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16 Harnessing The Power Of PMI In Reliability InvestigationsPositive material identifi cation can quickly reveal the root causes of bad welds,

parts failures and more. It also can help verify on-spec conditions.Greg Mann and Michael Porfi lio, Anderson Laboratories, Inc.

25 ■ Big Money TalksWilliam C. Livoti, Contributing Editor

26 ■ Using KPIs To Monitor And Improve Pump PerformanceMonitoring and tracking pump-system performance can be highly profi table.

Just how profi table often hinges on which KPIs are followed.Gunnar Hovstadius, Ph.D.

CAPACITY ASSURANCE SOLUTIONS34 Listen For Machine Faults: Let Sounds Verify Vibration Data

This vibration analyst explains how audio replay capabilities have enhanced his toolkit (and could be doing the same for yours).

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UTILITIES MANAGER

ContentsFEATURES

DEPARTMENTS DEPARTMENTS

YOUR SOURCE FOR CAPACITY ASSURANCE SOLUTIONS

©AN

DREI

MER

KULO

V —

FOTO

LIA.C

OM

6 My Take

8 Stuff Happens

10 Uptime

13 Motor Decisions Matter

14 Don’t Procrastinate… Innovate!

23 Automation Insider

40 Technology Showcase

47 Solution Spotlight

48 Marketplace

54 Information Highway

54 Classifi ed

55 Supplier Index

56 Viewpoint

NOVEMBER 2012 • VOL 25, NO 11 • www.MT-ONLINE.com

CAPACITY ASSURANCE SOLUTIONS

The Maintenance & Reliability Technology Summit is:An annual, four-day educational experience and professional-development opportunity

Created for plant and facility managers, maintenance leaders and crew members, reliability engineers, industrial technicians and all other capacity-assurance professionals

Composed of two days of Conferences (60-minute sessions) and two days of Workshops (full-day sessions) presented by industry experts.

Scheduled for April 30-May 3, 2013 at the Hyatt Regency O’Hare, Rosemont, IL.

For more information, visit www.MARTSConference.com today!

The Maintenance & Reliability Technology Summit is:®

NOVEMBER 2012 MT-ONLINE.COM | 3

ARTHUR L. RICEPresident/CEO

[email protected]

BILL KIESELExecutive Vice President/Publisher

[email protected]

JANE ALEXANDEREditor-In-Chief

[email protected]

RICK CARTERExecutive Editor

[email protected]

ROBERT “BOB” WILLIAMSONKENNETH E. BANNISTERContributing Editors

RANDY BUTTSTADTDirector of Creative Services [email protected]

GREG PIETRASEditorial/Production Assistant

[email protected]

ELLEN SANDKAMDirect Mail

800-223-3423, ext. 110 [email protected]

JILL KALETHAReprint Manager

866-879-9144, ext. 168 [email protected]

Editorial Offi ce:1300 South Grove Ave., Suite 105

Barrington, IL 60010847-382-8100 / FAX 847-304-8603 WWW.MT-ONLINE.COM

Maintenance Technology® (ISSN 0899-5729) is published monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Barrington, IL 60010. Pe-riodicals postage paid at Barrington, Illinois and addi-tional o� ces. Arthur L. Rice, III, President. Circulation records are maintained at Maintenance Technol-ogy®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Maintenance Technology® copyright 2012 by Applied Technology Publications, Inc. Annual subscription rates for nonquali� ed people: North America, $140; all others, $280 (air). No sub-scription agency is authorized by us to solicit or take or-ders for subscriptions. Postmaster: Please send address changes to Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: [email protected]. Submissions Policy: Maintenance Technology® gladly welcomes submissions. By send-ing us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technol-ogy Publications, Inc. permission, by an irrevocable li-cense, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.“Maintenance Technology®” is a registered trade-mark of Applied Technology Publications, Inc.Printed in U.S.A.

Subscriptions:FOR INQUIRIES OR CHANGES CONTACT JEFFREY HEINE,

630-739-0900 EXT. 204 / FAX 630-739-7967

Your Source For CAPACITY ASSURANCE SOLUTIONS

4 | MAINTENANCE TECHNOLOGY NOVEMBER 2012

November 2012 Volume 25, No. 11

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6 | maintenance technology NOVEMBER 2012

MY TAKE

C old winds have already begun blowing across Chicagoland—early and often, like they always do. About this time each year, my thoughts start wandering off to warmer places. While Texas and Alabama typically get my nod, I currently have Florida on my mind. You should, too. That’s because Applied Technology Publications is sponsoring three great 2-day workshops, January 14-15, 2013,

at the Lake Buena Vista Resort in Orlando. Presented by several members of our All-Star Team of industry experts, these workshops offer a cost-effective and convenient professional-development avenue for you and/or members of your own All-Star Teams. Check them out, then sign up for the one of your choice:

Workshop #1: “Introduction To Planning & Scheduling” Instructor: Ken Bannister, Contributing Editor, Maintenance Technology and Lubrication Management & Technology

Workshop #2: “Pump System Optimization: Uptime, Reliability, Efficiency” Instructor: Bill Livoti, Contributing Editor, Maintenance Technology and Lubrication Management & Technology

Workshop #3: “Oil Monitoring Analyst Preparation Class” Instructor: Ray Thibault, CLS, OMA I, OMA II, Contributing Editor, Lubrication Management & Technology

You know these instructors. You read them. You respect them. Their Orlando workshops provide a wonderful opportunity to learn from and network with them and—let’s just say it—pick their brains. The practical information and techniques that workshop attendees take away from these classes will be invaluable to their respective operations. For details on the content of these in-depth workshops, along with pricing lodging and registration info, please visit www.mt-online.com/wintertraining13. Or call Kathleen Jaros at 847.382.8100 x 117.

Please take note: Our January All-Star Team Workshops will be held at the same venue as the 2013 IR/Info Conference, presented by our good friends at Infraspection Institute. Paid attendees at our workshops will be able to network with the exhibitors and attendees of IR/Info, at no charge.

I urge you to begin planning your January trip to Florida, ASAP. Registration for our All-Star Team Workshops is open, but space is limited. Don’t let this early-winter opportunity get away from you and your team. Ken, Bill and Ray look forward to seeing you in Orlando. MT

[email protected]

PS: For information on Infraspection Institute’s 2013 IR/Info event, go to: www.irinfoconference.com

On The Road With An All-Star Team Of Experts

Jane Alexander, Editor-In-Chief

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STUFF HAPPENS

MAINTENANCE TECHNOLOGY

What was your biggest work-related challenge in 2012 and how did you overcome it? Go to MT-online.com/question with your answer.

New Certifi cation For Professional

Energy Managers

NEWS

QUESTION OF THE MONTH SOUND-OFF: Tell us what you think. . . Really. . .

Online, On Your Schedule, At Your PaceSchneider Electric has launched a Professional Energy Manager (PEM)™ certifi cation for its online, vendor-neutral Energy University™ program. Developed with the Institute of Energy Professionals (IEP), the longest-running energy-education program in the U.S., the initiative gives energy-focused individuals a new professional-development ave-nue toward earning a highly marketable credential in the growing fi eld of energy management.

According to the company, this online PEM certifi cation program offers conveniences that aren’t typically available through traditional classroom environments, including fl exible schedules, free tuition and a self-paced curriculum that can reduce the program learning length. Additionally, participants may complete and purchase the PEM certifi -cation exam online through Energy University. The program prepares students for the exam via a proprietary learning path comprised of free, self-paced, on-demand courses offered in 12 languages. Topics include identifying effi ciency opportunities; prioritizing opportunities through the qualifi cation of data; and assembling the resources needed to defi ne, sell and implement an effi ciency program.

(EDITOR’S NOTE: Schneider Electric reports that since its introduction in 2009, Energy University has trained more than 130,000 professionals worldwide by way of more than 150 courses. The newly launched online PEM certifi cation initiative represents just one part of a signifi cantly expanded investment by the company toward advancing education that prepares current and future workers to manage increasingly intelligent energy infrastructures and processes. Among other things, this aggressive investment strategy includes integrating Energy University with the Schneider Electric Data Center University™, a move that refl ects the importance of an ever-busier intersection of energy, IT and data-center facilities.)

UK-based Smiths Group plc has announced the recent appointment of Duncan Gillis as President & CEO of John Crane. A U.S. national, Gillis formerly held senior posts in a number of countries for Procter & Gamble, McKinsey and United Technologies. He comes to his new position from Algeco Scotsman, where he was serving as President & CEO.

During its formal 20th Anniversary Celebration in Orlando, FL, last month, the Society for Maintenance & Reliability Professionals (SMRP)took some time to toast a number of the individuals who played key roles in the organization’s two decades of resounding success. Among those so honored were Bob Baldwin, the Founding and long-serving Editor of Maintenance Technology magazine. Baldwin also was one of the two original founders of SMRP. Another of those receiving shout-outs was Jackie Inglis, otherwise known (affectionately) as “Mama SMRP.” Inglis ran the association during its fi rst fi ve years, keeping membership records, spearheading annual meet-ings, serving as a liason between the members and staff and driving growth. For more on SMRP’s great past and bright future, see Bob Williamson’s November “Uptime” column (pg. 10).

UK-based Smiths Group plc has

PEOPLEPEOPLE...

BIZBUZZ


STUFF HAPPENS NEWS

Inspiration For Those Battling The Enemies Of Reliability & Productivity

Send your favorites to [email protected]. We’ll be selecting one or two (maybe even three) to feature each month. Be sure to give full credit to the individual (dead, alive, real or fi ctional) that uttered or wrote the words, and why those words inspire you. Don’t forget to include your complete contact info.

Have you read, heard, seen, thought or written down something that falls into the realm of

“� ghtin’ words” for the maintenance and reliability community? !

FIGHTIN’ WORDSFIGHTIN’ WORDS

The second was provided by Mitchell Howard, Senior HEP Operator at the Mojave Power

Plant, Devils Canyon Power Plant, East Branch Extension. He wrote that one of his site’s

mechanics, Jay Holdaway, made this keen observation years ago, “and it is still true!”

We just had to run these thought-provokers in tandem. Thanks much, Pete and Mitch!

ITT Corporation has signed an agreement to acquire Bornemann Pumps, a global provider of highly engineered pumps and systems for the oil and gas industry. According to Bob Pagano, President of ITT’s Industrial Process business, “Bornemann’s twinscrew technology and multiphase applications experi-ence would align strategically with the Industrial Process business, complement our Goulds Pumps brand and expand ITT’s presence in upstream oil and gas production.” He also emphasized that the acquisition would be bringing together two companies with strong aftermarket and emerging-market focus, as well as management teams and employees with shared values and commitments to quality, performance and customer satisfaction. In addition to its inter-national installed base of multiphase systems forthe oil and gas industry, Bornemann also serves the industrial, food and pharmaceutical sectors. Founded in 1853 and headquartered in Germany, Bornemann’s operations are supported by more than 550 employees around the world.

Emerson Process Management has embarked on a program to strengthen its support-service capabilities for customers everywhere. In 2012, Emerson extended its current footprint of 374 global service locations by opening eight full-service facilities staffed by trained, certifi ed personnel. Going forward, it plans to increase that number by nine per year, while expanding its support staff “at a pace roughly double the underlying automation market growth rate.” Within a year, the company expects to open two new service centers in Asia, two in the Middle East and Africa, one in Latin America and three in Europe. It’s also adding new capa-bilities to meet customer needs. For example, its Certifi ed Repair and Quick Ship product manu-facturing and service centers provide machining, manufacturing, fabrication, actuation, instrumen-tation and quality assurance services, and are designed to operate at speeds faster than factory lead-time KPI Responsiveness Standards. These include service-center sites less than two hours from customer plants; 24-hour replacement-parts delivery; 24/7 repair availability (onsite and depot) to customer timeline requests; and new-product delivery in fi ve days (10 days for systems).

“No job is too hard for the guy not doing it!”

Digging deep into our mailbag this month, we discovered two quotes that seemed to complement each other nicely. The fi rst,

attributed to Charles Darwin, came from a previous contributor to this section,

W.C. “Pete” Peterson, a Contract Reliability Engineer at the W.R. Grace Curtis Bay Works.

“Ignorance more frequently begets con� dence than does knowledge.”


UPTIME

Bob Williamson, Contributing Editor

SMRP: Make it Personal And Prepare For The Future

SMRP, the Society for Maintenance & Reliability Professionals (“by professionals for professionals”) has been celebrating its 20th Anniversary throughout 2012. Held in Orlando, FL, last month, this year’s annual conference wasn’t just a nod to two great decades, it was among the best of the best SMRP events ever. It also offered one of the most revealing looks into the future of “maintenance and reliability” and our role in helping maintenance and reliability professionals prepare for that future. But first, let’s look at who/what made this year’s annual event a success:

n 918 attendees (351 first-time attendees)

n 167 exhibitors

n 42 guests

n 46 states represented (Texas, South Carolina, Florida, Ohio and Minnesota, in that order, sent the most attendees)

n 23 foreign countries represented

n Top-five participating companies: Hormel (30), Michelin (26), Agrium (24), CBRE (15), Freeport McMoran Copper & Gold (13), Georgia Pacific (13) and Mundy Companies (13)

Attendees reflected a cross-section of industry types. Their companies represented the full spectrum of manu-facturing and assembly, petro-chemical, specialty chemi-cals, fertilizers, foods, pharmaceuticals, primary metals, cement, mining, pulp and paper, healthcare, wood prod-ucts, auto automotive manufacturing, pipelines, building materials, engineering services, power generation, public utilities and more. The attendees’ job roles included senior executives, management, supervision, team leads, techni-cians of all types, maintenance mechanics and electricians, planners, schedulers, storeroom specialists and engineers of all types, from both union and non-union companies. While the audience was made up primarily by individuals in maintenance and reliability roles, it was punctuated with a number of others in production-operations and business-administration roles.

Many skilled and knowledgeable attendees of all ages proudly sported their Certified Maintenance & Reliability Professional (CMRP) and their Certified Maintenance and Reliability Technician (CMRT) badge ribbons for all to see. Certification exams were also offered to those who had not yet achieved these globally recognized and respected distinctions.

This year’s annual conference offered 24 day-long workshops, 60 conference sessions and five outstand- ing local facility tours for intensive learning, plus networking with special interest groups, task forces and committees. Beyond that, one of the most valu-able benefits came from networking with others from diverse groups and industries and exploring what new tools and technologies the nearly 70 vendor displays had to offer. This is the place where the serious maintenance and reliability professionals meet, learn, share and develop life-long professional friendships.

Thinking back to the beginnings of SMRPOf course, there were those of us who attended the very first SMRP conference in Nashville, TN, in 1993. That one was a truly memorable event, with over 250 in attendance—well up from the hoped-for number of 160 to break even! From that point on, the organizers and their followers continued to bring on dozens of like-thinking volunteers, recruits and kindred souls to spread the word and grow the unparalleled benefits of the SMRP. It took passion and action to build this association to attract and develop true professionals in maintenance and reliability across countless business and industry sectors. It took a powerful vision among SMRP‘s founders to set the stage for professional develop-ment and growth in workplace disciplines that were not always among the most appreciated: mainte-nance and reliability.

Discussions about future trends and roles of main-tenance and reliability pros started with gusto at that first SMRP conference in Nashville. On the technical discipline side, we were learning about Reliability Centered Maintenance from the late John Moubray—who had launched his RCM-II book in the USA in 1992. Fresh from the UK and hot off the press, the passion

n


UPTIME

reflected in Moubray’s book on the subject of RCM was unbounded.

At the same time, Total Productive Maintenance (TPM), with its focus on both the people and technical sides of maintenance, was gaining momentum. My own passion was for TPM, having learned the princi-ples several years earlier through Seiichi Nakajima, the father of this methodology, as well as through ongoing work with several clients on their transformations.

We had many a debate at SMRP (often fueled by Maintenance Technology’s Founding (and long-serving) Editor Bob Baldwin) in panel discussions and over beverages: “So, will it be RCM or TPM, Engineering-technical solutions or culture change?” Baldwin would ask. While John Moubray’s emphasis was clearly “RCM,” we would eventually agree that the answer to both questions was “YES.” (BTW: John Moubray passed away in January 2004, leaving with us huge legacy and his great passion for RCM-II).

Let the generational shift begin…From my perspective, the 2012 SMRP conference served as a real window to our future. The “old guard” (Sorry guys… I’m one too) rubbed shoulders with rapidly growing numbers of young, bright-eyed, hungry-for-learning professionals and soon-to-be leaders in their industries and the SMRP. The gray hairs were teaching the new guard, and the new guard was telling stories of early successes from their own maintenance and reliability journeys. In some cases, long-time attendees had already passed the torch to their younger counterparts or were teaming at this year’s event as mentors and coaches.

But, it’s not just a human generational shift that’s taking place: There’s more—much more—shifting in our profession. Maintenance and reliability is rapidly becoming a bigger competitive business advantage.

The new maintenance and reliabilityThe spectrum of “maintenance and reliability” is being expanded at a rapid pace. In many cases, this expan-sion is being accelerated because of a grossly under-estimated skills shortage coupled with the demands for longer-lived, more reliable, more profitable, safer and sustainable plants and facilities.

On one end of the spectrum are the technicians and maintainers: These are the folks that are graduating from turning wrenches to operating the new-tech tools of our trade. Their social networking and instant access to information on the World Wide Web easily surpasses anything that existed 20 years ago.

On the other end of the spectrum is the emerging field of “strategic asset management”—powerful concepts for the future of physical capital-intensive businesses —represented by PAS 55 and ISO 55000. These global best practices are starting to show significant results in cost savings, performance and reliability improvements associated with the hard assets we’re used to dealing with: equipment, process systems and facilities.

Maintenance and reliability technicians are hungry for knowledge and skills. They want to hit the ground running in their roles—if they’re not already in the race. Their needs are often different from what was tradi-tionally offered through the SMRP. Basic maintenance skills refreshers and best practices for the plant-floor level are sorely needed due to failing public schools and decades of decline in trade and technical schools. Yes, some of these schools may be coming back. But there’s a generation of maintainers who have missed out on the skill sets needed in industry today (and tomorrow). They’ve learned on the job, from vendors and suppliers and from workshops and short courses. They’re hungry for so much more. We need to figure out the best ways of delivering to them.

Strategic asset management is a whole new field on our horizon. But, it is much more than merely complying with PAS 55 and IS0 55000 for Asset Management. These new asset-management speci-fications and standards will require a whole new set of skills and knowledge beyond the technical reli-ability skills we’ve honed and fine-tuned for the past 20 years.

Asset management as codified in PAS 55 and ISO 55000 will require the skills of understanding strategic business cases, collaboration with others who are not typically part of the maintenance and reliability scope of work, and much more. People skills as well as technical skills will be in demand in our profession. Why? Maintenance and reliability management is a very small, but essential, subset of

n

It took great vision for SMRP’s founders to build an organization around

maintenance and reliability, disciplines that weren’t always appreciated.


UPTIME

asset lifecycle management. We must master a variety of interdependent relationships and partnerships for the future of our assets and to be successful as maintenance and reliability professionals.

Now is the time to begin learning what is embodied in the new Asset Management specifi cations and standards. Because when it comes, it will likely be aimed at our busi-nesses by business outsiders, launched by senior execu-tives and sweep across our plants and facilities much like ISO-9000 Quality Management did a few decades ago. Insurance companies, investors and owners will likely demand it—and plant leadership will respond accordingly. Maintenance and reliability professionals have a consid-erable body of knowledge and best practices to apply to Asset Management, but we must learn how to engage ourselves in the process without trying to use the tech-nical jargon of our trade.

Conquering new frontiersThe new frontiers for maintenance and reliability professionals will include—but extend well beyond—the foundations of mainte-nance and maintenance-management best practices. These fron-tiers will reach much further than reliability and maintainability, RCM and TPM and the latest EAM software. Strategic advantage will go to those businesses that can demonstrate better than best-in-class asset performance and reliability throughout the entire lifecycle of their equipment and facilities.

The Society for Maintenance and Reliability Professionals is a leading-edge organization with access to tens of thousands of members’ experiences that we can harness in taking charge of our future. New frontiers are ready and waiting for us. Now is the time to learn, to grow and to challenge the traditional paradigms of maintenance and reliability. Now is the time for a whole new body of knowledge. Make it personal and prepare for the future.Thank you, SMRP, for 20 inspiring and wonderful years. MT

[email protected]

Now is the time to take charge of our future. New frontiers are waiting for us.

A Leader in Electric Motor Testing


32 | MAINTENANCE TECHNOLOGY OCTOBER 2007

Are You Asking The Right Questions?

BOOSTING YOUR BOTTOM LINE

N

The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Effi ciency (CEE), a North American nonprofi t organiza-tion that promotes energy-saving products, equipment and technologies. For further information, contact MDM staff at [email protected] or (617) 589-3949.

ow is probably as good time as any to take our motor management quiz. That’s because it’s true: An ounce of prevention is worth a pound of

cure. By answering a few simple and timely ques-tions, you can improve the operating effi ciency of important motor-driven equipment such as pumps, fans, conveyors, blowers and air compressors. Even more importantly, addressing these issues early can improve system reliability, preventing system failure and costly downtime.

The following three questions (along with your responses to them) will go a long way in helping you assess the state of your facility’s motor system management. Remember, planning for effi ciency and reliability is easier than managing unexpected equipment failure and downtime.

#1. Does your facility have a current motor inventory?A motor inventory is a list of every motor in a facility, its size, nameplate effi ciency, operation, load factor, run-hours and maintenance history. With an up-to-date motor inventory, you can ensure that the most effi cient motors are the most often used, track “problem” motors (those with histories of repeated failure), identify candidates for cost-effective replacement and keep these motors in stock to minimize downtime. Ask a vendor or service provider in your area for assis-tance, or use the simple inventory feature in DOE’s Motor Master+ [Ref 1].

#2. Does your facility have guidelines for repair-replace decisions?It is easier to manage a plan than a crisis. Know what will be done with every motor upon failure by creating repair-replace decision guidelines. The information in your motor inventory, along with local motor repair prices, purchase prices and electricity rates, will assist you in determining the cost-effective choice. (A free MDM calculation spreadsheet, the 1*2*3 Approach [Ref. 2] can help you do this in three easy steps.)

#3. Does your facility specify best-practice repair?Best-practice rewinds, as defi ned by the ANSI/EASA AR 100 standard [Ref. 3], return a motor to its name-plate effi ciency. Without this type of specifi cation, a repair could result in a unit that operates less effi -ciently and, in the event that this motor has signifi cant damage, could compromise reliability. Take the time to check out the best practice repair resources avail-able through the Motor Decisions Matter Website, and contact your motor service provider to develop a specifi cation for your facility.

If you answered “yes” to all three questions here, you are on your way to preventing unexpected downtime through motor system management. Fortunately, many organizations can help you plan for reliability, including your local electric utility, motor distributor, motor service center, and govern-ment agencies. Additionally, the MDM Website (www.motorsmatter.org) has resources specifi cally designed to help you get started. Why wait for a crisis? Prevent it with proactive motor system management. (BTW: Visit the MDM site for a bonus question on variable speed drives.) MT

1. http://www1.eere.energy.gov/manufacturing/

tech_deployment/software_motormaster.html

2. http://www.motorsmatter.org/tools/123approach.html

3. http://www.easa.com/sites/default/fi les/AR100-

2010_1010-2.pdf


NOVEMBER 2012 MT-ONLINE .COM | 13


DON’T PROCRASTINATE…INNOVATE!

Championing maintenance-improvement pro- jects in tough economic times isn’t easy. Many will recall the infamous 1990s downsizing era, when countless maintenance departments suffered deep cuts in their capital and oper-ating budgets, which, in turn, lead to a crip-pling deferred maintenance approach.

The subsequent recovery period brought about a better understanding of how to defend against future indiscriminate cutting back of programs through improved setup and use of the CMMS (computerized maintenance management system asset management reporting tools). In the early 1990s, the maintenance department that was able to articulate in “bottom-line” terms the economic consequence of deferred maintenance as a direct result of budget slashing was the maintenance department that not only saved its existing budget, it often was able to capture additional funding for further cost-saving initiatives.

Articulating the consequences of deferred maintenance was typically accomplished through a simple Cost/Benefit Analysis report. Such reports position maintenance as an investment in corporate well-being and depict the financial impact of a new or existing initiative or a proposed maintenance budget cut. The Cost/Benefit Analysis provides a statement of record, usually for an accounting department, which likes to review costs and benefits in terms of “dollars and cents”.

To invest in something is to dedicate funds and/or time to a project that’s expected to yield a profit or income. In the case of maintenance initiatives, the profit or income almost always was categorized in the past through the ability to increase opera-tion throughput productivity/quality as a result of increased asset availability and reliability. Those gains would then be translated into dollars-and-cents monetary terms.

Moving forward 20 years, not every business deci-sion is now fiscal-based, and today’s maintenance department finds itself in a much more sophisticated

corporate environment: That means competing against every other department for a slice of an ever-decreasing investment pie. Remuneration success is still awarded to those departments whose programs return a quick economic benefit, but it’s the inno-vative program—one that delivers both “dollars and sense”—that now takes the biggest slice of pie! In other words, today’s maintenance departments must be innovative in categorizing their programs’ benefits, not simply in fiscal returns, but in different “currencies” that make sense to the corporation.

Available ‘currencies’ Delivering dollars and sense requires home-work—and that often commences with the corpo-rate mission and vision. Delivering programs that dovetail directly into the corporate direction is a powerful benefit. Most companies spell out their missions and visions for the world to see in their annual corporate reports or on the home pages of their corporate Websites. Making sense of a project is often a matter of better understanding your company’s business and the impact the corporation strives to make on its investors, customers and the world at large. The ability to put forth programs and initiatives that tangibly categorize additional benefits that make sense to the corporation are more likely to achieve project approval. The following examples show how a maintenance department can be innovative in positioning its Cost/Benefit reports:

Meeting and exceeding regulation requirements. If you work in a regulated industry like power gener-ation, food processing or pharmaceutical, you are subjected to regulatory audits that you must pass in order to keep your business-operating license. Due diligence through effective maintenance tracking and performance is a MUST in regulated industries and often speeds up the audit process, reducing the impact of the audit process to the organization. Investigate the ramifications of a license suspension or loss, and the impact to your corporation if such an event were to occur.

Ken Bannister, Contributing Editor

Dollars & Cents Vs. Dollars & Sense


DON’T PROCRASTINATE…INNOVATE!

Standards accreditation and award programs.Being accredited to specific standards such as ISO 9000 (quality), ISO 14000 (environmental) and PAS 55/ISO 55000 (maintenance) can be a man- dated customer requirement for bidding on and performing work. Along with award programs such as the NAME (North American Maintenance Excellence) Award, accreditation serves to project a trustworthy corporate image that can be capitalized on with new customers and help increase corpo-rate/workforce self-esteem.

Increased safety. Everyone wants to feel as safe as possible in their workplace. Companies that can demonstrate a good safety record are rewarded handsomely by substantial reductions in their workman’s compensation insurance costs and having staff that turns up for work every day.

Working-capital reductions. Reducing MRO inven-tories through lifecycle costing initiatives and use of just-in-time (JIT) and “pay as you go” vendor-managed inventories significantly decreases (or eliminates) oper-ating capital tied up on inventory shelves.

Environmental sustainability via reduced energy. Effective lubrication programs can cut electricity consumption 4-18% by putting the right lubri-cant, in the right amount, in the right place, at the right time. Effective condition-monitoring programs can deliver energy reduction in a number of ways (i.e., by helping identify and plug simple air leaks in compressed-air systems; by helping eliminate mechanical-drive transmission power losses with laser alignment of driver/driven components; by helping eliminate electrical energy loss to ground through infrared detection of loose connections; and by helping eliminate converted steam losses due to faulty steam traps and poor line insulation with the aid of ultrasonic and infrared technology). Energy consumption also tracked on the basis of natural gas used in heating systems and gasoline/diesel fuels in fleets. When looking to monitor energy use, try to work with suppliers who have equipment that can be utilized for free—and who may offer rebate credits you can take advantage of.

Sustainability through a reduced carbon footprint. In many parts of the world, carbon credits have become trading commodities worth millions of dollars to corporations—whether buying or selling. In July 2012, Australia became the latest country to impose a carbon tax on industry. North America could impose a carbon tax in the future as well, and companies need to be ready.

Improved energy management, along with improved maintenance practices, can play an impor-tant role in reducing a corporation’s CO2 impact. For every kWh hr of energy we save, we reduce our carbon footprint by 0.000537 tons of CO2. To put that in perspective, finding a simple loose connec-tion in a 400 hp, 480v, 3-phase motor is the equiva-lent of saving $11,875 in electrical energy per year at 9.5c/kW—and an amazing 67 ton of CO2!

Many of these benefits often can be compounded (i.e., a single program or initiative can deliver a two, three or even four times the benefits). For example, an engineered lubrication program can increase bearing life, reduce downtime, reduce energy, reduce carbon footprint and increase safety while meeting regulation and a standards requirement (all for very little capital outlay). Making sense of what you do in tangible terms can get you the dollars every time!

A call to actionDo you have an innovation story that has yielded dollars and sense? Tell us and others about it by entering our “2012 Maintenance & Reliability Innovator of the Year Award” program. You have nothing to lose and plenty to gain, including some great prizes and bragging rights! Procrastina-tion gets zip. Visit www.reliabilityinnovator.com for full details and entry forms. The deadline is December 31, 2012. Good Luck!

Ken Bannister is a world-class asset management consultant and best-selling author of Energy Reduc-tion Through Improved Maintenance Management Practices. Telephone: (519) 469-9173; or email: [email protected].

Making sense of what you do in tangible terms

can get you the dollars every time.





Harnessing The Power Of

In Reliability Investigations

Harnessing Harnessing When good stuff goes bad (or not)...

In Reliability In Reliability PMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMIPMI

A non-destructive form of

positive material identifi cation

can be a shortcut to uncovering

the root cause of bad welds,

parts failure and more. It also

can be an effective way to

verify on-spec conditions in

your equipment and systems.

Greg Mann and Michael Porfi lioAnderson Laboratories, Inc.

When the maintenance manager

at a Midwestern water treat-

ment plant was confronted

with a wet fl oor in the facil-

ity’s pump room, his crew was perplexed.

The team could see that a cracked pump

housing was the culprit and knew they

could repair it with weld fi ller mate-

rial. What they didn’t know was the type

of material that had been used in the

manufacturing of the pump's housing—

key information that would let them

select the proper weld fi ller. After a brief

discussion, the next step was obvious:

Contact a materials testing laboratory to

determine the material used in the pump.


MT-ONLINE.COM | 17




Defi ning PMI Materials testing labs use a process called “positive material identifi cation” (PMI) to determine the makeup of metallic alloys. As in crime-scene investigations, where a number of tools are used to help unravel mysteries, PMI is one means of tracing a material back to its original Material Test Report (MTR), which is a certifi ed chemical analysis that identifi es metallic components. Originally, PMI was a destructive technique performed using wet chemical analysis methods for comparison to material-grade compositional require-ments. The process was highly accurate—but labor-intensive, time-consuming and costly.

As technology has progressed, advances in technology and electronics have led to portable, handheld X-ray analyzers that are capable of providing valuable chemical information that was previously only available using fi xed laboratory equipment. Portable X-ray fl uorescence (XRF), for example, provides a fast, easy, non-destructive analysis with minimal capital investment (see Sidebar below). Originally designed as a means of identifying high-alloyed corrosion-resistant materials used in the petroleum industry, this technology has demonstrated the ability to provide analysis for most metallic engineering materials used across industry today.

X-ray fl uorescence (XRF) spectrom-etry is a technique for the analysis of elements that has broad application in both science and industry. It’s based on the principle that individual atoms, when excited by an external energy source, emit X-ray photons of a characteristic energy or wavelength. By counting the number of photons of each energy emitted from a sample, an element may be identifi ed.

XRF technology is an outgrowth of Wilhelm Röntgen’s discovery of high-energy radiation, which he dubbed X-rays, in 1895. In 1913, English physicist Henry Moseley advanced the concept when he constructed an X-ray spectrometer to measure the frequency of certain types of X-rays produced from tubes with different electrode materials.

Moseley's results showed that the ordering of the wavelengths of the X-ray emissions of the elements happened to coincide with the ordering of the elements

by atomic number. This relationship is now known as Moseley's Law.

X-rays can be used to identify elements because of the characteristic radiation emitted from the inner electronic shells of the atoms. This radiation is comprised of X-ray photons whose specifi c energies permit the identifi cation of their source atoms. The X-ray photons are emitted during fl uorescence, which is the emis-sion of an X-ray photon that occurs when atoms in a tested material are rearranged by the external energy source. By detecting this photon and measuring its energy, an element can be determined.

While the fi rst commercially pro-duced X-ray spectrometer was devel-oped in the 1950s, modern, handheld XRF instruments have revolutionized the fi eld. Capable of analyzing solid, liquid, and thin-fi lm samples for major and trace components, the analysis is rapid and sample preparation is usually minimal or not required. As noted in

the accompanying article, handheld analyzers allow XRF technology to be used onsite to quickly gather key infor-mation, offering a low-cost alternative to the more detailed, but time-consuming laboratory techniques that involve fi xed machinery and sample destruction. In the industrial maintenance and reli-ability arena, XRF technology is used most often on metals—to determine components of alloys in parts, equipment and raw stock—and on chemicals, espe-cially petrochemicals.

Growth opportunities for these systems were advanced signifi cantly with passage of the European Union’s Regu-lation of Hazardous Substances (RoHS) directive and the Waste Electrical and Electronic Equipment (WEEE) direc-tive, which restrict the use of certain metals in products.

Sources: University of Missouri, National Science

Foundation, Northern Arizona University

A Look Inside X-Ray Fluorescence

Fig. 1. Positive material identifi cation using X-ray fl uorescence (XRF) analysis can provide material validation at any point in the manufacture of a fi nished product.



XRF analyzers work by exposing a material sample to a beam of X-rays generated from an internal source. The X-rays interact with the sample surface, locally exciting atoms that emit energy after excitation. This emitted energy is character-istic of the elements present in the sample and is identifi able as a characteristic energy level. The intensity of these unique energy levels represents the relative concentration of each element of interest that is collected on a solid-state detector. This approach can gather qualitative and often quantitative information. Modern software packages have the ability to identify hundreds of commercially recognizable alloy grades.

PMI using XRF analysis has become an important tool for quality-assurance applications in nearly all areas of industry, but especially in petroleum processing, nuclear building materials, foundry and scrap. Quality systems are increas-ingly demanding complete traceability for all materials used in production. This can mean that at any point in the design, manufacture or assembly of components into a fi nal product, material traceability may be required on demand. When traceability for production machinery is required and not available, material validation using portable XRF may be indicated to provide a PMI link to an original MTR.

Most modern instruments are designed to permit spot analysis for applications. This is ideal for limited-access areas and for inventory control and material-sorting processes that are based on differences in chemistry. Material validation of incoming stock and fi nal assemblies demonstrate that proper materials are being used. And while the XRF-PMI technique is best suited for high-alloy carbon steel, stainless steel, nickel and cobalt materials, it can analyze other materials. Rapid quantifi cation with reliable results is possible with minimum sample preparation, such as a light surface abrasion.

XRF techniques can also be used to recreate lost infor-mation, such as stock-traceability paperwork. The instru-ments used in this type of PMI can provide comparison to hundreds of alloy grades and families.

Industry-accepted procedures and work instructions for PMI using portable XRF devices defi ne acceptance and rejection criteria and aspects to the testing requirements. These consider-ations include minimum required radiation safety training and safe practices to be used when operating this equipment.

XRF limitations and successes PMI using portable XRF has broad applications—but also some limitations. These include the inability to provide anal-ysis of light elements such as carbon. This is an issue in anal-ysis of carbon steel, where carbon may be the only element separating grades of material, allowing for identifi cation of the alloy family or materials. Other light elements, including Mg, Al, Si, P and S, suffer from poor limits of quantifi ca-tion, which may impose further restrictions on the effective application of the technique for some materials.

Still, XRF-PMI remains a highly effective way to verify most materials, as its many successes prove. Here are a few of the many mysteries that have been solved by XRF-PMI:

The case of the leaky water pump…Let’s return to the water treatment plant’s pump problem. In this case, the crew removed the pump and took it to the materials testing laboratory to verify the weld material around the footing and the inner surface of the cover for fi ller-material compatibility to the base material. PMI testing techniques showed the housing to be nickel-based Inconel 825. The analysis also showed the wrong weld fi ller had been used originally, which caused corrosion and the subsequent leak after just a few years of service. Because the characteris-tics of Inconel 825 prevented making a repair weld without heat-treating—which the crew couldn't perform—the plant had to purchase a replacement pump.


Fig. 2. Handheld XRF devices offer a fast, easy way to conduct a non-destructive analysis with minimal capital investment.

Fig. 3. PMI analysis of a leaky water-treatment plant pump verifi ed that the wrong weld fi ller had been used around the footing and inner surface of the cover, thus preventing the maintenance crew from making a repair weld without heat-treating (which the crew couldn't do). Verdict: The plant had to replace the pump.



The case of the critical pressure vessel… In preparation to go online, a new coal plant needed to ensure that its critical components had been built/fabri-cated to specifi ed requirements—which included verifi cation of base materials and weld fi llers. Of particular interest was a fabricated meter housing body with more than 30 fabri-cation sections and welds. Because this critical component would be in daily operation in severe conditions, manage-ment ordered a quick, onsite PMI analysis. Each panel and every six inches of weld material was verifi ed to ensure compliance. After the analyses confi rmed that the unit passed all requirements, the plant was able to put it into service immediately.

The case of the suspected mixed-material fl at stock… When an aftermarket performance-motorcycle fabrication shop was having trouble making bends in formed metal components, a lab was called in to check for mixed material in the stock room. The lab assisted by restoring traceability of two mixed lots of steel. The material intended for the work was alloy steel 4130 (UNS G41300), which contains numerous elements, including 0.80% to 1.10% chromium. Because XRF analysis can detect chromium, as well as nickel and molybdenum, in signifi cant quantities, the process enabled the lab to sort the shop’s materials using this element alone. It determined that some stock contained lower levels of chromium than required (0.03% to 0.05%), and was set aside for other uses.

Fig. 4. Before going online, a new coal plant needed to ensure that its critical components had been built to specifi ed require-ments (which included verifi cation of base materials and weld fi llers). Quick, onsite PMI analyses of each panel of a 30-section fabricated meter- housing body and every six inches of weld material confi rmed that this component passed with fl ying colors. The unit went into service immediately.

Fig. 5. When an aftermarket performance-motorcycle fabrication shop had trouble making bends in formed metal components, PMI analysis helped trace the problem back to two mixed lots of steel in the shop’s stock room.


Putting PMI to work in your operationsWhether monitoring incoming and outgoing materials, reverse engineering, contract satisfaction or product repair, portable XRF provides the ability to quickly verify material-grade composition using non-destructive testing. As an indisputable value-add in an era of high-quality expectations, counterfeit parts and product traceability, this type of PMI could easily become one of your favorite investigative tools. MT

Greg Mann is Chemical Analysis Group Leader/Materials Specialist, for Anderson Laboratories, Inc., in Greendale, WI. Telephone: (414) 421-7600; or email: [email protected].

Michael Porfi lio is Director of Operations at Anderson Labora-tories. Telephone: (414) 421-7600; email: [email protected].


Established in 1939, Anderson Laboratories is an

independent materials testing facility located in

Greendale, WI. Specialties include chemical analysis,

mechanical testing, welding procedure and perfor-

mance qualifi cation, failure analysis, environmental

and corrosion testing, as well as on-site evaluations.

Analyses are performed by skilled personnel with

a combined experience of more than 70 years, and

instrumentation is programmed for the majority of

engineering alloys used in modern manufacturing.

Anderson’s tensile capabilities range from several

grams to 200,000 pounds force, both in tension and

compression. Computer-controlled testing equipment

can determine many properties in both English and

Metric units. Compliance to the appropriate ASTM,

ASME, EN, JIS and other applicable specifi cations is

considered of vital importance in obtaining accurate

mechanical testing results. Anderson Laboratories

is accredited to the International Organization for

Standardization (ISO) 17025 through the American

Association for Laboratory Accreditation (A2LA)

and Det Norske Veritas (DNV). Learn more at www.

andersonlabs.com.

More About Anderson Laboratories, Inc.



At no extra charge, Neil Bloom will be available on Friday, Nov. 30 to mentor attendees on how to implement his RCM process on speci� c systems and equipment. For personal attention, bring your own plant-speci� c P&IDs, plant schematics or design drawings.

Due to high demand, the dates for this workshop have been changed:

November 27-29, 2012Chicago Marriott O’Hare | Chicago, IL

For Full Course Details, Lodging Info And Online Registration, Go To:

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AT THIS WORKSHOP, ATTENDEES WILL LEARN:

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50115_bloom_ad.indd 1 9/4/12 12:57 PM


AUTOMATION INSIDER

Diagnostics Mark The (Trouble) Spot

By Gary Mintchell

Years ago, many of us took part in the “Great Fieldbus Wars” that raged across

the automation side of manufacturing. If you worked on the maintenance and

reliability side of an operation, you were either a bystander—essentially kept

in the dark—or some type of “collateral damage” in these wars. Debates about

the technical merits of different “fi eldbus” technologies and discussions of the

benefi ts to be realized for manufacturers of all types seemed to be never-ending.

Things eventually settled down (as they usually do). The many digital fi eldbuses

that were proposed in the 1990s gradually coalesced into two main ones—Foundation

Fieldbus, promulgated by the Fieldbus Foundation, and Profi bus PA, promulgated by

Profi bus International. Although the initial benefi ts were touted as labor cost savings

due to wiring reductions, the real benefi ts involved enhanced diagnostics. If mainte-

nance and operations could devise ways to capture and use that information, many

additional benefi ts would ensue. These included better information about the status

of processes and the ability to react more quickly to problems.

Going digitalLarry O’Brien, Marketing Director for the Fieldbus Foundation, recently engaged

me in a discussion about the benefi ts of digital networks. “The diagnostics issue

is really an information management problem that can be solved with the tech-

nology we have today,” he observed. “NAMUR NE 107 diagnostics have been part

of our specifi cation since 2010. NAMUR NE 107 is extremely valuable because it

not only creates standard symbols and terms for reporting diagnostic conditions,

it makes it a lot easier to classify diagnostics in terms of severity and root cause.”

O’Brien continued, “When you go completely digital, the volume and type of

diagnostics that are available to you increase exponentially, as does the bandwidth

to report these diagnostic conditions. All of a sudden, you fi nd yourself able to

access thousands of diagnostic parameters at a time from many different devices

across your fi eldbus network.”

Think about the “exponential increase” O’Brien describes: This takes diagnos-

tics into a whole new dimension, where it becomes part of your overall plant

optimization strategy. MT

Gary Mintchell, [email protected], is Co-Founder and Editor in Chief

of Automation World magazine and blogs at www.garymintchellsfeedforward.com.


By Gary Mintchell By Gary Mintchell




For more info, enter 72 at www.MT-freeinfo.comFor more info, enter 72 at www.MT-freeinfo.com

©

Presented ByPresented ByPresented ByApplied Applied Applied Technology Technology Technology Technology PublicationsPublicationsPublicationsPublications

Go For It!Categories:Innovative Devices, Gizmos & Gadgets

Innovative Processes & Procedures

Innovative Use of Third-Party Resources

Categories:Innovative Devices, Gizmos & Gadgets

Innovative Processes & Procedures

Innovative Use of Third-Party Resources

Time Is Running Out!Entries Must Be ReceivedBy December 31, 2012

Time Is Running Out!Entries Must Be ReceivedBy December 31, 2012

Are your innovative juices fl owing?

Are your light bulbs going off?

They better be!

Are your innovative juices fl owing?

Are your light bulbs going off?

They better be!

Sponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators AtSponsored By The Innovators At Time Is Running Out!

Tick...

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Tick...Details & Entry Forms Available At

www.reliabilityinnovator.comGrand Prize Winner And 3 Runners-UpAnnounced In Early 2013

Details & Entry Forms Available At www.reliabilityinnovator.com

Grand Prize Winner And 3 Runners-UpAnnounced In Early 2013


VOLUME 2 / NO. 2 UTILITIES MANAGER | 19

XX UMBIG MONEY TALKS UM

The Power Industry At A Glance: Redux

William C. Livoti, Contributing Editor

This topic may seem repetitious (I’ve written about it several times). But as the Power Generation sector continues to evolve, a discussion of its current state at a given point—

and its future as far as we can see—needs to be revis-ited from time to time. So I’m bringing it up again: What’s the state of the Power Industry today, where is it going and what will it look like over the next decade?

As I monitor developments in Power Generation, I’m fascinated by the changes and—in my opinion—some of the knee-jerk decisions the industry makes these days. In many cases, those reactions are driven by proposed legislation; in others, public sentiment and the media are doing the driving.

One can’t begin to speculate on the future of Power Generation without factoring in the economy. Here we are: at the very threshold of the second decade of the 21st century and we are STILL struggling to recover from the recession/depression (depending on whom you ask or what you’re reading, hearing or seeing). And, now, with the recent devastation wrought by Hurricane Sandy, that struggle to recover probably won’t be getting much easier or moving much faster for a while. Even before Sandy made landfall, though, most economists felt that 2013 wouldn’t be very pretty.

Current stateLet’s look at the state of the Power Industry from the perspective of Fall 2012 (pre-Hurricane Sandy):

• The U.S. coal industry is bracing for tighter—and more costly—regulation of its waste. The associ-ated costs, of course, will be passed on to the coal industry’s customers (i.e., the power generators).

• Natural gas seems to be the fuel of choice—for now. The power companies have had little control over this matter due to legislation and public sentiment.

• Renewable energy seems to be moving forward—and should continue to do so as long as the incen-tives for it remain in place.

So much for the big power producers…For the rest of us—end-user consumers—the primary concern should be how to cost-effectively run, protect and ensure the sustainability of our power-using opera-tions. Fortunately for us, there is (fi nally) renewed interest in Combined Heat and Power (CHP).

Leveraging available technologiesCHP is an effi cient, clean and reliable approach to generating decentralized power (DE) and thermal energy from a single fuel source. CHP can increase operational effi ciency and decrease energy costs, while reducing emissions. Makes sense to me. Let’s look at a few more advantages to CHP and DE.

Centralized electric power is produced at large generation facilities and shipped over transmission and distribution grids to end-users. DE and CHP offer several advantages over centralized power:

• Distributed-generation power is produced near its point of use, minimizing the risk of power loss.

• CHP’s multiple energy sources (steam, electricity, hot water) maximize energy (fuel) usage.

• Control of electrical cost reduces impact of peak-demand charges, power-factor correction, etc.

Future stateLike other industries, the Power-Gen sector is evolving. As I have often written, though, all indus-tries need to adapt to the times, be proactive, avoid knee-jerk reactions and leverage all available tech-nology. That said, it may also be benefi cial to look into the past for solutions today. UM [email protected]



26 | utilities manager Volume 7 / no. 4

Savvy energy staffers

know that monitoring

and tracking the

performance of their

pumping systems can

be a very profi table

undertaking. Just how

profi table, though, often

hinges on which key

performance indicators

are followed over time.

A noted expert suggests

a combined approach.

Gunnar Hovstadius, Ph.D.Consultant

Pump systems in industry often are connected to various types of monitoring and control systems. Typically, end users will only monitor one or several parameters, such as fl ow rate, pressure, power and/or current. That rather limited type of monitoring, though, really doesn’t provide a full view of a pump’s performance.

By just monitoring a few individual parameters, a company risks overlooking impor-tant information about system performance as a whole.

It is diffi cult to fi nd useful key performance indicators (KPIs) to track in the quest for improved effi ciencies in a pumping system. Tracking maintenance costs by them-selves certainly can provide good data on the health of a system. But, in many cases, better information can be obtained by combining several parameters into a one KPI and following it over time. One way to do this is to relate fl ow and power, rather than to simply measure them independently. Let’s examine how this can be done.

Fluid system relationshipsFor pump systems, the relationship between fl uid power, fl ow rate, pressure (head) and specifi c gravity of the fl uid can be expressed in the following equations:

Fluid Power (bhp) = Head (ft ) * Flow (gpm) * specifi c gravity (Equation 1) 3960

In order to determine the electrical power used by the system it is necessary to divide the fl uid power by the effi ciencies of the different components that produce it: i.e. motor, drive and pump effi ciencies.

Specifi c energySpecifi c energy (E

s) is good measure to use for calculating the cost of pumping. This is

the energy used to move a certain volume through the system. It is measured as Watt hours/gallon, or any other suitable units, and it has the advantage of being a direct measurement of the cost of pumping once you know the cost of energy. (This is the same as measuring the miles per gallon for a car.)

Energy Used = Specifi c Energy (Equation 2)Pumped Volume

Es = Pin * Time = Pin (Equation 3)V Q

Fig. 3. Controlling output of a centrifugal pump

Using KPIs To Monitor And Improve Pump Performance

UM

MT was proud to publish this article by one of the most recognized and respected technical experts in the pump world as part of our very fi rst Utilities Manager supple-ment in February 2006. Almost seven years later, its recommendations are as relevant as ever for reliability- and effi ciency-focused users of pumping systems.

UM

Volume 7 / no. 4 utilities manager | 27

Fig. 1. Specific energy as a function of head for

different overall efficiencies

Fig. 2. Combined motor/drive efficiency when attached to

different drives (DOE)

Fig. 3. Controlling output of a centrifugal pump

12.0

10.0

8.0

6.0

4.0

2.0

0.00 100 200 300 400 500 600 700 800 900 1000

30%

40%

50%

60%

70%80%90%100%

Total Head (ft)

Spec

ific

Ener

gy (W

h/G

allo

n)

20 40 60 80 100

88

86

84

82

80

78

76

74

72

70

Shaft Power, % rated

Com

bine

d Ef

ficie

ncy,

%

Best

Average

Worst

50 60 70 80 90 100

88

86

84

82

80

78

76

74

72

70

Speed, % rated

Com

bine

d Ef

ficie

ncy,

%

Best

Average

Worst

Note: 38kW, 2-pole, standard efficiency motor (89% efficient @ full load)

45

30

15

0

0 50 100 150 200 250

Hea

d, (m

)

Flow, (l/s)

System Curve

Original Operating Point

Pump Head Capacity Curve

Pump Operation When Using aVariable Speed Drive

Reduction in PressureLoss Using a vsd

Pump Operation WhenThrottling Discharge Valve

UM

28 | utilities manager Volume 7 / no. 4

As seen in equation (3), the instantaneous value of the specific energy equals the input power divided by the flow rate. Using the equation for Fluid Power and dividing by the various efficiencies we get Equation 4:

Input Power (kW) = Head (ft) * flow (gpm) * Sp. gravity* 0.75 ηdrive * ηmotor * ηpump * 3960

From this we get Equation 5:

Es = Head (ft) * Sp. gravity * 0.75 η

drive * η

motor * η

pump * 3960

If there is no drive in the system, the corresponding term is replaced by 1.

Specific energy is a useful measure for comparing different system solutions and the cost of pumping. In systems where the flow is constant, this is a simple task by using the equations above. In systems with varying flow rates, it becomes a little more complicated.

First, Es needs to be calculated as a

function of flow rate, which requires information from pump, motor and drive manufacturers. The pump manufacturer has to provide pump curves for variable speed operation, while the motor and drive suppliers have to provide efficiency curves as a function of load and speed.

Specific energy (Es) is a linear function

of the head if the other factors are constant. We can, therefore, plot it as a function of head for different overall efficiencies. See Fig. 1 where the overall efficiency is the product of the different component efficiencies from Equation 5.

The lowest line in the diagram represents 100% effi-ciency, which, of course, is not reachable. If input power, flow rate and head are available at a specific duty point, it is relatively easy to mark the value of E

s as a point in Fig.

1, and then interpolate the overall efficiency. Using a program such as the U.S. Department of Ener-

gy’s (DOE’s) Pump System Assessment Tool (PSAT), the best available pump and motor efficiencies for a specific duty point can be found and a lowest possible specific energy can be calculated for the duty point in ques-tion, if there is no VSD involved. It is harder to find out what the efficiency of a motor/drive combination is, as it varies depending on how well these two components fit together. The drive, if present, introduces additional losses in the motor that should be accounted for.

(Fig. 2 gives an idea about the combined efficiency of a drive and motor. Motors react differently to different drives. It is, therefore, a good idea to buy a drive and motor

from the same manufacturer to assure a combination that is well matched. Modern drives have improved consider-ably compared to those available some years ago.)

After using the PSAT, a new point below the first can be plotted in the specific energy diagram. (See Fig. 4, where this has been done.) Potential savings from using better-matched equipment at the upper duty point can be calculated from the difference in specific energy. PSAT does it automatically.

Pump control methodsIn many applications, pump flow is routinely controlled by throttling a control valve on the pump discharge. The throt-tled valve can be controlled to maintain a designated flow rate, pressure or any other parameter to satisfy system needs. When a valve is used to control flow, the flow rate is decreased by increasing resistance in the pipe system and moving the operating point up the pump head curve as shown in Fig. 3.

From the information in Fig. 3, it is possible to estimate the head necessary to produce a certain flow in the system if there were no throttling. (One way of getting the pump to operate at such an unthrottled duty point would be to use a variable speed drive to reduce pump output.) Head requirement without throttling can be read on the original unthrottled curve below the throttled oper-ating point. Using PSAT, the best motor and pump efficiencies for this unthrottled operating point can be found and Es can be calculated and plotted in the specific energy diagram. The result is a good graphical repre-sentation of where the system is operated from a cost point of view and where it could

operate if optimized and without throttling losses (see Fig. 4).In the Fig. 4 example, the original specific energy is

about 4.8 Wh/Gallon at 700 ft. The optimized pump/motor combination is about 2.8, and the specific energy with an optimized pump/motor combination without throttling losses is around 1.2 Wh/Gallon at 300 ft.

Avoiding throttling losses is of the utmost importance when it comes to economic pumping. In the case of varying flow rates, E

s has to be calculated for different flow rates. The

corresponding head is obtained from the pump curve. The total operational cost can be obtained if the flow distribu-tion as a function of time is known.

Key performance indicatorsAs indicated above, it is very useful to track the performance of a pump system not only to see how efficiently it is oper-ating relative to optimum, but also to be able to easily and quickly discover deviations from the norm. It is, therefore, suggested that power-divided-by-flow rate would be a very useful KPI if flow rate and power are monitored.

There is a strong relationship between

reliability and efficient operation. Inefficiently

operated pumps usually cost more, not only to run,

but also to maintain.

UM

Volume 7 / no. 4 utilities manager | 29

In many industries, motor current is monitored instead of power. The current is roughly proportional to power and can be used as a substitute for power. In both cases, the quotient will be a very good measure of the system efficiency and also sensitive to system changes.

In a recent assessment of a pump station, it was found that one of three parallel pumps was drawing about 100kW, but contributed almost nothing in flow. The pump was practically dead headed by the other two pumps since the wear rings were badly worn and the delivered head, therefore, was lower than for the other pumps. As the system was set up to monitor total flow and motor currents independently, the problem with the pump was hidden. If the current-divided-by-flow rate for the system as a whole had been monitored and tracked, the problem would have caught someone’s attention sooner.

Another very valuable performance indicator is the repair record of a pump. Pumps are generally quite reli-able. If they are operated close to their best efficiency points (BEPs), they should last for a long time. If a specific pump deviates from the rest of the pumps in a facility, or shows a rising curve for the cost of main-tenance, there is good reason to investigate it further. Remember, there is a very strong relationship between reliability and efficient operation. Thus, an inefficiently operated pump usually costs more all the way around–not only to run, but also to maintain.

ConclusionPump systems should be continuously monitored and tracked using key performance indicators (KPIs) to discover performance improvement possibilities.

Maintenance costs are particularly telling. Don’t under-estimate the benefits of using maintenance cost records for individual pumps as KPIs.

Power divided by flow rate also can be a very useful KPI for the task. This method gives a number that is directly proportional to the cost of pumping and is sensitive to changes in the system. Furthermore, it can easily be demonstrated graphically, so that operators get a visual picture of how efficiently their system is operating.

Tracking these types of KPIs will provide crucial clues in your quest for improved efficiency. MT

12.0

10.0

8.0

6.0

4.0

2.0

0.0

0 100 200 300 400 500 600 700 800 900 1000

30%

40%

50%

60%

70%

80%90%100%

Total Head (ft)

Spec

ific

Ener

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h/Ga

llon)

Fig. 4. Specific energy at different operating points

Following a long, distinguished career with ITT, including many years as Director of Technology for the corporation’s Fluid Technology business (i.e., ITT Flygt, Goulds Pumps, etc.), Gunnar Hovstadius went on to build a highly successful consulting prac-tice in the field of pump-system efficiency. When he wrote this article in 2006, he was spending much of his time consulting with the Industrial Efficiency Alliance, based in Portland, OR. These days, Dr. Hovstadius continues to travel for and work with industrial and governmental clients around the globe. Among other things, his busy workload currently includes serving as a Pump System Optimization Expert for the U.S. Department of Energy and UNIDO. Email: [email protected].


UM

30 | UTILITIES MANAGER VOLUME 7 / NO. 4

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Schneider Electric’s recently released StruxureWare™ Power Monitoring for Data Centers incorporates a full range of capabilities that let facility teams identify, respond to and investigate the root causes of power-system events; measure utility and facility power quality; measure power usage effective-

ness (PUE); calculate power distribution losses; understand UPS and generator system power loading; and audit generator system testing. The software actively monitors and analyzes the electrical power distribution infrastructure of a data center, including medium voltage, low voltage and IT fl oor power. Comprising hardware, software and communication components and integrated with professional services, all elements are modular and interoperable to provide better continuity of supply, enhanced safety and easier installation. In addition to providing deep insight into a data center’s electrical system, this new tool can help trim energy-related operating costs in the facility and boost the ROI of its electrical assets. The software’s compatibility with third-party systems will make it easy for a facility to leverage its existing investments.

Schneider ElectricPalatine, IL

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According to U.S. Tsubaki, its Lambda Chain delivers long-term clean operation without additional lubri-cation. Packaging, food processing or any application that must be lube-free or where manual lubrication is unfavorable are just some of the applications for which this product is suited. The company points to a

number of additional features and benefi ts that Lambda Chain offers, including, among other things:

◆ Strong, reliable operation, with longer wear life than standard chain◆ Less downtime and reduced maintenance costs due to the lube-free design◆ Oil-impregnated bushings that minimize chain elongation◆ The ability to perform well in temperatures up to 302 F◆ Smooth roller engagement that cuts sprocket wear and replacement costs◆ The same maximum allowable loads as U.S. Tsubaki’s standard chains

Lambda Chain is available in both drive and conveyor (with attachments) styles.

U.S. Tsubaki Power Transmission, LLCWheeling, IL

ccording to U.S. Tsubaki, its Lambda Chain delivers long-term clean operation without additional lubri-

Lube-Free Chain Reduces Operating Costs

Lambda Chain is available in both drive and conveyor (with attachments) styles.

UM


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According to Platinum Control Technologies, there’s more to burner management than lighting an igni-tion. Solutions like the company’s scalable BMS-731 system can help end-users in the oil and gas arena record essential data and safely automate heating processes, thus reducing injury risk, maximizing well

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Henry Dreisilker came to America from Germany in 1954 seeking opportunity and gainful employment. Hard work and integrity landed him his fi rst job in a small motor repair and appliance business. Seven months later, he purchased the business, founded Henry Dreisilker Electric Motors and Appliance Service and began by specializing in commercial motor repair and sales. Combining old-world craftsmanship with advanced technology, the company grew steadily from three employees to over 120. Today, Dreisilker Electric Motors, Inc. provides complete electric motor solutions to commercial, industrial and municipal customers nationwide. It distributes new electric motors, parts, accessories and controls from major OEMs and offers a range of value-added, reliability-related services.

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Even so, the use of these devices has not made listening an obsolete art. Sound remains an important element in the early recognition of deteriorating conditions and in validating potential faults in rotating machinery. When used in conjunction with vibration waveform plots, playback of recorded sounds supports the existence of a fault, helping to convince persons who may have diffi culty reading graphic plots. Often, analysts must deal with managers who see only meaningless squiggly lines when shown a waveform or spec-tral plot. Add sound, and the lines suddenly make sense.

Put on your headphonesThe sounds coming from machines provide important clues that may be missed by relying on vibration data alone. That’s why I advocate the wearing of headphones by technicians who are collecting vibration data. I always try to watch the data as it is being acquired to detect abnormalities in amplitude or

pattern. In most plants, there’s so much noise-making activity (i.e., associated with vehicle traffi c, people, machines, etc.) that it can be diffi cult to watch every reading as it is taken. By listening to the accelerometer signal, it’s possible to instantly recognize a change from the normal hum of a smoothly functioning machine.

I’ve been wearing headphones during route collec-tion of vibration data for many years in order to hear unfi ltered sounds covering the entire frequency spec-trum. Emerson’s portable CSI 2130 Machinery Health Analyzer records the waveform vibrations emanating from a machine. Anytime I hear something abnormal, I make a “note” on the analyzer to take a careful look at the waveform data after uploading it to a computer. When reviewing the data later, I’ll see the note calling attention to the waveform collected from that particular machine.

Over the years, technicians have listened for sounds made by machines in order to

identify evolving problems as early as possible. By the time a fault becomes serious

enough to be heard in a noisy plant, however, it could be too late to prevent damage.

Now, portable vibration collection devices aid in the early detecting of problems and

maintaining the health of rotating machinery.

Do you hear what I hear?

Jim CroweJim Crowe Vibration Technologies

Listen For Machine Faults:

Let Sounds Verify Vibration

DataAudio-replay capabilities have enhanced this author's

vibration-analysis toolkit and could be doing the same for yours.©STOCKSHOPPE - FOTOLIA.COM



The analyzer generates plots of frequency spectra as well as the waveforms. Analysts look at the waveform to determine the severity or impact of the vibration, and they look at the spectrum to determine the cause—be it imbalance, a bearing defect, a lubrication-related issue or something else. The infor-mation can later be uploaded to computer-based software for detailed analysis. That's where the latest version of Emer-son's AMS Suite: Machinery Health™ Manager comes in.

It incorporates the ability to convert the audio portion from waveform data collected periodically or online. Users can actually hear an audible indication of a problem.

The easiest way to do this using the Machinery Health Management software is to plot the waveforms to be played, right-click on the waveform, and select “Play Audio” to launch the Waveform Audio Player (Fig. 1). A loop button allows repetition of short-duration audio replays for close study.

Fig. 1. Waveform audio replay starts by clicking on the Play Audio button.

Fig. 2. Two waveforms are easily compared using the audio replay.



What you’re listening forThe sound of a waveform collected from a “problem” machine is distinct from that of a similar machine where no fault is present. Similarly, waveforms collected from one machine at different times can be used to demonstrate a change in performance.

In practice, any vibration data obtained during a routine collection can be used as a benchmark, as sound from each machine is obtained at the same time as the physical vibration data. If an abnormal sound is heard on a subse-quent round, the audio portion of each waveform can be compared, as in Fig. 2. This can be played back or sent to someone with minimal understanding of vibration data in a format anyone can grasp. Simply put, it’s like listening to the machine at different times with a stethoscope.

Some caveats in the use of this technology…

■ Care must be taken to be sure both recordings are set at the same scale and not to let each fi le autoscale. The volume on both clips should be the same as when they were generated. This way they will all be set at the same scale. When they are played back with the loop icon selected, the recording will play in an endless loop.

■ Waveforms used for comparison should be acquired using the same units and same fmax setting. If different fmaxes are used and the energy from a fault is above the lower frequency selected, the abnormal sound on the lower one will not be heard. If the data collection technician thinks he/she is hearing high-frequency energy from a fault that may be the result of poor lubrication, it’s necessary to acquire and analyze a waveform with a much higher fmax than normal route data so it can be heard when

replayed. Remember: The signal that a technician hears is not fi ltered, so it could be a lot different than the low-pass fi ltered data acquired by the portable data collector.

■ Long-term time waveform data can also be taken if the analyzer has Transient capability. This data can also be stored and played back as a sound fi le. Any energy that is above a chosen fmax will be fi ltered out and not heard on replay.

A real-world value propositionData taken recently on a motor with a severe bearing inner-race defect was compared with data from a motor on an identical machine (since no historical data on the faulty bearing was available). These sound clips were attached to a vibration report that was sent to the maintenance manager to illustrate the severity of the defect. This individual had no vibration training, but the sound clips clearly illustrated the difference between the machines in a way he could recog-nize. As a result, the motor was changed out before the faulty bearing could fail and cause damage to the machine—and possibly disrupt production.

An unplanned failure of this particular machine would have resulted in three to four hours of downtime. I maintain that this type of situation—as well as other costly unsched-uled events—can be avoided by listening to sounds recorded during vibration collection. MT

Retiring after 30 years in mechanical maintenance at the Alcoa Warrick Operations (including 18 of them spent as a Reliability Technician), Jim Crowe established Jim Crowe Vibration Analysis, based in Rockport, IN, in 1999. Telephone: (812) 430-2457; email: [email protected].

Sounds clips can clearly illustrate machinery

vibration problems, even for individuals who have

had no formal vibration training.


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Moving through state-of-the-artThe EYESIM solution is the centerpiece of a new state-of-the-art training center that will help bring online a new generation of zero-emission IGCC power plants. The formal EYESIM site acceptance test was completed on July 16, 2012, after a complete plant startup, culminating a long-term project that began in 2008, when Invensys was awarded a contract by the DOE to simulate the IGCC process using its DYNSIM process modeling software.

“Training IGCC operators require us to simulate the chem-ical process of coal-gasifi cation with CO2 capture together with combined-cycle power generation,” says Stephen E. Zitney, Ph.D. and Director of NETL's AVESTAR Center. “No one has ever done that before, but now with help from Invensys, we can simulate almost any operating scenario, including disturbances, malfunctions and emergency shut-downs. We can even train operators on different coal and biomass feed stocks. The developments we’ve accomplished and the technology we’ve installed at the AVESTAR Center show the growing viability of IGCC power plants and indicate the growing demand for a well-trained workforce. We look forward to working with Invensys as we train and enable the clean-coal operators of the future.”

The U.S. Energy Information Administration estimates that the United States has enough coal to last more than 200 years, but plants that continue to use conventional fossil-fuel tech-nologies will emit unacceptable levels of CO2 and other pollu-tants. IGCC with carbon capture offers an environmentally friendly alternative by capturing 90% of the CO2 produced in traditional fossil-fuel-burning processes while at the same time reducing sulfur, mercury and other NOx emissions. The IGCC process is more environmentally friendly than other coal-burning processes, but is also extremely complex and requires skillfully trained personnel to operate what is effec-tively both a chemical processing plant and a power plant.

The EYESIM solution is also fully integrated with plant operating models, using the DYNSIM modeling solu-tion, so actions taken by a fi eld operator affect the plant’s process, and actions performed in the control room change the information visible to the fi eld operator. Fully interac-tive animations respond and react to the actions of plant personnel, illustrating how various pieces of equipment will operate under almost any scenario and condition. As a result, fi eld and control-room operators learn to collaborate and perform as a team.

Benefi ts here, now and laterCombining high-fi delity, real-time IGCC dynamic simula-tion with a fully interactive 3D virtual plant environment allows both control room and fi eld operators to coordinate their actions and collaborate as a team. Additional benefi ts include training for safety-critical tasks, rare occurrences and emergency shutdowns. Aside from training, education and research applications, the DOE and its partners will use these realistic, hands-on, dynamic simulator-based systems to showcase clean-coal technologies that support a clean energy future.

“Our EYESIM immersive training system makes the theoretical and conceptual side of training more realistic and tangible by allowing operators and trainees to become familiar with the layout of the physical plant and how it will operate under almost any condition,” notes Tobias Scheele, Ph.D., Vice President, Advanced Applications, Invensys Operations Management. “The solution combines stereoscopic 360-degree views with collision effects, sounds, lighting and weather conditions to give the plant operator a realistic walkthrough environment and simulated hands-on experience with the plant’s physical operation, helping plant personnel improve operations excellence.”

A separate EYESIM virtual-reality training system will be installed and commissioned at West Virginia University in Morgantown for student education and simulator training as part of assigned course work. In addition to training and plant design functions, the NETL and its research and devel-opment partners, including Invensys, will use the simulator to showcase the feasibility of clean-coal technology as a means to support future electrical generation demand without emit-ting environmental pollutants or greenhouse gases.

By offering a comprehensive IGCC training program, the DOE aims to develop a workforce well prepared to operate, control and manage commercial-scale gasifi cation-based power plants with CO2 capture. MT

To learn more about AVESTAR and the NETL, visit www.netl.doe.gov/avestar. For details on other Invensys SimSci-Esscor simulation solutions, visit iom.invensys.com/EN/Pages/SimSci-Esscor.aspx.

A gas-leak training scenario displayed in the IGCC immersive training system at NETL’s AVESTAR Center.

SUPPLY CHAIN LINKS


Eni Refi ning and Marketing, Italy’s largest international refi ner, is using a novel training solution built on Invensys Operations Management simula-tion technology. Combining immersive 3D virtual-reality software with its own refi ning expertise, Eni has installed EYESIM training kiosks at several of its facilities around the globe, providing a unique approach to refi nery process training.

Using proven Invensys simulation software, which has been integrated with a gaming console controller, trainees, operators and other personnel can walk through a virtual refi nery, learning process operations and procedures. They can also score and improve their performance with unrestricted access to the kiosks, which offer a fully lifelike plant experience. The focus is on reducing risks, improving safety and increasing the productivity and effi ciency of the refi nery.

The EYESIM solution enables engineers and operators to see and safely interact with the refi nery and the processes they control. Applying gaming and other skills familiar to a new generation of employees, the solution combines virtual-reality technologies with high-fi delity process and control simulation, computer-based maintenance and documentation management and other applications to provide a highly realistic and safe training environ-ment for improving operating effi ciency and skills.


More Real-World Simulator Training


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SOLUTION SPOTLIGHT


Satisfying An Appetite For Real-Time Data

Upon acquiring a new manufacturing plant, a multi-national food manufacturing company discovered that the operation’s custom-made batch software and

human-machine interface (HMI) system were on the way to becoming obsolete. Translation: increased maintenance costs, wasted batches and limited production flexibility.

Not only were the plant’s legacy systems aging and out of compliance with the new owner’s corporate standards, they were no longer supported by the OEM or by company resources. The custom-batch system had no scheduling or historical batch record-keeping capabilities, making it difficult to manage production. Often, managers only became aware of wasted batches when shortages of raw materials for given recipes occurred—because needed ingredients had already been used. Moreover, the system’s inflexibility prevented the plant from making software-programming changes for routine enhancements.

Bringing in the newThe new owner wanted a new solution—in the form of off-the-shelf batch software and an HMI system to deliver increased control and visibility. This solution needed to generate detailed records of batch and process data, as well as integrated enter-prise resource planning (ERP) system data. It also needed to be flexible enough for repeat uses in other corporate operations.

The company contracted the services of control and information-systems integrator Cybertrol Engineering (Minneapolis, MN), a member of the Rockwell Automa-tion PartnerNetwork™ program. Cybertrol implemented a manufacturing-intelligence solution utilizing the Rockwell Automation FactoryTalk® software suite.

The FactoryTalk suite includes FactoryTalk Batch soft-ware, which provides operators with electronic reports and access to real-time data through tighter integration with the plant’s ERP system. The enhanced integration allows the company to drive the batch schedule from—and store all recipes in—the ERP system. All procedures remain in the FactoryTalk Batch software, allowing for enhanced reli-ability for recipe execution and flexible product changeover, and less operator actions and probability for operator error.

Cybertrol also implemented:

n FactoryTalk VantagePoint EMI software to provide data analysis to business network users, as well as to plant oper-ators who can use it to gain access to historical production data throughout the facility: This software taps into infor-mation from systems across operations that have been automatically identified, gathered and stored by Facto-ryTalk Historian software. FactoryTalk VantagePoint EMI provides management reports to track and compare batch

cycle times, so users can identify and correct maintenance and procedural problems that impact productivity. For example, if a transfer pump begins to wear, operators will see transfer times increase and have the ability to schedule a rebuild with minimal interruptions to production.

n FactoryTalk View Site Edition software to provide production personnel the ability to set up unique param-eters, like agitator and transfer pump speeds: Utilizing FactoryTalk Security not only helps protect critical machine settings, it also requires supervisor overrides for certain functions, reducing losses previously caused by incorrect operator actions.

Counting on results*As Ben Durbin, Cybertrol President, notes, “With plant floor and ERP system integration, plus access to real-time data, our client was able to immediately identify and correct produc-tion issues that had been causing lost batches all along.”

Thanks to Cybertrol and Rockwell Automation, the plant estimates it now saves at least one batch per month. Based on this type of proven success, the corporate business has already rolled out similar manufacturing-intelligence solu-tions in its other facilities. MT*Specific results may vary for other customers.

Rockwell AutomationMilwaukee, WI

Special To MT


Allen-Bradley, FactoryTalk and PartnerNetwork are trademarks of Rockwell Automation, Inc. Trademarks not belong- ing to Rockwell Automation are the properties of their respective companies.


CAPACITY ASSURANCE MARKETPLACE




Multiprocess Welding Power Source

Miller Electric’s Multimatic 200 is an

all-in-one, portable multiprocess welding power source capable of performing MIG, stick and TIG welding processes in one compact design. The Auto-Set Elite feature allows operators to quickly and easily set weld parameters based on material type and thickness, as well as fi ne-tune those parameters to match each specifi c application. The system weighs 29 pounds, and connects to common 120- and 230-volt power receptacles with the Miller-exclusive MVP multi-voltage plug.

Miller Electric Mfg. Co.Appleton, WI

Elite feature allows operators to quickly and easily set

Pipe Inspection Software For Tablets

Designed for touchscreen data entry

on a tablet PC, WinCan ProT-ouch from Pipe-line Analytics allows operators to easily document pipe inspections made with a video crawler, push camera or zoom survey camera. ProTouch generates basic reports that include schematics and captured images, and can also export inspections to freely distributable viewer software. Data is fully compatible with the company’s WinCan v8, which means an operator can transfer the data to exploit v8’s enhanced reporting, querying, GIS features and standards support.

Pipeline AnalyticsPittsburgh, PA

Water-Soluble Cutting Fluid

Prolong® Super Lubricants notes that its

Ultra Cut 1 Water Soluble Cutting Fluid can help eliminate uneven cuts, reduce power consumption and increase tool life. Designed to maximize results in sawing, grinding, boring, turning or milling processes that require coolants, it protects metals from corrosion and extends the life of cutting solutions and tools. It also can be used as a fl ood coolant and for making emulsions in machine shops. Ultra Cut 1 comes in gallon-size bottles, 5-gallon buckets and 55-gallon drums.

Prolong Super LubricantsPomona, CA

VSD-Equipped Single-Stage Compressor Lineup

Sullair has expanded its line of V250S

Single-Stage Rotary Screw Air Compres-sors with models that include Variable Speed Drive (VSD) technology. Based on the same footprint and operating characteristics of the company’s comparable constant-speed designs, the new units incorporate Sullair’s WS Microprocessor Controller. Featuring an easy-to-read graphics display that highlights frequently used compressor information, this control system is programmed to monitor all necessary functions and provides a WSPC interface for service diagnostics and trending capabilities. Sullair’s VSD-equipped models range from 250 to 350 hp, with capacities of 1085 to 1580 cfm, and pressures of 100 to 125 psig.

Sullair Corp.Michigan City, IN

on the same footprint and operating characteristics of the

milling processes that require coolants, it protects

line Analytics allows operators to easily document pipe




Expanded ElectronicParts Catalog

Allied Electronics has released its 2013 Allied Catalog, which showcases 10,000 new products

in addition to the 115,000 that were already featured in the book. New to this year’s catalog is an extensive product offering from Siemens. Other new suppliers include FLIR Commercial Systems, Interfan, Keithley Instruments/Tektronix, Spacecraft, wakefi eld-vette, WIKA Instrument Corporation and Yokogawa. This year’s catalog selection is complemented by over two million parts accessible online.

Allied Electronics, Inc.Fort Worth, TX

Industrial Diesel Engine With Notable Power Density

Caterpillar’s latest generation of its Cat® C9.3 ACERT™ industrial engine

is designed to meet U.S. EPA Tier 4 Final/EU Stage IV emis-sion standards. The engine is a six-cylinder, 9.3-liter platform that produces excellent power density, with ratings from 300-400 hp (224-298kW). It is equipped with a robust, fully-integrated Clean Emission Module (CEM), which includes a diesel oxidation catalyst (DOC), diesel particulate fi lter (DPF), and selective catalytic reduction (SCR) technology that reduces NOx.

Caterpillar, Inc.Peoria, IL

fully-integrated Clean Emission Module (CEM), which includes a diesel





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Fluid Storage With Spill Containment

IFH Group’s Fluid Storage & Dispensing Systems incorporate spill containment

systems that can prevent costly clean-ups, make fl uid dispensing easier and provide compliance with EPA regulations such as 40 CFR 264.175. All 21 IFH standard centralized systems are equipped with a drip pan, making dispensing of fl uids into containers from self-closing faucets quick and spill-free. For all two-, three- and four-container systems with outboard console mounting, a spill containment pan is provided at the base of the system to collect any accidental spills.

The IFH Group, Inc.Rock Falls, IL

all two-, three- and four-container systems with outboard console mounting, a spill containment pan is provided at the

High-Speed Gearbox Series

David Brown’s HX high-speed gearboxes are designed specifi cally

for critical applications such as pumps, compressors and generators in the oil and gas and power industries. The line’s core platform is easily adaptable to suit all pack-aging requirements through a fl exible case design and multiple oil inlet/outlet positions, combined with optimized oil fl ow. The gearboxes are fully compliant with major international standards such as API and AGMA. Bearing choices are available to suit all application demands.

David Brown Gear Systems Ltd.Huddersfi eld, UK

positions, combined with optimized oil fl ow. The gearboxes





CONTROL SYSTEMS

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Steam-System Component Literature

Spirax Sarco has released the 14th edition of its Mechanical Product

Manual. Subtitled “First for Steam Solutions,” it provides a complete range of information needed to evaluate and apply steam-system components. It includes technical information about Spirax Sarco’s regulators, steam traps, condensate recovery, strainers, high-purity, liquid drain traps, pipeline auxiliaries, humidifi cation and engineered products. For a free copy, visit www.spiraxsarco.com/us or contact your local Spirax Sarco representative.

Spirax Sarco, Inc.Blythewood, SC

system components. It includes technical information about Spirax Sarco’s regulators, steam traps, condensate

DPM-Reading Technology Goes Wireless

Cognex Corp.’s DataMan® DPM-reading technology has gone mobile. The

industrial-grade DataMan 9500 mobile computer can even the most challenging DPM (direct part mark) codes in applications where operators need to view the data on an integrated handheld device. Designed for the factory fl oor, the product features the 2DMax™ algorithm for decoding diffi cult-to-read codes, including dot peen and laser-etched, on any metal surface. Small and lightweight, the computer connects to factory networks via 802.11 a/b/g protocols on the 2.4GHz and 5GHz bands for real-time wireless communication.

Cognex Corp.Natick, MA

the data on an integrated handheld device. Designed for the




MCC Combats Arc Flash Incidents

According to ABB, its new MNS-MCC Low Voltage Motor Control Center is the fi rst product of its kind to address the causes of arc

fl ash incidents while providing superior equipment and personnel protection. For fl exibility and mini-mization of downtime, the product offers a plug-in type, withdrawable and full-height-unit technology, with up to 4000A horizontal bus and 1600A vertical bus. The design is available in a variety of unit types, including starters, softstarters, variable frequency drives and mains and feeder breakers. The company notes that no other MCC allows operators to remove a unit with the door closed, with no tools and without disconnecting wires.

ABB Low Voltage Products New Berlin, WI


High-Performance Metalworking Fluid

NuSoL® Alumax 89 from Chemtool is specifi cally formulated for all operations on non-ferrous alloys, exotic ferrous alloys

(including titanium), Inconel and Monel, plastics and composites. According to the manufacturer, while NuSoL Alumax 89 provides the type of wetting, detergency and boundary lubrication that’s associated with other NuSoL metalworking fl uids, this product incorporates a new performance-enhancing additive package that demonstrates lower foaming characteristics for typical use concentrations (5-15%).

Chemtool, Inc.Rockton, IL


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Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certifi cation exams. Exams can be arranged to take place at your site immediately following the training.

For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certifi cation Domain of Knowledge Content.Contact ENGTECH Industries Inc at 519.469.9173 or email [email protected]

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Compressor Solutions For Large-Scale Oil & Gas Applications

York by Johnson Controls provides a single-source solution for large-scale process applications in the oil & gas industry. These compressors and controllers

ensure facilities stay up and operational while lowering maintenance costs and increasing effi ciency. The company’s Quantum™ HD controller offers secure networking features that enable remote control and systems monitoring from any Web-enabled device. The controller has been developed to operate as a single platform with custom programmed features, including compressor sequencing, condenser control, digital output control and real-time historical trending. The enhanced design features a high-defi nition display, as well as open access to all points for easy service and components that can be individually replaced.

Johnson ControlsMilwaukee, WI

Heavy-Duty Slurry Pumps

The ITT Goulds Pumps XHD Extra Heavy-Duty Lined

Slurry Pump is designed for extreme slurry appli-cations and can replace existing slurry pumps with minimal baseplate and piping changes. The pump can be maintained even while running with more accessible and adjustable parts than other slurry pumps. The XHD is intended for applications such as primary metals, mineral processing, non-metallic mining, power utilities and sand and aggregates.

Goulds PumpsA subsidiary of ITT Corp., Inc.Seneca Falls, NY

pump can be maintained even while running with more accessible and adjustable parts than other slurry pumps. The


For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: [email protected]

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PIP is a consortium of process plant owners and engineering construction contractors harmonizing member’s internal standards for design, procurement, construction and maintenance into industry-wide Practices. PIP has published over 450 Practices. A current listing of published Practices is available on the PIP website at: http://pip.org/practices/index.asp.

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Web Spotlight: Grace Engineered Products

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U.S. Tsubaki Power Transmission, LLC is excited to announce the integration of KabelSchlepp America into its operations as part of the Tsubakimoto Chain Company’s global acquisition of the German-based Cable & Hose Carrier manufacturer. KabelSchlepp America will now operate as a division of U.S. Tsubaki and will ex-pand Tsubaki’s presence in the U.S. market by adding cable & hose carrier systems to its already extensive product lineup.

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Your Source For CAPACITY ASSURANCE SOLUTIONS

November 2012 Volume 25, No. 11

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A.T.S. Electro-Lube Int’l Inc. .....................................www.atselectrolube.com ....................................... 71 .............................23

ALL-TEST Pro, LLC ...................................................www.alltestpro.com/c/244 .................................... 69 .............................21

ATP Lists.......................................................................www.atplists.com ................................................... 87 .............................52

Baldor Electric Company ..........................................www.baldor.com .................................................... 92 ..........................IBC

CRC Industries............................................................www.crcindustries.com/ei .................................... 86 .............................52

CyberMetrics Corp. ....................................................www.faciliworks.com ............................................ 62 ...............................1

Dreisilker Electric Motors Inc. ..................................www.dreisilker.com ................................................ 74 .............................33

Engtech Industries Inc. ..............................................www.engtechindustries.com ................................ 88 .............................53

Fluke ..............................................................................www.fl uke.com/vibrationmeter .......................... 67 ...............................7

Grace Engineered Products. Inc. ..............................info.graceport.com/pesd_mt5 ............................ 78 .............................45

Grace Engineered Products. Inc. ..............................info.graceport.com ................................................. 89 .............................54

Grainger .......................................................................www.grainger.com/green ...................................... 63 ...............................2

IAVA ..............................................................................IAVA.org ................................................................... 75 .............................37

Innovator Of The Year Award ..................................www.reliabilityinnovator.com ............................. 72 .............................24

Inpro/Seal, LLC C/O Waukesha Bearing, Inc ........www.inpro-seal.com .............................................. 93 ............................BC

MARTS-Applied Technology ...................................www.martsconference.com .................................. 79 .............................46

Meggitt Sensing Systems ...........................................www.wilcoxon.com ............................................... 64 ...............................4

Meltric Corporation ..................................................www.meltric.com ................................................... 76 .............................41

Neil Bloom Workshop ...............................................www.mt-online/rcm .............................................. 70 .............................22

Palmer Wahl Instrumentation Group ....................www.wahlheatspy.com .......................................... 82 .............................50

PdMA Corporation ...................................................www.pdma.com ..................................................... 68 .............................12

Process Industry Practices .........................................www.pip.org ............................................................ 84,91 ...................51,54

Revere Control Systems .............................................www.reverecontrol.com ........................................ 85 .............................51

Scalewatcher ................................................................www.scalewatcher.com ......................................... 73 .............................32

SKF CMC-Fort Collins .............................................www.bakerinst.com ............................................... 81 .............................49

SPM Instrument, Inc. ................................................www.spminstrument.com.................................... 83 .............................50

SPM Instrument, Inc. ................................................www.leonovabyspm.com ..................................... 61 .......................... IFC

Strategic Work Systems, Inc. .....................................www.swspitcrew.com ............................................ 65 ...............................4

TEAM Industrial Services .........................................www.teamindustrialservices. ................................ 66 ...............................5

U.S. Tsubaki Power Transmission, LLC ..................www.kabelschlepp.com.com ................................ 90 .............................54

Access MT-freeinfo.com and enter the reader service number of the product in which you are interested, or you can search

even deeper and link directly to the advertiser’s Website.


viewpoint

Today’s operational leaders must navigate unprec-edented levels of ambiguity and complexity. Rising customer expectations, relentless cost competition, capital constraints and rapid technological change

are redefining performance requirements and forcing managers to quickly adapt and identify new ways to innovate within the production environment.

Foresight is the foundation of competitive advantage. Winners and losers are often differentiated by the ability to anticipate trends and address emergent operational needs in advance of disruptive change, such as shifting workforce demographics, the introduction of new production or engineering standards or the launch of a breakthrough technology.

Widely regarded as best practice for continuous operational improvement, proven methodologies such as Lean or Six Sigma are well-suited for optimization of existing business processes through iterative analysis and change implementation. Likewise, promising “Big Data” technologies such as predictive analytics and prognostics are potential game-changers for improving manufacturing production and maintenance efficiency.

However, following best-practice processes or deploy- ing the latest enabling technology alone rarely results in something truly unique. Real innovation requires a clear understanding of how the future can unfold, as well as the organizational discipline and fortitude to act in ways that positively influence that future.

No longer reserved for senior executives, business strategists or technical visionaries wearing black turtlenecks or hoodies, innovation is for everyone. Many leading companies have formal innovation programs designed to capture, analyze and implement new ideas for generating customer and shareholder value. These ideas come in the form of new products or services, new business models, new processes or new technologies and can range in potential business impact from the incremental to the breakthrough.

If your company doesn’t have an organized inno-vation program, you can apply a simple yet effective

process across all levels and functions within an orga-nization. It only takes a few steps to get started:

Turn on the “Forward Radar” . . . Effectively capture a diverse set of market-based inputs from a range of stakeholders inside (functional, technical) and outside (customers, analysts, suppliers) of the organization.

Identify Articulated or Unarticulated Needs . . . Use these inputs to anticipate future trends and identify emergent or unmet customer needs.

Develop a Value Hypothesis . . . Recognize how you could potentially serve these needs in ways that create value for customers and shareholders.

Execute . . . Harness the passion, conviction and courage necessary to implement the plan and turn an idea into a business reality.

One way to jump-start the innovation process is to assemble cross-functional “scout teams” to work directly with customers, suppliers and/or channel partners to discuss emerging trends and identify unmet or unarticulated needs. Focused, fast-paced and fun, the scout team sessions allow participants to shift the conversation from the day-to-day trans-actional to a more strategic discussion about the future. Starting with a specific trend or problem statement can help scope the exercise and keep the team focused.

Regardless of how you choose to initiate an innovation process within your organization, the underlying objective is to encourage individuals to reject the status quo, understand future possibilities and empower positive action to shape that future. By applying this mind-set and a few basic steps to improve the innovation process within the produc-tion environment, others may soon be following your “best practice.” Mt

John Swann, President, SPX Hydraulic Technologiesand Former VP, New Venture Development, SPX

Looking Beyond Best Practice

the opinions expressed in this viewpoint section are those of the author, and don’t necessarily reflect those of the staff and management of Maintenance Technology magazine.

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