WWW.PLANTSERVICES.

COM

P E R F O R M A N C E | R E L I A B I L I T Y | E F F I C I E N C Y | A S S E T M A N AG E M E N T

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Plant to
Enterprise
Assaulting the
barriers to mobility

Save Motors from Stray Currents p.29

Keep Boilers Safe p.26

Improve Shutdown Management p.17

Define Energy Efficiency p.38

Whats New in Coatings p.19

Actions Speak Louder with Words p.15

Reality vs. TV p.11

DECEMBER 2009

PS0912_01_Cover.indd 1 12/3/09 10:48 AM

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PS0912_FPA.indd 4 12/1/09 4:26 PM
 TABLE OF CONTENTS
DECEMBER 2009 / VOL. 30, NO. 12

FEATURES
20 / COVER STORY
Plant to Enterprise
Assaulting the barriers to mobility

29 / MOTORS
Shaft Grounding
Keep motors alive on variable-frequency drives

26 / BOILERS
Boiler Inspection and Maintenance
Follow these tips to keep your heating system safe,
reliable, and efficient

SPECIALISTS
15 / HUMAN CAPITAL
Actions Speak Louder with Words
In the absence of full disclosure, people assume the worst

17 / ASSET MANAGER
EXCLUSIVES Improving Shutdown Management
Its a matter of timing, scale, and using the CMMS
Enter Plant Services Best Practices Awards
Our Best Practices Awards recognize management tech- 19 / TECHNOLOGY TOOLBOX
niques, work processes, product and service implementations Whats New in Coatings?
as expressed in a short application story. The contest is open Thermal indicators, no-cure coatings, diamonds, and plant bat-
teries are what
to anyone with a good story and the right to tell it. The entry
deadline for the Management category is Jan. 15, 2010. 38 / ENERGY EXPERT
www.PlantServices.com/bestpractices/index.html Define Efficiency
How you measure can significantly affect your success
Pressure Relief Valve Maintenance
This is what you should expect from your repair facility.
www.PlantServices.com/articles/2009/206.html COLUMNS AND DEPARTMENTS
7 / FROM THE EDITOR 13 / WHAT WORKS
Heavy Lifting Equipment Boosts Results for Hazardous
Bow to None Turbine Retrofit Adds
Glass and Glass-Product Industries
Winners know how to use Remote Monitoring
Reduce on-the-job injuries, increase productivity, improve
everything theyve got Control update gives HPI the
morale, and reduce turnovers with innovative material
ability to protect, integrate,
handling equipment. 9 / UP AND RUNNING
and communicate
www.PlantServices.com/articles/2009/186.html ARRA funds industrial energy
projects Sleep better during 34 / IN THE TRENCHES
Measuring Shock Pulse daylight Digital Disarray
Exploring the Shock Pulse Method and the resulting Acme learns something
11 / CRISIS CORNER
savings that the Hallsta Mill in Sweden realized from about the finer points of
Reality vs. TV e-mail expertise
using it as the primary component of its condition-based Solid customer service is
maintenance program. the right way to promote the 36 / CLASSIFIEDS/AD INDEX
www.PlantServices.com/articles/2009/187.html profession

WWW.PLANTSERVICES.COM DECEMBER 2009 5

PS0912_05_TOC.indd 5 12/3/09 10:09 AM

PS0912_FPA.indd 6 12/2/09 11:21 AM
 Putman media, inc.
555 W. Pierce Rd., Ste. from the editor
301, Itasca, IL 60143 paul studebaker, cmrp
Phone: (630) 467-1300,
Fax: (630) 467-1120

mike brenner
Group Publisher
mbrenner@putman.net

editorial staff Bow to None

paul studebaker, cmrp
Editor in Chief Winners know how to use everything theyve got
pstudebaker@putman.net

russell l. kratowicz, p.e. cmrp Many people, including some Plant mobile computing. Huntsman Chemicals
Executive Editor
russk@putman.net Services readers, continue to decry the technicians use hand-held devices to re-
rising strength of non-U.S. manufactur- cord accurate process data and communi-
Alexis Gajewski
Associate Editor, Digital Media ing, especially in Asia, most notably cate work order information. The expected
agajewski@putman.net in China. Its painful to see emerging results of more accurate entries, higher
stephen c. herner
economies continue to grow and invest workforce productivity and real-time ac-
Group Art Director in U.S. securities while the United States countability for technicians were met. But
sherner@putman.net experiences high unemployment, a huge the technicians were pleasantly surprised
jennifer dakas trade deficit, and a weakening dollar. to find that real-time, accurate condition
Art Director Some go so far as to see the current information and safety notifications also
jdakas@putman.net
situation as evidence that the United
david berger, p.eng. States has lost it not its status as the Like a mixture of air and
Contributing Editor
worlds leader (yet), but the resourceful- vaporized gasoline, just
peter garforth ness, ingenuity, and work ethic that put bringing technologies
Contributing Editor
us there. They think weve gotten lazy
or groups together is
sheila kennedy and stupid, lost our priorities, our cre-
Contributing Editor
ativity, our can-do attitude. not enough.
joel leonard Well, as someone whose job is to
Contributing Editor
understand as well as possible how to op- hold management accountable for solving
bob sperber timize productivity, I have to paraphrase problems and providing resources. Now
Editor at Large Mark Twain and suggest that any report the highly motivated maintenance staff has
of the death of the American spirit is a new way to bring the plant up to their vi-
publication services
highly exaggerated. sion of safety, reliability, and efficiency.
carmela kappel Every day, for every piece of bad news Resourcefulness isnt putting lead
Assistant to the Publisher
ckappel@putman.net about the economy, competitiveness, paint on toys, melamine in food, or cor-
and the future of manufacturing, I see at rosives in drywall. It isnt lots of people
jerry clark
V.P., Circulation least 10 descriptions of higher produc- doing what theyre told, or else. Its every
jclark@putman.net tivity, better quality, improved energy individual thinking about the greater
jack jones efficiency, or stunning innovation. I have good, their job, and how they fit together,
Circulation Director no doubt that U.S. manufacturing is rap- then doing what makes sense with the
jjones@putman.net
idly improving, as it has for each of the help of their coworkers.
rita fitzgerald 30-odd years Ive been on the job. If you have an example of how innova-
Production Manager Its often been noted that innovation tion and cooperation have improved
rfitzgerald@putman.net
takes place at the intersections of previ- your plants performance, please con-
claudia stachowiak ously apparently unrelated developments, sider sharing it with me and your fellow
Reprints Marketing Manager
Foster Reprints like calculators and telephones. I assert plant professionals by entering our Best
(866) 879-9144 ext. 121 that it also favors the intersections between Practices Awards (www.PlantServices.
claudia@fostereprints.com
previously independent communities, such com/bestpractices). The deadline for our
administrative staff as IT and engineering, or production and Management category is January 15.
maintenance. But like a mixture of air and If not, well, get cracking.
john m. cappelletti
President/CEO
vaporized gasoline, just bringing technolo-
gies or groups together is not enough you
julie cappelletti-lange
Vice President
need a spark to get them fully engaged and
working with each other. PAUL STUDEBAKER, CMRP, Editor in Chief
keith larson In this issues cover story, that spark is pstudebaker@putman.net, (630) 467-1300 x433
V.P., Content

rose southard
IT Director www.PLANTSERVICES.com December 2009 7

PS0912_07_Editorial.indd 7 12/2/09 4:59 PM

 GE Energy

I promise

Andy Winston, Cement Industry Leader,

Filtration Technologies

GE Energys Filtration Technologies Team promises a better experience. In how we work with you, how we
deliver for you and how we help you solve your toughest problems. An example of this commitment can be
found in our PulsePleat Pleated Filter Elements. These filter elements offer significant savings compared
to bags and cages. Estimate your own savings at ge-energy.com/cementsavings. Or speak with one of our
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PS0912_FPA.indd 8
GE-56774_PlantServices_MECH.indd 1 12/2/09 11:05
8/14/09 11:24AM
AM

ARRA Funds Industrial Energy Projects
Combined heat and power, district energy lead the list
The U.S. Department of Energy (DOE) recently awarded
more than $155 million in funding under the American Re-
covery and Reinvestment Act (ARRA) for 41 industrial energy
efficiency projects across the country. These awards include
funding for industrial combined heat and power systems,
district energy systems for industrial facilities, and grants to
support technical and financial assistance to local industry. The
industrial sector uses more than 30 percent of U.S. energy and
is responsible for nearly 30 percent of U.S. carbon emissions.
To remain globally competitive, American industry needs
to be energy efficient. The funding for industrial energy ef-
ficiency technologies announced today will support a robust
American industrial sector and help to usher in a clean energy
economy, said Energy Secretary Steven Chu. Many com-
panies already realize that improving efficiency saves money
while helping the environment. These projects will make
energy efficiency technologies more widely available, cutting
energy use and reducing carbon pollution across the country.
Nine projects will promote the use of combined heat and
power, district energy systems, waste energy recovery sys-
tems, and energy efficiency initiatives in hospitals, utilities,
and industrial sites. Combined Heat and Power and District
Energy Systems generate both the heat and power needed for
industrial processes on-site, instead of using electricity from
the grid, and can be nearly twice as efficient as conventional
heat and power production. These nine awards, totaling ap-
proximately $150 million, will be leveraged with $634 mil-
lion in private industry cost share for a total project value of
as much as $785 million. The projects will result in almost 14
trillion Btu in estimated energy savings, which is equivalent
to more than 112 million gallons of gasoline per year.
The remaining 32 awards will provide local technical
support for the industrial sector through university-based
Industrial Assessment Centers, state agencies, regional part-
nerships, and a national technical assistance provider. This
funding will enable DOEs Industrial Technologies Program
(ITP) to provide technical and financial support for local
businesses and manufacturing facilities to save energy and
reduce their energy costs, obtain financing to realize signifi-
cant gains in efficiency and productivity, and save and create
manufacturing and industrial sector jobs across the country.
The 32 projects are an extension of DOEs successful Save
Energy Now initiative, which provides plant energy assess-
ments and technical assistance to energy-intensive indus-
PS0912_09_10_UpRun.indd 9
up & Running
trial facilities. Since the programs inception in 2006, more
than 2,300 assessments have been completed. More than
1,500 industrial facilities implemented the identified energy
measures, which have saved $218 million, 35 trillion Btu and
2.3 million metric tons of carbon dioxide each year.
The announcement includes projects at Seattle Steam Co.,
Rhode Island LFG Genco, Air Products and Chemicals, Ridge-
wood Renewable Power, ArcelorMittal, Verso Paper Corp., The
Dow Chemical Company, and Clean Tech Partners.
Industrial Assessment Centers are to be funded at Bradley
University, Georgia Institute of Technology, Lehigh Uni-
versity, Mississippi State University, North Carolina State
University, Oklahoma State University, San Diego State,
Tennessee Technological University, Texas A&M University,
University of Alabama, University of Dayton, University of
Delaware, University of Louisiana at Lafayette, University of
Michigan, and West Virginia University.
For more information on the awards, see www.energy.gov/news2009/
documents2009/Project_Descriptions_ITP_ARRA_Awards.pdf.
Get Recognized
for Energy Savings
Manufacturing plants across the United States are
participating in Save Energy Now energy assessments of-
fered by the Industrial Technologies Program (ITP), and
facilities that have made progress in implementing the as-
sessment ecommendations to save energy and cut costs are
being recognized by Save Energy Now.
To qualify for an award, your company must participate
in a Save Energy Now energy assessment and report the
progress on schedule. The assessment can be completed by
an Energy Expert or an Industrial Assessment Center.
Selection is based solely on energy savings activities that
have been fully implemented not those that are in progress
or planned. Only activities that have been completed upon
submission of the final progress report will be considered for
recognition.
Once you meet the criteria, your plant will be selected for
one of the following awards:
www.PLANTSERVICES.com December 2009 9
12/2/09 4:09 PM
 up & Running
Energy Saver Plant: More than 75,000 MMBtu total
energy savings or more than 7.5% total energy savings.
Energy Champion Plant: More than 250,000 MMBtu total
energy savings or more than 15% total energy savings.
Energy Champion Team: More than 10% total energy
savings in the original plant and replication in two or
more plants.
As soon as ITP determines that your plant has met the
qualifying criteria based on submitted progress reports, you
will be notified that you are eligible for an award. Once you
accept your award, your company will be publicly recog-
nized at major industry meetings or ITP events each year,
and on the Save Energy Now Web site. In addition to an
award, you will receive a promotional award template that
includes logos and a customizable banner to help you pu
blicize your success throughout your company and in your
corporate communications.
At the request of the company, the award can be extended
to suppliers who the company feels have helped them reach
their award level.
For more information, contact the EERE Information Center at
www1.eere.energy.gov/industry/bestpractices/info_center.html or
call (877) 337-3463.
Sleep Better
During Daylight
Chronobiology International, Informa Healthcares
journal on how biological rhythms affect the systems of
living things, has published a new study which shows that
the use of blue light-blocking eyeglasses can help facilitate
daytime sleep for shiftworkers.
The study recruited permanent nightshift workers from
Canada Posts distribution center in Quebec City. Workers
were asked to wear specialized blue light-blocking glasses
when outdoors. The glasses block the transmission of blue
light because this is the portion of the light spectrum that
most affects the bodys circadian clock and sleep-wake
rhythm. They also wore light monitors on their wrists.
Workers obtained 30 minutes more sleep within the same
time in bed, suggesting fewer awakenings and better sleep
efficacy. A good days sleep for those who work through the
night is important to the health of the worker and the safety
of those around him or her. w
For further information, contact kirstin.stocker@informa.com.
10 December 2009 www.PLANTSERVICES.com
PS0912_09_10_UpRun.indd 10
resources
Did you miss Automation Fair?
If you wish you were among the 8,000 attendees from
60 countries in Anaheim, Calif., November 11-12,
you can feel like you were there by selecting the most
interesting topics from ControlGlobals live coverage at
www.controlglobal.com/articles/2009/RAF09_22.html.
WET DUST WONT EXPLODE
Or will it? Decide for yourself whether wet dust removal
is right for your application. Tri-Mers Whirl Wet brochure
describes updated technology for high-efficiency collection
of soluble and insoluble particulate, 3 microns and larger.
It includes application profiles from Kraft, Barnes Aero-
space, Florida Tile, Musashi Auto Parts, and others. View
it at www.tri-mer.com/pdf-files/WhirlWet_brochure.pdf.
Keep hazmat regs handy
Labelmasters 2009 Early 49 CFR Parts 100-185 is
in the same format as the government release, but
with additional features that make it easier to locate
the information youre looking for. Find requirements
for markings, labels, placards, shipping papers, train-
ing, emergency response, packaging, and domestic
transportation in a convenient booklet at www.label
master.com/Shop/books/dot/2009-10-early-49-cfr.
Put PID tuning tips in your pocket
ControlSoft Inc.s PID Loop Tuning Pocket Guide is now
available in its 4th edition. The new edition of this con-
cise, 12-page publication includes tuning instructions
for cascade loops and an expanded reference section on
common controllers. Find it at www.controlsoftinc.com.
Test your knowledge, test your luck
Proper Selective Coordination can help increase the
reliability of your facilitys electrical distribution system.
Find out how much you know about it by taking Ferraz
Shawmuts latest PIQ Quiz and enter a sweepstakes for a
$100 gas card. See http://us.ferrazshawmut.com/PIQPR.
calculate bearing isolator ROI
Inpro/Seal Co.s motor cost justification worksheet is an
Excel module that identifies energy and operational savings
a plant can attain through the use of bearing isolators. The
worksheet works with motors and other types of rotating
equipment, calculating ROI for bearing isolators based on
repair costs and energy savings. Visit www.inpro-seal.com.
12/2/09 4:09 PM

Reality vs. TV
Solid customer service is the right way to promote the profession
Last summer, Bruce Price, past president of the Port-
land, Wash., chapter of the Association for Facilities Engi-
neering, invited me to keynote the Washington State Society
for Healthcare Engineers conference. Some years ago, Bruce
left the manufacturing world to become the facilities engi-
neer for a hospital. He learned that the healthcare profession
also is fighting the maintenance crisis and thought that I
could offer some ideas to help them with this critical issue.
This hits close to home. My father, a doctor, often dropped
me off in the hospital waiting room while he made his
rounds. Thats where a six-year-old child learned that what
was depicted on TV didnt reflect real life.
For example, on The Flintstones, when a man cried, the
laugh track fired up. If Fred dropped a bowling ball on his
foot and cried, everyone laughed. Ill never forget the first
time I saw a real man cry in the waiting room. I did what
I thought I was supposed to do, I laughed. Soon, my father
appeared, pulled me by my ear to the vending machines, and
asked why I was embarrassing him and laughing at a crying
man. Daddy, I learned from TV, when a man cries, youre
supposed to laugh. He said, Son, that mans child fell off a
ladder and will never walk again. How is that funny?
I shared that moment with the attendees to show that TV
doesnt depict reality. I asked what body part a plumber is
known for. Everyone responded, posterior cleavage or the
non-PC term, plumbers crack. I asked if that image helps
recruitment of future generations to pursue this career.
Despite the economy, 12 of the attendees had open techni-
cian positions that pay more than $20 per hour. More than
80% were in their 50s and several were beyond retirement
age. They complained that the pipeline for qualified replace-
ments for their management jobs is small or doesnt exist.
To change our professions image, we must upgrade our
customer service. Below are the points of my presentation:
Be reliable and provide reliable care
D  o what you said youd do when you said youd do it
Do it right the first time, on time
B  e credible when you give assurance it will be done right
Be attractive because sloppiness affects quality perception
B  e responsive to downtime: someone is losing money
Be empathetic: put yourself in the customers shoes
N  ever ignore a customers opinion: listen to what they
tell you, dont tell you, and cant express
Provide answers to customer questions before they ask
PS0912_11_Crisis.indd 11
Crisis corner
Joel Leonard
Make customers feel good about being your customer
Each day, ask yourself, Am I ready to meet customer
needs?
Get your staff more training to handle more problems
Dont just give excellent customer service subtly make
them aware of your great service
Despite the economy, 12 of the
attendees had open technician
positions that pay more than
$20/hour.
Ask customers about their unmet wants
Treat customers as life-long partners
Set service quality goals and rewards
Select and train your front-line service staff carefully
Get out of the office and find out whats really happening
Be patient but never be satisfied
Respond to needs and those internal customers will
become more responsive to yours
Show more respect and youll get more respect
W hen complimented, simply say, Thanks, and we could
do even better for you if we had a (fill in the blank).
Provide responsive service and your requests for re-
sources will be taken seriously
After I finished, an engineer told his story. To help elevate
patient care, his hospital has a rapid-response team that
goes in after a patient leaves to repair scratches, disinfect the
bathroom and shower, touch up paint jobs, replace cracked
laminate, repair leaky faucets anything to help leave a
pristine room for the next patient. At first, nurses resisted
releasing the room. After piloting this project and seeing
satisfied patient responses, they now support the move.
Perhaps we in manufacturing could learn from this and
implement rapid-response teams to perform PMs, like rac-
ing pit crews, to elevate our customer service image. And
if proactive, customer service-sensitive engineering and
maintenance teams became the standard, well minimize
the disastrous effects of the maintenance crisis and relieve
future crying moments that will certainly not be funny.
E-mail Contributing Editor Joel Leonard at joel@skilltv.net.
www.PLANTSERVICES.com December 2009 11
12/1/09 3:48 PM
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Turbine Retrofit Adds Remote Monitoring
Control update gives HPI the ability to protect, integrate, and communicate
When a large Southern utility dusted off a fleet of unused
combustion gas turbine engines to modernize them for
generating backup electricity during peak energy-consump-
tion periods, it called on project developer HPI LLC (www.
hpi-llc.com) to upgrade the control systems. HPI supplied a
standardized, digital control system offering improved reli-
ability, enhanced turbine control and diagnostics informa-
tion, and remote start capabilities.
HPI specializes in providing retrofit controls for
gas and steam turbine power generation, compres-
sors, and mechanical drive systems. The company
opened its doors in 2002. Its team of engineers and
technicians have completed more than 70 gas turbine
models for more than 20 manufacturers.
Four General Electric MS5001 (Frame 5) turbo-
generator packages were fitted with Allen-Bradley
ControlLogix controllers. HPI chose ControlLogix for
its ability to integrate discrete, motion, process control,
batch, drive systems and safety using a single develop-
ment environment and a single, open communication
protocol. We used to buy separate controllers and wire
them together, but the Rockwell Automation Logix
controller allows us to provide turnkey solutions that go
beyond just the gas turbine control, says Jerry Wheelwright,
vice president of engineering, HPI.
For networking and visualization, HPI networked Allen-
Bradley FLEX I/O modules with copper and fiberoptic
ControlNet and EtherNet/IP network communications. The
remote, panel-mounted control system includes digital, ana-
log, and temperature-monitoring modules., The terminals,
fuses, relays, and conduits were preinstalled in subpanels to
reduce the amount of on-site wiring.
The utility can operate the system from a remote site
five miles away. Engineers also developed a live feed from
explosion-proof cameras within the turbine enclosure at
other customer facilities.
The ability to monitor and control the turbines at any time
of the day from a remote location is a significant benefit to
this customer, Wheelwright says. The utility can have gas
turbines spread around the state and run the controls through
larger steam turbine plants that are manned 24 hours a day,
helping to eliminate the need to staff each individual site.
To reduce the condition-monitoring system costs, the
utility wanted to retain the existing vibration probes, so HPI
PS0912_13_Works.indd 13
what works
Remote, panel-mounted control
systems for four General Electric
MS5001 turbo-generator
packages include vibration,
speed, and temperature-
monitoring modules.
used Rockwell Automation XM-120 dynamic measurement
modules. Two of the two-channel modules on each of the
four turbines interface with the equipment via ControlNet
to DeviceNet interface modules.
In retrofit situations, HPIs customers typically have an
overspeed protection system that is either obsolete or hydraulic,
which makes the system difficult to test and maintain. For the
Southern utility project, HPI replaced the overspeed protection
systems with XM-220 dual-speed modules. The XM-220 mod-
ule is an intelligent, two-channel measurement module that ac-
cepts input from two tachometers. The module measures speed,
rotor acceleration, and peak speed and is capable of detecting
zero speed, locked rotor, and reverse rotation.
The turbines havent experienced a start failure since the
control upgrade. HPI was pleased with the flexibility of the
XM series, the ease of configuration, and the ability to see
that the protective circuits are working, and decided to stan-
dardize on the equipment for future upgrades.
We chose the XM series for two reasons, says Wheel-
wright. One was availability. It was on the shelf when we
needed it. The second reason was its ability to interface with
other probes and the rest of the system.
www.PLANTSERVICES.com December 2009 13
12/2/09 4:26 PM
 Get new performance
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At Robinson Fans, we pride ourselves on being your trusted source for new fans. But we also have a
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PS0912_FPA.indd 14 12/3/09 12:00 PM


Actions Speak Louder With Words
In the absence of full disclosure, people assume the worst
Not long ago I was at the home opener of the local high
school football season. To be clear, our team has had a dis-
mal recent history; theyve won only three games in the past
two years. With a new coach and a new attitude, these young
men had won their first road game in convincing fashion, so
expectations were high.
The rival from the next town over would be a legitimate
test, and our team was answering the call. We were ahead
by six points at the beginning of the 4th quarter and driving
for another touchdown with the ball on our opponents 11
yard line. Then it happened A pass play across the middle.
A defensive back clearly ran into our receiver before the ball
got to the receiver. The ball deflected off our receivers hands
and was caught by another defender. For the mere seconds
it took for the official to throw the yellow penalty flag on the
field, we held our breath. When the flag was finally thrown
we were high-fiving each other because we knew the penalty
would put the ball on the goal line.
Then the referees huddled and the head referee bent over,
picked up the flag, and waived it over his head; this meant
no penalty. Worse than that, the other team was awarded
an interception, giving them possession of the ball and end-
ing our scoring drive. The home town crowd was enraged.
What are you doing?!, Whos paying you off, Ref? and the referee simply given the motion indicating the ball had
other utterances of disbelief were heard for several minutes.
The opposing team eventually scored and the home team
lost by one point.
Weve all experienced something like this. When people
dont know whats going on, they tend to think in negative
terms. In the situation that night on the football field, it
seemed as though the officiating team was biased. For the
record, Ill state that 99.9% of all amateur and professional
officials in every sport are not biased. But the emotions of
circumstances often make us think the worst.
When game films were scrutinized the next day, it was
realized that a defensive lineman actually had tipped the
ball. That meant that, by definition, a defensive pass interfer-
ence penalty could not be called and the officials had made
the right call.
Most high school football games dont have instant replay
on the big screen, nor do they have microphones on the of-
ficials as they do in major college and professional football.
Because of this, the officials reasoning and decisions were
not readily available to the fans.
PS0912_15_HumanCap.indd 15
HUMAN CAPITAL
Tom Moriarty, P.E., CMRP
In the workplace, supervisors and managers often dont
take the time to educate their staffs and team members on
the full scope and realities of what they are up against. In
the absence of information and understanding, people tend
to believe the worst. Its human nature. Its like the fans that
were too far away to see what the referee sees.
A defensive back clearly ran
into our receiver before the
ball got there.
Some team members are ultimate fans and want to know
as much as possible. Other team members are like spouses of
football fans who dont follow the games, but can appreciate the
scope and complexity of the rules. You see, its not just about
making everyone into wanna-be supervisors; its about giving
them access to the big picture. Transparency and inclusiveness
lead to building and sustaining trust.
Decisions dont always make sense when you dont know
the whole picture. That night on the football field, had there
been slow motion instant replay on the Jumbo-Tron, or had
been tipped, a lot of inappropriate thoughts about the offici-
ating teams heritage and integrity might have been avoided.
In good or difficult economic times, it may become the
path of least resistance for managers and supervisors to
avoid interacting with employees who may ask difficult
questions. What tends to happen is that the workforce
spends more time thinking about whats going on, and less
time thinking about doing their job in the safest and best
way possible.
When there is a lack of information there is a void that
often is filled by guessing at the managers or supervisors
intentions. The greater the level of trust within the organiza-
tion, the less negative are the thoughts attributed to those
intentions. Facing difficult situations head-on is not always
comfortable, but it is, by far, a more respectful way of treat-
ing your team. Interact with your team proactively, keep
them informed, give them access to the big picture.
Tom Moriarty, P.E., CMRP, is president of Alidade MER Inc.
Contact him at tjmpe@alidade-mer.com and (321) 773-3356.
www.PLANTSERVICES.com December 2009 15
12/1/09 3:49 PM
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PS0912_FPA.indd 16 12/1/09 4:28 PM


Improving Shutdown Management
Its a matter of timing, scale, and using the CMMS
One of the most resource-intensive activities you can
undertake is planning and executing a outage or shutdown.
Many people use the terms outage, shutdown, and turn-
around interchangeably to mean the period of time during
which major assets or an entire facility are taken off-line to
complete maintenance work thats difficult or impossible
to perform otherwise. Shutdowns are complex, costly, and
disruptive. Thats precisely why theres usually potential for
improvement, especially if the maintenance department is
constantly putting out fires. Consider the opportunities.
Timing
Many companies shutdown during the summer when office
and operations staff take vacations. Try a cost/benefit analysis
on the shutdown timing to find the most cost-effective time
slot. Some companies have saved millions simply by moving
the shutdown away from summer or other heavy vacation
periods. This is especially advantageous if you can move the
shutdown to a low point in the annual cycle when product
demand is slow. Some companies struggle to recover from
a summer shutdown, spending too much on overtime and
inventory stockpiling to deal with peak demand.
Technical resources, internal and external, are more readily
available outside of summer months. Its difficult to encourage
the maintenance staff to stick around during a shutdown while
everyone else is taking advantage of nice summer days. Hiring
contractors during peak vacation periods is problematic, and
many companies have to hire less experienced resources or pay
premium rates. Similarly, availability and premium pricing also
applies to special equipment, spare parts, and utilities.
Size matters
Another opportunity lies with shutdown scale, frequency,
and quantity. Many companies shifted from a large-scale,
bang-bang approach to more mini-shutdowns performed
more frequently. This lessens operations and maintenance
disruption, reduces labor costs, and cuts production losses
and start-up costs that arise after prolonged downtime.
A good CMMS can gather and analyze different job plans
and schedules with associated cost data to better understand
the cost/benefit of the options. For example, if you have
a single, two-week plant shutdown each year, explore the
idea of shutting down different areas, lines, or equipment in
sequence so the plant is covered during the course of a year.
PS0912_17_18_AssetMgr.indd 17
asset manager
david berger, P.Eng.
This can result in less downtime with some stockpiling of
work-in-process inventory, but not to the extent needed for
a full shutdown. You also might be able to establish redun-
dant processes to limit outages, outsource some production
during mini-shutdowns, use condition-based monitoring to
Many companies benefit
by shifting from a large-scale,
bang-bang approach to a higher
quantity of mini-shutdowns
performed more frequently.
reduce shutdown frequency, and re-engineer equipment to
allow safe maintenance while equipment operates.
This is similar to the thinking of 20-plus years ago,
when annual production and spare parts inventory counts
required shutting down the plant for days, hiring people to
count, check, record, and analyze data. As ERP systems and
CMMS packages improved, cycle counts made it possible to
spread inventory counts throughout the year on a rotational
basis with little disruption and cost.
Planning and scheduling
The key to an efficient shutdown is detailed plans and sched-
ules. CMMS packages and specialized turnaround software
optimize plans and execute schedules accurately. The soft-
ware features and functions facilitate mobilizing the right
resources at the right time, with the right materials and job
plan. Features include ability to input:
Planned and actual work orders, including standard
tasks; estimated labor hours/dollars; skills, parts and
tools required; quality standards; inspection metrics and
triggers; precedent relationship with other tasks/work
orders; safety procedures, and technical documentation
Work breakdown structure from project level to master
work order level to task level
Schedule sortables by crew, date, location, etc.
Budget linked to breakdown structure and timeline
Contingency planning for delays; what-if analysis or
simulation to find best/realistic/worst-case scenarios
The software tool also should assist with key processes:
www.PLANTSERVICES.com December 2009 17
12/2/09 4:10 PM
 asset manager

Procurement, to plan the timing of purchased materials and

services, expedite them, and report on variances
I nventory management, to ensure stocks are optimized and
parts are inspected, kitted and released on a timely manner
T  echnical analysis and reporting, to expose and solve prob-
lems through Pareto analysis, root cause analysis, etc.
W  arranty analysis and reporting, to ensure recovery of costs
Fluke 1AC-I P  roject tracking, to determine if the plant shutdown is on
time, on budget and maintaining the expected quality level
VoltAlert In general, the greater the level of detail, the easier it is to man-
NEW! Always On, uses age the plan execution. Given that a multi-week plant shutdown
special low power can cost as much as the maintenance budget for the balance of
circuitry to sustain the year, its well worth the time and money to do it right.
battery life and added
dependability Stakeholder involvement
NEW! Includes innovative Keeping key stakeholders involved from the planning stages to
Battery Check button the post-implementation review improves the quality and buy-in
function to ensure of the plan. Senior management should develop the shutdown
battery is in good philosophy and strategy in light of the corporate vision and strat-
condition when using the egy. The shutdown team develops and implements of the detailed
tester, giving peace of plan. The shutdown team should include senior representation
mind any from maintenance, operations, engineering, and finance (in-
time you are testing cluding capital planning and purchasing). Marketing might be
involved to ensure customers are served during the shutdown.
CAT IV 1000 V
Its also critical to communicate often and effectively with
overvoltage
shop-floor personnel such as technicians, operators, stockkeep-
rated product
ers, and so on. Specialized training might be required to ensure
front-line staff and contractors are adequately prepared for
executing shutdown procedures safely and efficiently.

Performance measurement
The shutdown team needs to define success for the program by
establishing performance targets for various drivers and tracking
them using the CMMS. Drivers and performance targets include:
Check out the full line of Project management (lower shutdown costs)
Fluke VoltAlerts, go to
www.fluke.com/voltalerts Customer satisfaction (higher quality of output)
Operational capability (equipment reliability)
Risk management (decreased lost-time injuries)
Enter for a chance
After the shutdown, conduct a post-mortem to determine what
to WIN 2 tickets to to improve for future shutdowns. Continue tracking the perfor-
Super Bowl XLIV. mance measures on the CMMS to ensure that you achieved your
Go to www.fluke.com/footballsweeps targets. If not, determine what can be done differently in the
2009 Fluke Corporation. SUPER BOWL a registered trademark
short term, or for the next plant shutdown.
of the National Football League. Ad 02375s

E-mail Contributing Editor David Berger, P.Eng., partner, Western Man-

agement Consultants, at david@wmc.on.ca.

Non-contact (Editors note: The Plant Services CMMS/EAM Software Review, at

voltage detection www.PlantServices.com/cmms_review, provides a comparison of
more than a dozen popular software packages.)
you can rely on
18 December 2009 www.PLANTSERVICES.com

47697
PS0912_17_18_AssetMgr.indd 18 12/2/09 4:11 PM
3530195A_02375s_PlantSvcs.indd 1 9/22/09 1:51 PM

Whats New in Coatings?
Thermal indicators, no-cure coatings, diamonds, and plant batteries
New formulations, capabilities, and applications are
driving improvements in coating reliability, performance,
and economy. The developments reduce energy, materials,
and maintenance while being easy on the environment.
Clean air compliance: Manufacturers are required to
minimize the volatile organic compound (VOC) content
in their products. Ford Motor Co. engineers and suppliers
responded by developing a cost-efficient and low-VOC paint
and automated application process being rolled out glob-
ally. Ford used to apply three layers of paint in separate stages
using bulky, energy-intensive equipment. The new 3-Wet paint
technology allows primer, base, and enamel coats to be applied
sequentially while still wet, without manual intervention, in an
integrated booth. The technology meets Fords standards for
chip, scratch, and etch resistance; durability; and appearance.
The high-solids, solvent-borne formulation produces fewer pol-
lutants than current waterborne and solvent-borne paints. The
robotic application process eliminates equipment and associ-
ated pollutants and reduces the cycle time by 20% to 25%.
This should produce 6,000 metric tons less CO2 per year
compared to waterborne systems and 8,000 metric tons less
CO2 compared to conventional solvent-borne systems. Also,
theres a VOC emissions savings of 5% related to processing.
Temperature indication: One protective coating changes
color to pinpoint the source of a maintenance problem. For
instance, refinery and petrochem process equipment that
operate at high temperature might overheat because the
interior refractory lining failed or its bypassing hot gases.
Dampney Companys silicone-copolymer Thurmalox 260
TIC Series coatings reveal the hot spots that indicate over-
heating by changing color. Designed for the 400F to 650F
range, the heat-resistant, self-priming, VOC-compliant coating
changes color permanently at intervals of 25F to 50F, depend-
ing on formulation. The corrosion-resistant red, blue, yellow, or
violet coatings provide weathering and UV stability.
Efficient application: The hang, spray, and bake method of
applying coatings to metals is labor- and energy-intensive and
consumes large amounts of powder. Greenkotes thermochemi-
cal surface treatment requires 50% less energy and 90% less
powder than regular diffusion coatings. The corrosion-resistant
coatings are free of hexavalent chromium. The liquid-free pro-
cess is applied in bulk to save cost. The parts and powder are
introduced to a rotating oven, where the powder content and
thermal cycle define the characteristics of the coating and
PS0912_19_TechTool.indd 19
Technology Toolbox
Sheila Kennedy
surface. This high-performance, low-cost is an alternative to
other methods such as chemical or electrodeposition, CVD,
PVD, and diffusion. Savings range from 20% to 70%.
Tunable deposition: A diamonds strength, durability,
and chemical resistance make it an appealing material for
coatings in harsh or demanding environments. sp3 Dia-
mond Technologies enhanced its ability to cost-effectively
A new protective coating changes
color to provide a visual clue
that pinpoints the source
of a maintenance problem.
deposit or grow uniform diamond films to reduce heat
generated during sliding friction and increase component
reliability. The companys chemical vapor deposition (CVD)
capability includes coatings ranging from super smooth
nanocrystalline films (surface roughness less than 10 nm) to
controlled microcrystalline films (surface roughness greater
than 10 um). They can be deposited on silicon carbide, ce-
mented carbide, silicon, tungsten carbide, and graphite.
In addition, sp3 sells its CVD reactor technology to com-
panies that want to apply diamond coatings in-house. The
reactor controls film growth and properties, which.
Novel engineering: Researchers at Uppsala University in
Sweden discovered a way to coat algae blooms to make batter-
ies. Cladophora algaes cellulosic nanostructure serves as an
coating substrate for batteries. The cellulose has a large surface
area that, when coated with a thin layer of conducting poly-
mer, reportedly produced a battery that is virtually weightless
and set new charge-time and capacity records. The research
highlights the potential for eco-friendly, lightweight and cost-
effective energy storage systems.
E-mail Contributing Editor Sheila Kennedy, managing director of
Additive Communications, at Sheila@addcomm.com.
Reference Web sites:
www.ford.com www.sp3diamondtech.com
www.dampney.com www.uu.se
www.greenkote.com www.sspc.org
www.PLANTSERVICES.com December 2009 19
12/1/09 3:50 PM
 20 December 2009 www.PLANTSERVICES.com

PS0912_20_25_CvrStry.indd 20 12/2/09 4:56 PM


Capital investments are scarce, employment is
down, and manufacturing is barely ticking over in much
of the world, but purveyors of mobile computing hard-
ware, software, and wireless infrastructure are still seeing
steady in some cases, aggressive growth. Word is out
about increases in productivity, effective knowledge man-
agement, and positive culture change in companies that
hand out handhelds. Now the barriers to implementation
are under siege.
Life is more competitive, says Joe Granda, executive
vice president, marketing, Syclo (www.syclo.com), which
is expanding its mobile software and systems integration
workforce. Organizations have gone to a lot of effort to
streamline activities six sigma, asset management, supply
chain and theyve done a pretty good job of improving
productivity and processes. So whats the next step? Mobile.
Mobile computing lets companies leverage office system
improvements in the field. You can reduce cycle times to
reduce labor costs, improve customer satisfaction, and
increase product quality; get information into the hands
of people and back into the system; and handle regulatory
compliance with documentation for the EPA, FDA, and
Sarbanes-Oxley.
Better information management is breaking down bar-
riers between production and maintenance. As companies
put in more maintenance management systems because
costs are high and equipment is breaking down, they find
that they now know what the backlog is, but theyre not
catching up, says David Dollar, product manager for In-
telaTrac at Wonderware (www.wonderware.com). Operators
can collect condition data to help them operate within the
design envelope and keep the process or machine tuned.
They can extend the time between maintenance and notify
maintenance earlier if a problem starts to occur, so you
replace a bearing instead of a shaft and bearing, Dollar says.
Along with extending intervals based on more proactive
operation, you can empower operators with correct pro-
cedures and focused advice, and lead them through minor
troubleshooting.
Mobile devices also are being used to capture unin-
strumented process data. Some 40% of equipment isnt
instrumented or has only local gauges. Operators often
open or close valves manually, setting positions with
verbal communications, and the records are poor. Mobile
devices can bring those values into the process historian,
PS0912_20_25_CvrStry.indd 21
MANAGEMENT / Production Optimization
Table 1. Mobile Consequences
Key Benefits* Key Challenges*
1. Empower employees 1. Security concerns/risks
to be more productive
2. Reduce labor costs 2. Cost of hardware,
total cost of ownership
3. Work order accuracy, 3. Cost of software,
asset tracking accuracy integration, service,
and support
4. Improved compliance 4. Integrating mobile
documentation applications with
infrastructure
5. Impact on revenue 5. Hardware quality
generation
* Manufacturers responses to What are your organizations key
benefits and challenges with regard to the deployment
of mobile and wireless technologies? (Motorola)
allowing the operator to feed information into multiple
systems of record.
For example, EPA requires inspections of flanges and
valves for fugitive emissions. You attach RFID tags not
bar codes that can be copied at the locations, Dollar says.
You have to be within two inches to scan them, then answer
questions to confirm the inspection. Reports are e-mailed
to the EPA. The EPA visits less often because the inspections
are rigorous and documented, and the EPA accepts them.
The same wireless infrastructure can be shared among
mobile computing, security, building management, and con-
trol systems. It can reduce capital expenditures and improve
reliability when adding measurements for monitoring and
controlling equipment, energy, and emissions.
The business case for mobile workers is compelling, says
Paul Brooks, business development, networks, Rockwell Au-
tomation (www.ra.rockwell.com). But as shown in Table 1,
research shows that manufacturers also see some challenges.
Engineer Your Ethernet
Most industrial facilities are settling on wireless Ethernet
(WiFi) as the primary plant-floor mobility backbone,
with radio, cellular, GPS, Bluetooth, etc. used where
needed, as needed. Infrastructure costs are coming down
www.PLANTSERVICES.com December 2009 21
12/3/09 10:10 AM
8,000
6,000
4,000
2,000 MANAGEMENT / Production Optimization
0
Jan-07
Feb-07
Mar-07
Apr-07
May-07
Jun-07
Jul-07
Aug-07
Sep-07
Oct-07
Dec-07
Nov-07
as architectures are standardized, application engineers
and installers become more familiar with industrial
requirements, and competition heats up among industrial
and commercial suppliers.
Ethernet 802.11 is being accepted as the network,
says Marty Jansons, networking consultant, industry com-
munications group, Siemens Industry (www.usa.siemens.
com/industry). People are giving wireless a go, trying it in
an area thats unreachable by wires or using it to upgrade a
fieldbus system. We see 802.11a, b, g and n.
In a plant, wireless applications as diverse as security
video and real-time crane control can be integrated on one
wireless infrastructure by supporting different radios that
dont interfere. 802.11g on 2.4 GHz offers three channels,
Pondering Platforms
Here are seven areas users might examine to streamline
implementation, according to Joe Granda, executive
vice president, marketing, Syclo (www.syclo.com):
1) Business continuity: capabilities such as server
clustering with failover so people can keep
working, and load balancing to keep up with
adding users.
2) Mobile device management: Know where the
devices are and perform upgrades, patches,
and troubleshooting from a central location.
Handle increasing numbers of diverse devices.
3) Online, offline: Follow business rules and perform
validation without compromise whether on a LAN,
WiFi, WiMax, cellular or no network. Manage costs
by prioritizing data transmissions by network.
4) L
 ean and clean architecture: No intermediate
database, no heavy server-side processing they
dont scale up, and can cause latency issues.
Both 32- and 64-bit compatibility for speed.
Load balancing and support for virtual as well as
dedicated hardware servers.
5) Devices and peripherals: Support multiple devices
(laptops, Windows handhelds, iPhones, Black-
berries) with the same software logic, without
rewriting code. Youre going to have them all
thrown at you, along with peripherals such as
barcode, RFID, meters and GPS.
6) Productivity and QA tools: Wizard-driven envi-
ronments ease code development and test.
7) S ecurity: Support services (LDAP [lightweight
directory access protocol], active directory, single
sign-in for multiple applications (CMMS, financial,
HR), remote wiping of devices that are lost or
stolen. Everything should be encrypted whether
its over the air or not.
22 December 2009 www.PLANTSERVICES.com
PS0912_20_25_CvrStry.indd 22
Separate the Networks
Business
L4 network
Wireless
application L3.5
network Control
L3
network
L2
L1
Figure 1. For safety and security, the mobile computing,
control, and business networks should be separated and
firewalled. (Apprion)
802.11n offers three on 2.4 GHz and 22 on 5 GHz, Brooks
says. Sharing time is fine for PCs and emission controls, but
not for controlling a heater or a crane.
For safety and security reasons, the mobile computing,
control, and business networks should be separated and
firewalled (Figure 1), asserts Steve Lambright, vice presi-
dent, marketing and customer services, Apprion (www.
apprion.com).
Now your wireless infrastructure can support many ap-
plications maintenance, process control, business systems,
condition monitoring, security video, emergency notifica-
tion, voice so you can share up-front costs, Lambright
says. You dont have to justify it on just one application.
That justification begins by defining what you want the
network to do. Wireless is a shared medium, says Jan-
sons. You can have eight people fighting for access, or you
can separate them into channels to guarantee access. On
802.11g, you can segregate traffic and have separate names,
encryption, and passwords. What do you want, what do you
need, what are your security requirements?
Then, find out what it will take to install it in your facil-
ity, starting with a site survey. WLAN and mesh network
planning software can do predictive analysis of coverage in
a given facility, says June Ruby, director, manufacturing
solutions group, Motorola (www.motorola.com). Its a cost-
effective way to plan.
Software can tell you if the IT network will interfere with
plant data transfer, overlap will compromise the security of
office wireless, or structures will interfere. Metal shelving
and concrete walls can be put into software and simulated
using algorithms, says Jansons. The survey lets you know
what coverage you can expect, decide wired versus wireless,
and weigh cost versus coverage.
Wireless can be expensive if a lot of hard wiring is neces-
sary to connect wireless access points. Repeaters have made
that cheaper, but areas with lots of metal are still a prob-
12/2/09 4:53 PM
 MANAGEMENT / PRODUCTION OPTIMIZATION

lem, says Dollar. You can afford 90% coverage much more
reasonably than 100%, so consider applications that are de-
signed to run in an occasionally disconnected environment.
Mesh networks are coming that may be better.
When calculating ROI, consider how long the system will
run. Five years? 10 years? asks Jansons. Some people use
commercial equipment that runs either a, b, or g. You may
want ruggedized, industrial components that run all three
or any one or two. Then you can put the control system on
801.11a and communicate on 802.11g. Youll need separate
antennas, and you get separated traffic with no interference
or data overload.
Every site is unique, or as Jansons put it, The medium is
standard, but theres always an X factor.
In most facilities, plant engineering initiates the wireless
infrastructure project . They want to try to do a project
wirelessly but dont know how, Jansons says. Its a chal-
lenge for IT to understand the requirements of the plant
world, but once they do, they can handle it. Start with what
you want to do. Learn the technology, and get a site survey
from the plant perspective. Then involve IT.
When its time for installation, some plants do it them-
selves. Some hire system integrators, and some use their IT
department. We do application engineering, and can help
with or coach the installation, Jansons says.
Expect a learning curve. Over the course of an extensive
implementation at Huntsman Chemicals Port Neches,
Texas, plant, the electrical contractors learned better ways
to set up, install, and commission. Number 100 went in
in a third of the time of number 1, says Lambright. Every
facility has its own way of doing things. Weve learned to
combine our best practices and theirs. Over time, weve
been able to establish proven best practices to design, install,
tune, go live, and operate complex networks.
INNOVATIONS DRIVE ROI
Advances in soft ware and devices are speeding ROI by mak-
ing it faster and easier to develop and implement applica-
tions. Mobile has become more reliable, versatile, and able to
handle mission-critical applications. To ease implementa-
tion, use a soft ware platform as a foundation and run pre-
built, pre-integrated applications, says Granda. Once you
have a platform, each application takes less time, training
and IT to implement.
Industry is comfortable with Windows Mobile as an operat-
ing system, according to Dollar. Through Windows Mobile 5,

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 MANAGEMENT / Production Optimization

Devices can use the most appropriate available network

Table 2: Pay Now or Later? for the application. GPS allows triangulation and real-time
Model Components TCO* location you can use to marshal personnel in an emergency.
With the right management software, you can get notifica-
$50,000 customization tion if a device doesnt move or is inactive for too long.
Mobile enterprise Handhelds range from slightly rugged smart phones
Built-in mobile device
application $992 optimized for bar-code scanning to Class I, Div. 1 devices
management
platform (MEAP) you can drop on concrete. Devices have become so critical
Minor upgrade path to businesses, they dont want to be without them, Ruby
adds. Some service plans even offer rapid swap-out for
$20,000 server license damaged devices.
Packaged, Bear in mind that whatever you choose is likely to be only
$1,080
on-premises a starting point, with additional ROI coming from applica-
Ongoing upgrades
tions youll discover later. First, acquire or develop applica-
tions that make maintenance more productive. That makes
$200,000 customization
Build from the infrastructure more attractive, says Whitehead. Once
Varies
scratch Major upgrade at its in place, theres no limit. The ability to make it mobile
three to four years depends less on the devices than on the creativity and abili-
ties of users, and we never know what people will come up
$20,000 customization with. The market pulls us into new, creative applications.
Software as a
$2,340
service (SaaS)
Ongoing upgrades Your cost may vary
The same software tools that streamline commercial mobile
*Three-year total cost of ownership per seat for 500-seat phone and IT support are making life a lot easier for admin-
mobile field service management system (Gartner Group) istrators of industrial handheld devices, and lead to the same
kind of choices for how to source a system (Table 2). The
Gartner Group (www.gartner.com) associates the lowest per-
then 6.1 and now 6.5, the platform has really improved over the unit, three-year costs with a strong customization of a mobile
years, with a lot more capabilities for a richer interface. Its cer- enterprise application platform (MEAP), estimates somewhat
tified on many devices, all of which can run the same code. It higher costs for hosting a packaged system on-site, and sees
handles full VGA, VGA, Motorola, Honeywell, he says, and scratch-built systems as a wild card. Gartner finds the low
the same software runs on Windows XP and Vista, so we have up-front costs of software as a service (SaaS) to be more than
to do less development just what we need to support barcode offset by monthly fees before the three years are up.
readers and condition-monitoring devices. Seven areas of concern and how your implementation
Device manufacturers offer handhelds at every price model affects them are described in the sidebar, Ponder-
point, set of capabilities, ruggedness, and certification, the ing Platforms.
right device for every purpose, says Ruby, including voice Regardless of how its implemented, remote administra-
over wireless LAN and interfaces for PBX and mission- tion is unequivocally a boon to commanders of fleets of
critical private radio. devices, allowing software changes and hardware enable/
The mobile worker can have a walkie-talkie, push-to-talk disable over the network. With our mobility services
phone, and palm-top computer with docking, all in the
same device. Now, technicians are familiar with the devices more resources at www.plantservices.com
and just want to access the applications, says Cliff White-
Going Mobile: Power Tools for Culture Change
head, business development manager, strategic applications,
www.plantservices.com/articles/2006/161.html
Rockwell Automation. They just expect it to happen.
A security guard might only need a rugged, two-way ra- Mobile Mindset: The Reasons to Hand Out Handhelds
dio, or he might also need to access video surveillance feeds www.plantservices.com/articles/2007/230.html
with a rugged, hand-held, mobile computer. A maintenance
Case Study: Huntsman Extends IT to Its Field Operations
technician needs to eliminate paper and capture data, and
www.apprion.com/ApprionExpertise.CaseStudies.asp
might use Bluetooth to collect data from accelerometers or
temperature probes. Views of the process control system al- White Paper: Unlocking the Value of Mobile Computing
low them to see and acknowledge alarms, and variables such www.syclo.com/resources/resource.php?id=7&category=19
as tank levels and flow rates.

24 December 2009 www.PLANTSERVICES.com

PS0912_20_25_CvrStry.indd 24 12/2/09 4:54 PM

 platform (MSP), you can drill down into devices and do revi-
sions, operating system patches, even disable or wipe from
a central location, says Ruby. You dont have to physically
bring in devices.
Users may have thousands of mobiles deployed around the
world. With Microsoft Systems Center Mobile Device Man-
ager, we can turn capabilities on and off, says Dollar. For
instance, if security requires it, we can turn off the camera on
hundreds of handhelds without touching them. A lost hand-
held can be remotely wiped so it cant log in.

Get It Done
With so many tools available on mobile devices the CMMS,
operator screens, accessing machine operating conditions,
work orders, instructions, one trip for parts and tools, the
case for a wireless infrastructure is becoming a no-brainer,
Whitehead says.

But because so many departments have a stake in the out-

come and a use for a mobile computing and wireless network-
ing infrastructure, a critical factor for success is communi-
cation among groups maintenance, engineering, security,
safety to agree on needs and priorities.
Brooks sees the necessary disciplines converging in four areas:
I n network technology, one software tool makes a com-
mon platform.
I n the physical network, one infrastructure separated logi-
cally for different applications.
C  ulturally, maintenance and IT are recognizing their
interdependence and more often share responsibilities,
goals, and a common language.
O  rganizationally, maintenance and IT remain different
people, but more often have the same boss: a production
director who wants to take responsibility for things critical
to production, including IT.
Any battle between maintenance and IT is a waste of time,
Brooks says. The leaders will be the ones most adaptable to
the others needs.
When mobile computing is working well, it helps every-
body. The fact that a work order can be completed on loca-
tion, quickly, accurately, and in real time, drives accountabil-
ity down to the operator, says Lambright. But it also drives it
back up to management. Now the operator can make manage-
ment aware of the situation here and now, and its incumbent
on them to take advantage of it.
At Huntsman Chemical, this concept changed the perspec-
tive of operators and technicians. It lets them hold management
accountable for what they think is important to the plant.

PS0912_20_25_CvrStry.indd 25 12/2/09 4:54 PM

 Boilers can be dangerous if not inspected and main-
tained. Each year, countless accidents, breakdowns, and
shutdowns occur among the approximately 43,000 industri-
al boilers in the chemical, food processing, paper, refining,
and primary metals industries throughout the United States.
Boiler breakdowns can cost thousands of dollars in equip-
ment repairs as well as hundreds of thousands in property
damage and income losses. Accidents also can cause loss of
life and structural damage to plants, facilities, and equip-
ment. Compared to one unplanned plant shutdown, the cost
of boiler inspection, maintenance, and repairs is minor.
While boiler safety devices are designed to prevent
dangerous conditions from turning into disasters, only
proper maintenance prevents the development of dangerous
operating conditions in the first place. Proper boiler mainte-
nance, servicing, and inspection is not only a safety issue, it

ITS NEVER RECOMMENDED

THAT A BOILER BE OPERATED TOO CLOSE
TO THE SAFETY VALVE SETTING.

also can be an economic matter. Downtime can shut down

operations and production, and every hour that its stopped
can cost hundreds of thousands of dollars. No plant wants
emergency shutdowns or downtime, and the plant manager
doesnt want to be responsible if boilers (or other equipment)
arent serviced, inspected, and maintained properly.
Regular boiler inspection is the law, most often governed
by the state, but in some cases governed by a municipality
and city. Boilers must be inspected by certified inspectors
according to a mandated schedule. The day-to-day boiler
maintenance and service is the responsibility of plant en-
gineers or plant managers. Remember that most problems
dont occur suddenly. They develop slowly over a long time.
So slowly, in fact, that the maintenance staff can grow accus-
tomed to the change without realizing it has taken place.
Also, regular inspections provide optimal function and
energy efficiency. Boilers are voracious energy users. Inef-
ficiency means wasted energy and increased operating costs.
Regular inspections also can extend the life of the vessel.
As every plant owner and manager knows, industrial boilers
are a major investment, costing upwards of $200,000.

KEY BOILER SAFETY FEATURES

Boilers have a variety of safety features designed to prevent
accidents and keep them functioning at optimal efficiency.
Safety valves are the primary safety feature. Designed to
relieve the pressure if other systems fail, every steam and
water-heating boiler must have at least one safety or safety
relief valve of sufficient capacity to match burner output.
The ability of a safety valve to function properly can be
affected by internal corrosion or restricted flow. Internal

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 Safety / Boilers

corrosion typically is the most common cause of freezing
or binding in safety/relief valves. This is generally caused by
slight leakage or simmering caused by an improperly seated
valve disk, and is a condition that must be corrected im-
mediately. Its never recommended that a boiler be operated
too close to the safety valve setting because the set pressure
can cause the valves to leak slightly, resulting in an corrosion
buildup that eventually prevents the valve from operating.
Water level control and fuel cutoffs have separate func-
tions, but sometimes are combined in one unit. They provide
a water level control function and a safety feature of a low-
water fuel-cutoff device. Piping must be open and free of
scale or sludge buildup at all times. Properly installed piping
uses cross tees for easy cleaning and inspection. Check low-
water fuel cutoffs periodically for proper operation. Because
this test requires boiler water to go to the minimum safe
level, qualified personnel should use extreme caution.
In addition to periodic tests of the low-water device, flush
the float chamber on the water level control and the low-wa-
ter fuel cutoff thoroughly to remove accumulated sediment.
Disassemble, clean, and check both controls annually.
The water gauge glass on a boiler lets you verify the ac-
tual water level in the boiler. If not cleaned and maintained,
the sight glass might show theres sufficient water when the
boiler is actually operating in a low water condition. A stain
or coating sometimes develops on the inside of the glass
where its in contact with boiling water, and this can give
the appearance of adequate water levels, especially when the
glass is either completely full or empty of water.
If necessary, replace the glass even if the boiler must be
shut down to do so. The piping leading to the glass gauge
can become clogged and should be cleaned and inspected
regularly to avoid false water level readings.
Stack temperature gauges monitor the temperature of the
flue gas. A high temperature indicates that the tubes might
be developing a soot or scale buildup. Also, the interior baf-
fling might have deteriorated or burned through, allowing
hot gases to bypass heat transfer surfaces.
The fuel system, particularly the burner, requires periodic
cleaning and routine maintenance. Failure to maintain the
fuel system in good working order could result in excessive
fuel costs, loss of heat transfer, or even a boiler explosion.
Boiler log records are probably the single best method
to ensure a boiler is getting proper maintenance. The logs
provide a continuous record of operation, maintenance, and
testing. Because operating conditions change slowly over
time, a log is the best way to detect significant changes that
might otherwise go unnoticed. Boiler log success is deter-
mined by how vigilant you are in regularly updating it.
Efficiency and performance tips
A boiler accounts for much of a plants energy budget, and
even a small decrease in efficiency can cause a sharp increase
in energy costs. Key factors influence boiler efficiency:

General tips for optimal boiler safety and maintenance

Its important that you regularly observe and check on the status of a variety of boiler components.
Some basic and general tips include:
Test for proper functioning of controls, including the pressure gauge, low-water cutoff devices, thermometers,
temperature controls, gauge glass, and pressure relief valve.
Test drains and blowoffs to ensure theyre functional.
Check the fuel system for leaks and ensure that fuel filters and strainers are replaced regularly.
Ensure that shut-off valves are leak-tight. If unsure, perform a leak tightness test.
Ensure that the valves in instrument lines are functioning properly.
Open the boiler vent valve or top tri-cock to vent air and fill the boiler with treated water to its proper level.
Check that the expansion tank is properly filled.
Verify that vent valve on gas-fired boilers is operating as required and that the vent isnt clogged.
Verify that the flame scanner or sensors are properly connected and functioning.
Check instruments and safety devices for proper setting. Ensure that the water pressure regulator
functions as required.
Ensure the recirculation pump works as required.
Confirm that there are no signs of overheating, corrosion, or erosion.
Check that heating system isolation valves are functioning properly.
Verify that there are no leaks from any part of the boiler or external piping. Have a qualified contractor repair cracked
surfaces immediately. Bulges or other deformities indicate defective controls or safety devices, or improper
burner operation.
Test safety valves on a regular schedule. Replace leaking safety valves.
Inspect low-water fuel-cutoff control for proper sequence and operation. Verify that it shuts off the fuel supply
to the boiler as required.

www.PLANTSERVICES.com December 2009 27

PS0912_26_28_Boilers.indd 27 12/1/09 3:54 PM

 Safety / Boilers
more resources at www.plantservices.com
TOPIC SEARCH
Waste fuels Burning waste paper pellets
Steam audits Get a grip on the Steamer
For more, search www.PlantServices.com using the keywords boiler,
economizer, and fuel.
Optimal air-to-fuel ratio is impor-
tant because a boiler requires just the
right amount of oxygen to ensure ef-
ficient combustion. Excess air consumes
energy because its being heated un-
necessarily and released up the stack. If
theres too little air, not all the fuel burns
and this also wastes fuel. The unburned
fuel continues to move through the sys-
tem, and leaves behind soot. Additional-
ly, too little air might cause a build up of
carbon monoxide and smoke. Analyze
the flue gas to measure the amount of
Boiler log records are probably
the single best method to ensure a boiler
is getting proper maintenance.
oxygen and the stack gas temperature to
calculate efficiency. Make adjustments o
optimize the excess air and incoming air
temperatures.
To measure the ratio, use a comput-
er-based distributed control system
(DCS), which automatically reduces
oxygen levels as needed, optimizing
the air-to-fuel ratio.
Treat feedwater before pumping it
into a boiler. Raw water can cause corro-
sion or sediment buildup, both of which
reduce efficiency. Impurities waste
energy because they necessitate routine
blowdowns. The cleaner the water sup-
ply, the fewer blowdowns youll need.
Clean heat transfer surfaces to re-
move the soot buildup that acts like an
insulator, and diminishes the efficien-
cy of heat transfer between combus-
tion gas and steam generation.
Heat loss can waste a huge amount
of energy. To minimize it, install an
economizer to recover waste heat from
the stack. The heat can then preheat
28 December 2009 www.PLANTSERVICES.com
PS0912_26_28_Boilers.indd 28
the feedwater. Be sure to have the boil-
er cleaned and tuned before installing
an economizer to get an accurate mea-
surement of stack gas temperature.
Additional heat can be extracted from
the flue gas (below 300F) by use of a
condensing economizer.
A stack temperature gauge indicates
the temperature of the flue gas. The
lower the flue gas temperature, the more
efficient the system. Approximately 1%
of boiler thermal efficiency is lost for a
40F increase in stack temperature.
Collect condensate from steam traps
for reuse as feedwater. This reduces
boiler operating costs and usually is
more cost-effective than using fresh
utility water. It takes less fuel to convert
recovered condensate into steam than
the cooler fresh utility water. The tem-
perature of recovered condensate is high
(160F to 200F), whereas the fresh water
temperature usually doesnt exceed 80F.
Boiler inspectors can educate you
Ask your boiler inspector for more
information about how your boiler
works and tell them about any
problems youre experiencing. Their
extensive knowledge and practical ex-
perience can help you learn everyday
procedures to ensure a long lifespan
and safe vessel operation.
Stephen Kleva is CEO and president of
Insparisk, LLC in Glendale, N.Y. Contact
him at skleva@insparisk.com and (888)
464-6772.
12/1/09 3:54 PM

Shaft
Grounding By Adam Willwerth
Keep motors alive on
variable-frequency drives
Already common in HVAC, pumping, and industrial
automation systems, the use of variable-frequency drives
(VFDs) is growing. VFDs are smaller and more powerful,
more reliable, easier to program, and less expensive than
ever. But, VFD/motor systems must be designed for reliabil-
ity and trouble-free operation to keep the energy savings,
which can reach 20% or more, from being wiped out by a
system failure.
VFDs can induce electric currents on motor shafts that
ruin bearings, shorten motor life, and diminish system reli-
NOT VERY MUSICAL
Figure 1. Fluting is a problem that sparking inside a bearing can
promote.
PS0912_29_33_Motors.indd 29
RELIABILITY / MOTORS
ability. One way to mitigate the effects of these currents is
to ground the motor shaft to protect bearings and eliminate
expensive repairs.
ENERGY-SAVING POTENTIAL
The VFD converts line power to direct current and fi lters
it to smooth the waveform. A pulse-width-modulation
inverter turns the DC back to AC, but now in variable form.
The typical output frequency, also called the carrier or
switch frequency, is between 2 kHz and 12 kHz.
VFDs that drive motors directly in constant-torque ap-
plications avoid using any more power than necessary. With
encoder feedback, a VFD also can control motor speed.
Regardless of the application, engineers who select the
VFD should understand the entire system, including the
possible current paths. A pulse-width-modulated wave-
form has high-frequency components (harmonics) that are
coupled capacitively to the motor shaft and can discharge
through the bearings. Even inverter-duty motors are vulner-
able to bearing failure from VFD-induced currents.
These currents can cause pitting, fusion craters and flut-
ing (Figure 1). This electrical-discharge machining leads to
bearing noise, premature bearing failure and motor failure.
There is considerable evidence to prove that VFD-induced
bearing damage is a large and growing problem. Consider:
Most motor bearings are designed to last 100,000 hours,
yet motors controlled by VFDs can fail within one
month (720 hours).
WWW.PLANTSERVICES.COM DECEMBER 2009 29
12/2/09 4:34 PM
 Reliability / Motors

See the problem An HVAC contractor recently reported that every 30 hp
to 60 hp fan motor he installed in a large building proj-
ect failed within a year (two within six months). Repair
costs totaled more than $110,000.
Several large pulp and paper companies noted that
VFD-controlled AC motors typically fail within six
months because of bearing damage.
The largest motor manufacturer in the United States has
cited eliminating drive-related motor failures as its No. 1
engineering challenge.
A lmost a dozen Internet blogs focus on VFD-induced
shaft currents.
Other problems appear if the motor isnt designed for
use with a VFD, or if the motor or VFD are mismatched to
the load. For example, when maintaining constant torque,
a motor loses efficiency and runs hotter at lower speeds
Figure 2. An oscilloscope trace reveals the presence of pulsing
(but hotter still when controlled by a VFD). If the motor is
shaft currents.
operated at less than 30% of maximum speed, it might need
Race tracks extra cooling or thermal protection.
Similarly, a VFD-controlled motors torque might drop
more quickly at lower speeds than when using pure sine-
wave power. For constant-torque loads, a VFD should be
rated for 60 seconds at 150% of the load. A VFDs current
rating also limits the load-acceleration rate.
The cable connecting a VFD with a motor shouldnt
exceed 50 ft. total length to avoid standing waves that meet
at the motor terminals, in effect doubling the voltage to
the motor. If a longer cable is required, use additional line
filtering to protect the motor and other nearby sensitive
equipment from harmonic content and radio-frequency
interference (RFI). RFI also can be reduced by enclosing mo-
tor leads in a rigid conduit. Regardless of length, the cable
between a VFD and the motor it regulates can be enclosed in
a corrugated aluminum sheath or another kind of grounded,
Figure 3. Normal minimal wear from ball-race contact. low-impedance shielding.
VFDs might not be appropriate for pumps that maintain
Not the cake icing
high pressure. During periods of low flow, the motor might
not be able to slow down enough while maintaining pres-
sure. VFDs that shunt excess energy from the DC bus can be
used in systems that require dynamic braking.

Look at bearing damage

Figure 4. The phenomenon known as frosting is caused by
electrical discharge that forms small craters inside the bearing.
Short of dismantling the motor, there are two ways to check for
bearing damage from induced shaft currents: measuring either
voltage or vibration to look for energy spikes in the range of 2
kHz to 4 kHz. Both methods require special equipment and
experienced personnel to conduct tests and analyze the results.
Both are best used early on to establish a baseline and to moni-
tor trends later. Neither method is foolproof.
By the time a vibration test confirms bearing damage, it usu-
ally has reached the fluting stage. Likewise, the main benefit
of a voltage test might be the relief it provides when the results
indicate no bearing damage. If a baseline voltage measurement

30 December 2009 www.PLANTSERVICES.com

PS0912_29_33_Motors.indd 30 12/2/09 4:35 PM


more resources at www.plantservices.com
Topic Search
Shaft currents Bearings and electricity dont mix
Solid lube coatings Bearings roll with solid lube coatings
Nanotech lubricant Harnessing nanotechnology
Graphite-metal bearings Five bearing killers
For more, search www.PlantServices.com using the keywords bearing,
grounding, and VFD.
is taken when a VFD is installed, succes-
sive tests might provide early warning
of harmful current loops. But, there are
many variables predicting bearing
damage is not an exact science.
Induced shaft currents, which are
sometimes called common-mode volt-
age, can be measured by touching an
oscilloscope probe to the shaft while
the motor is running (Figure 2).
Rotor voltages build to a threshold
before discharging in short bursts
along the path of least resistance to the
frame (ground), which all too often
runs through the bearings. Serious
bearing damage is thought to be more
likely in systems that have a high car-
rier frequency, a constant speed or
inadequate grounding. A high carrier
frequency means a high discharge rate.
For this reason, use a VFD that permits
fine tuning of the carrier frequency in
increments of no more than 1 kHz. In
general, its advisable to keep the VFD
output frequency below 6 kHz.
Theres some debate about whether
constant-speed operation makes
VFD-controlled motors more vulner-
able to electrical bearing damage. Ob-
viously, the question is moot because
VFDs are seldom used in constant-
speed applications. Theres no doubt
that inadequate grounding increases
the possibility of bearing damage.
Viewed under a scanning electron
microscope, a new bearing race wall
is a relatively smooth surface. As the
motor runs, ball bearings form tracks
in the wall. With no electrical dis-
charge, the wall is marked only by this
mechanical wear (Figure 3). Without
proper grounding, electrical discharg-
PS0912_29_33_Motors.indd 31
Reliability / Motors
the most common cause of bearing fail-
ure in VFD-controlled AC motors.
In the phenomenon called fluting,
the VFDs frequency causes concen-
trated pitting at regular intervals
along the bearing race wall, forming
washboard-like ridges. Fluting can
cause excessive noise and vibration. In
an HVAC system, the noise might be
magnified and transmitted through-
out the building via ductwork.
es can quickly scar the race wall.
During every VFD cycle, these Mitigating damage
discharges leave small fusion craters in Electrical damage to motor bearings of-
ball bearings and the bearing race wall. ten begins at startup and grows progres-
Before long, the bearing race becomes sively worse. The induced current must
riddled with pits known as frosting be diverted from the bearings by means
(Figure 4). The damage leads to noisy of insulation, shielding, or an alternate
bearings, but by the time the noise is path to ground. These technologies vary
noticeable, bearing failure often is immi- in terms of cost and effectiveness.
nent. Because many motors have sealed Insulating the motor bearings often
bearings, electrical damage has become shifts the problem elsewhere. Blocked
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Boston | Evansville | New Orleans | Seattle
www.AzimaDLI.com | sales@AzimaDLI.com | (+1) 781.938.0707
www.PLANTSERVICES.com December 2009 31
12/2/09 4:36 PM
 RELIABILITY / MOTORS

by insulation, shaft current seeks the
next easiest path to ground. Attached
equipment, such as a pump, often
provides this path and takes on bear-
ing damage of its own. Insulation is
subject to contamination, and
PltSvcs1109half-alm-ol-cs4.pdf 1 10/7/2009 3:15:08 PM
C
be self-defeating: In certain circum-
stances, the insulating layer exhibits
a capacitive effect on high-frequency,
VFD-induced currents, allowing them
to pass right through to the bearings it
might was supposed to protect.
A Faraday shield grounded conduc-
tive material such as copper foil or paint
between the stator and rotor can be
installed. If built to the proper speci-
fications for the motor, this can block
most of the harmful currents that jump
across the motors air gap. However,
this measure often is difficult to imple-
ment, and attached equipment could
still be vulnerable to deflected currents.
Nonconductive ceramic ball bearings
divert currents from the motors main
bearings, but might leave attached
equipment open to damage of its own.
Ceramic bearings can be costly and
might have to be resized to handle static
and dynamic mechanical loads.
Another approach uses conductive
grease, which, in theory, bleeds off harm-
ful currents by providing a lower-imped-
ance path through the bearings. In prac-
tice, however, the conductive particles in
the grease can increase mechanical wear.
Metal grounding brushes that contact
the motor shaft to provide alternate paths

M
IN GENERAL,
Y
ITS ADVISABLE TO KEEP
CM THE VFD OUTPUT
MY FREQUENCY BELOW 6 KHZ.
CY

CMY
to ground certainly help. Unfortunately,
they also wear and corrode, thus requir-
ing regular maintenance.
K

Alternate discharge paths to ground,

when properly implemented, are prefer-
able to insulation because they neutral-
ize shaft current. Techniques range in
cost and sometimes can only be applied
selectively, depending on motor size
or application. A viable solution would
provide an effective, low-cost, very-low-
resistance path from shaft to frame, and
could be applied broadly across all VFD/
AC motor applications. A grounding
ring with conductive microfibers meets
these criteria. It uses the principles of
ionization to boost the electron-transfer
rate and promote extremely efficient
discharge of the high-frequency shaft
currents that VFDs induce (Figure 5).
The technology is scalable to any

32 DECEMBER 2009 WWW.PLANTSERVICES.COM

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 RELIABILITY / MOTORS

SEE THE DIFFERENCE

lation on larger shafts without the need
to disassemble equipment. A mounting
adaptor facilitates installation on motors
with shaft shoulders, slingers, bearing
caps, or end-bell protrusions.

MAINTENANCE ISSUES
Once installed, the rings require no
maintenance. Unlike conventional
shaft-grounding brushes, the nearly
frictionless conductive microfibers cause
no wear; are unaffected by dirt, grease,
Figure 5. Without some form of mitigation, VFD-induced shaft currents (shown on left
or other contaminants; and last for the
oscilloscope screen) can cause damage. The screen on the right demonstrates how
effectively a microfiber ring reduces these currents by channeling them safely to ground. life of the motor regardless of speed. Test
results show surface wear of less than
NEMA or IEC motor regardless of where motors have ceramic bearings, at 1 mil per 10,000 hours of continuous
shaft size, horsepower, or application. least one ring should be used to ensure operation and no fiber breakage after 25
The rings have been applied to power that shaft voltage doesnt pass to other million direction reversals.
generators, gas turbines, AC traction equipment.
and brake motors, cleanrooms, HVAC The rings are available in two ver- Adam Willwerth is development
systems, and a long list of other indus- sions: a full-circle design for most manager for Electro Static Technology,
trial and commercial applications. NEMA- and IEC-frame motors and a Mechanic Falls, Maine. Contact him at
For VFD-equipped motors of less split-ring design that allows field instal- sales@est-aegis.com and (207) 998-5140.
than 100 hp (75 kW) and shaft diam-
eters below 2 in. (50 mm), a single ring
on the drive end of the motor shaft, the
www.rigalite.com
preferred location, is typically sufficient
garybarber@azz.com
to divert harmful shaft currents. RIG-A-LITE 713-943-0340
Large AC motors (100 hp/75 kW, or
more) and even large DC motors, espe-
cially those with shaft diameters greater Solutions in Industrial Lighting since 1938
than 2 in. (50 mm), are more likely to
have high-frequency circulating currents
(as well as EDM-type discharges) that
can damage bearings. Motors with roller
bearings also are vulnerable to damag-
ing currents because roller bearings
have a greater surface area and a thinner
lubricant layer. Such applications benefit
from the combination of a microfiber
ring on the drive end and insulation on
the other end. This also might be the
solution in situations where installing XP Series
a ring on the non-drive end would be
impractical because of encoders, fans, or
other special circumstances. This also
is a common solution for motors above
500 hp (375 kW), and most manufactur-
ers already use this approach. However,
when insulation on the drive end isnt
designed into the motor or cant be
installed easily, two microfiber rings SSFN Series
might suffice. In critical applications SAF Series
XPEX Series

WWW.PLANTSERVICES.COM DECEMBER 2009 33

PS0912_29_33_Motors.indd 33 12/2/09 4:38 PM

 in the trenches
Digital Disarray
Acme learns something about the finer points of e-mail expertise
Through no fault of his own,
Terry Hote found himself out of work
at the tender age of 48 years. The
owner of the plant where he worked
outsourced every single function and
shuttered the entire factory, tossing
90 people out on the street. Neverthe-
less, Terry had built a solid history of
success in manufacturing operations
management during the 20 years he
worked there.
His impromptu search for a source
of regular income morphed into a
full-time detective job that lasted for
more than 16 months. Terry became
quite adept at ferreting out any job
ad that bore some rational relation-
ship to the skills he had to offer. In the job hunt, Terry built
a growing library of customized cover letters and resumes
that could be fitted to every possible job. Terry became a job-
hunting machine.
He had a good feeling when he saw the ad saying Acme was
seeking an operations manager for its plant that manufactured
high-end plumbing fixtures. It was good that the plant was only
one town away from where he lived. This fortunate confluence
prompted a diligent online research effort that armed him
with the company history, the names and titles of the power
structure at the plant, financial reports, and some details about
Acmes plant operations. Terry gathered everything he could
find on manufacturing ceramic fixtures. He was ready.
He crafted a very special resume version and a hard-
hitting, one-page cover letter and, following the instructions
precisely, submitted them via e-mail to Acmes HR manager,
Perry Winckkel, well before the published deadline.
Thus began the waiting game. Terry knew that it was only
the rare, courteous employer that acknowledges receipt of
a job hunters resume. Still, Terry had a good feeling about
this one. It was too perfect to be true.
About 10 days later, he received an e-mail that bore
Acmes domain name. Eagerly, Terry clicked it open and
was surprised to discover it came from Jack Cousey, Acmes
CEO. The e-mail header showed that it was addressed to
three other Acme employees (Terry recognized the names
from his research). What was most confusing was Couseys
34 December 2009 www.PLANTSERVICES.com
PS0912_34_35_Trenches.indd 34
annotation that read, Damn. Check
this out. Im not sure what to think
about this one. Hes probably an old
guy wanting something to do.
This is all some kind of mistake,
Terry thought. So, he waited patiently,
but received no more communication
from anyone at Acme concerning his
job application. After two weeks, he
concluded that Acme rejected him
simply because of his age. What else
could it be? His credentials were good.
His skill set matched what Acme was
seeking. The pay range he requested
was somewhat below market value.
So, like many of the protagonists in
this monthly series, Terry filed an age
discrimination claim with the states employment discrimi-
nation agency and another with the Equal Employment Op-
portunity Commission, which sent him a letter saying that
he had a right to sue Acme.
How could this situation have been avoided? Is e-mail the
best vehicle for submitting a job application? Is it the best for
responding to a job applicant? What should be done to ensure
that e-mails go where theyre intended to go? Is it the best use
of a CEOs time to get involved in hiring decisions? Should
employers show enough courtesy to acknowledge resumes,
solicited or not?
A plant engineer says:
This situation could have been avoided if Jack had taken the
time to check his e-mail before he sent it. I believe people
can become too relaxed and casual in business communica-
tions. Jack might receive a costly education in business com-
munications if Terry elects to follow through with a law suit.
I believe e-mail is an acceptable vehicle for submitting
a job application but not necessarily the best vehicle. The
response to a job applicant should use the same medium
by which the application was submitted. In any case, the
response should be reviewed carefully by the Human Re-
sources Department before its sent to the applicant.
The only way to ensure an e-mail goes where its intended
to go is to carefully view the address line before sending it
on its way. Even then theres no guarantee that the person
12/1/09 3:56 PM
 who receives it wont send it to an improper address. We live
in a world where little value is placed on checking or double
checking our work, especially when it concerns communica-
tions by electronic devices. Texting and instant messaging
communications have conditioned us to quick responses
without much thought. In business, we must train ourselves
to refrain from operating this way.
If this is the best use of a CEOs time, its the CEOs call. If
he wants to see the applicants for a position, that is his deci-
sion to make. But, I believe a company should only acknowl-
edge solicited applications.
Jeffrey L. Strasser, Bacova Guild
(540) 863-2656, Strasser.Jeff@bacova.com
An academician says:
Yes, e-mail is the way to go in todays recruitment market.
It seems that every company is doing it. And dont expect a
reply to the letter or resume that you send, particularly if the
job was posted on the Web. Company recruiters tell me that
they might receive as many as 5,000 to 10,000 responses to
a job posted on Monster.com or some such site. Most of the
people responding dont have the qualifications, but try to
put something in their resume that appears to relate to the
job. So, recruiters are inundated with applicants (usually
unqualified) and sorting them out is a major problem.
A suggested, and effective, process is to post the job and
then have one of the HR people do the first sort, pulling
out three to five applicants that seem to have the qualifica-
tions. For those not on the final list, you might send them a
pleasant rejection e-mail letter. However again, this depends
on whether you have the capability to handle the number
of applicants. Then, call the short-listed candidates to get a
better feel for who they are, where theyve worked, get some
references, what salary theyre expecting, etc. That often
narrows the list. Also, check to make sure the information
on the resume is accurate a lot of resumes contain false
information. This is usually the time that some other people
would get involved, particularly the people to whom the ap-
plicants would report.
At this point the process has a couple of alternatives, how-
ever, each certainly should involve a face-to-face interview
with the candidates and the key people (maybe the CEO)
with whom they would be working. For the finalists, the ac-
ceptance and rejection should be done by phone.
Following this process should eliminate much of Acmes
recruitment problems and give it a good set of finalists.
It would also keep applicants e-mail addresses out of the
hands of the CEO.
Professor Homer H. Johnson, Ph.D., Loyola University Chicago
(312) 915-6682, hjohnso@luc.edu
PS0912_34_35_Trenches.indd 35
An attorney says:
Isnt this everyones worst nightmare the misaddressed
e-mail? With the wonders of modern technology, a slip of
the finger or in imprecise glance of an eye can land one in a
cyberspace nightmare. Behold Acme.
There are three ways in which this catastrophe could have
been avoided. First and foremost, Acme should make its hir-
ing decisions not on the basis of age but on the basis of valid
job-related and non-discriminatory factors, such as educa-
tion, experience, and skills.
Second, employers should be extremely careful about
what they put in writing, whether that writing is an
e-mail, letter, note in the file, or diary entry. Anything
in writing remains for all time to become evidence that
Texting and instant messaging
communications have conditioned
us to quick responses without
much thought.
might either help or hurt a company. In addition, employ-
ers should be very cautious in deciding which aspects of
a situation to put in writing. For example, Terry might
have been totally unqualified for the operations manager
position at Acme. But rather than reflecting that fact in
an e-mail, the CEO chose to be flip and to refer to the fact
that he was probably old. This might not have been the
sole reason that Terry wasnt considered- or even one of
the reasons. All the CEO had to do to improve the situ-
ation was to refer to some legitimate factor. Even a com-
ment like, Get a load of this guy. Hes been out of work
for more than 16 months hes so desperate, he thinks
he can do the plant managers job! Not a very flattering
comment, but a perfectly legal one.
While employers have become savvy enough to know that
they need to document an employees problems that lead to
termination, many dont think about the opposite end of the
employment relationship. Every hiring decision an em-
ployer makes is open to attack by a rejected applicant, whose
numbers are legion in this downtrodden economy. Hiring
decisions should be documented as carefully as termination
decisions, at least with respect to the companys reasons for
not hiring an applicant.
Finally, employers need to avoid the slip of the keyboard
phenomenon. Haste, as the age-old maxim promises, does
indeed make waste.
Julie Badel, partner, Epstein Becker & Green, P.C.
(312) 499-1418, jbadel@ebglaw.com
www.PLANTSERVICES.com December 2009 35
12/1/09 3:56 PM
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Putman media, inc.
Company PAGE 555 W. Pierce Rd., Ste. 301,
Itasca, IL 60143
ARC Advisory Group/Automation Research Corp. . . . . . . . . . . . . . . . . . . . 32 Phone: (630) 467-1300,
Fax: (630) 467-1120
Arkema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Azima DLI Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,31 PLANT SERVICES (ISSN 0199-8013) is published monthly
by Putman Media, Inc., 555 West Pierce Road, Suite 301,
Azz-Ral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Itasca, IL 60143. Phone (630) 467-1300, Fax (847) 291-
4816. Periodicals1/13/09 9:40atAM
Postage paid Itasca, IL and additional
mailing offices. Canada Post International Publications
Baldor Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Mail Product Sales Agreement No. 40028661. Canadian
Mail Distributor Information: Frontier/BWI,PO Box 1051,
Fort Erie, Ontario, Canada, L2A 5N8. Printed in U.S.A.
Carrier Rental Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 POSTMASTER: Send address changes to PLANT SERVICES,
Putman Media, Inc., PO Box 3435, Northbrook, IL 60065-
Fluke Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3435. SUBSCRIPTIONS: Qualified reader subscriptions are
accepted from PLANT SERVICES managers, supervisors
and engineers in manufacturing plants in the U.S. and
GE Consumer and Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Canada. To apply for qualified-reader subscriptions, please
go to www.plantservices.com. To non-qualified subscribers
GE Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 in the U.S., subscriptions are $96 per year. Single copies
are $15, except the September and December issues which
are $36. Canadian and foreign annual subscriptions are
Hawk IR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 accepted at $145 (Foreign airmail $200/yr). Single copies
are $81. 2009 by Putman Media, Inc. All rights reserved.
The contents of this publication August not be reproduced
IFS North America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 in whole or in part without consent of the copyright owner.
In an effort to more closely align with our business partners
Lubriplate Lubricants Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 in a manner that provides the most value to our readers,
content published in PLANT SERVICES magazine appears
on the public domain of PLANT SERVICES Website,
MacroAir Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,25 and August also appear on Websites that apply to our
growing marketplace. Putman Media, Inc. also publishes
Robinson Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CHEMICAL PROCESSING, CONTROL, CONTROL DESIGN,
FOOD PROCESSING, INDUSTRIAL NETWORKING, THE
JOURNAL, PHARMACEUTICAL MANUFACTURING and
Turbomachinery Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 WELLNESS FOODS. PLANT SERVICES assumes no
responsibility for validity of claims in items published.

36 December 2009 www.PLANTSERVICES.com

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 energy expert
peter garforth
Define Efficiency
How you measure can significantly affect your success
When compared with the other two large energy users,
transportation and buildings, industry has done by far the best
job in managing energy. It has managed to globalize good en-
ergy practices better than any other sector, and on an indexed
basis theres less than a 20% spread in energy use between the
North American and the European averages. This spread wid-
ens to 40% or higher for transportation and as much as 150%
higher in homes and buildings. Theres a certain irony that the
sector that has clearly done the best job in energy efficiency has
such a struggle to define what it means.
The CFO also tends to want
to see the real numbers,
also known as cash.
This was brought home to me recently in discussions with
a major manufacturer with excellent energy management
teams and processes. As part of its ongoing improvement
process, the question of how energy productivity should
be measured and reported was reexamined. That should be
easy enough to define, right? Wrong!
One of the most common criticisms of energy management
professionals is that they overcomplicate the topic and make
it hard for non-experts to get engaged. Its the engagement of
the financial and business leadership that often makes the dif-
ference between a great program and the rest. To address the
question of what should be a basic tracking index, we looked at
a single plant with a pretty straightforward continuous material
conversion process for a three-year period.
During that period, the total energy use, measured in
MWh equivalent, had dropped by 3%. On the surface, not a
bad result, but hardly the stuff of headlines. But total energy
usage doesnt mean very much if the volume of production
isnt considered. Factoring it in, the plant energy use in kWh
equivalent per unit of production had dropped by 1%, rais-
ing a reasonable challenge over the degree of improvement.
Efforts to explain that the somewhat reduced volume tends
to have this effect might fall on deaf ears.
The CFO tends to want to see the real numbers, also known
as cash. In this case, the total energy costs rose by 10% at the
same time the usage went down 3%. This tends to overwhelm
the mildly positive usage story. Even worse, when expressed per
38 December 2009 www.PLANTSERVICES.com
PS0912_38_Energy.indd 38
unit of production, energy costs rose 13%. From my experi-
ence, similar percentage increases in materials, healthcare, or
labor costs would have people scrambling. For some reason this
rarely happens with energy. When examined in terms of the
market value of the product, the energy costs per million dol-
lars of sales also rose, but by a much more modest 6%.
So, even in this very modest and simple example, we can
variously define energy productivity over this snapshot of
36 months in a range of a 3% improvement to a 13% decline.
The energy professionals among us understand the reasons
and the interplays, but all too often lack the measurements
and expertise to communicate them in ways that elicit ra-
tional long-term decisions, supported by clear priorities and
decision-making criteria. Until this happens, the numbers
that should be tracked and managed might be somewhat of a
lottery and differ from site to site.
In the coming months and years, life for the energy man-
ager will get even more challenging as managing greenhouse
gas becomes the next measurement challenge.
Back in our plant, unlike the total energy use, which
decreased by 3%, the associated greenhouse gas emissions
increased by 2%. This highlights the error of the commonly
held view that energy efficiency and greenhouse reductions
are in lockstep. The emissions index in kilograms of CO2
equivalent for each unit of production rose by a similar 2%,
whereas the emission index in tons of CO2 equivalent per
million dollars of sales fell by 4%. So, depending on how its
presented, the greenhouse gas performance ranged from a
4% reduction to a 2% increase. This is before we start factor-
ing in the financial losses and gains from emissions trading.
Even after decades looking at this question, I dont have
a simple answer. Regardless of which efficiency index you
choose, a case can be made why its not a good measure. At
the same time, if you try to communicate the holistic com-
plexity of energy productivity, and increasingly, greenhouse
gas emissions, the very audience that needs to be at the table
becomes disengaged. Then we default to management by cri-
sis not the best way to build long-term energy productivity.
This is definitely an area where I would appreciate your
view on the apparently simple question: What is industrial
energy efficiency and how do we measure it?
Peter Garforth is principal of Garforth International LLC, Toledo,
Ohio. He can be reached at garforthp@cs.com.
12/2/09 4:41 PM
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