PLS20120301

Wrench
Time
by
Design
Plant upgrades are opportunities to
bring engineering and maintenance
departments together
WWW.PLANTSERVICES.COM
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Sustainability at Volkswagen / p.11
Take Your Lube Practices to a Higher Level / p.21
Does Your CMMS Suffer From TMI? / p.37
U.S. Army Battles Waste and Emissions / p.50
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Covered by one or more of the following U.S. Patents: 6,244,821; 6,589,016; 6,817,835; 6,939,108; 7,252,478; 7,284,960; D587,799; D607,988; 7,654,798 and other patents pending.
2011 Delta T Corporation dba the Big Ass Fan Company. All rights reserved.
WWW.BIGASSFANS.COM | (877) BIG FANS
The Problem: Gas bills were going through the roof at Federated Co-ops 300,000 sq ft
distribution center in Saskatoon, Canada.
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are on the floor reducing gas bills by $19,800 in one winter alone.
Want to know your payback number? Call now to
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Trevor Carlson
Environmental and Technical Services Manager
Federated Co-operative Ltd.
The patent-pending SmartSense365 fan
controller is an automated system with three
user modes: winter, summer and manual. Its
engineered to modulate fan speed according
to ceiling- and oor-level temperature readings,
maximizing year-round energy savings and
comfort with just the push of a button.
FROM WINTER OPERATION!
PS1203_FPA.indd 3 2/29/12 11:15 AM
Eric Rieger, President of WEBIT Services, had a major server
room emergency after three off-the-shelf A/C units quit. Now
he has a MovinCool Offce Pro 12. And greater peace of mind.
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For computer servers to operate properly, they've got to be kept
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retail A/C units from a local big box store. Rieger, President of
WEBT Services, a managed technology services provider in the
Chicago area, thought he had found an ideal solution. But all
three subsequently failed. The last one on Christmas Day. After
quickly contacting his local distributor, Rieger chose a MovinCool
Offce Pro 12. ts performance and reliability are impressive, he
reports. And the peace of mind it delivers is priceless.
The self-contained MovinCool Offce Pro 12 pumps out 12,000
Btu/hr, works on standard 115v power and requires no costly
installation. Just roll it in. Plug it in. Turn it on. And its programmable
digital controller easily integrates into offce automation systems.
even recommend MovinCool to clients, concludes Rieger.
From mission critical cooling applications to computers and
manufacturing processes and people, MovinCool is the solution.
2012 DENSO Sales California, nc. MovinCool, SpotCool and Offce Pro are registered trademarks of DENSO Corporation. QR Code is a registered trademark of DENSO Wave.
ts performance and
reliability are impressive,
and the peace of mind it
delivers is priceless.
To read more about Erics application
story, visit: MovinCool.com/Webit
Scan to see the top 50 reasons
why MovinCool products are the
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MovinCool.com/50Reasons
PS1203_FPA.indd 4 2/29/12 11:15 AM
WWW.PLANTSERVICES.COM MARCH 2012 5
22 / COVER STORY
Wrench Time by Design
Plant upgrades are
opportunities to bring
engineering and maintenance
30 / COMPRESSED AIR SYSTEMS
Central or Departmental
Air System?
Size and congure air piping
for the right t
37 / ASSET MANAGEMENT
SOFTWARE
Too Much Information
Part II
Work breakdown structure in
CMMS can streamline project
cost tracking
41 / MOTORS AND DRIVES
More Torque, Less Money
Fewer components give worm-
gear reducers a single-stage
advantage
44 / PRODUCT ROUNDUP
Thermal Technologies
Resources support HVAC and
combustion processes
FEATURES
SPECIALISTS
COLUMNS AND DEPARTMENTS
9 / MR. SUSTAINABILITY
Stale Fixed Costs
Can Spoil Prots
How long ago were energy
costs baked into your
overhead?
15 / HUMAN CAPITAL
Step Up to The Plate
Rethink reliability in terms
of your equipments on-base
percentage
17 / ASSET MANAGER
Conguration Without
Customization
Modify software with no
expense or risk
21 / TECHNOLOGY TOOLBOX
Well-Oiled Testing
and Training
Formulations are just part of
lubrication improvements
50 / ENERGY EXPERT
Wage War on
Energy Impact
The U.S. Army recognizes the
value of net-zero waste, water,
and emissions
7 / FROM THE EDITOR
Call Me Rockheaded
Should I be worried that the
Cloud can read my mind?
11 / WHAT WORKS
00
2
cleaning system
reduces environmental
impact and reject rates
48 / CLASSIFIEDS / AD INDEX
TABLE OF CONTENTS
MAR0H 20T2 / \0L. 32, N0. 3
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Economy in Conict: Sustainability Vs. Consumerism
Is the economy suffering from the effects of a contradiction?
http://community.plantservices.com/content/economy-conict-
sustainability-vs-consumerism
Supplies at Work: Automating a Lead and Zinc Processing
Plant and More
In Lhs nsLamenL. Emerson Lo auLomaLe ead and znc panL,
Honeywell to deliver control and safety system for Australia
Pacfc LN0 Pro|ecL, and ABB awarded mne hosL order.
http://community.plantservices.com/content/supplies-work-auto-
mating-lead-and-zinc-processing-plant-and-more
You Know Dust Collectors, but Do You Know TCO?
These three steps will help you calculate total cost of ownership.
http://www.plantservices.com/wp_downloads/Camll-Farr-dust-
collector-lter.html
Plant Maintenance and Reliability Strategies Webinar
Join Plant Services editors and industry experts as we engage
in lively discussions about hot topics challenging todays
manufacturing plant.
http://webcast.streamlogics.com/audience/index.
asp?eventid=53496950
PS1203_XX_TOC.indd 5 2/29/12 11:19 AM
Put alidonenergy waste
Copyright 2011 Atlas Copco Compressors LLC. All rights reserved.
Hi, I'm Bob, Senior Marketing Support Specialist at Atlas Copco Compressors. For the last 38 years,
I've been part of the team taking care of our valued customers in the United States. Today, let me tell
you how Variable Speed Drive technology represents a great value proposition for your production.
All across the globe, customers are compressing air that just goes to waste. Energy can represent
over 80% of a compressors lifecycle cost and generating compressed air can account for more than
40% of a plants total electricity bill. Most production environments have a fluctuating air demand
depending on the time of day, week or even month. So put a lid on those energy costs with Atlas
Copcos VSD technology that mirrors air usage, automatically adjusting the motor speed depending
on the demand, making major energy costs savings a reality while helping to protect the environment
for future generations.
Our mission is to continue to bring sustainable productivity through safer, cleaner, more energy-
efficient, and cost-effective compressed air technology. Simply log onto www.atlascopco.us/bobusa
or call 866-688-9611 to learn more about us, our products, and how we have earned and will continue
to earn our reputation.
PS1203_FPA.indd 6 2/29/12 11:23 AM
FROM THE EDITOR
MIKE BACIDORE, EDITOR IN CHIEF
CALL ME ROCKHEADED
Should I be worried that the Cloud can read my mind?
As we leave February in the rearview
mirror and speed headlong into March,
lets check the GPS, or, better yet, ask Siri
where were headed. Siri is an application
that works on Apples iOS. But it is so
much more than just another app.
Siri is the automated intelligent per-
sonal assistant whose help is there for
the asking. It understands your natural
speech and will even ask you for more
information, if necessary. Youve seen
and heard the ads on TV From now
on, Ill call you Rock God, OK?
When you receive information from
Siri, you also share information with Siri,
just like you would a real personal assis-
tant. Siri knows all. And, because Siri ex-
ists in the Cloud, it grows smarter by the
second, pooling and analyzing data from
all users and giving it an almost Borg-
like collective intelligence. Resistance is
futile. You will be assimilated.
Te information superhighway is
paved with technology and driven by
data, but ideas on where were going are
far from road-tested. My favorite place
to kick the tires on informed specula-
tion and bankable prediction is at the
ARC World Industry Forum. Almost
700 individuals from 21 countries at-
tended. Andy Chatha, president and
CEO of ARC Advisory Group (www.
arcweb.com), began the conference with
his annual assessment of whats impor-
tant. Tis year, he identifed the top four
transformational technologies social
media, analytics, the mobile Internet,
and cloud architecture.
Tese are no longer consumer
technologies, he explained. Tey have
matured to the point where you can use
them across the enterprise.
Social media means being always con-
nected with faster response and immedi-
ate access to experts. Analytics are now
much easier to use. Tey can now run in
seconds, instead of days. And the strug-
gle or challenge with the mobile Internet
is in managing all of the devices. Tere
are now more mobile devices than there
are people on this planet, said Chatha.
His cloud architecture is a bit less
ambitious than that of the Borg, but for
good reason. Industrial manufacturers
are interested in production ef cien-
cies. Te architecture would include, for
example, an E&D applications platform
and an operations applications platform
within an enterprise applications plat-
form, explained Chatha.
John Berra, former chairman of
Emerson Process Management (www.
emersonprocess.com), shared a real-
world application of the concept, when
he explained how one company reduced
its total maintenance costs by 30% from
using the predictive intelligence it had
collected from 27 plants in its own pri-
vate cloud.
Road-tested? Yes. Driven by data? Ab-
solutely. Transformational? You betcha.
Te path to manufacturing proftabil-
ity is a winding road that is best seen and
understood from the birds-eye view. Te
more information were able to analyze,
the smarter our maintenance strategies
become. Surrender your data.
Resistance is futile.
THERE ARE NOW MORE
MOBILE DEVICES THAN
PEOPLE ON THIS PLANET.
PUTMAN MEDIA, INC.
555 W. Pierce Rd., Suite 301,
Itasca, IL 60143
(630) 467-1300 Fax: (630) 467-1120
MIKE BRENNER
Group Publisher
mbrenner@putman.net
EDITORIAL STAFF
MIKE BACIDORE
Editor in Chief
mbacidore@putman.net
RUSSELL L. KRATOWICZ, P.E., CMRP
Executive Editor
russk@putman.net
ALEXIS GAJEWSKI
Associate Editor, Digital Media
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V.P., Creative Services
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ANGELA LABATE
Associate Art Director
alabate@putman.net
DAVID BERGER, P.ENG.
Contributing Editor
PETER GARFORTH
Contributing Editor
SHEILA KENNEDY
Contributing Editor
TOM MORIARTY, P.E., CMRP
Contributing Editor
PUBLICATION SERVICES
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Assistant to the Publisher
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Production Manager
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JILL KALETHA
Reprints Marketing Manager
Foster Reprints
(866) 879-9144 ext.168
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EXECUTIVE STAFF
JOHN M. CAPPELLETTI
President/CEO
JULIE CAPPELLETTI-LANGE
Vice President
KEITH LARSON
V.P., Content
ROSE SOUTHARD
V.P., Technology
Mike Bacidore, Editor in Chief
mbacidore@putman.net, (630) 467-1300 x444
PS1203_XX_EV.indd 7 2/29/12 11:25 AM
PS1203_FPA.indd 8 2/29/12 11:27 AM
STALE FIXED COSTS CAN SPOIL PROFITS
How long ago were energy costs baked into your overhead?
I had lunch again the other day with a childhood friend,
a tool and diemaker whos worked his way up and is now
quoting jobs for his multinational metalworking company.
He said the poor economy has driven smaller, specialized
mom-and-pop shops out of business, and hes bidding on
quite a few exotic new jobs. Hes seeing more requests for
quotes on familiar kinds of work as demand is picking up.
With plants here and in Mexico and China, he has options
for how and where to plan the work. Along with stellar qual-
ity and service, he expects to have the lowest cost, but hes
surprised by reality. Some competitors are beating us on
price, he told me. I dont know how they can do it.
We talked about how and why some companies might
take a job at a loss. And we acknowledged that any company
can have a costing structure that misleads them about the
margin on a specifc part, causing them to think theyre
making money on it when theyre not. Ten, I asked him
how well his company is paying attention to overhead items
such as insurance and energy. He knew theyd done some
work on the air compressors, but overhead isnt really in his
area of responsibility.
His facility might have a better handle on its fxed costs,
but its still not uncommon for even successful perhaps
especially the most successful facilities to be complacent
about overhead. If those successful companies have been
in business a long time, theyre likely to have energy costs
baked into that overhead, where theyre easy to ignore.
Some plants ignore energy costs until its too late. As Bill
Holmes, owner of Holmes Energy (www.holmesenergy.com)
observed, its a bad idea to wait until your plant is on the
chopping block before you go afer energy opportunities.
For example, participating in demand response gives
electric power users an opportunity to save cash with little
or no investment. But only about 20% of the market for load
shedding signed up.
Time-of-use rates are cited as an advantage of smart grid,
so I asked Gregg Dixon, senior vice president, EnerNOC
(www.enernoc.com), if broader acceptance of automated load
shedding is waiting for a consensus on smart grid standards.
Not at all, Dixon told me. Today, we can put in a site
server an industrial PC with UPS and a wireless broad-
band modem and connect it to the building management
system or plant SCADA with a dry contact or Ethernet, said
Dixon. Te site server is connected to our energy network
operations center (EnerNOC), and the sofware automati-
cally curtails the load, for example, by raising the HVAC set-
point, turning of lights, or shutting of non-critical loads.
Te operations center monitors the curtailment to see that
it performs according to the commitment and then bills the
power company. Its not rocket science, said Dixon.
Tat sounds OK for a college campus or a shopping mall,
but what about industrial facilities, I asked, where the main
loads are critical for production? EnerNOC has a number of
clients, including a steel mill that can turn of arc furnaces.
If you schedule it properly, its just like scheduling produc-
tion, with two-hour notifcation or whatever is needed to not
compromise safety or productivity, said Dixon.
EnerNOC employs process experts, including refnery and
chemical engineers, wastewater, and refrigeration techni-
cians. We know their operational sensitivities, said Dixon.
We know what to look for. We sit down with plant person-
nel and talk about the options, and we almost always fnd
loads that can be curtailed.
Along the way, they ofen fnd energy efciency and peak
load trimming opportunities plants can exploit 24/7, not just
during a demand response event. We call demand response
the skeleton key to energy efciency, said Dixon.
EnerNOCs consulting and system installation are done
at no charge to the industrial facility.
Dixon said that, so far, demand response penetration is
only about 20% of the opportunity. We estimate theres
about 80,000 MW available, and about 16,000 MW has been
done, he said.
Say 20% of companies are spending less for electricity.
Tat means, all else being equal, one plant in fve can quote
a lower price and still get their margin on a new job.
Email Paul Studebaker, editor in chief of Sustainable Plant
(www.sustainable plant.com), at pstudebaker@putman.net.
PAUL STUDEBAKER, CMRP
MR. SUSTAINABILITY
ITS STILL NOT UNCOMMON FOR EVEN
SUCCESSFUL PERHAPS ESPECIALLY
THE MOST SUCCESSFUL FACILITIES
TO BE COMPLACENT ABOUT OVERHEAD.
PS1203_09_MRSUSTAIN.indd 9 2/29/12 11:32 AM
COMPRESSORS
Beware of small
expenses. A small leak
will sink a large ship.
Your compressed air system may cost you more
than you think.
It takes more than good equipment to make an efcient air
system. Thats why our air system specialists are here for you.
We look beyond the basics to nd savings in the whole system
and determine what you need to run at peak performance.
Kaesers compressed air energy audits stand out in the
industry for completeness and accuracy. Our Air Demand
Analysis (ADA) will identify and help you eliminate
inefciencies related to controls, leaks, articial demand,
inadequate piping, and storage as well as reduce waste
and scrap caused by inconsistent pressure in production
equipment. It will also help you cut maintenance costs by
optimizing run time and reducing excess cycling. ADA docu-
mentation will even help you apply for electric utility rebates.
Add in superior products plus our reputation for strong
customer service, and its no wonder Kaeser delivers the best
value. Let us to put our expertise to work for you.
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Built for a lifetime is a trademark of Kaeser Compressors, Inc. 2011 Kaeser Compressors, Inc.
Only 59% of compressed air is
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PS1203_FPA.indd 10 2/29/12 11:33 AM
Less is more. Volkswagen Plastics Technology in Braun-
schweig, Germany, started using a single-layer painting
system for an interior component. Te process reduces the
consumption of resources and emissions. However, the
painting system demands an absolutely clean, residue-free
surface. Tis has been achieved with a dry CO
2
snow jet
cleaning technique designed to be gentle on materials.
CLEANLINESS
Every day, Plastics Technology processes approximately 45
tons of material to manufacture injection-molded parts.
About 450 interior components of diferent colors are
produced and installed into various passenger vehicles
around the world. Some of the injection-molded parts have
a high-gloss fnish and can be installed without needing to
be coated. One of the latest vehicle models is ftted with a
high-gloss panel made from acrylonitrile-butadiene-styrene,
polycarbonate (ABS-PC) blend, which is subsequently paint-
ed with a semi-transparent high-gloss metallic paint. Tis
paint is applied to the component as a single layer without
an undercoat, so the surface has to be fawless, explains
Uwe Strauss, painting systems/plastics technology planning
at the Braunschweig plant. Te tiniest dust particle or water
mark would cause rejects. Terefore, we needed a cleaning
solution that is efcient, is gentle on materials, and guaran-
tees consistent results.
CO
2
SNOW
Te classic alternative wet-chemical cleaning with
a powerwash system was rejected for reasons of cost-
efectiveness and sustainability. Due to its high space
requirements, it would have been impossible to install such
a cleaning system upstream of the paint shop. In tests with
conventional dry-ice cleaning systems, the coarse ice pellets
damaged the sensitive surface of components. Te CO
2
snow
jet process from Advanced Clean Production (ACP, www.
acp-micron.com) gave Volkswagen an alternative. We told
one of the companys employees about what we needed,
recalls Strauss. It wasnt long before we were sent a pro-
posal and tests confrmed that we could achieve optimum
cleaning results with the process. With the CO
2
snow jet
technique, liquid carbon dioxide is used instead of dry-ice
pellets. Carbon dioxide gas is a by-product from a variety
of manufacturing processes in the chemical industry; it is
environmentally neutral and gentle on resources.
RESIDUE-FREE
Te modularly constructed CO
2
snow jet system achieves
its cleaning power via the supersonic two-component ring
nozzle integrated into the compact cleaning head. Liquid
carbon dioxide is guided through the nozzle and expands
on exit to form a mixture of snow and gas. Oil-free com-
pressed air accelerates the non-toxic, non-combustible CO
2
snow crystals to supersonic speed. When the jet impacts
on a surface, the snow crystals liquefy and sublimate. Te
sublimation impulse causes any particulate contamination
present to detach and be carried away. In the liquid phase,
carbon dioxide acts as a solvent that removes organic con-
tamination. At the same time, the low degree of hardness of
the snow crystals ensures gentle and reproducible cleaning
results on the high-gloss surface. We carried out test series
with other components made of diferent materials, reports
WHAT WORKS
CARRIED-AWAY CONTAMINATION
CO
2
cleaning system reduces environmental impact and reject rates
CARBON DIOXIDE IS A BY-PRODUCT
FROM A VARIETY OF MANUFACTURING
PROCESSES IN THE CHEMICAL
INDUSTRY; IT IS ENVIRONMENTALLY
NEUTRAL AND GENTLE ON RESOURCES.
The CO
2
snow jet system has been integrated into a large paint
booth measuring 5.5 x 4 x 3 m together with a turning station.
(Source: Volkswagen Plastics Technology)
PS1203_11_12_WHATWORKS1.indd 11 2/29/12 11:55 AM
WHAT WORKS
Strauss. Tis proved that the CO
2
cleaning process can be
implemented for our entire range of workpieces.
PAINTING INTEGRATION
ACP designed a robotic cleaning system with a nozzle array
containing seven cleaning heads. Te component-specifc
programs fled in the robots controls ensure that each
workpiece is cleaned fully and automatically, according to
its geometry. Oil-free compressed air and liquid carbon
dioxide stored in tanks are fed to the array via a hose system.
Te robot is integrated into a booth measuring about 5.5
by 4 by 3 m. Te cleaning cell located at the rear wall has a
continuous extraction unit. Tis prevents cleaned parts from
becoming recontaminated by dirt as its removed. A turning
station, which can be switched on separately, is located in
the booth downstream of the cleaning process, allowing
suspension gear to be rotated by 180. ACP provided us
with ideal support both during the test phase and afer-
ward, when we started implementing the cleaning system,
enabling us to integrate it into the painting process within
the space of just three months, says Strauss.
SERIES OPERATION
Te CO
2
snow jet system has been running in three-shif
series operation at the Volkswagen plant since August
2010. Several thousand plastic parts are cleaned every day.
Te workpieces are suspended on special painting
racks at the injection-molding plant, explains Strauss. If
high-gloss parts are handled, workers wear gloves. Te
racks are mounted on trolleys, transported to the painting
line, and fed into the painting chain. Te frst station in the
line is the cleaning unit. To prevent dust from sediment-
ing on the workpieces afer cleaning, theyre fed through
two ionizing rods. Afer being transported along a short
stretch designed as a cleanroom, paint is then applied to
the components by two robots in the painting booth. On
leaving the evaporation zone, the parts are then dried at
around 80 C.
With the CO
2
snow jet system, weve not only found
a cost-efective and reliable cleaning solution, weve suc-
ceeded in reducing the workload on our staf, decreasing
environmental pollution, and also lowering our reject rate
by another 3%, summarizes Strauss.
OWN YOUR ENVIRONMENT.
HAZARDOUS LOCATION PANELBOARDS
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PS1203_FPA.indd 14 2/29/12 11:35 AM
STEP UP TO THE PLATE
Rethink reliability in terms of your equipments on-base percentage
As I removed my laptop to get some work done on a
three-and-a-half-hour fight home the other night, the fight
attendant announced what the in-fight movie was going to
be. Im probably among the last people to have seen the movie,
Moneyball. It might be that Im too cheap to buy an $8.50
movie ticket, $5 bag of popcorn, and $4 Coke (Diet Coke, no
less). I wanted to see the movie because it involved baseball
and a view of things from a diferent perspective.
So, while the laptop remained on the tray table, it was
benched for the fight.
Te story was about Major League Baseballs Oakland Ath-
letics, a small-market team that couldnt compete economi-
cally with larger-market teams. Te As had good coaches
and developed some great players. However, they didnt have
the money to induce top talent to stay or to come over to the
team. Tis meant that they would forever be handicapped
in their quest of a World Series title. Tis isnt unlike many
industrial plants its hard to fnd good talent to replace the
aging workforce, and its even tougher to keep them as com-
petitors ofer a little more.
Tere were a number of interesting lessons from the story
of Billy Beane, the general manager, and his unassuming
sidekick a young, Yale-trained, economics major named
Peter Brand, who had no baseball experience, but could boil
baseball success down to one thing getting on base repeat-
edly. Veteran scouts looked for attributes they believed would
do two things draw in fans and give the team a reasonable
chance to win. Tey used an old formula that everyone else
used, but one with which the As couldnt compete.
Te two main characters, Beane and Brand, developed
a strategy that involved fnding players with high on-base
percentages who werent high-salary guys; it didnt matter
whether they were hits or walks. Te old guard Manager
Art Howe, the veteran players, and the scouts didnt like
the new strategy because it took them out of their comfort
zone. Te old guard knew better than some college kid, or
so they thought. Te strategy foundered as the manager
circumvented the plan, a key player had to learn a new posi-
tion, and an aging veteran player wasnt brought in to relieve
another player.
Te manager resisted the plan as Beane tried to reason
with him. Eventually, Beane took decisive and controversial
action trading two of the teams best players. Tis kept
Howe from reverting to the old management style. Beane
also showed confdence in the player who had to learn a
new position and stuck with him. Te aging veteran, David
Justice, had a key role to play, and Beane appealed to him to
be the veteran leader.
Beane faced decisions at a couple of key moments in the
movie, each of which had serious consequences for his ca-
reer. Because his vision and strategy were so unorthodox,
he most certainly would have been on the unemployment
line if it didnt work.
Manager Howe needed much more than an explanation
of Beanes vision and strategy. Pivotal actions taken clearly
could have led to Howes walking of the job.
It was a risk Beane took because the manager had to get
in line or be gone. Combined with trading two young, star
prospects in the middle of the season, Beanes actions were
akin to the old adage of landing the troops and burning the
boats there was no turning back. It was bold and made
people aware of his deep commitment to the strategy. Beane
also showed commitment by sticking with the player who
had to learn the new position acknowledging shortcom-
ings, but staying the course as the player learned new skills
to ft into the overall plan. In dealing with David Justice,
Beane showed respect for the experienced player but asked
him to step up and be a leader among his peers.
As with plant reliability, the practice of quickly fxing
equipment and rewarding that practice is an out-of-date
strategy. Getting on base, or avoiding outs in the frst place,
is like having reliable equipment. Te strategy in how to get
to the vision of high on-base percentages or high equipment
reliability needs to be enacted by people, through focused
and consistent leadership.
Beane was open to new thinking. But he also was ultimately
accountable for the results. Its why he made the big bucks.
Tom Moriarty, P.E., CMRP, is president of Alidade MER. Contact
him at tjmpe@alidade-mer.com and (321) 773-3356.
HUMAN CAPITAL
TOM MORIARTY, P.E., CMRP
AS WITH PLANT RELIABILITY,
THE PRACTICE OF QUICKLY FIXING
EQUIPMENT AND REWARDING THAT
PRACTICE IS AN OUT-OF-DATE STRATEGY.
PS1203_15_HUMANCAPITAL.indd 15 2/29/12 12:00 PM
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of an agile, fully integrated enterprise resources planning (ERP) suite. So you can implement
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PS1203_FPA.indd 16 2/29/12 11:38 AM
CONFIGURATION WITHOUT CUSTOMIZATION
Modify software with no expense or risk
There are many factors to consider when selecting a
CMMS, including an ability to meet your technical specifca-
tions, vendor track record, and pricing. In this dynamic world,
plants need sofware that can mold to the constant changes
customers, employees, management, and regulatory bodies
precipitate. CMMS vendors and their solutions must be fex-
ible, agile, and confgurable to meet the changing demands.
In earlier years, sofware packages were customized to
close the gap between user requirements and the applications
capability. Typical areas of customization were industry- or
company-specifc anomalies, interfaces to other applications,
and more complex requirements for data entry, reporting,
and business logic (error-checking algorithms and workfow).
Custom changes required considerable time and money to
implement, and there was no guarantee that future releases
of the base package would be compatible with the customized
source code. Moreover, as business grows and needs evolve,
the custom code no longer fts with current business realities.
Modern CMMS sofware can be confgured to meet the
needs of today and tomorrow without the expense and risk
associated with customization. Confguration doesnt require
changes to the source code. Usually, all thats required to con-
fgure the sofware is a one-time setup, for example, ticking a
box on a master fle, selecting a menu option, or dragging and
dropping an object on a particular screen. Tis typically can
be done by a system administrator or super-user, as opposed to
the vendor. Lets highlight some advanced features and func-
tions that help you stay relevant as your business needs change.
USER CONFIGURABILITY
One of the most visible diferences between modern CMMS
packages and older, less fexible applications is the ability to
tailor the sofware to a given user or user group, such as plan-
ners. Examples of screen confguration options are:
- the language used for screens, reports, and forms
- security level access that includes which features, func-
tions, and data felds are visible to the user
- menu items, tabs, and icons that the user can see
- feld labels, positions, and the space they occupy on screen.
Sophisticated CMMS packages also will allow the addition
of user-defnable felds on a given menu, tab, or screen. In
some cases, this includes whatever algorithm or Boolean logic
that might be necessary to generate a value, such as generating
a default value.
NAVIGATION AIDS
Another popular feature that ensures greater agility is the
ability for users to navigate throughout the system to get at
information quickly and easily. For example, the better CMMS
packages not only have drill-down capability to reveal greater
and greater levels of detail, but they allow users to drill around
to fnd related information. For example, when viewing a pur-
chase order line item on screen, a user might wish to jump to
the relevant items master information, then do a where used
query, and then drill into one of the assets that use the item.
A powerful navigation aid is the MS Explorer-style lookup
capability for equipment, parts, projects, and many other data
hierarchies. Te more sophisticated CMMS packages allow
users to drag and drop elements of the hierarchy, for example,
moving a serialized component from one asset to another,
including carrying its full history. Other high-end features are:
- a favorites" menu, where users can store frequently used
links to screens within the CMMS
- a navigation bar showing where you are in the system
- a history" tab to show where you have been within
a user-defned period of time
- a search engine to locate a given screen or feld.
WORKFLOW ENGINE
A workfow engine is the backbone on which a CMMS is built,
carrying the business rules and sequencing of virtually every
process the sofware governs. For example, companies need
to be able to adjust approval limits and signatories, as well as
conditions (budget remaining) or contingencies (approver on
vacation). Te workfow engine can launch notifcations or
alarms when certain conditions are met, such as when a criti-
cal PM is signifcantly past due or when a budget is exceeded.
Some CMMS vendors have a graphical workfow engine,
where activities, arrows, and decision boxes within the fow
can be dragged and dropped to allow users to build or adjust
the workfow logic easily. For some packages, the procedural
help (how to initiate a work order) can be linked to the graphi-
cal workfow. Users can toggle back and forth between the
YOU NEED THE FLEXIBILITY TO ADD
FIELDS THAT ARE RELEVANT TO A
GIVEN ASSET CLASS OR TYPE.
ASSET MANAGER
DAVID BERGER, P.ENG.
PS1203_17_ASSET.indd 17 2/29/12 12:07 PM
ASSET MANAGER
process fow and the appropriate help screens.
USER-DEFINABLE SPECIFICATION TEMPLATE
Diferent businesses describe their assets diferently. Computer
screens are sized in inches by referring to the diagonal distance
across the screen. A motor has horsepower, voltage, speed, and
torque. You need the fexibility to add felds that are relevant
to an asset class or type such as computer monitors, motors,
doors, and sewers. Tis is accomplished with user-defnable
templates for entering and reporting on tombstone data.
FORMS AND REPORT GENERATORS
Tere are three major activities for which your CMMS
provides tremendous support data entry, data analysis,
and reporting. Te forms generator gives users the ability to
confgure data input forms (work request, purchase request,
timesheet) to maximize efciency and reduce the chance of
error. Modern features include:
- spreadsheet mode, not a tabular mode, for data entry
- ability to hide, add, and format felds and labels
- ability to associate Boolean logic (<, >) and formulae to a
given data entry feld for the purpose of error checking
- copy feature for entering repetitive data
- extensive default values based on optional algorithms
(most frequent, last used, fxed value, formula based).
Data reporting must be easily modifed, including:
- ability to hide, add, and format felds and labels
- ability to apply simple math, Boolean logic, or more ad-
vanced math to any feld or grouping of data
- sort and flter capability for reports, listings, and queries,
including use of Boolean logic, simple math, and formulae
- drill-down capability on any feld
- extensive graphics capability for displaying data or a subset
thereof, including a user-defnable dashboard.
DOCUMENT MANAGEMENT
Another feature that brings tremendous fexibility is sophis-
ticated document management capability. Relevant external
documents such as equipment manuals, drawings, safety
sheets, and contracts abound. Documents arrive in multiple
formats, from handwritten notes scribbled on a scrap of paper
to 3-D CAD drawings or training videos. It should be easy to
attach these documents to the CMMS master fle (drawings on
the asset registry) or to objects such as work orders or purchase
orders. More sophisticated features to look for are version
control (management of change), application launch option,
and the ability to edit, index, and redline.
Email Contributing Editor David Berger, P.Eng., partner, Western
Management Consultants, at david@wmc.on.ca.
Sustainable industrial production means
long-term, holistic thinking. Key examples
include minimal unplanned downtime, less
friction and reduced lubricant consumption.
The effect: lower energy consumption,
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PS1203_17_ASSET.indd 18 3/1/12 11:42 AM
PS1203_FPA.indd 19 2/29/12 11:38 AM
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TECHNOLOGY TOOLBOX
SHEILA KENNEDY
WELL-OILED TESTING AND TRAINING
Formulations are just part of lubrication improvements
Choosing the right blend of lubrication training, testing,
business processes, and formulations can help keep your
machines and components healthy and running smoothly.
Te training and development of lubrication skills is the
hottest thing out there right now, and I believe it will be with
us for a long time in the future, says Bill Lyons, mainte-
nance optimization manager at Holcim U.S., a cement and
component manufacturer in Waltham, Massachusetts.
During the past few years, many lubrication improvement
projects were launched in most of Holcims 12 manufactur-
ing plants, from storage and handling to regreasing bearings
using ultrasonic measuring tools, explains Lyons. I see our
plants moving further with in-house oil analysis, helping to
move us to a more proactive approach to better understand-
ing the lubrication condition, he says.
Lyons believes that increasing skill levels and using new
technology has a great efect on costs. I looked at our bear-
ing spend fve years ago, and the amount seemed very high
to me, he says. Recently, I ran the same report, and I now
see our bearing spend has dropped more than 50% since the
previous report.
Organizations such as the International Council for Ma-
chinery Lubrication ofer certifcation programs for lubrica-
tion technicians and oil analysts.
Lab testing approaches: Independent oil analysis labs must
adapt to evolving customer requirements and technology
continually. Insight Services keeps its technicians abreast of
changing base stocks and additive packages, and its improv-
ing its testing and reporting capabilities.
Were currently working on two changes to oil analysis
testing in our laboratory varnish analysis and flter debris
analysis, says David Kirkwood, business development man-
ager for Insight Services. Varnish analysis improvements
include changes that will allow us to categorize the type of
varnish, the make-up of the sof contaminant, and ultimate-
ly pinpoint the origin of the problem. Also, Insight will be
able to use flter debris analysis to capture the organics that
make up the varnish for closer examination.
Reliability-focused practices: Lubrication process im-
provement providers use existing products to get better
results. Manufacturers are becoming wise to the value that
machine lube processes can deliver, says Mike Johnson,
principal consultant for Advanced Machine Reliability Re-
sources. Johnson developed an analysis tool called
LubeCoach, a grease interval and volume calculator. It aids
in selecting or correcting lube types, application volume,
and frequency, and in solving process problems such as
overfeed and underfeed. LubeCoach, available in multiple
bearing application formats, is presently spreadsheet-based
but will soon be ofered in a Web-based format.
Advanced ester chemistry: Polyol ester (POE) fuid de-
velopments resulted in new industrial lubricant products.
POEs are fantastic long-range solutions for air compressor
lubrication. With fuid analysis, a customer can realize more
than 8,000 hours of fuid life with POEs in air compressors,
says Jim Girard, vice president and chief marketing ofcer
at Lubriplate Lubricants. Because fuid life is extended, less
used oil requires disposal. POE-based fuids also minimize
harmful air compressor deposits.
Targeted applications: Lubricant formulations ofen are
designed to meet specifc industrial conditions. Summits
SumTech FGCO calcium oleate grease was designed specif-
cally for the food service, beverage, and food processing in-
dustries. Among its properties are excellent water washout,
higher weld load, and lower wear scar.
Te Hydroguard hybrid breather from Des-Case increases
lubricant reliability in low-fow applications by preventing
contamination. Suitable for multiple industries, the product
uses check valves and an expansion chamber to prevent
moisture ingress. It breathes when pressured, and the air
is cleaned and dried before it enters the system.
Email Contributing Editor Sheila Kennedy, managing director
of Additive Communications, at sheila@addcomm.com.
www.holcim.us
www.lubecouncil.org
www.testoil.com
www.precisionlubrication.com
www.lubriplate.com
www.klsummit.com
www.descase.com
REFERENCE WEB SITES:
INDEPENDENT OIL ANALYSIS LABS MUST
ADAPT TO EVOLVING CUSTOMER
REQUIREMENTS AND TECHNOLOGY
CONTINUALLY.
PS1203_XX_TECHTOOL.indd 21 2/29/12 4:19 PM
Plant upgrades and overhauls mean involving the
engineering department and having the foresight to not only
change what is lacking, but plan for future needs, as well.
Tree plants took advantage of facility modifcations and
parlayed them into better maintenance and reliability.
In the frst example, the addition of secondary wastewater
treatment necessitated an upgrade in emergency standby
power, which meant installing a new system that matched
the existing one. Te improvement allowed the treatment
plant to meet EPA standards and gave it the backup power it
required in the event of an outage.
Equipment stress protection made a diference in the
second example, in which a frearm manufacturer increased
reliability and productivity by implementing functional
interface stress hardening. Engineering, operations, and
maintenance personnels ability to work and plan together
allowed the facility to mitigate equipment downtime.
Finally, when a food production plant had expanded to
the point where it was unequipped to handle the breadth
and volume of its products, a complete facility overhaul al-
lowed for more ef cient operations and the plant moved to a
predictive maintenance strategy.
STAND BY YOUR POWER
Built in the late 1990s, the South Bay International Waste-
water Treatment plant is a joint efort between Mexico and
the United States to treat sewage from Tijuana, Mexico, and
eliminate environmental concerns in the Tijuana River Val-
ley just south of San Diego. Te plant is located on a 75-acre
site in the United States. Te International Border and Water
Commission (IBWC, www.ibwc.gov), the plants operator,
needed to add secondary treatment to improve the quality of
the discharge water because it was found not to meet current
environmental standards set by the EPA.
Te South Bay wastewater treatment plant has a capac-
ity of 25 million gal/day. Its original design consisted of
advanced primary treatment, which involved the addition of
chemicals to the infuent to promote removal of solids and
dissolved organic compounds through settling. Te treated
water was then discharged via a 4.5-mile pipe extended out
into the Pacifc Ocean near the Mexico-California border.
Secondary treatment involves bacteria-activated sludge
combined with aeration and additional settling. Encouraged
by the large supply of oxygen bubbled through the sewage,
aerobic bacteria consume the remaining organic compounds
in the ef uent. Te sludge is then removed by additional
settling and then recycled to reuse the bacteria. Afer
secondary treatment, the water quality is much improved
and meets EPA standards. Adding secondary treatment
has greatly increased the plants electrical load. Te large
aeration pumps and activated sludge system necessitated the
addition of another 2,000 kW of emergency standby power,
so the plant turned to MTU Onsite Energy (www.mtuonsi-
teenergy.com).
22 MARCH 2012 WWW.PLANTSERVICES.COM
ENGINEERING / PLANT MAINTENANCE
By Mike Bacidore, Editor in Chief
Wrench
Time
by
Design
Plant upgrades are opportunities to
bring engineering and maintenance
PS1203_XX_XX_COVERSTORY.indd 22 2/29/12 5:05 PM
Te plant hasnt been expanded in terms of overall ca-
pacity, says Steve Smullen, area operations manager, IBWC.
It was originally designed for both advanced primary treat-
ment and secondary treatment, but the secondary facilities
were not immediately funded. Recently, we got the funding,
and now weve added a biological system, aeration and set-
tling facilities to meet our EPA permit requirements. As a
consequence of completing the secondary treatment, we also
added quite a bit of additional electrical load to the plant to
operate three 700 hp aeration blowers and related equip-
ment. In case of a utility outage, we needed the additional
standby generation to handle those larger loads.
Te plant wanted the new power system installation to
physically match that of an existing 2,000 kW generator that
was installed during the original construction in the late
90s, says Tim Oergel of W.W. Williams, the local distributor
for MTU Onsite Energy. Getting the two generators to ft
into identical packages was a challenge, he says.
One design issue was that the MTU Onsite Energy unit
was 16 years newer than its companion, which was from a
diferent manufacturer. Te new unit operates at 12.47 kV
housed in a specially designed ISO container. Tis newer
generator set is EPA-certifed to meet Tier 2 emissions regu-
lations, whereas the existing generator set was manufactured
at the beginning of Tier requirements and was compliant
with, but not EPA certifed to, Tier 1 standards.
In addition to not having modern emissions control
hardware, the existing generator drive engine set did not
have an electronic governor or other electronic controls to
help it synchronize with the new generator drive engine. To
get the two generators to communicate with each other, the
existing generators governor was replaced, along with many
other controls. Te overhaul also included new paralleling
switchgear, automatic transfer switches, and various com-
munications interfaces.
While the MTU Onsite
Energy EPA-certifed Tier 2
generator set is more fuel ef-
fcient and has signifcantly
cleaner exhaust, it also has
higher heat rejection that
requires a specialized radiator, says Oergel. Because we
had to match the size of the original 40-f ISO container, we
had to be creative in designing a radiator with higher heat
rejection to ft in the same-sized package as the original
generator set. Te solution was a specially designed radiator
from R.F. Partridge & IEA Radiator that was direct-driven
through a planetary gear of the engines crank shaf. With
a larger surface area and greater airfow, the special radia-
tor was able to ft inside the container and still provide the
necessary cooling.
Te physical installation of the containers is unique, as
well. Each containerized generator set is mounted on a con-
crete pad outside of the plants main building. Because the
plant is located in earthquake country, both generator-set
containers are supported by a seismically reinforced mezza-
nine structure consisting of I-beams connected in crisscross
patterns (Figure 1). Tese structures support the weight of
the containers and are bolted to the concrete pad to prevent
damage to the generators in the event of an earthquake.
Installation, fnal commissioning, and load-bank testing
were completed in the summer of 2010 to make sure that
both units could carry the full plants load while operating
in parallel. Getting the diferent units to operate together
was a challenge, says Oergel. Tere were many sequence-
of-operation changes that were needed to make sure both
units functioned properly and could carry the load.
TEACH A MAINTENANCE ENGINEER TO FISH
Sturm Ruger (www.ruger.com) manufactures American-
made frearms for the commercial sporting market, ofering
more than 400 variations on more than 70 products across
25 product lines. Its main rife and pistol components
manufacturing plant in Newport, New Hampshire, is more
ef cient and proftable today than it was in 2007 because of
a proactive maintenance department and a vice president of
operations who understands the value and the necessity of
reliable equipment.
In 2007, with unscheduled downtime on the automa-
tion and manufacturing controls and CNC machine tools,
David Ford, the hydraulic maintenance specialist, requested
a portable oil fltration system to cut down on hydraulic oil
contamination, save some money on oil costs, and, hope-
fully, boost machine uptime.
Tom Sullivan, vice president of operations at the Newport
plant, thought it was a good idea, but not all oil flter systems
are equal. He asked Howard Cooper at Amemco (www.
amemco.net) to prepare a plant-wide equipment survey and
conduct an orientation semi-
nar on functional interface
stress hardening (FISHing).
Tese meetings brought the
maintenance and manu-
facturing engineers, plant
management, and maintenance specialists together to hear
Cooper explain how to replace preventive maintenance with
condition-based maintenance (CBM) and how to maximize
uptime and equipment reliability by going FISHing.
Coopers facility and equipment survey revealed one
root-cause stress to be frequent power surges and voltage
transients that were afecting CNCs, PLCs, computer and
electronic controls, and drive systems. Te survey identifed
and prioritized other root-cause stresses and resulted in a
machine-by-machine stress protection solutions report. Tis
document served as a stress-hardening protection recom-
mendation and installation guide.
AT LEAST ONCE OR TWICE A WEEK, YOUD
HEAR FROM A CNC OPERATOR THAT THE
MACHINE HAD JUST STOPPED.
PS1203_XX_XX_COVERSTORY.indd 23 2/29/12 5:04 PM
Kim White, Sturms maintenance manager, authorized
Bill Ross, Sturms maintenance electrician, to test the pro-
posed solutions in the report. Te initial testing involved
installing high-speed clamping/fltering transient voltage
surge suppression (TVSS) units from Total Protection Solu-
tions (www.tpssurge.com) and air-to-air heat exchangers on
two Portland reamers in the gun forge molding department.
Historically, Sturm Ruger was replacing at least one of
these motion axis drives every other month and experienc-
ing the loss of production. Since the replacement, there have
been no costly axis drive replacements needed and no scrap
being generated from marginal and failing axis drives.
Summer heat also was afecting the companys Tech-
nidrills and Extrom Carlson CNCs in the woodworking
department. Frequently the cabinet doors were lef open
to keep the controls from malfunctioning or failing. Te
report included the size and type of control coolers to use,
the proper connection points, and mounting details for the
TVSS devices. Te woodshop hasnt experienced downtime
or quirky malfunction problems since making the changes.
Based on these pilot-test results, Sturm Ruger began
implementing the FISH report suggestions across the manu-
facturing facility. From the time I started with Sturm Ruger
back in 2003, says Ross, at least once or twice a week,
youd hear from a CNC operator that the machine had just
stopped or wouldnt start up correctly. Wed have to shut of
the main power switch feeding the machine tool and turn
it back on again to reset or reboot it. Tat seemed to fx the
problem until the next occurrence. Since completing this
equipment stress protection project, Ive not heard of that
happening again.
Te overall efect was like installing a large UPS on every
machine tool, but the real savings came from increased reli-
ability, productivity, and uninterrupted profts.
Shortly afer restructuring maintenance, the concepts and
methods of the original project were expanded to include
additional machining and process control areas, as well as
TPS suppressors to protect Sturms low-voltage lighting.
FOOD PRODUCTION OVERHAUL
Minnesota-based Faribault Foods (www.faribaultfoods.
com) is no stranger to the importance of sustainability in
food production. As a producer of many foods including a
wide variety of beans, chili, organic soup, juices, and canned
pasta, Faribault Foods is a member of the Sustainability
Initiative Team (SIT), a part of the Foundation for Strategic
Sourcing. Te group is comprised of executives from major
consumer packaged goods, contract manufacturing, and
More green cleaning solutions
PS1203_22_28_COVERSTORY.indd 24 3/1/12 11:40 AM
packaging supplier companies that work together to develop
industry standards to promote sustainability.
While business drivers might have progressed in recent
years, the bean production process hasnt changed much in
the companys 115-year history. Beans come to the primary
production facility from all over the Midwest. Teyre placed
into a soaking and rehydration system, and then blanched
and transferred to a canning line, where broth, sauce, or
brine is added for favor. Te cans are sealed and sent to the
cooking system, where theyre held at a particular tempera-
ture to make them a commercially sterile product. Finally,
the cans are cooled, packed on pallets, and shipped to thou-
sands of retail locations across the country.
Te Faribault bean plant was designed as a seasonal
vegetable canning facility, explains Phil Hines, director of
engineering, Faribault Foods. When I joined the company
in 2005, it was being operated year-round as a rehydrated
bean canning facility. We needed to modernize our produc-
tion infrastructure to meet long-term business goals and
deliver the high-quality, sustainable products our customers
have come to expect.
With several hundred varieties of product going through
the facility each year, it simply wasnt designed to keep pace
with the companys growing business. In addition to pro-
ducing several of its own brands, the company also produces
private-label brands for many large grocery retailers and
provides copacking, or contract manufacturing services as
well. We needed to demonstrate and document reliable,
repeatable production practices to our customers particu-
larly to those working with us on copack products, explains
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and steam (WAGES) resource consumption (Figure 2).
Once the company decided to invest in a complete facility
overhaul, Hines and his team designed a comprehensive
plan to identify opportunities for improvement, documenta-
tion requirements, and an ongoing timeline for implementa-
tion. We knew this wasnt going to be a one-time efort,
explains Hines, who, along with his team, selected a process
solution based on the Rockwell Automation Integrated
Architecture system, featuring eight Allen-Bradley Control-
Logix programmable automation controllers (PACs). Each
PAC communicates via a ControlNet network to intelligent
feld devices and 12 human-machine interface (HMI) sta-
tions comprised of Allen-Bradley PanelView Plus termi-
nals and industrial computers running FactoryTalk View
SE sofware. Te control system monitors the production
infrastructure in real-time, including WAGES consumption
information. Faribault Foods implemented instrumenta-
tion from Endress+Hauser for seamless integration. When
we started this project, we were in the beginning stages
of automating of our production system, explains Hines.
As a result, this project represented a substantial technol-
ogy change for the maintenance department. Te biggest
challenge was training. Every maintenance person needs
to understand the functionality of the new sensing and
controls devices in order to troubleshoot the operation and
TIGHT CONTROL
Figure 2. The control system monitors the entire production
infrastructure in real-time, including WAGES consumption
information, allowing the Faribault Foods team to identify
opportunities for improvement.
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to be able to diferentiate between
control system issues and mechanical
issues. We implemented a training
program for all maintenance staf and
specialty training for a selected group
who would focus on maintaining and
updating the new control systems.
As part of the project, Faribault
standardized many of the devices, says
Hines. For example, we use the same
VFD model throughout the facility,
he explains. We also included elec-
tronic documentation of the location,
description, and function of each
device and the ability to allow outside
vendors to access our system through
a VPN connection for data collection
and troubleshooting.
To ensure a smooth transition,
Hines wanted to train his staf on the
new technology as soon as the system
was online. Previously, one or two
staf members possessed 90% of the
control system knowledge, he says.
With the new system, we wanted to
make sure everyone understood how
it worked.
Te companys heat-and-energy-re-
covery system reuses 100% of the heat
from the can cooling process to warm
city water for the soaking, blanching,
and cooking operations. Te result is
a 38.2% decrease in natural gas usage,
which won the company Xcel Energys
2009 award for the largest natural gas
reduction among industrial customers
in the state of Minnesota. In addi-
tion, the system reuses cooled water to
reduce the temperature of the cans in
the cooking process, which cuts down
on the companys overall water usage
by more than 100 million gal/year.
Tighter control of the process also
allows for reduced waste in the manu-
facturing process. To accommodate
the cooking process, the company
leaves head space in each can es-
sentially an air pocket between the
can lid and the beans. Previously, at
the end of the manufacturing line, the
head space would be pushed out along
with a few ounces of canning fuid,
which would be fushed down the
drain. Now, thanks to the increased
process accuracy and reliability, the
plant-foor team can fll to exact levels,
ensuring that no fuid is wasted when
the head space is forced out of the can.
As Faribault Foods moves to a
predictive maintenance strategy, the
asset management and training sup-
port also are proving useful. Faribault
Foods is now producing the same
amount of product in fve days that
previously required seven.
When Hines frst started the
upgrade process, the plant typically
was running at 75% of its maximum
throughput. Now, the facility runs at
90%, and it has better product quality,
as well.
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Which is better a classical centralized air system or a
departmental compressed air system? Reports suggest that
neither system is better. Quite ofen, the right choice is a
combination or variation of both. Heres why.
A central air system satisfes total plant air demand. Air
from one or more compressors is distributed from a central
point to areas requiring service. Tese compressors are in-
stalled in a powerhouse with other utilities. In a departmen-
tal air system, several compressors are located at principal
points of use throughout the plant. Tis approach can be
used instead of, or in combination with, the central type.
VARIATION CAN PAY
Each has its advantages and disadvantages. In deciding
which is best, weigh the benefts gained against the draw-
backs for the choice. Te case for one system over the other
isnt always clear cut. Te judicious plant engineer, afer
weighing the facts and fgures, might arrive at a combination,
or even a variation. Heres a hypothetical example.
A 50,000-cfm centralized air system has several compres-
sors. However, the units have a 100-psig maximum discharge
pressure. Te plant requires 2,100 cfm at 150 psig in one
department, 24 hours a day. Two options are available.
- Install a complete air system delivering 2,100 cfm at 130
psig in the department. A complete system such as this
will use about 500 hp and cost approximately $150,000 to
$175,000, uninstalled.
- Install a booster compressor to provide the required
2,100 cfm by kicking the 100-psig system pressure to the
required 150 psig. A correctly applied, double-acting,
single-stage reciprocating booster, requiring only 125 hp,
will do the job for about $40,000 to $50,000, uninstalled.
Tis small booster represents savings. At a utility cost
of $0.04/kWh, saving 375 hp can amount to more than
$100,000 per year in power savings alone, not including the
cost of the 100-psig inlet air. If all or part of the 2,100 cfm
of 100-psig air is available from blow of, this might gener-
ate more savings. Tere are many situations ofering the
plant engineer a chance to save on air system installation
and operating costs. It takes planning and correctly applied
knowledge of compressed air, compressed air systems, and
compressed air equipment.
Its important to understand the classical approaches to air
systems and compressor selection. You also should be aware
of what modern materials, air compressor designs, and com-
pressed air requirements have done to increase the opportu-
nities for both initial and continuing cost saving.
To get more work and ef ciency out of compressors, many
manufacturers of production machinery and tools now
require higher pressure and air thats dryer and cleaner than
the standard afercooler untreated air. Compressor manufac-
turers responded with a variety of designs.
High-performance, oil-cooled rotary compressors, both
vane and screw types available as fully packaged air systems,
RELIABILITY / COMPRESSED AIR
CENTRAL OR
DEPARTMENTAL
AIR SYSTEM?
Size and congure air
piping for the right t
By Hank van Ormer, Air Power USA
PS1203_30_36_FEATURE1.indd 30 3/1/12 9:37 AM
ofer nearly complete installation fexibility. Tese continu-
ous duty units with oil coolers are relatively small and quiet.
Tey can be used for departmental air and compromise
nothing in durability. Single-stage, oil-cooled rotaries ofer
pressures to 175 psig, and two-stage units can go even higher.
Rotary units, lobe or screw type, non-lube, air- or water-
cooled, two-stage compressors provide good efciency and
continuous duty from 50 hp to 600 hp. Teyre usually higher
in initial cost and somewhat less efcient than the air-cooled
two-stage lubricant-cooled rotaries. Single and two-stage
double-acting reciprocating, water-cooled units are the most
expensive to buy, but they incur the lowest power cost com-
pared with other types of similar sizes.
Modern compressor design produced heavy-duty, short-
stroke, higher-rpm, smooth-running, lightweight, single-act-
ing reciprocating, air- and water-cooled units that require no
special foundation. Teyre suitable for providing high pres-
sure air for localized or departmental applications. Heavy-
duty units generally are available from 5 hp to 75 hp, 20 cfm
to 170 cfm, and 150 psig to 5,000 psig. Tey ofen serve as a
departmental air to supply a special process requirement.
Te need for flters that deliver instrument-quality, oil-free
air continues to increase. Filter technology has come so far
in recent years that virtually any degree of cleanliness can be
reached economically with reasonable or no pressure drop.
Afer you determine what kind of system best suits your
plant, you must address other considerations.
- What kind of air distribution system:
- What will be the key air supplier:
- Is the air lubricated or non-lubricated:
- Should the compressed air be dried:
- If so, then how dry, how clean, and how much hydrocar-
bon is acceptable:
CENTRALIZED SYSTEM: ADVANTAGES AND DISADVANTAGES
Centralized systems have several advantages.
- Maintenance and care are simplifed because the units
are in one area. If an overhaul is needed, the liing/trans-
port equipment and tools usually are available nearby.
- Important utilities, such as water and electric, are lo-
cated in the same area.
- It's more ecient to centralize the storage and drying of
air compared with dispersing those functions.
- Larger air compressors generally are used in a central-
ized system. Tese ofer longer maintenance intervals
than smaller air-cooled units.
- Heat reclamation from the air and oil coolers on rotary
screw compressors can help reduce plant heating costs.
Tis form of energy conservation is achieved more ef-
fectively from a central system.
Tere are disadvantages to a central system, too.
- A centralized system requires larger and more expensive
air pipes to avoid energy-draining pressure losses associ-
ated with carrying greater air volumes longer distances.
- Central air doesn't satisfy localized demand for dier-
ent, particularly higher, air pressures.
- e air quality isn't easily varied. Some applications
might require non-lubricated air or very dry air, while
others won't. We generally recommend drying the air
to at least a +40 F pressure dewpoint.
DEPARTMENTAL SYSTEM: ADVANTAGES AND DISADVANTAGES
A departmentalized system ofers certain advantages.
- Smaller and less expensive air lines carry smaller
amounts of air shorter distances. Air systems can be in-
stalled at lower cost and with minimum pressure losses.
Smaller compressors might have lower power ratings.
- Varying air pressures can be provided easily to meet
each departments requirements.
- Any quality air can be delivered to each department
without over-cleaning or over-drying the total system.
- Correct piping procedures allow tying the various de-
partmental air systems together, enabling each depart-
ments air system to back up the other.
Te disadvantages of a departmental system are numer-
ous, as well.
- When compressors are spread out, maintenance and
service tend to be more of a problem. Sometimes theres
uncertainty about who is responsible and less diligence
about getting the job done. Service might need to be
CONDENSATION ACCELERATES
COATING BREAKDOWN, WHICH DEPENDS
ON WHERE THE COATING IS THINNEST.
Table 1. Typical pressure limits for thermoplastic pipe and ttings
are a function of temperature and line size. (N/R = not recom-
mended)
Temperature (F)
Max pressure rating (psi)
1/2 to 2 in. 3 to 4 in.
100 185 185
105 185 172
110 185 160
115 171 147
120 157 135
125 143 N/R
130 128 N/R
135 114 N/R
140 100 N/R
32 MARCH 2012 WWW.PLANTSERVICES.COM 32 MARCH 2012 WWW.PLANTSERVICES.COM
relegated to the using department,
rather than to plant maintenance.
- e plant might need specialized
equipment for major overhauls.
- Adequate water and electric power
might be hard to bring in for units
that require them. However, this
can be mitigated by using smaller
air-cooled units if theyre adequate
for departmental air needs.
- Installation is more complex for a
central air management system.
PIPE FOR CENTRAL SYSTEMS
Air piping probably has had more
pages written about it than any other
topic, even storage. Like many topics
in practical compressed air technol-
ogy, a signifcant portion is controver-
sial. ese guidelines aren't intended
to replace the appropriate volumes of
information or misinformation and
aren't designed to answer all ques-
tions regarding a specifc installation.
ey're designed to provide basic
principles that always apply and, when
followed, provide a well-performing
system. As with any set of guidelines,
theyre based on performance and
measured critical feld data molded
with theoretical performance.
TYPES OF PIPING
Consult federal, state, and local codes
before deciding on the type of piping.
e usual standard to be applied is
ASME B31.1. e compressed air pip-
ing materials can be divided into two
types: metal and non-metal.
Non-metal pipe, commonly called
plastic pipe, has been ofered for
many years as compressed air piping.
- It's lighter than most metals and
easier to handle.
- It can be installed without special
tools such as welders or pipe dies.
- It's generally corrosion resistant.
- Installation with the appropriate
gluing material is fast.
- e labor cost, which can be
unskilled, is lower than for most
metals, and the system ofen can
be installed less expensively.
Early on, PVC was used for com-
pressed air piping, and it wasn't long
before it was evident that PVC some-
times shattered when it failed, sending
shards throughout the area. New prod-
ucts use material that doesnt shatter.
However, this material and others still
have signifcant limitations.
- Most are limited to an operating
temperature of 140 F to 200 F. A
non-performing afercooler can
easily reach or exceed these num-
bers. PVC, for instance, is limited
to about 160 F at 123 psig, but it
starts to weaken at 70 F.
- Most plastics aren't compatible
with compressor oils in general,
and many synthetics in particular.
- Although pipeline fres are rare,
when there's one in plastic pipe,
there's a good chance that it will
melt the plastic pipe and migrate
around the plant.
- A fre in the plant with the com-
pressed air line active could melt
the pipe from the outside causing
additional catastrophic problems.
- If new thermoplastic materials are
used, the piping system becomes
quite expensive, certainly more
than a high-quality extruded alu-
minum alloy with push-to-connect
or compression ftting connections.
A FIRE IN THE PLANT
WITH THE COMPRESSED
AIR LINE ACTIVE COULD
MELT THE PIPE FROM
THE OUTSIDE.
Table 2. Comparisons of standard 100-psig class compressed air systems.
Feature Stainless Black iron Copper Thermoplastic Aluminum
Weight Sch 10 lighter Sch 40 heavy Less weight Lightweight Lightweight
Corrosion resistant? Yes No Yes Yes No
Strength Good Good Good Low Good
Ease of installation Less hard Hard Less hard Easy Easy
Connection types Welded
Flange/threaded/
welded
Flanged/soldered Cold glue Sealed reusable
Pressure drop Low High Low Low Low
Fouls? No Yes No No No
Modify easily? Yes No No Yes Yes
Special tools? Yes Yes Some No No
Skilled labor? Yes Yes Yes No No
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As with other thermoplastic com-
ponents, the maximum non-shock
operating pressure is a function of
temperature (Table 1). Remove the
heat of compression so as not to exceed
maximum temperature ratings.
Te pressure ratings for typical
thermoplastic piping and fttings are a
nearly constant 185 psi for all line sizes
at temperatures from -20 F to 100 F,
and are gradually reduced above 100
F. Te compressed air industry hasnt
accepted any type of plastic pipe as
appropriate and safe for discharge and
downstream compressed air. I agree
with this view, given whats available
in todays material, data, and available
alternatives. Tere are no apparent
benefts to ofset the risk.
METALLIC OPTIONS
Metal pipe can be black iron, stainless
steel, copper,, or extruded aluminum
alloy having appropriate thermal and
pressure characteristics.
Black iron or steel pipe corrodes
when exposed to condensate and thus
becomes a source of system contami-
nation. Tis pipe usually is threaded
3-in. or smaller and is welded or
fanged to pipe of a larger diameter.
Compared to copper and extruded alu-
minum alloy, its heavier and harder to
install, but less expensive. Internal cor-
rosion is much more signifcant with
oil-free air and associated aggressive
high-acid condensate characteristic
than with lubricated compressors.
Extruded aluminum-alloy and
stainless-steel compressed piping have
become popular. A smooth, low-
friction inner surface eliminates self-
contamination and ofers enhanced
fexibility to meet ever-changing air
distribution needs. Tis is particularly
desirable in such plants with evolving
assembly and subassembly areas. Most
extruded aluminum alloy pipe is rated
at +4 F to 140 F or 176 F. Te piping
material usually has a melting point
greater than 1,100 F. For maximum
fexibility, these ofen are installed with
reusable fttings.
Copper pipe is a common selection
for sensitive air systems. Its rugged
when selected and connected correctly.
Its working pressure is 250 psi for
Type M hard, Type L hard, and Type
K sof, and 400 psi for Type K hard.
Because 50/50 solder melts at 421 F,
copper lines are more resistant to high
temperature. If it does fail, it will do so
predictably the pipe ends separate.
According to the Piping Handbook, 6th
edition, the working temperature limit
for copper piping is about 400 F.
Extruded aluminum alloy pipe
can be installed in most areas where
copper can be used. Alloy ofers some
signifcant advantages:
- much lower initial price
- as good or better resistance to cor-
rosion, depending on conditions
- install, remove, and reinstall with
no skilled labor or soldering
- lightweight
- has internally fush connections.
COATINGS FOR AIR PIPING
Te question of using galvanized
piping instead of Schedule 40 black
iron pipe for the nominal 100-psig air
systems comes up ofen. Galvaniz-
ing ofen is the coating of choice with
many design engineers.
Galvanized inlet piping resists cor-
rosion better than standard iron pipe.
However, when corrosion sets in, the
zinc can peel of. Te inlet pipe then
produces potentially damaging solid
contaminants between the flter and
the compressor. Tis is dangerous to
the integrity of any compressor.
Galvanized discharge and distribu-
tion piping used for interconnecting
and distribution piping exhibits the
same problem once it begins to peel. In
all probability, because of condensates
aggressive acidic characteristics, the
galvanizing life might be much shorter.
Tis discussion about material
selection as a function of use has fve
facets inlet piping, discharge pip-
ing, interconnecting piping, main line
distribution, and distribution from the
header to the process.
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INLET PIPING
Te inlet pipe brings air from the flter to the compressor
with no pressure loss and shouldnt exhibit any interior
contamination. Te ambient inlet air might well dictate the
selection of one type of pipe over another.
During high humidity, its conceivable that condensation
will form in the inlet pipe. Te OEM installation manu-
als usually recommend a drain valve be installed upstream
of the compressor inlet. Condensation accelerates coating
breakdown, which depends on where the coating is thinnest.
Stainless steel inlet piping is an excellent material for large
diameter, and low-pressure inlet air, as long as its installed
properly and the inside is cleaned properly. Also, there are
many grades of thermoplastic material suitable for inlet air
piping. I recommend either stainless steel or proper thermo-
plastic type material for inlet piping in lieu of galvanized pip-
ing. Extruded aluminum alloy will work well but, depending
on circumstances, might not be the economical choice.
Extruded aluminum alloy tubing can be assembled easily
with hand tools to bring a great deal of fexibility to an oper-
ating air system or subsystem. Tis approach is particularly
efective for areas that are rearranged on a routine basis.
DISCHARGE PIPING
Tis side of the compressor has more complex consider-
ations. Te discharge air can be at 250 F to 350 F (for
centrifugal, oil-free rotary screw, and reciprocating units),
or from 200 F to 220 F (for lubricant-cooled rotary screw
compressors). Te pipe must be able to withstand those
temperatures and any oil or condensate that might be highly
acidic. Even if theres an afercooler to drop the temperature
to 100 F or less, consider the consequences if the afercooler
were to fail.
Air condensate tends to be acidic. In oil-free compressors,
such as centrifugals and oil-free rotary screw, its usually
particularly aggressive without the oil to neutralize it.
INTERCONNECTING PIPING
Its purpose is to deliver compressed air to the flters and
dryers and then to the production air system with little or
no pressure drop, and certainly with little or no self-con-
tamination.
Regardless of the thermoplastic pipe manufacturers
claims, we never recommend any non-metallic material for
interconnecting piping and rarely for distribution header
piping. Most of these materials carry cautions about not
being exposed to temperatures greater than 200 F and
avoiding any type of oil or lubricant. We never recommend
any type of above-ground nonmetallic or PVC piping for air
or gas at any pressure.
Here again, stainless steel or appropriate extruded alumi-
num alloy is the top recommendation for interconnecting
piping between the compressor and the flter and dryers,
From small lubricated air station packages to
variable speed and oil-free compressors,
CompAir offers the total range of air
compressors, accessories and service.
Combine our world class distribution and
service expertise with a highly engineered
product and you have the perfect partnership.
CompAir delivering more than just air.
www.compair.com
perfectly
matched.
Delivering compressed air solutions,
service and expertise.
CompAirThe perfect partner.
if the compressed air is oil-free. Tis
material of construction resists corro-
sion much better than standard Sched-
ule 40 black iron pipe and copper.
Here are some other considerations.
- Most jurisdictions allow Schedule
10 stainless steel in lieu of Sched-
ule 40 black iron.
- For a given diameter, stainless
steel is much lighter and easier
to handle, which usually reduces
installation labor cost.
- For welded connections, stainless
steel usually requires one bead,
while black iron usually requires
three beads (weld, fll, and cover).
Tis also reduces labor costs.
- Stainless steel doesn't seal well
when threaded. It performs much
better with grooved connections if
welding is impractical.
- In sizes 6 in. and below, extruded
aluminum alloy oers the same
features at a probable lower
installed cost. It also brings great
fexibility.
DISTRIBUTION PIPING
e objective of a main header is to
transport the maximum anticipated or
projected fow to the production area
and to provide an acceptable supply
volume for drops or feeder lines. Mod-
ern designs consider an acceptable
header pressure drop to be zero psi.
e drops and feeder lines deliver
the maximum anticipated fow to the
work station or process with mini-
mum or no pressure drop. Te line
should be sized for near-zero loss.
Controls, regulators, actuators, and air
motors need a minimum inlet pres-
sure, thereby introducing some pres-
sure loss. Table 2 summarizes some
of the pros and cons for each type of
piping material.
Hank van Ormer owns Air Power USA
(www.airpowerusainc.com) and is an
Advanced Level Compressed Air Challenge
(www.compressedairchallenge.org) instruc-
tor. Contact him at hank@airpowerusainc.
com and (740) 862-4112.
00 lll0 l0 f00f Ff0(00l Nll0
fl00f 80ll0f000 lll8.
The SewerGard210S-Sprayable polymer
lining delivers lower permeability than
aggregate-flled systems and a high degree
of fexural strength. Its spray application
minimizes installation downtime,
as well. This protective lining
with fber reinforcement
enables longevity for
municipal infrastructure
subject to corrosion and abrasion.
emai l : quest i ons@sauer ei sen. com
Pi t t sbur gh, PA 15238 U. S. A
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OPTIMIZATION / ASSET MANAGEMENT SOFTWARE
Tis is the second of a two-part series on work breakdown
structure. Te frst part appeared in the January 2012 issue of
Plant Services.
With the work breakdown structure (WBS) stored inside
the CMMS sofware, work orders can be tied to WBS cost
accounts, purchase orders, receiving, and invoices. Te
result of this is one system, one report, and immediate
cost analysis.
Quite ofen CMMS users will decide to use multiple
sofware tools for managing outages, also called shut-
downs, and turnarounds. Asset-intensive industries ofen
categorize work orders as to the system condition required
for performing work. If this work is marked as outage,
planners can quickly pull together a scope based on prior-
ity and cost.
Te goal of any outage manager, once given a budget,
is to create scope, get it approved, line up materials and
resources, and establish a critical path using a scheduling
tool. And once the outage is started, he wants to manage
this scope, monitor schedule status, and track cost.
KEY DEFINITIONS
- WBS-style project cost tracking places an emphasis on
cost management within the CMMS and links work
orders to cost accounts, and cost accounts to activities.
- Cost accounts are at the lowest level in the WBS and
contain the budget, actual costs, and estimate-to-com-
plete (ETC) values.
BENEFITS OF WBS-STYLE PROJECT COST TRACKING
A WBS provides the best start to managing a project. Upper
management wants to be informed of project status from the
cost perspective but does not want a detailed schedule or list
TOO MUCH
INFORMATION
PART II
Work breakdown structure in CMMS
can streamline project cost tracking
By John Reeve, Cohesive Information Solutions
PS1203_37_40_FEATUREWBS.indd 37 3/1/12 9:51 AM
of work orders. By tracking costs with
a cost report from within the CMMS,
you can see a summary and indented
view of the project, providing an over-
view of problem areas. Tis strategy
allows for standard comparison of
efort across the feet, where similar
projects are being implemented.
OUTAGE TIMELINE
Outage preparation is important. If
this process is to function, potential
outage work must be properly catego-
rized and planned within the CMMS
(Figure 1). Important milestones in an
outage timeline are:
- outage scope objectives and mis-
sion statement
- start date and duration
- CFO budget delivery
- scope fnalization
- freeze date determination
- outage start
- outage completion and assessment
- report success and cost overruns.
Once the CFO provides the outge
budget, the project coordinator sweeps
up the work coded for the shutdown,
assesses the schedule, and identifes the
total cost. If it exceeds the budget, work
must be cut to favor high-priority work.
TRACKING SYSTEM CHANGES
Manage scope and cost by using a
single point of entry and project cost
tracking reports. CMMS system re-
quirements for outage work categoriza-
tion and cost tracking are:
- ability to link work order to a
planned shutdown event
- ability to dierentiate between
on-line maintenance work and
shutdown work
- ability to track shutdowns in a
separate application
- ability to link WBS number and
cost account number to the work
order main screen
- ability to identify deadlines associ-
ated with individual work orders,
such as regulatory dates
- ability to mark work as required
before outage starts
- ability to code work order priority,
plus a separate feld to code level-
of-importance for shutdown work
must, need, want
- outage work orders should have a
duration value that can be used for
scheduling purposes
- ability to code work as to type,
such as welding, painting, HVAC,
which helps the contracts manager
when building/releasing contracts
- ability to code work orders as to
owner, such as contractor work,
internal staf, or a mixture
- ability to categorize work orders by
plant system and subsystem
- ability to specify area coordination
and task owner, which is useful for
grouping like work and assigning
ownership
- ability to code work orders that
require design changes.
SETTING UP THE WBS
Defne the project scope clearly in
terms of mutually exclusive cost ele-
ments using a tiered level breakdown
to extract project cost reports. WBS
tracking for the shutdown should:
- integrate cost accounts to work
orders
- facilitate linkage of cost accounts
to schedule
- set up budgets inside WBS cost
accounts
- provide indented-level, project cost
tracking report
- capture actual costs through the
work order number (from labor,
materials and invoices)
- capture scope changes via transac-
tion tracking automatically.
OUTAGE SCOPE/COST REFINEMENT
Enable what-if cost refnement when
specifying the scope. Some of the scope
UPPER MANAGEMENT
TYPICALLY WANTS TO BE
INFORMED OF PROJECT
STATUS FROM THE COST
PERSPECTIVE.
IN RACING,
A BROKEN $20 PART
CAN COST YOU
MILLIONS.
THE SAME IS TRUE
IN YOUR PLANT.
coule|euce.|e||ab|ep|aul.com
8OO-597-54GO
1
2
3
4
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13
15
17
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5 33 15
IINNDDIIAANNAAPPOOOLLIISSS IINN MMAAff 11 JJ
Norias 13th Annual Conference & Exhibition
2
0
1
2
111 feee
May 1-3 | Indianapolis, IN
LONG PIT STOPS CAN COST YOU THE RACE.
DOWNTIME CAN COST YOUR PLANT MILLIONS.
LEARN BEST PRACTICES TO KEEP YOU ON TRACK AT
RELIABLE PLANT 2012.
coule|euce.|e||ab|ep|aul.com | 8OO-597-54GO
1
2
3
4
11
13
15
17
0 5 0 1 1 2
5
6
7
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5 33 15
IINNDDIIAANNAAPPOOOLLIISSS IINN MMAAff 11 JJ
Norias 13th Annual Conference & Exhibition
2
0
1
2
111 feee
May 1-3 | Indianapolis, IN
PS1203_FPA.indd 39 3/1/12 9:09 AM
is must-do, but other parts are optional. Tis approach allows
for dynamic scope selection and immediate visibility of the
calculated dollar total, which is then compared to the budget
cap. Minimize any deviation by changing the selection crite-
ria or changing individual work order priorities. Te screen
design shown in Figure 2 shows the what-if design capability
that allows for dynamic cost balancing. Teres also an auto-
matic capture of scope changes.
PROJECT COST TRACKING REPORT
One of the many purposes of project cost reporting is to
know whether the project is on schedule and on budget
before project completion. Tis report can be used by any in-
dustry performing project management. Transactional cap-
ture tells when, what, and why the scope was altered and who
approved it. Te change order column shows dollar changes.
Te report gets its data directly from the CMMS sofware.
And it allows for a written explanation if the cost account
manager determines the forecast will exceed the budget.
Project management is a critical process in many indus-
tries. Improvements in this area afect costs and productiv-
ity. Outage improvements can have a dramatic efect on
the corporate bottom line. WBS-style project cost tracking
embeds the WBS inside the CMMS product.
John Reeve is manager/practice leader maintenance & reliability so-
lutions at Cohesive Information Solutions. Contact him at jreeve@
cohesivesolutions.com or (423) 314-1312.
Outage-1
After completing
previous outage,
complete dept/team
critiques
Issue nal
outage report
CFO provides
rough budget
Query CMMS
for outage work
Select potential work
coded in CMMS for
this outage
Work package
preparation
90% done
Perform
what-if
scope
analysis
based on
budget
Download
work orders
Start
schedule
build
Verify all
materials
on-site
Stage material
and tools
Perform
pre-outage
work
Verify
tagouts
ready
Schedule
tasks
Establish
CPM
Resource
level
Verify
completion
date
Freeze outage
work scope in
CMMS
Issue
preliminary
schedule
Assign work
to crews and
contractors
Finalize
contingency
and risk
planning
Finalize
schedule
Begin daily
outage
meetings
Outage-2
Collect daily progress
and actual hours
Monitor critical path and manage
scope change requests
Produce nal
cost report for
CFO
Outage
complete
Daily
update
Plan for next outage
CATEGORIZE AND PLAN
Figure 1. The freeze date should be recorded in the CMMS such that any scope additions can easily be tracked.
CMMS/EAM system Work order screen Project Cost
Transactional
Work order number
Asset Calculate priority
Description Status
Project ID
Project description
Target start Duration
Actual start
Approved budget $13 million
Dynamic calculation $14 million
Revised budget
Status
Must Need Want
Type S/D
Target nish
Actual nish
Freeze date
Outage manager
Worktype
Glaccount
Location
Project ID
Pre-shutdown Y/N
Long-lead material Y/N
Outage type
Outage priority
Contractor work Y/N
Contract type
Parent work order
Planned
Overnight
Weekend
Annual
On-line
Must
Want
Need
Civil
Carpenter
Electrical
NDT
Welders
Divers
Scaffold
Cranes
Water treatment
Cleaning
HVAC
Gas/steam turbine
Once the Project Freeze Date is passed,
if any new work is linked up to this
Project ID (e.g., outage code), then
an INSERT statement is made to a
Transactional Table denoting, "ADD."
If scope was removed then an INSERT
statement is still made, but as "DELETE."
Planned
Forced
WO # Project ID Freeze Action Sysdate Who Reason
New App
Add
Delete
These toggles dynamically show total CMMS
BASELINE cost - based on MUST, NEED, WANT
TRACK, UPDATE, MANAGE
Figure 2. Manage scope and cost through work-order tracking.
CATEGORY / TOPIC
When a piece of equipment needs slow input speed and
high torque, its common to use an electric motor coupled to
an industrial gear reducer to achieve the desired speed and
torque. Te gear reducer multiplies the output torque from
the motor and reduces the motor output speed by the same
ratio. Tere are many kinds of industrial gear reducers from
which to choose. Internally, those gear reducers might use
worm gears, helical gears, or bevel gears to increase torque
and reduce speed. One of the most popular types of gear
reducers is based upon worm gears.
TORQUE VERSUS PURCHASE PRICE
When one selects a gear reducer, one of the most important
decision criteria is the relationship between the reducer cost
and the amount of torque generated from its output shaf.
Worm reducers are the leaders when it comes to the cost-
versus-torque comparison. A principal factor driving cost
competitiveness of worm reducers relates to the overall gear
reducer ratio. Te overall gear reducer ratio is the number
of rotations of the input shaf that results in one rotation
of the output shaf. Most worm gear reducers ofer ratios
of as much as 60:1 in a single stage of gearing, and a few
ofer even higher ratios. With only one stage of gearing, the
related multiple shafs, bearings, spacers, and other hard-
ware that would be required in a multistage reducer arent
required. Its typical for a 60:1 helical or helical-bevel re-
ducer to have three stages of gearing compared to one stage
of gearing in a worm reducer. Te gears, bearings, and shafs
are the most expensive gear reducer components. With
fewer of these, worm reducers cost less than other types of
gear reducers (Figure 1).
AVAILABILITY AND COMMONALITY
Most domestic manufacturers stock a substantial number of
reducers in their warehouses. Tose can be shipped on the
same day the order is placed. In addition to readily available
inventory, theres also dimensional commonality on critical
mounting dimensions among the major domestic worm
Fewer components give worm-gear
reducers a single-stage advantage
By Chuck Russell, Baldor
MORE TORQUE,
OPERATIONS / MOTORS & DRIVES
LESS MONEY
PS1203_XX_XX_FEATURE2.indd 41 3/1/12 9:59 AM
OPERATIONS / MOTORS & DRIVES
reducer manufacturers. Tose critical dimensions include
the output shaf diameter and length; mounting hole size
and location in the housing; output shaf height; and overall
reducer housing height. Te gear ratios ofered also have
been standardized. Some have increased the output and in-
put torque ratings of their products through improved gear
designs along with the use of high-performance materials
and synthetic lubricants. Tose increases in input and out-
put torque make it possible to replace an older reducer with
a new reducer from a diferent manufacturer. Te increased
ratings provide a larger service factor and longer life than
the original reducer.
MOUNTING OPTIONS AND FEATURES
Te worm gear in a worm reducer runs at a right angle to
the input worm shaf. Because the worm gear is mounted
on the output shaf, both ends are available for use. Avail-
able common output shaf confgurations include single
and double extended solid shafs along with hollow output
shafs. Te use of hollow output shafs is becoming more
common in the United States, as it ofers several advantages
over a solid output shaf (Figure 2).
An equipment OEM can extend its drive shaf a relatively
short distance and mount a hollow bore worm reducer on
the extended shaf. Tat mounting eliminates the need for
chains, belts, or other equipment to transmit torque from a
solid-shaf reducer to the application. Guarding is simpli-
fed, and the maintenance normally required for chains and
belts is eliminated. Several manufacturers ofer a sealed-
for-life reducer that doesnt require a vent plug or oil level
changes for diferent mounting positions. Tose features
allow mounting in multiple positions without the need to
relocate the breather or add lubricating oil. Because of the
popularity of worm reducers and the multitude of appli-
cations, theyre available in standard and food industry
washdown-duty packages, ofer C-face inputs for standard
NEMA motors, and have multiple options, such as mount-
ing fanges and bases (Figure 3).
One aspect of worm gearing to avoid is the self-locking
feature that some gear ratios might theoretically ofer. Be-
cause of the many variables that afect the reducers ability to
self-lock, most manufacturers recommend a brake motor or
other means to keep the reducer from being back-driven.
LONG LIFE
Industrial worm gear reducers have a hardened worm run-
ning with a worm gear of a sofer material a bronze alloy
selected with wear in mind. Unlike hardened helical or bevel
gear sets, a worm gear set is designed to wear in over time.
Some people think the wearing of the worm gear results in a
shorter life than other gearing types. However, the wearing
of the bronze drops of substantially afer the wear-in fnish-
es. When worm gear manufacturers select a bronze material,
they balance the resistance of the bronze to wear over time
versus the ability to wear-in. During wear-in, the worm gear
UNLIKE HARDENED HELICAL OR BEVEL
GEAR SETS, A WORM GEAR SET IS
DESIGNED TO WEAR IN OVER TIME.
HOLLOW BORE
Figure 2. The right-angle conguration and the hollow shaft give
the worm gear reducer more exibility in application.
I
n
c
r
e
a
s
i
n
g

c
o
s
t
Output torque
Helical-bevel
reducer
Worm reducer
COST-TORQUE RATIO
Figure 1. Its typical for a 60:1 helical or helical-bevel reducer to
have three stages of gearing compared to one stage of gearing in a
worm reducer.
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Clean, Dry Compressed Air Starts
with The Extractor/Dryer
Manufactured by
LA-MAN Corporation
Point of Use Compressed Air Filter to
Improve and Extend Equipment Life
Removes Moisture and
Contaminates to a 5-Micron Rating;
Lower Micron Ratings are Available
Models with Flow Ranges of 15
8CFM to 2000 8CFM Rated Up To
250psi are 8tandard
Differential Pressure Gauge
Built n to ndicate Required
Maintenance
Mounting Hardware
Included for Easy Installation
Weep Drain is 8tandard;
Float Drain or Electronic
Drain Valves Optional
temperature temporarily increases. A sofer bronze wears
in more quickly with lower break-in temperatures, but it
wont last as long. A harder bronze lasts longer but generates
higher break-in temperatures. A harder bronze is the best
compromise between wear-in and wear-out. When properly
sized to the application, worm gear reducers last at least as
long as other gearing types.
NOISE
All gear reducers generate noise depending on the type
of gearing used, the gearing accuracy, the quality of the
manufacturing processes, and product design. Worm gear
reducers have multiple advantages with respect to noise.
Teir teeth slide into contact with each other. Tat sliding
action avoids the abrupt tooth-to-tooth contact that occurs
with helical and bevel gearing. In addition to sliding into
engagement, well-designed worm reducers have more teeth
in contact in the gear mesh compared to a helical or bevel
reducer, which results in lower noise levels. Also, worm re-
ducers typically have only one set of gears that produce less
noise than the multiple sets in helical and bevel reducers.
Te fewer number of bearings also helps to keep the worm
reducer noise level lower.
Overall, gear reducers with worm gears ofer advantages
over helical and bevel gearing. Worm gear reducers have a
low cost-versus-torque ratio, and domestic models are readily
available and interchangeable. Te right-angle mounting of
a worm gear reducer, along with the hollow output shaf and
sealed-for-life options make worm-gear reducers suitable for
a host of applications. Also, the long life and reduced noise
from worm gearing have contributed to their popularity.
Chuck Russell is senior principal engineer at Baldor (www.baldor.
com). Contact him at (864) 281-2438 or crrussell@baldor.com.
SOUP LINE
Figure 3. A sealed-for-life reducer doesnt require a vent plug or oil
level changes for different mounting positions. A soup-producing
plant can use this same hollow-bore unit in multiple mounting
positions without the need to relocate the breather or add oil.
CONDENSING BOILERS
Tis line of condensing boilers
range from 300,000 to 850,000 Btu/
hr. Te Caliber boiler is a condens-
ing hydronic boiler with low emis-
sions of CO and NOx. Te product
line features a full stainless heat
exchanger suitable for hydronic
heating. Te boiler is equipped with
Honeywell SOLA control and a variable-speed premix
combustion system capable of a 5:1 turndown.
Fulton
(315) 298-5121 / www.fulton.com
AIR CONDITIONER
Te CMW30 water-cooled,
ceiling-mount air conditioner
features a cooling capacity of
29,400 Btu/hr total and 22,000
Btu/hr sensible for computer rooms. Te
CMW30 is 20 in. high, enabling it to ft above a drop ceil-
ing. No external condensing unit, refrigerant connection, or
charging is necessary. Te integrated-energy-efciency ratio
(IEER) of 17.0 is made possible by a variable-speed inverter
compressor and inverter fan motors. Additional features
include R-410A refrigerant and RoHS compliance.
MovinCool
(800) 264-9573 / www.movincool.com
AC/REFRIGERATION MANIFOLD
Te 557 Digital AC/Refrigeration System
Manifold features four valves and a built-in
vacuum gauge to analyze and maintain A/C,
heat pump, and refrigeration systems. Te 557
has two temperature inputs and can measure
and display superheat and subcooling simulta-
neously. It displays high/low side pressure,
displays line temperature, and calculates saturation
temperatures. It comes with two clamp probes, integrated
hanger-hook, built-in hose holders and a hard carrying case.
Testo
(800) 227-0729 / www.testo.com
VARIABLE-SPEED DRIVE
Te Z1000 variable-speed
drive is designed for building-
automation applications such as
fans and cooling towers having
capacities to 500 hp. Its features
begin with an LCD operator
with hands-of-auto functions.
An internal real-time clock with
time/date stamping and timer
is designed to control speed
variations without the need for
external controls. A built-in 5%
line impedance is designed to
reduce input harmonic distor-
tion, and it ofers a 5 kHz carrier
frequency with dynamic noise control. An on-board EMI/
RFI flter minimizes the efects of interference from sur-
rounding equipment.
Yaskawa
(800) 927-5292 / www.yaskawa.com
INDUSTRIAL FAN
Te Powerfoil X industrial fan has an airfoil and winglet
combination and is available in 8- to 24-f. diameters. Te
NitroSeal Drive, a custom-built gearbox, is flled with
nitrogen and sealed. Precision gearing is engineered to
provide low friction for reduced heat and nearly 50% less
backlash. Te pre-wired on-board fan controls reside in a
weather-resistant enclosure. A wall-mounted keypad con-
nects to a standard junction box to allow foor-level control
of multiple fans. Smoke detection, lights, cameras, and mo-
tion sensor systems can be integrated into the fan.
Big Ass Fans
(877) 244-3267 / www.bigassfans.com
PRODUCT ROUNDUP
THERMAL TECHNOLOGIES
Resources support HVAC and combustion processes
PS1203_44_46_ROUNDUP.indd 44 3/1/12 10:04 AM
ELIMINATE STRATIFICATION
Engineered to move air throughout
a building quietly, these fans are
designed to bring warm air down
in cold weather and, if air-condi-
tioned, force cold air to foor level
in the warm months. By eliminat-
ing the temperature diferential
between foor and ceiling, you can reap the fnancial bonus
of reduced energy costs while enhancing occupant comfort
year-round.
Zoo Fans
(859) 918-9982 / www.zoofans.com
DISCHARGE BLOWER HEATER
Line horizontal or vertical dis-
charge blower heaters at 20 kW
and 50 kW are now part of the
Chromalox HVH comfort heating
product line. Te HVH is designed
to ofer versatile mounting confgu-
rations for wall or ceiling, and its
compact size is designed to allow
for placement in tight spaces. Addi-
tionally, the HVH is designed to be
attractive in appearance, to be easy
to install, to require minimum maintenance, and to have
a long life. Chromalox HVH heaters are CSA certifed for
use in the United States and Canada, as well as CE certifed
to meet European standards.
Chromalox
(800) 443-2640 / www.chromalox.com
TEMPERATURE-MONITORING DEVICE
Te Delta T Alert is a self-contained, temperature-monitoring
device that attaches magnetically to electrical enclosure cov-
ers, revealing diferences between the temperature inside the
electrical enclosure and the ambient temperature in the room
containing the enclosure. Te unit collects data and sends it
wirelessly to a desktop or other computer, allowing
a building manager or
engineer to monitor
numerous points of the
electrical system from
a single online location.
Readouts and reports can
be generated daily.
Delta T Engineering
(877) 321-0576 /
www.deltatengineering.com
STEAM DESIGN SOFTWARE
Steam DesignPro sofware is designed to use a drag-and-
drop method for designing and modelling HVAC steam
systems. Te Windowsbased sofware is engineered to
allow for modeling steam generation, steam distribution,
steam utilization, and condensate-handling systems. Te
program automatically performs many of the engineering
calculations and design tasks that are currently accom-
plished manually, including head loss and static pressure
calculations, pipe and duct sizing, data recalculation,
component insertion, full psychrometic calculations, and
equipment changes on the fy.
Spirax Sarco
(800) 575-0394 / www.spiraxsarco.com/us
HIGH-TEMPERATURE HOSES
Flex-Lok high-temperature hoses
are made from materials that are
locked around a galvanized or
stainless steel metal clip and me-
chanically crimped in a continu-
ous process. Tese clip hoses are
rated for service from -65 F to
1,050 F and are available in sizes
ranging from 3 in. to 18 in. Te
standard hoses are constructed
with a single-ply, aluminum-coated fberglass fabric, double-
ply, silicone-coated fberglass, single-ply Kevlar, or single-
ply, neoprene-coated polyester. Other materials also are
available.
Flexaust
(800) 343-0428 / www.exaust.com
IMAGERS CAPTURE INFRARED AND VISIBLE LIGHT
Te P3 Series of imagers measure
temperature from -20 C to 600 C and
feature either a temperature color alarm
or dewpoint color alarm, and allow voice
annotation. Tey capture infrared and
visible light images and display them
fused together. All models feature high-
resolution displays with infrared detector
resolutions up to 320 x 240 pixels. Tey
come with a 2 GB memory card, two
rechargeable batteries that provide four
hours of operating time each, AC charger/
power supply, adjustable hand strap, and
hard and sof transport cases.
Fluke
(800) 760-4523 / www.uke.com
PORTABLE CHILLER
Te Iceman portable chillers
deliver low-temperature process
fuids as cold as -10 F on mod-
els to 10 tons with both air- and
water-cooled condensing. Te
chillers main feature is its semi-
hermetic discus compressor arrangement. Capacity control
is achieved with a cylinder unloading/hot gas bypass feature
and a microprocessor-based controller specifcally pro-
grammed for chillers. Te chillers use R-507 refrigerant.
Mokon
(716) 876-9951 / www.mokon.com
ELECTRIC IMMERSION HEATERS
Te SmartOne line of positive tem-
perature coefcient electric immersion
heaters is cULus listed. Te solid-state
ceramic heating elements are designed
not to burn out when operated in water
or air or surrounded by buildup. If the
temperature goes down, so does the
resistance, thereby increasing power output. If the heat
transfer is restricted, the temperature increases, as will the
resistance, resulting in reduced power output.
Process Technology
(800) 621-1998 / www.process-technology.com
WIRELESS HUMIDITY METER/THERMOMETER
Te Radio-Signal Remote Humidity Meter/Termometer is
designed to receive a radio signal from the remote wireless
sensors that send signals to the main digital display every
30 sec. Te unit transmits at 433 MHz with a range to 100 f,
depending on the location. Relative humidity range is 25%
to 90% and the thermome-
ter range is 4 F to 140 F.
Te main unit can display
data from three remote
sensors. A humidity and
temperature alarm can
sound when conditions
exceed the setpoints.
Control
(281) 482-1714 / www.control3.com
PRODUCT ROUNDUP
MRO MARKETPLACE
MIX THE AIR
Federated Co-op Ltd. installed
ve PowerfoilX fans for winter
indoor air destratication and
heating cost reduction. Trevor
Carlson, Environmental/Techni-
cal Services Manager says, The fans immediately started bringing
the heat down, keeping workers comfortable. We saw a 10% reduc-
tion in natural gas usage when we saw a 20% increase in rates.
We saved $19,800 in the rst year in natural gas consumption as
a result of the fans. Visit www.BigAssFans.com, call (877) BIG
FANS, or e-mail us at info@bigassfans.com.
Big Ass Fans
CLEAN YOUR COMPRESSOR
WHILE ITS RUNNING
Petroleum lubricants in rotary screw and ro-
tary vane compressors result in varnish and
carbon deposits. These deposits cause a
number of serious operational problems, re-
sulting in high maintenance costs. Summit
Varnasolv is a lubricant additive that removes
and suspends varnish while the compressor is in operation. Use
Varnasolv to clean heat exchangers and high temperature chains.
(800) 749-5823 www.klsummit.com/varnasolv.pdf
Summit Industrial Products
MAXIMIZE EFFICIENCIES AND MINIMIZE COSTS
Thats just part of
the plan for any
well-run facility.
Were here to help
with a wide variety
of energy efciency and rebate programs. From customized solutions
to equipment efciency, you can choose from a variety of options.
Visit ResponsibleByNature.com/Business to learn more.
(800) 481-4700
Xcel
ROTATING UNION CATALOG
Deublin has a new, updated 56-page catalog
that includes complete information for
selecting unions for a variety of applications,
from water and steam, to air and hydraulic,
oil and coolant. Both operating data and di-
mensional specications are provided in one
comprehensive catalog, along with
installation and service information. The
catalog is available free via reader response.
Call (847) 689-8600 or e-mail info@deublin.com.
Deublin Co.
OVERHEATING CONTROL PANELS?
Solve thermal problems before they start
or retrot existing NEMA enclosures with
a Noren Products Heat Exchanger. Use the
power of heat pipe technology and reduce
your energy consumption by as much as
90% over other solutions. Noren Products
Thermal Solutions for a high-tech world.
(650) 322-9500
www.norenproducts.com/ps
Noren Products
EXPANDED OIL SKIMMING
APPLICATIONS SOURCEBOOK
Abanakis 47-page handbook offers application
notes on 40 real-world implementations of oil skim-
ming, the lowest-cost way to remove oil from water.
Expanded second edition is indexed by industry and
application. Includes food processing, machining, manufacturing,
grease/water separation, groundwater remediation, and wastewater.
1-800-358-SKIM (7546) www.abanaki.com/216
Abanaki Corporation
PUMPS FOR INDUSTRIAL APPLICATIONS
As the worlds leading manufacturer of pumps and
pumping systems, Gorman-Rupp offers you access
to one of the largest and highest quality lines of
industrial pumps available in the marketplace today.
Our products include selfpriming centrifugal,
standard centrifugal, submersible, priming-assisted,
rotary gear, diaphragm and ReliaSource Industrial
Pump Packages. 419-755-1011 www.GRpumps.com
The Gorman-Rupp Company
AERO-MOTIVE COMPACT AB BALANCERS
Designed to allow workers to move suspended tools
or objects with minimal effort, the Aero-Motive
compact AB Balancers retain the same superior
spring performance for optimal tool balance, while
accommodating tighter work spaces and reducing
work area clutter and risk of accidental tool droppage
or start-up during handling. Suitable for a range of
manufacturing industries and assembly applications.
(800) 225-7724 www.molex.com
Molex
PS1203_47_AdLits.indd 47 3/1/12 11:56 AM
CLASSIFIEDS
PRODUCTS AND SERVICES
ADVERTISER INDEX
Adalet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Agilent Technologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Allied Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Atlas Copco Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AutomationDirect.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Baldor Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Big Ass Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Denso Sales California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diamond Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Eventful Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Flir Commercial Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fluke Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gardner Denver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
IFS North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Kaeser Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Kluber Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
La-Man Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Master Bond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Molex/Woodhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Nilsk-Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Noria Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,39
Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PCB Piezotronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Robinson Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sauereisen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SPX Flow Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Summit Industrial Products . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thomas & Betts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Xcel Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
MIKE BRENNER,
GROUP PUBLISHER
AR, AZ, Northern CA, CO, ID, IL, MN, MT, NE,
NV, NM, ND, OK, OR, SD, UT, WA, WI, WY
Phone: (630) 467-1300, ext. 487
Fax: (630) 467-1120
e-mail: mbrenner@putman.net
JERRY BURNS,
DISTRICT MANAGER
AL, Southern CA, CT, DE, FL, GA, LA, ME,
MD, MA, MS, NH, NJ, NY, NC, PA, RI, SC, TX,
VT, VA, DC, WV
Phone: (630) 467-1300, ext.427
Fax: (630) 467-1120
e-mail: jburns@putman.net
MICHAEL CONNAUGHTON,
ACCOUNT EXECUTIVE
IA, IN, KS, KY, MI, MO, OH, TN, Canada,
Literature Reviews, Inside Print and Digital Sales
Phone: (513) 543-6432
Fax: (630) 467-1120
e-mail: mconnaughton@putman.net
SALES OFFICES
POLLY DICKSON,
INSIDE SALES MANAGER
Classieds
Phone: (630) 467-1300, ext.396
Fax: (630) 364-4175
e-mail: pdickson@putman.net
NORM KLIEMAN,
INSIDE SALES MANAGER
Digital Sales
Phone: (630) 467-1300, ext.344
Fax: (630) 467-1120
e-mail: nklieman@putman.net
SUBSCRIPTION INFORMATION
(888) 644-1803 or (847) 559-7360
REPRINTS
JILL KALETHA
Reprints Marketing Manager
Foster Reprints
(866) 879-9144 ext.168
jillk@fosterprinting.com
PUTMAN MEDIA, INC.
555 W. Pierce Rd., Ste. 301,
Itasca, IL 60143
Phone: (630) 467-1300,
Fax: (630) 467-1120
CUSTOM REPRINTS
For additional information, please contact
Foster Printing Service, the ofcial reprint
provider for Plant Services.
Call 866.879.9144 or
sales@fosterprinting.com
New Product Announcements
Sales Aid For Your Field Force
PR Materials & Media Kits
Direct Mail Enclosures
Customer & Prospect
Communications/Presentations
Trade Shows/Promotional Events
Conferences & Speaking Engagements
Recruitment & Training Packages
PS1203_48_49_CLASS.indd 48 3/1/12 11:57 AM
HOT & DIRTY
CONTROL
ENCLOSURES?
Filter/Ventilators forcefully
blow out hot air & cool with
nely ltered ambient air!
Less $$ than AC or Vortex
Tubes! Five models for any
size enclosure! Since 1980!
Electra
Kool
WP
OILY WATER?
Collect economically! Several
types with 1 qt - 100 gph rates!
Reach from 5 to 100 ft. down!
Also use with coolants & parts
wash uids! Thousands in use
since 1990!
Mini & MAXI-Skimmers
TM
View product info at
www.wayneproducts.com
call 800 255-5665 or email to
info@wayneproducts.com
OIL MIST & SMOKE
IN YOUR SHOP?
www.mistcollectors.com
Tel: 1-800-645-4174
Buildings
available up to
300' wide.
Low in cost per
square foot.
Natural daytime
lighting.
Easy to relocate.
Expandable.
Sustainable Design-Build Solutions
fabric structures
Call one of our ClearSpan specialists at 1.866.643.1010
or visit us at www.ClearSpan.com/ADPS2.
TUBE TYPE OIL SKIMMERS
Contact Brian - sales@skimtech.com
330-774-5044 330-757-7606 Fax
x Skim Oils, Fats, And Grease 24/7
x TigerTube Collector Tubing
x Model 6V Skimmer Tubes
Save 30% On New Collector Tubes
www.skimtech.com
STAND OUT
FROM THE
CROWD
PLANT SERVICES HAS THE
CAREER RESOURCES
NEEDED TO FIND
THE PERFECT JOB.
Job search today at
JOBS.PLANTSERVICES.COM
Plant Connection
THE CAREER RESOURCE FOR PLANT ENGINEERING PROFESSIONALS
PS1203_48_49_CLASS.indd 49 3/1/12 11:48 AM
WAGE WAR ON ENERGY IMPACT
The U.S. Army recognizes the value of net-zero waste, water, and emissions
In January, I had the honor to speak at a meeting of an
organization thats spelling out its route to having net zero
energy impact for its facilities here and around the globe.
Te organization developed a logo for the program that
summarizes the pathway to zero waste, zero water, and zero
GHG emissions: Reduction, Re-Purposing, Recycling and
Composting, Energy Recovery and Disposal. With branding
like that, it might come as a surprise that this organization is
the U.S. Army and not a group of environmental optimists.
Armies from the days of Genghis Khan understood the
value of conservation. Te most key but vulnerable part of
any militarys efectiveness is its supply line, whether this is
diesel tankers under threat on the road to Afghanistan, the
electricity grid supplying West Point, or the horse and cart
bringing wood to warm Napoleons soldiers in a Russian
winter. Its the most expensive variable, with gasoline cost-
ing many times the price you pay at the local gas station.
Recognizing the strategic advantages of achieving near
100% renewable energy supply, the U.S. Army committed to
achieve net-zero emissions at fve major facilities by 2020.
Tis will be replicated across another 25 bases by 2025. Tis
is being done as much to reduce costs as it is to reduce risks
from non-conventional attacks and other supply failures.
Te U.S. Army benchmarked its performance around the
world before designing the program. It reviewed its facili-
ties and discovered its Japanese and European facilities were
among the most efcient. Te Army talked with agencies of
other countries through the International Energy Agency
to develop ways to retroft buildings and assets. In fact, the
U.S. Army Corps of Engineers chairs the committee that
produced one of most comprehensive tool kits for assessing
and retroftting government facilities.
Based on its benchmarking, the U.S. Army realized that,
to achieve net zero, it could borrow from the municipal and
neighborhood Integrated Energy Master Planning common
in Europes towns and cities. Recognizing that true patrio-
tism must be as efective as possible, the U.S. Army put the
not-invented-here argument aside and teamed with global
experts to develop energy master plans.
Te pilot sites for the program include West Point and
Fort Detrick, major training and storage sites in California,
along with the electronic intelligence site at Kwajalein Atoll
in the Marshall Islands, where electricity is produced from
diesel generators with the fuel shipped in by tanker. Te
value of energy conservation there is self-evident.
Te Army follows the classic loading order. Te highest
priority is energy and fuel efciency, supported by efec-
tive metering and controls. Tis is followed by integration,
including upgrading heating and cooling networks. Supply
security and efciency are enhanced by on-site cogeneration.
Once these are implemented, the site can be considered net-
zero-ready with the last gap to zero emissions closed with
various renewable electricity, thermal, and fuel options.
Te value of efciency was highlighted in Iraq. Insulating
tents vastly reduced the need for fuel to power air condition-
ing. Tis reduced the number of tankers that had to navigate
dangerous supply routes. Efciency was measured not only
in dollars, but, far more importantly, in lives not lost.
Te conference speakers exhibited a passion that went be-
yond serving their units mission through the rational use of
valuable resources. I saw their pride in being pathfnders for
the wider community. If a large base can go net zero, so can
the nearby city. I also detected that many clearly understood
the science and risks of climate change and that their eforts
could be the basis for a truly global contribution. Te U.S.
Department of Defense considers climate change to be one
of the greatest security threats to the United States.
Tere was also a clear understanding that becoming
net zero would require efective long-term planning and a
systematic process. Tis couldnt be achieved without engag-
ing the senior leadership and everyone else on the base, and
plans were developed to ensure this, as well. It was fascinat-
ing to see the clear understanding that doing the right thing
for the planet and the country wasnt an optional extra, but
was core and center to the U.S. Armys mission. Tere surely
are lessons for us to take from this level of understanding
and organizational commitment.
Peter Garforth is principal of Garforth International, Toledo, Ohio.
He can be reached at peter@garforthint.com.
ENERGY EXPERT
PETER GARFORTH
THE U.S. ARMY PUT THE NOT-INVENTED-
HERE ARGUMENT ASIDE AND TEAMED
WITH GLOBAL EXPERTS TO DEVELOP
ENERGY MASTER PLANS.
PS1203_XX_ENERGYEXPERT.indd 50 3/1/12 10:06 AM
PS1203_FPA.indd 51 3/1/12 9:10 AM
2012 Thomas & Betts Corporation. All rights reserved.
7IRE#ABLE-ANAGEMENTs#ABLE0ROTECTION3YSTEMSs0OWER#ONNECTION#ONTROLs3AFETY4ECHNOLOGY
Cut downtime, lower installed costs
BlueKote

Conduit Bodies
Trap-Eze

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MaxGard

Interconnection System
E-Z-Ground

Grounding Connectors
High-Temperature
Wire Joints
Extra High-Temp
Cable Ties
BlueKote
internal surface coating

reduces force required to pull wires
8 la]ers of corrosion protection
- including two la]ers of epox]
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Easil] installs aoove
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Connectors can oe
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Netal plugs and receptacles
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O-ringed interior components
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8O, OO, 1OO, 2OO and 4OO
amp connecting s]stem with
cast aluminum hENA 4X
interlocks. 8teel 8O, OO and
1OO amp for hENA 12
Rated for temperatures up to
15O C / 8O2 F, OOOV maximum
Nolded, one-piece n]lon
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Nade of extra high-temperature
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Change out electric motors faster, safer
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Eliminates need for exothermic
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PS1203_FPA.indd 52 3/1/12 9:11 AM

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