429
Gardner Denver
800-682-9868
GE Energy
203-373-2211
Send
Info
www.adalet.com
10
www.aggreko.com
35
www.alliedelec.com/agilent
9
www.alltestpro.com/c/199
34
www.amechicago.org
24
23
www.atlascopco.com/drivenbyefficiency
C-2
1
www.automationdirect.com
DuPont
800-207-0756
Electro Static Technology, Inc
866-738-1857
RSC
Number
C-4
60
www.baldor.com
33
25
www.bigassfans.com/pe
6, 16
5, 15
www.farrapc.com
www.donaldson.com
45
32
www.plant.realteflonbrand.com
41
29
www.est-aegis.com
8
www.flexicon.com
13, 15
11, 13
www.fluke.com
12
www.frycomm.com
17
16
www.savewithgardnerdenver.com
2
3
www.geindustrial.com/services
Advertiser
Industrial Automation
North America at IMTS 2012
312-924-1688
Page
Number
RSC
Number
80
Send
Info
www.ia-na.com
Inpro/Seal Co.
800-447-0524
22
21
www.inpro-seal.com
ITT
315-568-7659
46
33
www.ittproservices.com
Lubriplate Lubricants Co
800-733-4755
LUDECA, Inc
305-591-8935
26
24
18
18
www.lubriplate.com
www.ludeca.com
44
31
14
52
18
www.martinsprocket.com
12
www.masterbond.com
36
www.MotionIndustries.com
17
www.powerpusher.com
57
39
10
www.omega.com
www.orival.com
www.PfAdvantage.com
EN11
www.plantengineering.com/newsletters
20, 21
20
www.rittal-corp.com
42
30
www.seweurodrive.com
EN2, EN9
57, 58
www.usa.siemens.com/energyefficiency
39
28
www.stanleyproto.com
35
26
www.sullair.com
56
38
www.tapeswitch.com
36
27
www.tnb.com
55
37
www.ustsubaki.com/pe
C-3
59
www.yaskawa.com
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
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Title
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60 June 2012
PLANT ENGINEERING
INCONCLUSION
The endless journey of innovation
Bob Vavra
Editor/Content Manager
achieving success.
June 2012 61
A DV E R T I S E M E N T
A DV E R T I S E M E N T
A DV E R T I S E M E N T
A DV E R T I S E M E N T
Just about every manufacturing process makes dust and the Gold Series cartridge
dust collector from Camfil Farr APC can ensure a clean workplace in just about any
application. Superior performance features plus exceptional ease of installation and
service have made the Gold Series a popular choice.
Applications
Key applications include mining, welding
smoke/fume, pharmaceutical, powder/bulk
materials, sand blasting, nuisance dust
ventilation, carton folding and printing,
woodworking, seed processing, chemical
processing, foundry, paper scrap, plasma/
laser cutting, thermal spray, grinding, and
powder painting/pigments.
A new Gold Series brochure is available for download from the company web site at www.farrapc.com.
A DV E R T I S E M E N T
Equipment overview
Flexicon Corporation is a world leader in the design and
manufacture of bulk handling equipment and customengineered and integrated plant-wide systems that
transport, discharge, fill, weigh, blend, deliver and/or feed a
broad range of powder and bulk solid materials.
Flexicon products range from individual equipment to automated systems that source bulk material from interior and exterior plant locations, transport it between process equipment
and storage vessels, weigh it, blend it, feed it to packaging
lines, extruders, molding machines and storage vessels, and
load it into railcars and trailers.
A DV E R T I S E M E N T
425-446-5415 | www.fluke.com/805
input #45 at www.plantengineering.com/information
A DV E R T I S E M E N T
misalignment
unbalance
looseness
bearing condition
425-446-5415 | www.fluke.com/805
input #46 at www.plantengineering.com/information
A DV E R T I S E M E N T
EntelliGuard R Retrofill
Make the most of your existing equipment
EntelliGuard R Retrofill provides a streamlined solution to update
your legacy circuit breakers and gives your existing switchgear a
new lease on life. The EntelliGuard R Retrofill solution includes
the EntelliGuard TU Trip Unit for both arc flash protection and
selectivity at the same time. It offers a means to increase reliability
and enhance the protection of your existing electrical system.
A DV E R T I S E M E N T
Visit www.gouldspumps.com
for product information and technical literature on our extensive range of industrial pumps.
input #48 at www.plantengineering.com/information
A DV E R T I S E M E N T
A DV E R T I S E M E N T
Wire Production
Manufacturing at Omega starts near the bottom of the supply
chain. The company actually produces its own thermocouple wire
at a manufacturing operation that turns out tens of millions of
feet per year. Starting with bare wire stock in a wide range of
compositions and diameters, finished cable is made for a myriad
of Omega products. Specialized machines turn out braided, extruded, glass-wrapped, shielded, single conductor, multi-conductor,
twisted shielded pairs, Kapton coated, and PFA coated cable in
both solid and stranded styles.
Temperature Probes
Omega boasts an
automated probe manufacturing facility that is
unequalled. Starting with
coils of flat metal stock
and a wide range of wire
types, a highly automated
production line fabricates
probe sheath, with wiring
enclosed, in coils which
can be hundreds of feet
in length. Sheath sizes range from an incredibly thin 0.010 inches
up to a robust 0.375 inches. While other manufacturers make the
probes individually to a specific length, Omega can make any
desired length by simply cutting it from the probe coil.
Benefits of
In-House Manufacturing
Omega products are used in many
critical applications in manufacturing,
food processing, medicine, aerospace,
and science, to name a few.
By making the individual components
within the company, Omega can
achieve a measure of control not
possible when critical parts are
supplied by a variety of vendors with
a variety of reliabilities. This is key to
the high esteem Omega enjoys among
its customers and its reputation for
highly consistent, top quality products.
A DV E R T I S E M E N T
TorqLOC
TorqLOCs patented keyless hollow shaft and taper bushings eliminate
inefficient belts, chains, and spockets thus reducing maintenance and
energy costs while enhancing system safety.
Its spacious air gap provides easy mounting. Its tightening bolts provide easy
dismounting. No more tight tolerances. No more keys. TorqLOC even mounts
onto an existing shaft that has a keyway.
TorqLOC is available in carbon steel or stainless steel to meet all wet or dry
requirements. In addtion, its numerous bore sizes provide maximum flexibility
for new installations or retrofits.
A DV E R T I S E M E N T
www.usa.siemens.com/automation
A DV E R T I S E M E N T
A DV E R T I S E M E N T
A Company Profile
Sullair Corporation is one of the worlds leading
manufacturers of rotary screw air compressors.
An innovator since 1965, Sullair offers the broadest
range of air compressors in the world today. The
Company sets the standards for stationary air
compressors for industrial applications and portable
air compressors for the construction, mining and
energy-related segments. Sullair is also a globally
recognized manufacturer of compressed air
treatment equipment, and vacuum systems.
Green Initiative
Fundamental to Sullairs leadership is a dedication to
reduce the amount of natural resources consumed to
create electrical energy and to minimize environmental impact, both in the manufacture and use of all our
products. We are constantly exploring new ideas and
seeking new technologies to meet the ever-increasing
need for energy-efficient compressed air solutions,
quality and environmental sustainability.
A DV E R T I S E M E N T
With a portfolio of
more than 200,000
products marketed
under more than
45 premium brand
names, Thomas &
Betts products are
found wherever
electricity is used,
including in manufacturing facilities where
they help power
industrial machinery.
OCAL-BLUE
Type 4X Form 8
conduit bodies
offer double-coated
exteriors for
enhanced protection
in corrosive
environments, as
well as excellent
protection in washdown applications
and harsh outdoor
environments.
A DV E R T I S E M E N T
Motion Control
Our broad product range of servo systems includes
rotary, linear, and direct drive motors matched with
digital SERVOPACKS. These best-in-class servo
systems can be matched with our single or multi-axis
programmable automation controllers for a system
solution with the best quality and reliability in the
industry.
www.yaskawa.com | http://www.yaskawa.com/site/Home.nsf/home/home.html
input #56 at www.plantengineering.com/information
INDUSTRIAL AUTOMATION
NORTH AMERICA at IMTS 2012
International Trade Show for Factory, Process and
Building Automation Systems and Solutions
at
Organized by:
www.ia-na.com
Partner:
06/12
Industrial Energy
Management
Energy
in motion
Goods makers address the cost of
keeping things moving
EN3 Machine tool energy
efficiency
EN6 Energy-saving automation
at Nissan
EN10 Chillers and VFDs
EN13 A template for energy
management software
SUPPLEMENT TO
IndustrialEnergyManagement
EN3
Discussions
about the
efficient use
of energy are
becoming
pervasive in
many industrial
sectors,
including
more efficient
deployment
of machine
tools. Courtesy:
Heidenhain
Machine Tool
Division
Current Issues in
Machine-tool Energy Efficiency
A range of energy consumers including pneumatics, hydraulics and
lubricant processing influence a work centers power profile.
MACHINE TOOLS INCLUDE numerous motors and auxiliary components. Energy consumption varies significantly
during operations. The main spindle drive and the coolant
system, for example, work near rated power while roughing
at a high stock-removal rate, but power consumption during finishing is significantly lower. Close interdependence
exists between individual components and subassemblies
on the one hand and productivity and quality measures on
the other. From the process itself to individual component
power consumption, savings potential can be evaluated
and measures defined for more efficient energy use.
One area of potential savings comes from the machine tool base load, which consumes energy even in
nonproductive phases. The base load is determined substantially by the machines auxiliary components. Besides
use of energy-efficient motors in these components, many
opportunities for reducing the base load can be found.
Some energy consumers, for example, can be switched off
by the machine control during nonproductive phases.
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EN4
IndustrialEnergyManagement
Dry machining has great potential for improved energy
and resource efficiency. In many milling applications, however, doing without cooling lubricant increases scrap rate
and, therefore, raises mean energy consumption.
Compressed air is required for minimum spindle lubrication, tool changing, and work piece cleaning. Small
quantities are required as sealing air. Mean compressed
air power changes only slightly across production readiness, roughing, and finishing.
Machine electricity consumers include the CNC control with main spindle and feed-axis motors, as well as numerous auxiliary components, including the pallet changer
and cooling, hydraulics and automation systems.
EN5
to thermal displacement in the machine frame, scrap can
result. Selective auxiliary component switch-off therefore
functions best on machines with little inclination to thermal displacement.
CNCs can be the central control unit for machine tool
energy management, taking advantage of special PLC functions for linking events in the production process (such as
NC stop) with outputs for controlling auxiliary components.
Delay times can be assigned to events so that, for example,
motors can be locked and disconnected from current after
standstill. Functions for deactivating various auxiliary devices, axes, light in the working space, etc., can be generated on this basis. These basic functions are the responsibility of the machine tool builder. For users, it is helpful to
adapt energy management to specific usage habits.
The information in this article was provided by Dr. Johannes Heidenhain GmbH and edited by the Control
Engineering staff
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EN6
IndustrialEnergyManagement
Step by step
The first step in any plants energy-savings development
plan should be to identify the energy consumers that can
be idled during non-production times without causing
quality, production, or safety concerns. Many different
motors, heaters, lights, and compressed air lines are energized continuously in a typical plant. Each hour a component runs without producing product is money spent in
the form of utility usage that has no added value. Yearly
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EN7
by Josh Hauskins
Nissan North America
Looking at lighting
Automated lighting shutdown was the next step in
energy reduction strategy. Several products are currently
on the market that will work with an equipment PLC
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Quantitative measures
To view the savings from all of the improvements, a measuring system was developed as well. Each utility meter
of every type was wired to a PLC, so usage could be monitored during idle times. Data from the meters is logged
to provide trending of the numbers independent of the
utility company reports. Web reports were created to display the usage data. Because the data provided visibility,
the budget responsibilities could be divided more equally
among consuming departments. Very similar screens were
used to set the timer presets for monitoring equipment as
well. This portion of the project was not essential, but
the interface did provide measurable data, operator status
indication, and configuration convenience.
As a precaution, cost savings should not be the
only consideration when stopping equipment, turning
off lights, or removing compressed air from machinery.
SUPPLEMENT TO PLANT ENGINEERING
EN8
IndustrialEnergyManagement
The Nissan manufacturing plant in Smyrna, Tenn., took advantage of PLC and HMI technologies already in place to improve
and quantify plant energy efficiency. Courtesy: Nissan
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Siemens
usa.siemens.com/energyefficiency
IndustrialEnergyManagement
EN10
by Michael Grant
Yaskawa America Inc.
EN11
a compressor to perform the required heat transfer. This
process is known as the refrigerant cycle, and is depicted
in the diagram.
The refrigerant cycle employs four main components: a liquid metering device, evaporator, compressor,
and condenser. The cycle begins with the refrigerant in
the condenser, in a liquid state and at high pressure. From
there, the liquid refrigerant flows to the evaporator. Flow
is regulated by a metering device. The evaporator is at a
lower pressure than the condenser, so flow is naturally
induced from the higher to the lower pressure area.
In the evaporator, the refrigerant changes state from
liquid to gas by absorbing heat from the area where it is
unwanted, typically called the load. The refrigerant gas is
then discharged from the evaporator to the compressor,
which raises its pressure.
Next, the high-pressure gas discharges the unwanted
heat to the unobjectionable place, typically the atmosphere, changing state from a gas back to a liquid in the
condenser. The refrigerant then flows from the condenser
to the evaporator, and the cycle begins again.
With a basic understanding of the refrigerant cycle in
hand, we can now look at how a retrofit improves refrigerant cycle and overall chiller efficiency.
Plant Engineerings
Table: Advantages of
Chiller Optimization
electronic newsletters
www.plantengineering.com/newsletters
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ple201109_enewslttrs_halfHZ.indd 1
EN12
IndustrialEnergyManagement
COMPRESSOR
INLET
Diagram:
A chiller
uses a
SUCTION LINE
COMPRESSOR
OUTLET
COMPRESSOR
DISCHARGE LINE
CONDENSER
FAN
refrigerant
exchange
medium
able.
WARM
AIR OUT
and a
compressor
to move heat
from where it
is unwanted
to where it is
unobjection-
2
CONDENSER
LIQUID LINE
WARM
RETURN AIR
IN
COOL
SUPPLY AIR
OUT
EVAPORATOR
BLOWER
REFRIGERANT FLOW
EVAPORATOR
METERING DEVICE
DRIER
IndustrialEnergyManagement
EN13
by Kevin Totherow
Production Energy
Optimization Profile
EN14
IndustrialEnergyManagement
.. .. .. .. .. .. .. .. .. .. .. .. .............................. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
.. .. .. ..optimization
.. .. .. ...... ..empowers
. .. .. .. .. ..existing
.. .. .. .. .. .. ..
............... ... ... ... ... ... ...Production
... ... ... ... ... ... ...energy
.
......through
.. .. .. .. ..continuous
.. .. .. .. .. .. .. .. ..
.......... .. .. .. .. .. ..teams
.. .. .. ..to..reduce
.. .. ... ... ..energy
. ... ... ... ...waste
........ .. .. .. .. .. .. .. .. .. .. .. ..
.......... .. .. .. .. .. ..improvement
.. .. .. .. .. .. .. .and
. .. ..captures
. .. .. .. ...the
variable cost of
.
.. .. .. .. .. .. .. .. .. .. .. energy
.. .. .. .. per
.. .. ..product
.. .. .. ..produced.
.. .. .. .. ... ... ... ... ... ...... ... ... ... ... ... ... ... ... ...
.. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
.......
addition to the sustainability manager, the team should
include representatives from the following groups or departments:
Operations management uses the energy and the
PEO system
Facilities or maintenance owns most of the metering systems. Integration from PEO to the maintenance system could initiate service request in
the event of abnormal energy consumption
Engineering process automation owners
Information technology supports system, databases and network connections
Accounting needs the energy consumption per
grade for activity-based costing
Once the team participants are in clear view, the next
step is likely a discovery services study (DSS). This study
may have different names such as pre-engineering study,
scope development or project definition study. The important thing is that the team will either produce or
hire a company to produce a formal document that
includes the following:
Long-term system solution definition based on the
companys strategic goals
Proposed system architecture, including definition
of metering (including virtual meters), system integrations, and user interfaces
Data to be collected: key performance indicators
Implementation challenges
The overall project includes three major elements: submetering installation; computers and networking; and
software configuration and roll-out. Sub-metering is the
only step that may require downtime and outages.
1. Sub-metering of WAGES The DSS should have
defined all of the metering necessary; if virtual meters
can be used in the application; and if the PEO will read
WAGES data directly from the meters, from a process historian, or from the energy management system (EMS).
PEO is concerned with monitoring energy usage. Power
quality, power factor, disturbances, and other tools are
typically associated with energy management systems.
Often both are needed and custom dashboards can display metrics from both systems.
2. IT: Computers, databases, and communications
A clear, written understanding of responsibility for
loading software, communications, troubleshooting and
security is very important. Security, IP Addresses, domain
authentication, user accounts, network configuration,
firewalls, COM problems and communication drivers can
all delay work. Whats worse, these nuisance delays can
kill team morale and lead to a poor initial user experience.
3. The PEO software solution The DSS should
have answered most of the questions about what is to be
implemented. Schedule a time for implementation engineers and the system owners to meet. A general discussion of the project and long-term goals helps everyone
to better understand the needs and fosters good working relationships. The configuration should have specific
milestone delivery dates that drive early configuration.
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EN15
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NOTEWORTHY
When our engineers work on a motion project with you, they share everything thats in their
heads. Sometimes that means turning over 100 pages of notes, formulas and drawings. Other
times, its simply having straight forward conversations.
At the same time, Yaskawa customers share their proprietary knowledge because they can trust
us. Because we give their challenges a lot of thought. Because when they talk to us, they know
we are on their side.
Trusting the guys across the table from you with your most important product secrets.
Thats noteworthy.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
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