Rounding Into Shape: SPECIAL REPORT: Global Automation and Manufacturing Summit Preview

SPECIAL REPORT: Global Automation and Manufacturing Summit preview
PlantEngineering.com
Rounding
into shape
Strategic outsourcing helps
tire manufacturer deliver efficiency 39
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input #1 at www.plantengineering.com/information
success story
The Sweet Sound of Savings!

Dramatically reduced energy costs is music to the ears
Problem:
A music studio equipment manufacturer had problems
maintaining steady pressure with their compressed air system.
Additionally, there never seemed to be enough air to meet
production demand despite having both a 50 hp and a 75 hp
rotary screw compressor. Month after month, energy costs
soared with the compressors being the highest consumers.
And during the summer months, increased condensate in the
lines caused severe air quality issues.
Solution:
An Air Demand Analysis (ADA) revealed that the 50 hp unit
(with modulation control) was producing only a fraction of
its total capacity yet consuming full load kW. A single 50 hp
compressor with adequate storage could easily meet the
plant’s demand and provide significant energy and mainte-
kaeser.com
nance cost savings. The air quality issues were due to under-
sized storage and air treatment.
Result:
The new, energy-efficient 50 hp dual control compressor
provides all the air that’s needed and keeps the plant pressure
rock steady—with the 75 hp compressor still there for backup.
The new refrigerated dryer with energy-saving controls and
condensate management system have solved the air quality
issues, while the 361,099 kWh reduction in annual energy
consumption has this customer singing a happy tune.
Specific Power of Previous System: 59.74 kW/100 cfm

Specific Power of New System: 19.05 kW/100 cfm
Annual Energy Costs of Previous System: $52,981 per year
Annual Energy Cost Savings: $36,110 per year

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TOTAL FIRST YEAR SAVINGS: $78,031
Let us help you measure and manage your compressed air costs!
Kaeser Compressors, Inc.

COMPRESSORS
866-516-6888 • us.kaeser.com/PE
Built for a lifetime is a trademark of Kaeser Compressors, Inc.©2016 Kaeser Compressors, Inc. customer.us@kaeser.com
Invented here. Perfected here.
Poorly copied over there.
We’re flattered that our competitors have admitted the superiority of Rittal’s
patent-protected modular enclosure system. With more than 10 million
Rittal TS 8 modular enclosures sold worldwide, it’s clear to see why Rittal
is acknowledged as the industry leader and why customers depend on
Rittal to protect their critical electronics. So why settle for a cheap imitation
when you can have the original? Rittal….when quality matters.
And to our hopeful competitors…nice try.
RITTAL SHIPS QUICK! www.RittalEnclosures.com

Made in the USA (800) 477-4000
Change for the Better.
July/August 2016
Volume 70, No.6
Cover image courtesy: Toyo Tire USA
COVER STORY
39 Rounding into shape
Parts and repair outsourcing is one strategy that helped Toyo Tire build
a big success story in a small town.
Special Report
IA1 2016 Global Automation and Manufacturing Summit Global Automation & Manufacturing Summit
September 14, 2016, Chicago
The 2016 Global Automation and Manufacturing Summit

(GAMS), presented by CFE Media, will bring together experts
from all areas of the Industrial Internet of Things (IIoT) to look
at not just the current state of IIoT, but also the potential ben-
efits of deployment for the manufacturing industry. The third
GAMS conference takes place Wednesday, Sept. 14, beginning at Transforming
noon. It is held in conjunction with the Industrial Automation manufacturing
Robotics, IIoT discussions offer
North America (IANA) pavilion at the 2016 International Man- a look into the future
ufacturing Technology Show at McCormick Place in Chicago. P re s e n t e d b y :
The event is co-presented by Hannover Fairs USA.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 70, No. 6, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2016 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@
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addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST,
GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail
to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage
caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.plantengineering.com PLANT ENGINEERING July/August 2016 • 3

WHY WE DO IT
CLEAN AIR
MATTERS
Farr Gold Series®

Dust Collector
Handte EM Profi
Coolant Mist Collector
for machining
Dust, Mist and Fume Collectors

AIR POLLUTION CONTROL
www.camfilapc.com • e-mail: filterman@camfil.com • 866-354-8794
59
39
9 47 65
Electrical Solutions
47 Sleeve bearing clearance depends on many factors
With sleeve bearing motors (also known as babbitt bearings, white metal bearings and plain bear-
ings) the question is, “What’s the proper clearance between a shaft and the sleeve bearing it rides
in?” The answer depends on the application.
Mechanical Solutions
55 How to manage air quality to improve worker health, product quality
The containment of dust and other air particulates is one of the biggest quality control challenges
in virtually any industry. Given the range of potential problems it can cause, in-plant dust/
particulates are a dangerous issue that simply can’t be ignored.
59 Four causes of water hammer, and how to prevent damage

Water hammer is not only a system issue; it is primarily a safety issue. Understanding the nature
and severity of water hammer in a steam and condensate system will allow plants to avoid its
safety issue and destructive forces.
Maintenance Solutions
65 Choosing the right strategy to stay on the safe side
The best safety strategy is customized to fit the plant and that requires the maintenance experts to
ask the right questions. Which maintenance strategies fit the company, the plant, and the main-
tenance organization? And which strategy is suitable at what times and for which service param-
eters?
69 Sensors drive intelligence into maintenance

When executed consistently, condition monitoring enables an understanding of a more periodic
state of the equipment—a heartbeat of its condition, if you will—to help inform maintenance
planning.
What INside:
6 INsight
9 IN Focus
20 Research
88 INnovations
96 IN Conclusion

INSIGHT PlantEngineering.com
In tracking plant data, keep your head up 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph. 630-571-4070, Fax 630-214-4504
In the 1990s, I invested in Pokémon cards. CONTENT SPECIALISTS/EDITORIAL
By “invested” I mean I bought a lot of them BOB VAVRA, Content Manager
for my kids, and they played with them before 630-571-4070 x2212, BVavra@CFEMedia.com
discarding them on the floor of their bed- EMILY GUENTHER, Associate Content Manager
630-571-4070 x2220, EGuenther@CFEMedia.com
room and ultimately gave them away or sold
AMANDA PELLICCIONE, Director of Research
them or threw them out. It was no different 631-320-0655, APelliccione@CFEMedia.com
than my parents “investing” in baseball cards ERIN DUNNE, Production Coordinator
for me in the 1960s only to have me put them 630-571-4070 x2210, EDunne@CFEMedia.com
in the spokes of my bicycle wheels.
Pokémon, for those without kids in their EDITORIAL ADVISORY BOARD
20s, was a bit of Japanese marketing genius TIM DAWSON, IHS Technology
that included cartoons, game cards, video tim.dawson@ihs.com
games, and stuffed animals and a whole +44 1933 408076
mythology that allowed you to “train” your H. LANDIS “LANNY” FLOYD, Electrical Safety Group, Inc.
character to engage in these virtual battles. H.Landis.Floyd@gmail.com
The cards themselves became valuable for Bob Vavra 302-547-4298
a while, like Beanie Babies and Cabbage SHON ISENHOUR, Eruditio, LLC
Content Manager
sisenhour@EruditioLLC.com
Patch Kids, and then they weren’t valuable 843-810-4446
any more. August is the traditional month for
DAVE REIBER, Reiber Reliability
It resurrected last month when Nintendo a little sunshine and a little leisure, davereiber@gmail.com
released an interactive experience, Pokémon so here’s a selfie that combines 989-928-2307
Go, which was developed by a company both, at the Chicago area’s famed LARRY TURNER, Hannover Fairs USA
called Niantic. As I understand it players use Ravinia Festival. Send along your lturner@hfusa.com
their cell phones and GPS to travel around summer selfies, or images of your 773-796-4250
and find and capture different characters plant’s efforts this summer, to
in what was described as a “location-based bvavra@cfemedia.com. CFE MEDIA CONTRIBUTOR
augmented reality.” Kind of like Las Vegas, GUIDELINES OVERVIEW
I guess. Content For Engineers. That’s what CFE Media stands
To travel, players have to move and actu- embrace more human thought utilizing all for, and what CFE Media is all about – engineers sharing
ally walk, and so one of the immediate ben- of this information. with their peers. We welcome content submissions for all
interested parties in engineering. We will use those materi-
efits of Pokémon Go was that it was getting To put it in terms a Pokémon Go master als online, on our Website, in print and in newsletters to
these otherwise sedentary young adults up could understand, we need to keep our head keep engineers informed about the products, solutions and
off their couches and into the world. The up as we search for solutions in our plant. industry trends.
second thing it did was that it crashed the Information is available from all of our * www.plantengineering.com/contribute explains how
to submit press releases, products, images and graphics,
game’s servers in just under two weeks. plant devices, and it captures that informa-
bylined feature articles, case studies, white papers, and
There was the inevitable backlash, of tion more effectively and efficiently than we other media.
course. A few players weren’t paying atten- can as humans. The value of this information * Content should focus on helping engineers solve prob-
tion while they were walking and looking only is as great as our capacity to act on it in lems. Articles that are commercial in nature or that are
at their cell phones, and so there have been a meaningful way. If we spend our day with critical of other products or organizations will be rejected.
(Technology discussions and comparative tables may be
some injuries and even a couple of deaths just our data and not also on our plant floor, accepted if non-promotional and if contributor corroborates
attributed to distracted Pokémon Go playing. we know only what the numbers tell us. Our information with sources cited.)
The problem with augmented reality is that knowledge of our facility extends far beyond * If the content meets criteria noted in guidelines, expect
it’s still not reality. the spreadsheet or the handheld device. to see it first on our Websites. Content for our e-newsletters
comes from content already available on our Websites. All
Technology, we concede, is usually a great For one thing, there are people out there—
content for print also will be online. All content that appears
thing. It’s great for playing games, it’s great not virtual people; real people, with real in our print magazines will appear as space permits, and
for connecting with friends, and it’s great insights. We need to look those folks in the we will indicate in print if more content from that article is
for staying in touch with the world. It does, eye and ask a few questions. Now we have available online.
however, have its limits, and for me it’s a chal- machine data and human insight. Add our * Deadlines for feature articles intended for the print mag-
azines are at least two months in advance of the publication
lenge to not allow my technology to become own instinct and we’ve got a solid base to date. Again, it is best to discuss all feature articles with the
smarter than I am. build a plan to improve our operation. content manager prior to submission.
As manufacturing embraces more technol- If all we do is wander around with our
ogy—more robotics, more portable devices head down while we check our data, we will Learn more at:
managing more data, a more robust Indus- miss the world we live in. You’ve got to keep www.plantegineering.com/contribute
trial Internet of Things (IIoT)—we also must your head up. PE
6 • July/August 2016 PLANT ENGINEERING www.plantengineering.com

The Secret To Keeping Electronics Cool!
NEMA 12
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The NEMA 12 Cabinet
Coolers for large heat
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control cabinets, CCTV a control cabinet to fail, there is a panic to get
cameras, modular control
centers, etc. the machinery up and running again. The
• Measures 8" (203mm) high operator might choose to simply open the
• Mounts top, side or bottom panel door and aim a fan at the circuit boards.
• Enclosure remains dust-tight In reality, the fan ends up blowing a lot of
and oil-tight
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cooling effect is minimal. If the machinery
NEMA 4 and 4X
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NEMA 4 and 4X Cabinet repeated failure is great since the environment
Coolers for large heat is still hot (and threatens permanent damage
loads up to 5,600 Btu/hr.
They are ideal for PLCs to the circuit boards). Worse yet, that
and modular controls. open panel door is an OSHA violation that
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and 4X Cabinet Coolers Coolers for NEMA 12, 4 a slight positive pressure on
for small heat loads up and 4X applications are the enclosure to keep dirt
to 550 Btu/hr. are ideal available for heat loads from entering through small
for control panels, relay in many capacities up to holes or conduits. For use in
boxes, laser housings, 5,600 Btu/hr. non-hazardous locations.
electronic scales. • Suitable for ambients up to • Uses only 1 SCFM in
• Measures 5" (127mm) high 200°F (93°C) purge mode
• Mounts top, side or bottom • Ideal for mounting near • For heat loads up to 5,600 Btu/hr.
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some of our other machines were a constant maintenance project of their
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INTERACTIVE IN FOCUS
www.plantengineering.com
Two keys to measuring
Read this on your tablet
SPECIAL REPORT: Global Automation and Manufacturing Summit preview
operational improvements
The tablet and digital It’s not as easy as it seems, but getting good data
editions of this
publication are greatly PlantEngineering.com
can point to greater reliability.
enhanced for digital
subscribers. They also Rounding By R. Keith Mobley, CMRP functions, any attempt to measure them
include interactive into shape Life Cycle Engineering independently is difficult.
tools such as videos,
Strategic outsourcing helps
The best solution uses discrete perfor-

tire manufcturing deliver efficiency 39
Web links, and other

Tracking organizational performance mance indicators that measure critical
items. Update your
is not as simple as it might sound. Our performance variables at the lowest pos-
subscription, and
receive the digital edition in your e-mail dilemma begins because the criteria sible level.
in-box: that define performance vary depend- In addition to adherence to operat-
ing on the level within the organization. ing standards, operational performance
www.plantengineering.com/subscribe At the production-maintenance level, should also measure:
performance is measured as compliance • Cost per unit produced: the combina-
to the business plan and its production of labor and material costs consumed
tion schedule. Therefore, criteria used by operations, excluding direct materials,
2016 Upcoming webcasts to measure performance must vary, in the manufacturing or production pro-
but at the same time be consistent, so cess. It should include clear separation of
Register for educational webcasts at that measurements at the floor level the labor and material costs.
www.plantengineering.com/webcasts can be rolled up to meet the criteria at • Labor cost per unit produced (by
the organizational level and conversely SKU).
cascade down from organizational • Direct material cost per unit pro-
to floor-level measures. Once this is duced (by SKU).
understood, there are two other issues • Cost of quality: a measure of the
Engineering eNewsletters to be resolved. scrap, rework, and devalued losses cre-
The first problem with measuring ated within the operations function. The
Stay in touch with changes in the
change is selecting good measurements. total cost should include all incurred costs.
industry, including news, articles, and No one seems to be able to agree on the • Production output: a measure of the
product updates. NEW eNewsletters appropriate key performance indicators actual output of each production unit
include: Education & Training, IIoT Report, that define operations, maintenance, and or system versus business plan output
New Products for Engineers Showcase reliability effectiveness. If you agree that a requirement.
(COMING SOON), Predictive & Preventive valid measurement is one that accurately • Labor-hours per unit produced: a
Maintenance, and Product Focus. defines controllable variables that are measure of the actual labor-hours per
Subscribe to one or more eNewsletters at: within the purview of a single function, unit or units per labor-hour depending
www.plantengineering.com/newsletters then the options are limited. What about on industry. It measures the efficiency of
operations or reliability? There are few the workforce in the conversion or manu-
indicators that one can use to measure facturing process. Adherence to standard
isolated functional performance. Because hours required is a key measurement of
Join the discussion of the interdepen-
Facebook:
dence of these
www.facebook.com/PlantEng Among the
Google+: keys to track-
http://google.com/+plantengineering ing operational
excellence are
LinkedIn: selecting good
measurements
http://tinyurl.com/PlantEngineeringProfessionals
then inforcing
Twitter: standards. Image
www.twitter.com/PlantEngMag courtesy: CFE
Media
SlideShare:
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ONE SOURCE. IN fOCUS
HIGH QUALITY
SPRINGS. manufacturing performance and is a
prime source of losses in poor-performing
organizations.
stability and consistency of execution
performance. The missing third are
those reliability drivers that are outside
• Energy consumption per unit pro- their combined span of control. These are
duced: Energy cost varies with the effec- performance drivers that are determined
tiveness and efficiency of the production and controlled at the organizational level.
process and is a significant variable cost These variables include:
that can be controlled through adherence • Asset utilization: measures how
to standards and best practices. well the organization utilizes its installed
Maintenance effectiveness at the floor capacity.
level can be measured in a similar manner. • Cost of goods sold: measures the total
These measures should include: cost required to manufacture or produce
• Schedule compliance: measures both goods.
mean-time-to-complete the tasks or activi- • Total variable costs: measures all
ties and the interval or time when the activ- costs that vary with performance or vol-
ity was to take place. ume. It is compiled from values collected
• Resource utilization: measures how by operations and maintenance.
effectively the craft labor pool is utilized • Safety: measures safety using the
and measures the actual productive time of number of incidents and $/employee for
the workforce. There are two best-practice workers compensation.
standards for this measurement. The first, Without valid measurement param-
based on total craft workforce and used eters, improvement—even maintaining
to measure utilization based on payroll status quo—is difficult, but the problem
35,000 Stock Designs hours or headcount, is 55%. The second does not stop there. Once key perfor-
300,000,000 Springs benchmark, based on net available work- mance indicators are established, the
in Stock force, is 85%. Net available workforce is next challenge is how to reliably acquire,
the labor hours that are actually available interpret, and use this information. Too
Custom & Prototype Spring after deducting vacations, sick leave, light many performance measuring systems
Design & Manufacturing
duty, etc. rely on arbitrary input from individuals
Prototype to Full Production As in production, there are an infinite throughout the organization without any
Quantities number of parameters that can be mea- assurance that the input is accurate. Short
sured, but only those that measure true of full automation that removes humans
ISO 9001:2008 performance are required: from the process, the only way to improve
Stock Products • Total maintenance cost per unit pro- accuracy is to clearly define the source,
Ship Within 8 Hours duced: This is the total labor and materials calculation, and meaning of each indicator
costs, including contractors, of the mainte- as it applies to specific functions or areas
FREE 400+ Page Catalog. nance function. It is comprised of: of the organization.
Request Yours Today! o Direct labor costs: burdened labor cost You cannot manage, and certainly can-
of the crafts or technicians not improve, what you cannot accurately
o Indirect labor costs: all other mainte- measure. Today’s engineers are measuring
nance labor, such as planners, supervisors, tens if not hundreds of variables that are
clerical support, etc. perceived to measure performance, but
o Contract services: all contracted main- what are they really telling them about
tenance labor cost (contractor-supplied performance? Reliability is the reciprocal
materials should be included in materials of instability. It measures how stable an
costs) operation is. Organizational performance
o Materials cost: the MRO materials that is how well engineers are using their
are used or consumed in the maintenance installed capacity and human resources to
process and should not include inventory. meet market demand. Maintenance mea-
www.centuryspring.com sures show how well resources are used to
(800) 237-5225 The business of reliability provide value-added acitivities that will
Los Angeles, CA The criteria used to measure operations sustain reliability into the future. PE
and maintenance performance make up
two-thirds of the total reliability perfor- Keith Mobley has more than 50 years
mance evaluation. of direct experience in corporate manage-
When these values are rolled up to ment, process optimization, and reliabil-
the organization level, they define the ity engineering.
MADE IN THE USA
10 • July/August 2016 plant engineering www.plantengineering.com
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IN fOCUS
CHP a ‘powerful combination’ for plants
While combined heat and power faces challenges, it offers intriguing opportunities.
By Roy Palk Cogeneration clearly is poised for rapid May 2013, when Gov. Andrew Cuomo
LeClairRyan growth given the ongoing advances in announced $40 million in funding for
renewable-energy technology, the renewal these projects. Today, at least 53 state-
The pressure is on for industrial plants of the 10% Business Energy Investment Tax supported CHP projects are underway or
to become radically more energy efficient. Credit for CHP, and the increasing push on the drawing board across New York.
The ongoing renaissance in combined for CHP among regulators at both the state California continues to put a priority on
heat and power (CHP), also known as and federal levels. Installations are one bell- reducing its reliance on out-of-state power
cogeneration, is a major reason why. wether: According to a May 2016 report by supply resources, which can overburden
Stories already abound of industrial Transparency Market Research, the global transmission lines. In the most optimistic
plants using CHP to ramp up their effi- CHP installation market will grow from case, CHP could save California energy
ciency and reduce their environmental an estimated $525 billion in 2014 to $813 users up to $3 billion annually by 2030,
footprints. In Kentucky, one manufac- billion in 2024. according to a February 2012 report by
turer uses leftover sawdust and other consultancy ICF International.
wood waste as fuel for boilers that A competitive advantage The push for CHP also hinges on the
produce high-pressure steam to run Energy efficiency, in other words, is rap- need for better emergency preparedness.
turbines. This generates about 40% of idly becoming an even more essential part Hurricane Sandy, in particular, exposed
the plant’s electricity. A Kentucky wood of building and operating competitive the vulnerability of the nation’s critical
products mill uses CHP to meet 75% of industrial plants. This is particularly true infrastructure during major disasters.
its electricity needs. When the factory in states that take an aggressive stance on When powered by CHP, however, hos-
shuts down for the night, this system renewables. pitals, schools, and places of refuge are
feeds the excess power back into the grid New York, which wants 50% of its energy often able to enjoy uninterrupted elec-
for resale. That’s a nice residual benefit to come from renewable sources by 2030, tric service even during disasters. This is
for the company. has been a leader in CHP adoption since precisely why the federal government just
announced the Combined Heat and Power
for Resiliency Accelerator. The initiative
works to support and expand CHP across
the country.
Power stability
But greater stability isn’t just useful for
The MD III™ System includes emergency preparedness—it also makes
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Generators & Transformers mated 679 widespread power outages
occurred between 2003 and 2012 as a
Combine the power of Motor result of severe weather. These outages
Circuit Analysis (MCA™) and cost the economy billions of dollars in
Electrical Signature Analysis
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Auto diagnosis within instrument days. Figuring out the exact cost of power
providing an immediate health
status report outages is difficult, but a Congressio-
Route-based testing and trending – nal Research Service study from 2012
ideal for Predictive Maintenance estimated the inflation-adjusted cost of
Reports provide indication of weather-related outages at between $25
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Facing obstacles
Unfortunately, this optimistic example would not apply to
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rate, it still faces some obstacles. A 2012 paper by researchers Southern Parts & Engineering
from the University of Chicago, for example, highlighted that has compressor experts
CHP systems tend to be cost-competitive primarily in large- with 30+ years of
scale applications. To make CHP work at smaller scales, they
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ness Energy Investment Tax Credit is certainly helpful. part questions
While CHP might still be too expensive for some, consider and supplies.
the trajectory of solar to understand how those dynamics might
change. Not so long ago, solar panels were considered far too
expensive and inefficient for most. Today, however, the econom-
ics of solar installation are penciling out for a growing number
of businesses and other users. According to the Solar Energy
Industry Association and GTM Research, the U.S. solar market
will contribute about 72 gigawatts of new capacity between 2016 CALL NOW 888.793.4988
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trical usage. If these projections are accurate, solar will be a $30 input #10 at www.plantengineering.com/information
billion-a-year business by 2020, employing 420,000 Americans.
The same forces driving solar happen to be fueling the growth
of CHP. They include the greater efficiency and lower cost of
the technologies involved; the introduction of new federal, state,
and, in some cases, local incentives; and expanding competi-
tive pressures to ramp up energy efficiency and environmental
sustainability. It is therefore quite likely that CHP will become
increasingly doable in the years and decades to come.
For the owners and operators of industrial plants, then, the
time is now to start exploring your options with respect to CHP.
Work with your legal counsel to determine how you might inte-
grate CHP in compliance with existing regulations and to track
the growth and development of technology opportunities. You
could also investigate the viability of working with investment
partners to capitalize on this trend. Is your particular trade asso-
ciation talking about CHP? If not, consider working with associa-
tion representatives to put together more panel discussions and
other conversation-starters tailored specifically to cogeneration’s
potential to be a boon to your sector. industrial air control
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IN fOCUS
Refine your design and operation parameters
Modeling and simulation analyze production bottlenecks before going online.
By Michael Verdier and Sam Zhang we’ve always done it” thinking, local preferences, and static
BHDP Architecture versus dynamic analyses are inherently limited. With no way
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With all of the bottom-line benefits today’s modeling and simu- be wasted as stakeholders are unable to come to any agreement
lation (M&S) technology offers, why are so many companies con- or finalize plans.
tinuing to plan and design facilities, such as manufacturing plants, Data-driven M&S is a direct path to optimal manufacturing
through outdated approaches? Capital spending on greenfield or facility planning and design. It brings key decision makers into
upgraded facilities is one of the most visible and scrutinized invest- alignment quickly so that the project can move ahead. A fact-
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financial metrics are met, and the facility is both an immediate intended encourages swift, intelligent group decision making.
and long-term success.
Just as computer aided design (CAD) makes a science of machine 2. Easy scalability
development, M&S software tools help model, test, and refine plans The M&S model allows for evaluation of the effects of mul-
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data, M&S is used to create a realistic, virtual representation of an to manufacturing productivity if you change your layout or
existing or planned manufacturing facility—in action. Being able add more production or packing lines? What is the optimal
to accurately replicate the operation of an entire system in advance quantity and location of loading docks? Randomness through
of construction provides three key business benefits: the use of statistical distribution, failure modes, and schedule
variability can also be integrated as part of an M&S facility
1. “Smart” speed to market planning effort to ensure a robust design.
“Analysis paralysis” can overcome any group engaged in complex The benefits of M&S also come into play once the facility is
planning and design. Decisions based on emotion, “this is how in use. For example, the impact on productivity and cost of any
proposed changes in the business plan or capacity plan—such
as a speed-up initiative—can be analyzed in real time before
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Staying the course and continuing to execute projects utilizing
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possibilities. Either one has its own negative consequences.
Overbuilding leads to excessive capital spending, longer
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Application Note
1. Safety
Determine sources of electrical

Electricians are often required
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While energy expenditures are
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F r o m t h e F l u k e D i g i t a l L i b r a r y @ w w w. f l u k e . c o m / l i b r a r y
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6007719a-en
IN fOCUS
Plant Engineering names first
Editorial Advisory Board
In an effort to keep pace with global changes in manu- H. Landis “Lanny” Floyd
facturing, engineering and automation, Plant Engineering Lanny’s 45-year career with DuPont focused on electrical
has established its first Editorial Advisory Board. The first safety in the construction, operation and maintenance of
members of the Editorial Advisory Board are: DuPont facilities worldwide. His responsibilities included
• Tim Dawson, IHS Technology improving management systems,
• H. Landis “Lanny” Floyd competency renewal, work prac-
• Shon Isenhour, Eruditio, LLC tices, and the application of tech-
• Dave Reiber, Reiber Reliability nologies critical to electrical safety
• Larry Turner, Hannover Fairs USA performance in all DuPont opera-
tions. Floyd established Electrical
They will work with Plant Engineering content manager Safety Group Inc. to provide expert
Bob Vavra and other members of the Plant Engineer- consulting in electrical safety mat-
ing team to review and suggest ideas for content, and ters and is an adjunct professor in
provide their regular insight on issues affecting global the graduate school of Advanced
manufacturing. Safety Engineering and Manage-
“I’m so pleased to work with this group, and I appreciate ment at the University of Alabama
their willingness to serve our readers and the manufactur- at Birmingham. He is an IEEE Life Fellow, a professional
ing community,” said Vavra. “They all bring a great deal of member of American Society of Safety Engineers, a Certi-
professional and personal knowledge about manufacturing, fied Safety Professional, a Certified Electrical Safety Com-
and their collective insights will help us guide our global pliance Professional, a Certified Maintenance & Reliability
audience to a better understanding of how to operate their Professional, a Certified Reliability Leader and a registered
plants better, safer, faster and more efficiently in a chang- professional engineer in Delaware.
ing and challenging world.”
The new members of the Editorial Advisory Board bring Shon Isenhour, Eruditio, LLC
a wide variety of skills and experience to this role. Here’s Isenhour specializes in adult education, strategic plan-
a look at their background: ning, organizational change management, leadership,
asset management and reliability engineering and has
Tim Dawson, IHS Technology lead improvement initiatives for industries such as phar-
Tim Dawson is senior director of manufacturing technol- maceuticals, metals, petrochemical, paper, and power
ogy for IHS Technology. He manages a team of global generation, among others. He has been asked to speak at
analysts and has direct responsibility for the core strategy, numerous professional conferences on these topics in the
personnel, research, analysis, and commercial planning of U.S. as well as Europe, South America, Africa, and the
the division. He oversees a research Middle East.
portfolio covering discrete automa- Isenhour is an engineering graduate of North Caro-
tion, process automation, capital lina State University and has become an expert in the
equipment and machinery, motors implementation of holistic reliability solutions using tools
and motor controls, mechatronics, such as Total Productive Maintenance (TPM), Reliability
switchgear and cybersecurity. Centered Maintenance (RCM) and Root Cause Analysis
He has authored many studies on (RCA), as well as Six Sigma and
a variety of electronic component Lean to drive significant bottom
and end-equipment markets and line results.
undertakes custom research and Isenhour is past chairman of
strategic consultancy projects for the national board and past direc-
some of the world’s largest tech- tor of education for the Society of
nology providers. Dawson also is a regular voice in the Maintenance and Reliability Profes-
industry, presenting at industry events around the world. sionals (SMRP) and is a past com-
Tim holds a BEng (Hons) degree in Mechanical Engi- mittee vice chairman in the area
neering from Brunel University, London, and is located of benchmarking. He also serves
in Wellingborough, UK. on the boards of other global asset

management and training and development organizations. the Society of Maintenance and Reliability Profession-
He’s also is a Certified Maintenance and Reliability Pro- als and certified CPMM (Certified Professional Main-
fessional (CMRP). Isenhour also is a Plant Engineering tenance Manager) from the Association for Facilities
Engineer Leaders Under 40 honoree and was a speaker at Engineering.
the 2011 and 2014 USA Science and Engineering Festival
Nifty 50. Larry Turner, Hannover Fairs USA
Larry Turner is President and CEO of Hannover Fairs
Dave Reiber, Reiber Reliability USA (HFUSA), the U.S. division
An independent maintenance and reliability profes- of Deutsche Messe that develops
sional at Reiber Reliability, Dave Reiber’s long career and manages marketing programs
in maintenance and reliability includes several lead- at Deutsche Messe events in Han-
ership p ositions at G eneral nover, Germany and North America,
Motors (GM), including acting as well as in such key emerging mar-
as a skilled trans super visor kets as China, India, Mexico and
and general supervisor at two Turkey. Turner is responsible for
GM sites. He’s been a mem- numerous trade show portfolios in
ber of IBM’s Maximo Advisory the North American marketplace,
Board for many years, and has including industrial technology,
been both a global and North energy, and commercial vehicle
A m e r i c a n Ma x i m o b u s i n e s s focused events. In September 2016, HFUSA is staging five
lead. He’s been a sought-after industrial technology trade shows co-located with IMTS
sp e a ker at numerous e vents, 2016 in Chicago. The events cover a complete range of
including the 2011 Manufac- global manufacturing technologies and solutions from
turing and Automation Summit produced by Plant Engi- precision manufacturing to automation, drive systems to
neering and Control Engineering. He is certified CMRP parts and components, as well as surface treatments and
(Certified Maintenance and Reliability Professional) from lightweight construction. PE
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IN fOCUS
Implementing IIoT:
Five keys to success
Communications, training among the areas of focus.
By Colin Geis
Red Lion Controls
With all the acronyms in today’s tech landscape, executives are

finding it seemingly impossible to keep up. IIoT is no exception.
The Industrial Internet of Things (IIoT) and the many benefits
it offers to manufacturers might still be a concept that’s not yet
a reality. Believed to still be in an educational phase, manufac-
turers are just beginning to sort out how they can make IIoT
Reliability
a reality in their organization as a way to gain granular-level
insight, save costs, extend equipment lifetime, and improve
process visibility.
While there is no single framework to fit all organizations,
manufacturers can follow these five steps to successfully imple-
IS EVERYTHING ment IIoT technology in their operations efficiently, effectively,
and safely:
1. Connect and communicate: Whether the equipment was
deployed 50 or 5 years ago, integrating new or existing sensors
with wireless, Ethernet, serial, or fiber cables is the first step
in collecting data. Once sensors are properly connected, the
Gerald “Gerry” Bauer
President, EccoFab - Rockford, IL
machinery can then communicate locally and relay information
back to manufacturing teams.
u Sullair.com/GerrysStory 2. Monitor: After ensuring that all machinery is communi-
cating, manufacturers need the ability to continuously monitor
the data flowing around the facility. If the facility includes remote
locations, then a 3G or 4G/LTE network will help manufacturers
monitor equipment without actually being there.
3. Secure: In an era that is full of data breaches, manufactur-
ers need to ensure all sensitive data being transmitted—both
inside and outside the organization–is fully protected and out
of the hands of wrongdoers. Special consideration should be
paid to any older equipment that is being exposed to network-
It doesn’t quit. ing through the use of protocol conversion, as security may not
It doesn’t even think about quitting. have originally been designed into the equipment.
In fact, it doesn’t think of anything but the job at hand. 4. Analyze: Manufacturers need to know how to properly
gather and analyze data from each machine to gain actionable
Sound familiar? insights that help streamline processes in the plant, not make
Our compressors are a lot like the people who use them.
them more difficult. Protocol conversion, data logging, and
Discover the complete line of Sullair stationary air compressors, visual management will provide ways to collect, monitor, and
featuring the legendary Sullair air end. analyze real-time data to provide more visibility into operational
conditions revolving around productivity within the plant.
To learn more about our complete line, including air treatment 5. Train: The best way to ease into the new data-driven
products, contact your local distributor or visit our website. facility is to offer training to better understand IIoT-ready tech-
nologies and demonstrate how automation and networking
can help them succeed.
Within the next 5 years, we will be sure to see manufacturers

thriving with increased visibility and access to the insights they need
to remain innovative, productive, and ahead of their competition. PE
Colin Geis is director of product management for IIoT at Red

Lion Controls, www.redlion.net.
18 • July/August 2016 plant engineering

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Maintenance trends
research in small- to medium-
2016 MAINTENANCE STUDY: sized facilities
F
ifty-six percent of respondents to the Plant Engineer-
ing 2016 Maintenance Study work at a facility with 4. Unscheduled downtime: The most popular cause of
fewer than 250 employees. Below are six high-level unscheduled downtime within small- to medium-sized facili-
findings regarding maintenance strategies within ties is aging equipment (47%), followed by operator error
small- to medium-sized facilities: (16%) and lack of time (14%). Half of these facilities plan to
upgrade their equipment and implement preventive mainte-
1. Maintenance strategies: Seventy-four percent of small- to nance strategies in an effort to decrease downtime.
mediums-sized manufacturing facilities follow a preventive
maintenance strategy; 58% use a run-to-failure method and 5. Training: Eight in 10 respondents indicated that their
51% use CMMS. maintenance teams receive safety training. Other types of
training received include basic mechanical (67%) and electri-
2. Shutdown schedule: Standard production machinery and cal skills (59%) and motors, gearboxes, and bearings (50%).
less automated systems are generally shutdown only once
or twice each year for scheduled maintenance in small- to 6. Outsourcing: The average small- to medium-sized facility
medium-sized facilities, while material handling equipment is outsources 19% of their maintenance operations.
typically shutdown four to six times each year.
View more information at
3. Maintenance support: Fifty-six percent of small- to www.plantengineering.com/2016Maintenance.
medium-sized facilities’ rotating equipment receives the most Amanda Pelliccione is research director at CFE Media.
maintenance support, followed by fluid power (44%) and
plant automation systems (42%). See chart 1 (right) to see the top three types of technologies used.

83% of facilities perform
62% of facilities use a internal audits in order to enforce
computerized maintenance safety; other strategies used
management system (CMMS) include embedded safety controls,
to monitor/manage mainte- Lean/Six Sigma, and outside train-
nance. Source: Plant Engineer- ing consultants. Source: Plant
ing 2016 Maintenance Study Engineering 2015 Safety Study
Sixty-two percent of facilities have a
relationship with local utility companies
to develop their energy management
strategies. Of these facilities, the majority
reported the partnership to be successful.
Source: Plant Engineering 2016 Energy
Management Study
25% of plant personnel

don’t believe they are receiving
enough help from their facility’s
administration/human resources
department in addressing the
skilled workforce shortage.
Chart 1: The top three types of technologies small- to medium-sized facilities use to monitor/manage Source: Plant Engineering 2015
maintenance are CMMS (57%), in-house spreadsheets/schedules (56%), and paper records of mainte-
nance reports (44%). Source: Plant Engineering
Workforce Development Study
plantengineering_ad_fullpage_0616.indd 1 6/27/2016 1:28:54 PM

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IMTS Fact Sheet
Show Sponsor: AMT—The Association For • Tooling and Workholding Systems: features jigs,
Manufacturing Technology fixtures, cutting tools of all types and related acces-
Show Dates: September 12-17, 2016 sories.
Show Location: McCormick Place, Chicago • Fabricating, Laser and Additive: home
Show Hours: to waterjet, plasma-arc and laser systems,
• East and West Buildings: 9 a.m. to 5 p.m. welding equipment, heat treating, additive
daily manufacturing and related industries.
• North, C Hall and South Buildings: 10
a.m. to 6 p.m. daily Other pavilions at IMTS include:
• Abrasive Machining, Sawing and
About the Event Finishing
IMTS 2016 is the 31st edition of the premier • Controls and CAD-CAM
manufacturing technology show in North America. More • Electrical Discharge Machining (EDM)
than 2,000 exhibiting companies will occupy 1.3 million net • Gear Generation
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plex in Chicago. IMTS is held every even-numbered year • Quality Assurance.
in Chicago. In 2014, the event drew more than 114,000
buyers and sellers from over 112 countries, making it North Hannover Fairs USA
America’s largest manufacturing trade show. Among the co-located events at IMTS are five pavilions
produced by Hannover Fairs USA:
Exhibit areas • Industrial Automation North America
The 2,000 exhibitors on display are organized into prod- • Motion Drive, & Automation North
uct category pavilions: America
• Metal Cutting: contains everything from machining • Surface North America
centers and assembly automation to flexible manu- • ComVac North America
facturing systems and lathes. • Industrial Supply North America.
B:4”
T:3.5”
S:3.375”
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2016 Global Automation
September 14th, 2016
& Manufacturing Summit
Join Control Engineering, Plant Engineering and Hannover Fairs USA for the Global Automation and
Manufacturing Summit, part of the Industrial Automation North America (IANA) pavilion at the 2016
IMTS Show at McCormick Place in Chicago. This one-day summit is designed to bring plant managers,
control engineers, and manufacturing business leaders together to highlight plant
improvement opportunities and deliver strategies that manufacturing personnel
can take back to their plants and implement immediately.
Global Automation &

Manufacturing Summit Agenda
11:00am: Registration Presented in

partnership
12:00pm: Lunch with:
Sponsored by: Advanced Technology Services, Inc.
12:30pm: Keynote
Jack Nehlig, president and CEO of Phoenix Contact USA, will discuss his
company’s initiatives on the Industrial Internet of Things (lloT), both as an
industry supplier and as a manufacturer.
1:30pm: Cloud-Based Manufacturing: Who Will Rule the Clouds?

Sponsored
An overview of industry attitudes toward and adoption of IIoT in by:
manufacturing, followed by a panel discussion with Denis Cambruzzi
from IHS and Rob McGreevy from Schneider Electric.
2:30pm: Robotics: Rise of the Machines

An industry overview on the adoption and use of robotics in manufacturing
will be provided by representatives from the Control System Integrators
Association (CSIA), followed by a panel discussion led by Rick VandenBoom
of Applied Manufacturing Technologies.
3:30pm: How Maintenance and Big Data can Coexist

Sal Speda of ARC Advisory Group will provide the framework for the
panel discussion on maintenance in the age of IIoT, which will include
Franz Gruber, founder and CEO of FORCAM; Aurelio Banda, president and
CEO for North America of Beckhoff Automation and Chris Lebeau,
IT Director of Advanced Technology Services.
4:30pm: Reception and networking event

Sponsored by: FORCAM
GLOBAL AUTOMATION & MANUFACTURING SUMMIT
KEYNOTE ADDRESS: Wednesday, Sept. 14: 12:30 p.m.
‘The possibilities are endless’

Phoenix Contact president Jack Nehlig seeing the pieces come together
A s president of Phoenix Contact USA, Jack

Nehlig is responsible for managing the com-
pany’s domestic manufacturing and sales inter-
ests, and was named in 2016 to the Phoenix Contact
Group Executive Committee. Prior to joining Phoenix
The possibilities are endless with diversity of technolo-
gies and suppliers at their disposal, so putting boundaries
around the conversation is critical to providing true value
instead of simply engaging in “technology tourism.”
Contact, Nehlig spent 19 years at Honeywell in vari- CFE MEDIA: As a major manufacturer, how would you assess
ous sales, marketing, and executive positions. Phoenix your own implementation of IIoT?
Contact USA also was named Plant Engineering’s 2015
Top Plant recipient. NEHLIG: We have made great strides internally embracing the
The 2016 GAMS keynote speaker, Nehlig discussed IIoT/Industrie 4.0 theory. We have our own in-house machine
his vision of Phoenix Contact as both a U.S. and global solutions department that builds machines and systems that
company, and his views on how the Industrial Internet of today embrace and operate in this new realm. The nature
Things (IIoT) will change his business as a manufacturer, of our diverse product portfolio from connectivity to control
and as an industrial supplier: enables us to quickly implement it in our own factories.
CFE MEDIA: We’ve been actively talking about IIoT for the CFE MEDIA: Even though U.S. manufacturing’s growth con-
past two years, and it’s been looming on the horizon for tinues to be fairly steady, it’s also not explosive. How do you
years before that. Assess where manufacturing is today make the business case for investment in any technology
in both its understanding of, and implementation of IIoT. today?
NEHLIG: Manufacturing has been entering the IIoT world in NEHLIG: I think U.S. manufactures have to first and foremost
an organic way. Networking entered decades ago through think longer term on their investment strategies. One-year
fieldbus networks, and smart devices have been growing in paybacks on investments force bad decisions. Think of your
availability and utilization. The advent of the Internet, and own 401K. You do not day-trade your retirement, so you
popularity of cloud-based functionality have somewhat shouldn’t day-trade your company’s future.
acted as missing puzzle pieces to create the final image Investment in highly autonomous IIoT based manufactur-
of what IIoT can become. ing can provide the lowest cost, long-term return on invest-
ment. But the total supply chain and lifecycle management
CFE MEDIA: As an industry supplier, how do you approach costs must be taken into account, and the investment pay-
manufacturers on the hows and whys of IIoT? What are back scenarios have to be lengthened. If done in this way,
their primary questions about implementation and value the U.S. could once again become a leader in manufacturing.
that your sales and marketing teams are trying to answer?
CFE MEDIA: Globalization has been a hot political topic
NEHLIG: First and foremost we reinforce the importance of this summer. You’re a global company. Talk about the
utilizing only the highest quality manufac- value of global manufacturing, and how
turers of infrastructure components. For it has impacted your business and your
a system to operate autonomously and be employees.
accessible remotely through the Internet, the
owner/operator must have the highest level NEHLIG: Phoenix Contact’s approach to glo-
of trust in the systems integrity. balization manufacturing is simple. We have
Secondly, having secure remote access strived more and more to manufacture close to
through utilization of industrially hardened our customer. But we hold ourselves to global
security software and appliances is a must. design and manufacturing standards no mat-
Unsecured access to an IIoT system can ter where we build a product. In that way a
invalidate the intent of the IIoT concept alto- Phoenix Contact customer has universal trust
gether. Lastly, understanding the particular in our entire product portfolio. This approach
customers goals and challenges provides has helped our business grow significantly,
the framework for designing the right IIoT- and our employees enjoy part of our local
based system. success from our global footprint. IANA
www.ia-na.com Industrial Automation North America at IMTS • IA5

2016 GAMS overview
The 2016 Global Automation and Manufacturing Summit (GAMS), presented by CFE Media, will bring together
experts from all areas of the Industrial Internet of Things (IIoT) to look at not just the current state of IIoT but also at
the potential benefits of deployment for the manufacturing industry.
The third GAMS conference takes place Wednesday, Sept. 14, beginning at noon. It is held in conjunction with the
Industrial Automation North America (IANA) pavilion at the 2016 International Manufacturing Technology Show at
McCormick Place in Chicago. The event is co-presented by Hannover Fairs USA.
AgendA:
12:00 p.m. Lunch and networking sponsored by ATS
12:30 p.m. Keynote address from Jack Nehlig, CEO of Phoenix Contact USA and winner of the 2015 Plant
Engineering Top Plant Award.
1:30 p.m. Session 1: Cloud-Based Manufacturing: Who Will Rule the Clouds?
2:30 p.m. Session 2: Robotics: Rise of the Machines
3:30 p.m. BREAK
3:45 p.m. Session 3: How Maintenance and Big Data Can Coexist
5:00 p.m. Networking and cocktail reception, sponsored by Forcam
To register for the 2016 gAMS, go to http://industrialtechnology.events/gams.
Manufacturing convergence on display at 2016 GAMS

By Bob Vavra
At the 2016 GAMS conference, that potential now will
Content Manager, CFE Media
I
converge with information about actual ways manufacturers
can implement and benefit from IIoT technologies. Some
n the time of the Industrial Internet of Things (IIoT), one of the top experts and leading analysts in manufacturing
word that gets used over and over is “convergence.” will go past the theory and move into implementation.
We talk about how data and technology are converg- The half-day seminar is designed to round out the other
ing to deliver new knowledge to plant floor personnel. knowledge to be gained on the show floors at McCormick
We’ve heard about the “IT-OT convergence,” where the Place during the week-long IMTS show. We see the IMTS
long-estranged information technology and operation event as an investment. It allows plant floor leaders like
technology staffs now must work together to help the yourself to come away from the week with new tools, new
IIoT strategy reach its full potential. technologies and new strategies to improve your manu-
With the biannual International Manufacturing Technol- facturing operations. IANA
ogy Show (IMTS) converging on Chicago
Sept. 12-17, it brings with it more than
100,000 manufacturing professionals
from around the world to North Ameri-
ca’s largest manufacturing show. IMTS
is itself a convergence; 6 years ago,
show officials partnered with Hannover
Fairs USA to produce the first Industrial
Automation North America (IANA) pavil-
ion at IMTS. CFE Media produced the
first Global Automation and Manufactur-
ing Summit (GAMS) at that IANA event,
and we’re back for our third edition.
It’s no surprise that this year’s focus
for GAMS will be IIoT. This has been the
pervasive topic in manufacturing for the
past two years, as industry leaders have
discussed the potential of IIoT to be a
transformative force in manufacturing. Image courtesy: Hannover Fairs USA
IA6 • Industrial Automation North America at IMTS www.ia-na.com

SESSION 1: Cloud-Based Manufacturing: Who Will Rule the Clouds? Wednesday, Sept. 14: 1:30 p.m.
IIoT? First, get connected?

A strategic partnership needed to realize IIoT’s potential.
for manufacturing, the type, quantity and speed of the data
PANELISTS: used for analysis, as well as the security requirements for the
Rob McGreevy, vice president of operations, community of users. This provides a framework better suited
Schneider Electric for developing industrial reusable applications.
Rich Carpenter, product general manager,
GE Automation and Controls CFE MEDIA: IIoT is supposed to unlock a lot of information on the
W
plant floor. What is the untapped potential of data, and where
should manufacturers look to implement it first?
hile there are two schools of thoughts on the
Industrial Internet of Things (IIoT) architecture— CARPENTER: The first step of any IIoT strategy should be to get
proprietary versus open systems—everyone connected. Too often businesses jump three steps ahead with
agrees that IIoT is a transformative technology. Rich Carpenter a desire to optimize without even the basic infrastructure in
of GE, one of the panelists for this first summit session, dis- place to collect the data required for the optimization analytics.
cusses the idea of IIoT architecture and its implications on Getting connected with a standard approach to getting device
manufacturing operations and how it may impact the manu- data, bringing it to a Big Data environment and organizing the
facturing of the future: data in the right context are all critical to moving to the next step.
CFE MEDIA: We’ve been actively talking about IIoT for the past two CFE MEDIA: We’ve seen a traditional separation between infor-
years, and it’s been looming on the horizon for years before that. mation technology (IT) and operations technology (OT) in the
Assess where manufacturing is today in both its understanding plant. The emergence of IIoT promises to change that. Why
of and implementation of IIoT. is this important?
CARPENTER: There are two main advancements: CARPENTER: The interesting thing is neither the traditional IT
1. With various systems having been moved to cloud infrastruc- nor the traditional OT teams can implement IIoT initiatives
tures, customers are less concerned and more open than on their own. As more systems move to cloud or cloud/edge
they were when IIoT discussions first started. infrastructures, the IT and OT leaders need to form more of a
2. As technology has improved, it is not possible to use plant strategic partnership in order to take full advantage. IANA
floor data for Big Data/analytics initiatives without having to
disturb the plant floor control systems. RICH CARPENTER, GE
The product general manager for GE’s
CFE MEDIA: There seems to be more comfort among manufac- automation and controls product plat-
turers with cloud-based information. Assess the current state of forms, with worldwide distribution and
the use of the cloud for data management within manufacturing deployment capability for their control
plants and between plants. system, operator interface, industrial PC,
and new Field Agent Industrial Internet
CARPENTER: As network technologies, speed and security have products. The control system product
improved, the limits of the four walls of the plant are less rigid. lines are used throughout GE in their large
It is possible to put the data and analytics at the right place in equipment and plant controls for power
the architecture for the problem being solved. Since informa- generation and oil and gas businesses.
tion can now seamlessly be combined between cloud and
edge systems, a much better decision framework with insights
driven from analytics can be provided to plant floor operators. ROB MCGREEVY, SCHNEIDER ELECTRIC
As vice president of operations,
CFE MEDIA: There are two schools of thought around IIoT sys- information and asset management
tems: proprietary architecture where developers will create for Schneider Electric, McGreevy is
apps within the framework of the operating system and open responsible for defining and execut-
architecture. What do you see as the advantages and disad- ing the software product and business
vantages of each system? strategy. That business focuses on
industrial information management,
CARPENTER: A purpose-built industrial cloud has clear including enterprise data management,
advantages in terms of understanding the problem domain IIoT, cloud and mobile applications.

session 2: Robotics: The Rise of the Machines Wednesday, Sept. 14: 2:30 p.m.
Working hand in...hand?

It’s a new age in manufacturing as robots and humans begin to ‘mingle.’
the bandwagon. The model had been around decades

PanELists:
but only for large expensive capital equipment (e.g., a
Jose Rivera, CEO, Control System Integrators Association
turbine), long before IIoT. Vendors of these equipment
Rick Vanden Boom, automated systems group manager, were requiring service contracts in order to honor prod-
Applied Manufacturing Technologies uct warranties. This probably laid the foundation for the
Michael Lindley, vice president, business development, deployment of asset management to less expensive capi-
and marketing, Concept Systems Inc. tal equipment using IIoT.
In between the two ends of the spectrum of IIoT
R
deployment you have companies deploying IIoT, but not
necessarily realizing that what they are doing falls under
obotics hold great promise in manufacturing, the IIoT umbrella.
both as a way to allow human workers to avoid As prices for IIoT equipment have been coming down,
injury and to improve productivity. It also creates experimentation is taking place in plants by curious and
a world where robots and machines will have to work innovative personnel. Several suppliers have been encour-
as partners. The future of robotics in manufacturing will aging this with interesting entry-level “experimentation”
be examined in this session. We asked the panelists packages.
for their thoughts on the future roles of machines—and We have just started to see cases where capital goods
humans—in manufacturing. (e.g., big machines) have been offered on a subscription
basis, thus forcing the associated automation to be offered
CFE MEdia: We’ve been actively talking about the Industrial in this mode as well.
Internet of Things (IIoT) for the past two years, and it’s
been looming on the horizon for years before that. Assess CFE MEdia: Robotics is being integrated into many parts of
where manufacturing is today in both its understanding the manufacturing plant. How do manufacturers identify
of and implementation of IIoT. where robots can be effectively used in the plant?
VandEn BooM: I think manufacturing is just getting RiVERa: Robots have come a long way, and more and
started to consider the possibilities and benefits of IIoT. more applications are becoming available to them. There
Manufacturing systems typically have a high degree of is, of course, a cost-benefit analysis to be made to jus-
connectivity, but more on a local level (within the system tify any investment. On the cost side you have to also
itself or within a plant or company) and most often geared include things like worker health-related issues, like work
towards enabling system functionality and basic data that demands highly repetitive motions or work in toxic
reporting. We are just starting to see the possibility of environments. Allowing robots to take care of these tasks
self-monitoring machines and systems, self-optimization, may reduce cost and work-related injuries.
preemptive maintenance calls, and even ordering spare Other potential areas to explore are those where
parts. increased speed has a significant impact on productivity.
Robots have the potential to do work very fast.
RiVERa: On one end of the spectrum you have some com-
panies being very concerned about security and viewing LindLEy: The most common guidance offered is to look
IIoT as a threat. These companies have basically put a for dull, dirty, or dangerous manufacturing processes.
lock on their doors. Although this is a simplistic approach it does force a
On the other end of the spectrum you have companies company to acknowledge those tasks that are repetitive,
fully embracing it. An example often cited is Thyssen- that present an unsafe work environment based on regular
Krupp and their deployment of IIoT for doing predictive exposure to hazards, or require a worker to be in close
maintenance—technology guidance to technician going proximity to high-risk conditions. Those environments
to the site, etc. should be targeted first for analysis. Once an application
In my opinion, when it comes to IIoT the proven model is chosen, consider an ROI structure to quantify labor
has been around asset management. Here is where you savings, work safety events, increase production, and
have a quickly growing number of companies getting on reduce QA issues. Typically, companies are targeting

SESSION 2: Robotics: The Rise of the Machines Wednesday, Sept. 14: 2:30 p.m.
a 2- to 3-year return on their investment. The added duration is 3 to 3 ½ years it could still be a great project
benefit of robots is that they are designed to operate considering the long-term usage of the robot. Compa-
for 10 to 12 years, considering that annual maintenance nies also need to consider what other process changes
is performed. Companies can obtain their ROI in 2 to 3 a robot may present. Parts may need to be loaded and
years and potentially repurpose the robot multiple times presented differently or conveyors need to be rearranged.
within the equipment’s lifespan. A thorough work cell simulation will mitigate these risks.
Not all applications are designed for a robot, yet. Some Robots have changed a lot in the last 5 years, and cur-
part handling or bin picking applications can be too com- rent offerings are easier to integrate and often cost less
plex, or a part can have too many features to handle in a compared to their predecessors.
cost-effective manner. When we work with companies we When done correctly, a robotic work cell presents
simulate the proposed process using software provided significant advantages in worker safety, increased produc-
by the leading robotic manufacturers. Often, we will bring tion capacity, and reductions in manufacturing costs. IANA
in virtual representations of the work cell to ensure we
can achieve reach, speed, and payload requirements.
The simulation provides a client with a lot of confidence
that the proposed solution will work. MICHAEL LINDLEY, CONCEPT SYSTEMS
In his current role as vice president
VANDEN BOOM: Companies consider robotics (and auto- of business development and mar-
mation in general) for these basic reasons: reduce costs, keting for Concept Systems, Lindley
increase capacity, improve quality, and eliminate safety is focused on working with partners
and ergonomic concerns. These reasons can be quanti- and clients to bring advanced auto-
fied, and the decision to automate most often comes mation technologies to market. As
down to a calculation of cost versus benefit. part of the executive team at Con-
cept Systems, Michael has been a
CFE MEDIA: What are the challenges when incorporat- driving force in expanding the com-
ing robotics in manufacturing? What do you see as the pany’s robotic business.
advantages?
VANDEN BOOM: There are a range of technical challenges,

cost justification challenges, and human resource chal- JOSE RIVERA, CSIA
lenges in implementing robotics. Most can be overcome In his current role as CEO of the
with careful planning and setting the correct expectations. Control System Integrators Asso-
The advantages of robotics are many: cost reduc- ciation (CSIA), which he has held
tion, increased capacity, improved quality, and improved since March 2015, Jose Rivera
workplace safety. has worked to elevate the level
of the system integration industry
RIVERA: Robots have been around us for a while, but the by broadening the adoption of the
newer generations place robots in closer contact with associations’ “Best Practices” that
humans. Safety cages are being eliminated, and in some help independent system integra-
cases robots begin to look more and more like a human. tors build better companies.
This has implications on the workers on the plant floor.
Just like the challenges presented with any change, you
can’t afford to underestimate the impact, and you need RICK VANDEN BOOM, AMT
to manage this change. Rick Vanden Boom is the Automated Systems Group Man-
Some of this is to be done with training, where the ager at Applied Manufacturing Technologies (AMT). Rick
plant operators can see the benefits brought by robots has more than 30 years of experi-
and truly embrace the new technology. You need this ence in the manufacturing auto-
ownership as deployment of new technology will require mation industry. His background
lots of fine-tuning, and operators need to be part of this includes application engineering,
fine-tuning effort. sales, and operations manage-
ment. He has worked for several
LINDLEY: A common challenge that we see is first making international companies across
sure the project pencils out. Companies can often get multiple industries and has a
excited about the thought of a robot but overlook how track record of success in prod-
to pay for it or have unrealistic expectations about ROI. uct development and new market
If a project pencils in a year it is a no-brainer, but if the introductions.

session 3: How Maintenance and Big Data Can Coexist Wednesday, Sept. 14: 3:45 p.m.
Empowering the maintenance team

IIoT will change the conversation about how to keep the plant operating.
can be expected from their use in the context of their own
panEliStS:
applications. This is far more important than memorizing the
Sal Spada, analyst, ARC Advisory Group
various “definitions” of what IIoT is and what the different
Franz Gruber, CEO of Forcam controls vendors have to say about it. Any new technology is
Aurelio Banda, CEO and president, Beckhoff measured on how well it solves real-world problems.
Automation North America All that said, we are still in the early adopter phase of IIoT
and Industrie 4.0 technologies, but we are also living in the
Chris LeBeau, global IT director, ATS
critical time when the leaders in this aspect of industry will be
M
determined. IIoT is not yet a “must have” technology, but it
is a technology that will be the momentum for many compa-
aintenance holds the greatest promise for full nies to create significant new revenue streams and process
adoption of Industrial Internet of Things (IIoT). If optimization milestones.
data can help understand when in the future a
machine may fail, maintenance personnel can be proac- CFE MEdia: Maintenance is an area of IIoT deployment that
tive about repairs. This idea of prescriptive maintenance seems to hold the greatest promise for productivity improve-
is appealing, but how will it work on the ground? Our ment. Talk a little about your vision for maintenance and its
panelists for this final session will examine that issue from future with IIoT.
several angles.
Spada: Maintenance has been the Holy Grail for the IIoT
CFE MEdia: We’ve been actively talking about the Industrial because it promises to replace reactive, scheduled mainte-
Internet of Things (IIoT) for the past two years, and it’s been nance policies with predictive maintenance. The availability
looming on the horizon for years before that. Assess where of “Big Data” and remote analytics has improved the viability
manufacturing is today in both its understanding of and imple- of commercially available predictive maintenance because it
mentation of IIoT. is far easier for relatively small companies to deploy solutions.
GrubEr: The race for Smart Manufacturing—the Industrial banda: At Beckhoff, IIoT is being leveraged as a major agent
Internet—is internationally in full swing. All companies involved of change to improve numerous areas of plant maintenance.
have similar challenges: acceptance by staff, new talent, selec- Through better data collection and analytics, as made possible
tion of technology, connecting machines, training of stakehold- by IIoT and Industrie 4.0 concepts, there are great opportunities
ers, understanding data, and change management processes. to improve predictive maintenance technologies and establish
Needless to say, the winner in the race is not yet decided. a real-time stream of machine and equipment health informa-
The first significant driver for the advance of industrial tion. This data can be pushed to comprehensive maintenance
Internet solutions lies in the opportunity to integrate and better dashboards to track all manner of important criteria such as
manage horizontal and vertical value chains. measurements for temperature, vibration, energy consump-
The digitization and interconnection of products and ser- tion, air pressure, and much more.
vices (Internet of Things (IoT)) are important drivers to the Taking these kinds of measurements has been possible
industrial sector, which is to contribute $14.2 trillion to world for a long time, but the ability to access and expertly analyze
output by 2030. Another major driver is newly emerging (and the live data across the enterprise has reached new heights.
often disruptive) digital business models that offer significant This permits new optimum levels for machine availability and
additional value to customers through tailor-made solutions. throughput for maximum uptime. Benefits will spread to other
These new business models are characterized by a con- areas such as easier spare parts management, simplified sup-
siderable increase of horizontal cooperation across the value plier relationships, and more.
chains, as well as the integrated use and analysis of data to
fulfill customer requirements. GrubEr: The backbone of the Smart Factory is a flexible and
modular technology that can integrate with any machine and
banda: I’ll start by saying that general awareness of IIoT is quite existing IT-infrastructure. It is accessible from every location,
high in the manufacturing community, while true understand- time zone, and language, and allows for a competitive surge
ing of IIoT can vary greatly from person to person. Engineers in overall cost savings and reduction of waste. Full transpar-
should place an emphasis on learning what hardware and ency and connectivity are crucial for a modern factory to stay
software tools are available today and what specific benefits competitive in this day and age.

SESSION 3: How Maintenance and Big Data Can Coexist Wednesday, Sept. 14: 3:45 p.m.
SPADA: Plant workers will no longer be insular. The connected facility that is protected from all possible vulnerabilities. Today
worker will leverage remote data scientists that are extracting the strategy is to implement security so that it detects a vul-
insights into their operations. Recommendations on main- nerability as quickly as possible and limits the exposure to the
tenance and operational settings will all be affected by the plant. This being said, best practice is to undergo a security
services provided by remote data scientists. assessment with outside experts to ensure that infrastructure
is not exposed to vulnerabilities. IANA
LEBEAU: The reality of plant maintenance is that it is, and will
remain, a physical and mechanical occupation. Computeriza- SAL SPADA, ARC ADVISORY GROUP
tion and automation will continue to expand inside plants of Sal Spada is part of the discrete
all kinds, but maintenance will still look a lot like it does today. automation team at ARC Advisory
The conversation about maintenance, however, will be much Group. His responsibilities include
different. How it is planned, when it is done, and how effective studies in the Worldwide CNC, North
it is will all be based on the vast amounts of data coming from American general motion control, and
technologies like IIoT and the applications that collect, correlate, servo drive markets. Spada has more
analyze, and leverage that information. than 15 years direct experience in
Effective maintenance departments will embrace these motion control system design as a
changes to focus their work effort on the things that matter software developer, project manager,
most. This will be driven by plant management having increased and product marketing manager.
transparency allowing better decisions to be made on what to
do and when to maximize productivity and profit.
AURELIO BANDA, BECKHOFF
CFE MEDIA: One big issue with Big Data is security. How can we AUTOMATION
keep data more secure from both deliberate external threats Aurelio Banda is CEO and presi-
as well as internal threats? dent of Beckhoff Automation North
America. As president, Aurelio Banda
BANDA: Here again, the use of standards in PC-based control oversees all operations at the head-
platforms, along with the history of security expertise from the quarters of Beckhoff Automation LLC
IT world, serves as guides. There are multiple tools available in Savage, Minn. where administra-
to IIoT and Industrie 4.0 applications in order to establish data tion, sales and marketing, customer
security without requiring the manufacturer to have IT security service, and technical services and
experts on staff. OPC-UA, for example, provides data encryption support are managed.
and built-in security mechanisms to the vertical communication
layer from the plant floor to the cloud.
FRANZ GRUBER, FORCAM
LEBEAU: The key consideration is in the level of the data. Access- Gruber is the visionary behind For-
ing a database where you can see a sensor reported a tem- cam’s awarded Shop Floor Manage-
perature of 70oF, 60 times a minute for a year is not valuable. ment technology. With a technical
Understanding where that sensor is and what equipment it is education background and mentor-
associated with may have more value. ship while working at IBM and SAP,
Although I think there are new network security issues he created a solution for discrete
presented with the number of endpoints involved in IIoT, the manufacturing that reliably measures
security challenges are mostly the same ones we have already and evaluates the real-time perfor-
within the technology industry. mance of industrial machinery and
global factories.
GRUBER: There is no single product, technology, or methodol-
ogy that can fully secure a control system network. It is the
very combination of solutions and partners that extend beyond CHRIS LEBEAU, ATS
products and technologies. Those combinations of solutions Chris LeBeau is the global direc-
stretch alongside company-wide security systems and best tor of IT at Advanced Technology
practice designs, policies, and procedures taking into account Services Inc. (ATS). With more
the unique requirements of each customer and industry. than 25 years of unique experi-
ence combining broad technical
SPADA: I believe the security issue is well understood by many knowledge, LeBeau holds a thor-
practitioners in the industry. The latest thinking of the lead- ough understanding of business
ing security technologist is that it is effectively impossible or and the impact of technology to
possibly financially impractical to create an absolutely secure organizational achievement.

Industrial Technology Events
September 12 – 17, 2016
McCormick Place, Chicago, IL
www.industrialtechnology.events
n Find solutions
n Discover New Technology
n Meet key suppliers
n Strengthen your network
n Prepare for the future
CO-LOCATED WITH
POWERED BY

PRODUCTS
MACHINING TECHNOLOGY
The Vertex 55X-H will be demonstrated in Booth S-8519 during the IMTS
Show. It combines a precision-built, traditional CNC vertical machining center
with a spindle-adapted laser Direct Energy Deposition (DED) powder feed
nozzle. The nozzle loads into the tool changer like any conventional tool and
is changed automatically via the CNC program prompts, a milling/drilling
tool replaces it, and aspects of the workpiece can be machined convention-
ally—including internal features.
MITSUI SEIKI
http://mitsuiseiki.com/imts2016/
SIX-AXIS TOOL GRINDER

The GrindSmart 528XF with SmartChanger is ideally suited for long
drills. This machine is furnished with a traveling workhead, allowing drills
with a flute length up to 12 in. to be efficiently produced. In addition,
its versatility permits other carbide or HSS drills and high-performance
endmills to be manufactured. Among the many features are a camera
to locate small coolant holes and a six-station wheel/nozzle changer. It
also features a proprietary drill steady rest that can compensate for back
taper as well as a combination of back taper and cylindrical drill relief.
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OIL SKIMMER
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and avoiding the risk of kicking containers and causing spills. It can pick up hard-to-remove
oils that conventional skimmers leave behind. The Oil Boss skimmer keeps coolant free of
oil and extends tool and coolant life.
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CNC TURNING CENTER

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cal machining center. High rapid-traverse rates using 45 mm roller type
linear ways are also achieved to reduce noncutting time. It will be on
display at IMTS 2016 booth S-8536.
ABSOLUTE MACHINE TOOL
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PRODUCTS
BURNISHING TOOLS
Swiss ID Burnishing Tools are ideal for accurate sizing, low micro-finishing,
and surface hardening of ID holes down to 4 mm. They will be featured in
IMTS booth W-1292. With the tool body completely inside the tool block,
the new 5918 series features an adjustment knob, which protrudes from
the rear of the tool shank, thus allowing the burnishing tool size to be
adjusted for diameter without removal from the tool block. This cost-effective, easy-to-use tooling improves surface irregu-
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processes such as grinding, honing, and polishing by automating those processes in the primary CNC machine. Doing so
saves set-up and processing time and labor costs and also enhances machinery utilization and shop floor productivity.
MONAGHAN TOOLING GROUP
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ENCLOSURE CONTROL PLATFORM

The ARCA IEC nonmetallic enclosure offers supe- The M8 Series CNC controls will be on display at Booth E-4102
rior performance and security in harsh environ- at the IMTS Show. The M8 Series control platform is designed
ments. Molded in robust polycarbonate it offers to address the need
an easy-to-install affordable alternative to sheet for a fast, precise,
steel cabinets. It ranges in size from 200 mm by and affordable CNC
300 mm by 150 mm to 800 mm by 600 mm by system for complex
300 mm. ARCA IEC is UL-listed NEMA 4X; IP machining applica-
66; IK 10; EN/IEC 62208; and EN/IEC 61439-1-4. tions. The M800 is
FIBOX a high-grade CNC
Fiboxusa.com designed for high-
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control and features
the industry’s fastest
CNC, while the M80 provides high productivity and easy oper-
ability. Both offer 19-in. capacitive touch screens with icon-based
navigation for easy, intuitive, smartphone-like operation.
MITSUBISHI ELECTRIC
Us.mitsubishelectric.com
DIGITAL FACTORY
FASTSUITE Edition 2 assists with factory automation
tasks, from planning to ongoing operation—which
includes a wide range of production technologies.
All the technologies and functions interact seamlessly
and complement each other perfectly in a single, inno-
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control, while preventing data redundancy or the loss
of information. The range of solutions extends from
transferring engineering data to virtual start-up of pro-
duction systems.
CENIT
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COVERSTORY
Rounding into shape

Parts and repair outsourcing is one strategy that helped
Toyo Tire build a big success story in a small town.
A
By Bob Vavra
tire is a part unto itself. In reality, In the race to drive efficiency and effec-
Content Manager, Plant Engineering
it’s four parts on a car, which tiveness out of a process where more than
is itself a carefully orchestrated half the costs are material and equipment
collection of valves and rods, costs, Hawk looked at every option for ways
spark plugs and pip es. We to manage costs without slowing down the
don’t see a tire as a collection process. One was outsourcing his parts
of parts. department.
Jim Hawk knows better.
The president of Toyo Tire USA in White, In the center
Ga., Hawk sees it all—the rubber and poly- White, Ga., is easy to miss, even when
ester and chemicals; the machines that mold you’re driving right through the center of
and form those basic parts
into something useful and
vital. It’s also the sum of the
people and the machines that
keep Toyo running at a high
volume and high productivity
in the last place in America
you might look for a tire plant.
There are more than a half
million tires sitting at the back
of Toyo Tires’ 3-million sq. ft.
manufacturing facility, and in
90 days, they’ll be replaced
by another half-million tires.
Hawks has all of those tires
to keep track of, as well as all
the things that go into making
tires efficiently each day.
“One of the things I keep
driving at with our people
is OEE (overall equipment
effectiveness),” said Hawk.
“We’ve got a lot of built-in
(time) losses. We’re going to
do changeovers. We’re going
to do PM (preventive main-
tenance). We’re going to do
equipment upgrades.”
Toyo Tire USA president Jim Hawk has led the development
of a tire manufacturing hub, using an efficient operation that
uses both robotics and people to deliver quality. All images
courtesy: CFE Media

CoverStory
the gateway to the burgeoning
Mid-South automobile manu-
facturing plants in Georgia,
Tennessee, and the Carolinas.
And there’s the Port of Savan-
nah (“our secret weapon,” Hawk
said), which provides a sea lane
for parts and materials.
There are things that are less
obvious, like Georgia’s Quick
Start training program that
helps put engineers into Toyo’s
plants and helps drive the spec-
tacular growth the facility has
enjoyed.
In 2004, today’s Toyo plant
was a farm field. Three large
expansions later, Toyo now
o c c upi e s a m a s s i ve m anu -
facturing, distribution, and
employment footprint. It has
Parts management at Toyo Tire was outsourced to a third-party vendor to both create a c c ompl i she d t h i s w it h an
greater efficiencies and to free skilled staff within Toyo to concentrate on value-added increasingly autonomous man-
work. agement style from the home
office in Osaka, Japan.
town. Its listed population is less than 700, “It’s a very internationally-minded com-
and you can go through the town on High- pany,” Hawk said. “From the beginning,
way 411 in under a minute, even doing the they did not intend to run it as a Japanese
posted 40 mph speed limit. You have to plant. In the beginning, we were just trans-
look a little closer to see White’s value for ferring products and then we built the first
Toyo Tire. phase of operation. It was about training
There’s a railroad line running through and getting machines running. Since then,
the front yard. There’s Interstate 85 just a it’s gotten more difficult. We’ve installed
few miles from the front door, and I-85 is our own machines, and we develop new
The raw rubber is fed from

spools into the first stage
of a process that will pro-
duce a finished tire, which
are stored for distribution
in part of Toyo’s 3-million
sq. ft. plant in White, Ga.

COVERSTORY
specifications for the new machines. We That philosophy was exactly what Hawk
test rigorously.” wanted to align with. “You want to know
how this process started? I saw their ad
At the core in (Plant Engineering) talking about their
Toyo is a tire manufacturer, so its core com- work with Cooper Tire,” Hawk said.
petencies are the art and science of tire- ATS now manages more than 12,000
making. It’s a little of both. The tread design SKU. Over 4 years, the relationship has
is the art—finding the right combination of evolved as ATS has learned Toyo’s business
patterns that provide both performance and from the inside and been able to provide
aesthetics. However vital to your vehicle’s insight into other ways to streamline the
operation—just try driving tomorrow with- operation. “Our first contract was our
out one—a tire is a bit of a utility product. re p ai r abl e p ar t s m an age me nt ( R P M )
The tread is what’s fun and attractive. Where contract,” said Owens. “As we grew the
the rubber meets the road for a tire is where RPM program we noticed challenges in
the rubber meets the road. That part has to the storeroom with accuracy and staffing.
work. “Local and onsite repairs were anoth-
So it is no surprise Toyo values its engi- er issue that rose to the surface,” Owens
neering and maintenance staff. Part of that added. “ATS used data to show the value
value is related to their being able to perform of a dedicated team that would focus on
valuable tasks each day. Searching for parts onsite repairs. The data pointed towards
to repair doesn’t add value. sub-optimal ser vice quality from local
“The way we talk about it is that there are suppl i e rs . T he re w as a ls o s i g n i f i c ant
core and non-core functions,” said Jeff Owens, time being spent by the maintenance team
CEO of Peoria, Ill.-based ATS, which has been doing repairs; time that was needed to
Toyo’s parts management partner since 2011. focus on downtime and PM activities.”
“If your customer is going to buy the product ATS now has 10 staff on-site at Toyo,
and if the work your people do is going to integrated into the daily operations of
influence that buying decision, then that’s a the facility. “We have to be adaptable. We
core process. If it’s back behind the scenes, have to fit into that family,” Owens said.
and there’s a way to do it more efficiently, “When that doesn’t exist, it’s a nonpro-
then it’s a candidate to be looked at.” ductive relationship, and it doesn’t work.”
“Every manufacturing company has to Hawk sees that outsourcing the manage-
decide what’s a core function,” Owens added. ment, procurement, and repair functions
“What I find, as companies get older, there could deliver real value. “It lets us do
are more things that get to be non-core. We’re what we are really good at,” Hawk said.
great at non-core things.” “It goes way beyond stocking parts. It’s
“ (Outsourcing parts management)

lets us do what we are really good
at. It goes way beyond stocking
parts. It’s about the accuracy of the
inventory. We put intelligence into
the process.
”
Jim Hawk, Toyo Tire USA

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CoverStory
about the accuracy of the inventor y. We Rubber & Plastics News reported online in
put intelligence into the process.” 2014 that $2.75 billion was invested in tire
manufacturing in the Midwest and South,
A changing industry including Toyo’s expansion in White. South
The smell of hot rubber and the surge of Carolina has been a prime location to locate
heat come at you as you first step into the tire manufacturing. A key reason is to locate
manufacturing area at Toyo Tire’s facility. closer to the end user—in this case, both the
Making tires is a hot process with heavy new car and aftermarket customers.
objects, which is why much of the tire Tires can be made anywhere, so the com-
manufacturing at Toyo is automated. The plicated calculations of labor costs versus
intensity of the process is unforgettable. transportation costs, as well as balancing
Tire-making has been in Jim Hawk’s logistics and parts management, all figure
blood his whole life. He was born in Akron, into where to locate a plant. The formula
Ohio, long known as America’s tire capital, is only one part of developing successful
until that business went away from Akron manufacturing. The rest is in running the
and took jobs with it. That includes his most efficient operation possible—utilizing
father’s job; he worked for General Tire people and machines to take full advantage
for 3 months shy of 40 years before he of all of the inherent advantages a place like
was let go. White offers.
The tire business in America to day Hawk has been in the business a long time
is ver y different than in those days of and says he still has more to do. “It’s been a
Akron in the 1960s and 1970s. For one track meet for the last 10 years,” said Hawk.
ATS employees are embed- thing, automobile manufacturing is spread “We’ve made major, major investments, but
ded in the Toyo Tire facil- more widely across the country, and tire I’m not going to retire until we can imple-
ity, managing the parts, manufacturers have sprouted throughout ment a gain-sharing program for employees.
storeroom management and the Mid-South to take advantage of the We want to create pay bonuses based on
repair processes for Toyo. growth in that market. savings.” PE

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ELECTRICALSOLUTIONS
Sleeve bearing clearance
depends on many factors
Understand which application best fits the mechanical requirements.
I
By Chuck Yung t’s fair to say that one’s outlook on life is of us has a rule of thumb for this, probably
EASA colored by experience. A good example of related to shaft diameter. Some of these may
this with sleeve bearing motors (also known look familiar:
as babbitt bearings, white metal bearings • One thousandth, plus 1 per in. of diameter
and plain bearings) is the question “What’s • Two thousandths, plus 1 per in. of diameter
the proper clearance between a shaft and the • 0.0015 in. per in. of diameter
sleeve bearing it rides in?” Chances are each • 0.002 in. per in. of diameter.
They can’t all be right, yet many of us may

have used one of these rules (probably not the
same one, either!) with great success. Which
one, if any, is correct? The answer depends on
the application.
Focus on clearance
If your facility has slow-speed synchronous
motors, you’ve probably seen some operating
fine with more than twice the recommended
clearance. Someone who works primarily
with 2-pole petrochemical motors, however,
knows they can vibrate when the bearing
clearance is even slightly excessive.
One of the first questions to consider when
looking at bearing clearance guidelines is
whether the clearances are radial or diam-
etral. The focus here is on diametral (total)
clearance, because it can be determined by
physically measuring the shaft and bearing
diameters. Another reason to use diametral
clearance: In operation, a horizontal machine
rarely has the same radial clearance at the 12:00
and 6:00 o’clock positions.
Guidelines galore
To illustrate just how many different guidelines
there are for this simple topic, I’ve combined
the recommendations of five manufacturers
and three other reputable sources into a single
graph (see Figure 1).
The first thing to recognize here is that most
horizontal electrical rotating machines use a
Figure 1: Sleeve bearing clearance. All images

courtesy: EASA

eLeCTRICALSOLUTIONS
cylindrical overshot bearing design, a basic design factors for sleeve bearing
term that describes the lubrication meth- machines, starting with the relationship
od (i.e., oil supplied by oil rings). between power, torque and speed.
Considerations in sleeve Torque (lb-ft) = hp x 5252 / rpm

bearing design or
To understand why so many rules-of- Torque (N·m) = kW x 9550 / rpm
thumb exist, it may help to review some
Figure 2: Cylindrical overload, 2-lobe

and 4-lobe bearing shapes.
It follows that the higher the torque

(lower speed and/or higher hp/kW
rating), the larger the required shaft
diameter, and the heavier the rotor, the
bigger the bearing must be. Addition-
ally, the faster the speed, the smaller
the allowable journal diameter must be,
and the longer the bearing, the greater
the clearance required to get the oil out.
In order of importance, the major
factors that influence sleeve bearing
design therefore include:
• Weight to be supported
• Peripheral speed of shaft journal
• Viscosity of lubricant
• Operating temperature.

Designers of electrical rotating The longer and heavier the rotor, in turn require longer bearing brackets
equipment generally keep sleeve or the more flexible the shaft, the and larger machines.
bearing load pressure around 145 psi more shaft deflection (see Figure 3) The viscosity of the oil is less of a
(1 Mpa), as compared to 580-725 psi should be expected. Shaft deflection factor than the supported weight and
(4-5 Mpa) for internal combustion may force the designer to increase the peripheral speed, although one the
engines. Some older motors used even clearance between the sleeve bearing designer must consider. The OEM
lower bearing load pressure, so vintage and journal. Longer bearings also manual specifies the recommend-
machines sometimes have a larger bear- require longer shaft journals, which ed oils for the machine so, unless
ing than modern motors with similar
characteristics.
Excessive weight can distort soft
babbitt, so bearing cross-sectional
area increases proportional to the
load. Higher hp/kW ratings mean more
torque and hence require a larger shaft
diameter. Peripheral speed increases
with the rpm, or when the shaft diam-
eter increases. For hydrostatic, cylin-
drical overshot bearings (the sleeve
bearings most common to electrical
machinery), the upper peripheral speed
limit is approximately 6,000 ft (1,830
meters) per minute. Higher speeds
require special designs, starting with
2-lobe, then 4-lobe bearings, as well
as special lubrication methods (see
Figure 2).
Sleeve bearing lubrication on most
rotating electrical machinery is sup-
plied by oil rings, which requires a
minimum speed of around 25 to 30 ft
(7.5-9 meters) per minute to deliver
sufficient oil to the bearings. Be very
cautious when an application (such as
a VFD) significantly alters the original
design. A force-lubrication system may
be required, or even hydraulic jacking,
to lift the shaft onto an oil film before
starting.
When the peripheral speed limit I’m All About Precision.
restricts journal diameter, the designer
must increase the length of the sleeve
bearing. That brings us to the ratio of
bearing length to diameter (L/d). For
reasons of economy, the preference is
for a 1:1 ratio–e.g., a bearing with a
3-in. bore diameter and 3-in. length.
There are drawbacks to a proportion-
ally longer bearing. As the L/d ratio
increases:
• Less oil flow exiting the bearing =

higher bearing temperature
• Shaft deflection = diagonal contact
with ends of bearing Hard-working extended micro-tip for precision marking
• Longer machine = higher produc- and getting into hard to reach areas. Now that’s right for the job.
tion costs. Visit markal.com and find us on Facebook
plant engineering July/August 2016 • 49 input #30 at www.plantengineering.com/information
4.5 x 7.5 ISLAND-MARKAL.indd 1 7/21/2016 10:47:35 AM

eLeCTRICALSOLUTIONS
Figure 3: A heavy rotor increases shaft sag. The journal may rub the bearings at the places indi-
cated by the arrows. To prevent this, the clearance must be increased.
bearing design modifications have occurred, bearing clearance. A good guideline that
it’s usually best to stick with the recom- several manufacturers use is 0.002 - 0.004
mended lubricants. Sometimes, a 2-pole in. (0.05 to 0.10 mm), with more radial
machine may benefit from a lower viscosity clearance than the bearing. Obviously for
oil, but such changes should only be made a given shaft diameter, the labyrinth seal
in consultation with the OEM or service clearance for a vertical machine can be set
center and even then with caution. closer than for a comparable horizontal
machine.
Vertical machines: the difference There are lots of sleeve bearing clearance
Why are vertical machines different? To tables in circulation, some of which are for
begin with, on a vertical machine the specific types of motors–e.g., low-speed
same spindly shaft and heavy rotor does synchronous motors–and should never be
not cause shaft deflection as it would on a applied universally. In broad terms, several
horizontal machine. While the shaft rests principles apply:
on the bottom of a horizontal bearing, it
hangs more-or-less centered in the vertical • Low-speed motors can operate with
thrust bearing, so there’s no radial sag to more clearance.
worry about. • Longer bearings require more clear-
In addition, guide bearings for verti- ance.
cal sleeve bearing machines are not the • Vertical sleeve bearings require less
cylindrical overshot design, so they require clearance.
much less clearance than bearings on • Hermetic motor sleeve bearings require
horizontal machines with similar journal tighter clearance.
diameters. As long as there is sufficient • Labyrinth seals should be as close as
radial clearance for the oil film, the vertical possible, without contacting the shaft.
guide bearing needs no additional clear-
ance. Contact the OEM or your ser vice About those rules of thumb: If you’ve
center for guidance. had good success with one rule for the
motors in your plant, watch out for dif-
Labyrinth seals ferent types of sleeve bearing machines.
For labyrinth seals, the best rule of thumb Examples would include 2-pole versus low-
is that clearance should be a little more speed machines, a significantly different
than the bearing clearance. The closer the length/diameter ratio, or vertical machines.
seal is to the shaft, the better it will seal. In those cases, contact the manufacturer
Of course, if it touches the shaft both may or your service center for help. PE
be damaged, typically resulting in rapid
increases in temperature and vibration Chuck Yung is a senior technical sup-
levels (especially axially on the end that is port specialist at the Electrical Appara-
rubbing). Rather than determining laby- tus Service Association (EASA), St. Louis,
rinth seal clearance from the shaft diam- www.easa.com. EASA is a CFE Media content
eter, it’s better to work from the sleeve partner.

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DIGITAL REPORTS
Plant Engineering is excited to introduce our new Digital Reports.
It’s often called the “fifth utility.” Compressed air plays a vital role
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2016 Digital Report
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MECHANICALSOLUTIONS
The use of HVLS fans in large
warehouse spaces can help
reduce temperatures and
manage particulates within
a closed facility. All images
courtesy: Zoneworks
How to manage air quality to improve

worker health, product quality
Curtain walls and HVLS fans can improve air particulate exhaustion.
T
By Chuck Ashelin he containment of dust and other ignored. Any company engaged in a pro-
Zoneworks air particulates is one of the big- cess handling or particulate generating
gest quality control challenges in operation will benefit from proper control
virtually any industry. A common practices.
byproduct of operations like cutting, grind-
ing, welding, and mixing, air particulate can The troubles with air particulate
also cause a host of safety issues. Dust on plant equipment or any other
Given the range of potential problems surface in the facility is a matter of con-
it can cause, in-plant dust/particulates stant attention for cleaning and mainte-
are a dangerous issue that simply can’t be nance. Uncontrolled particulate matter can

mechanicalSOLUTIONS
“
spoil or degrade batches of differing
Fabric curtain walls also allow separation between critical materials and ruin products.
But even greater issues than dimin-
processing areas and clean rooms or finishing ished product quality can arise.
areas. Curtain walls also can be reconfigured if the Immediate safety problems, includ-
”
ing fires and explosions, can occur
facility layout changes. when there is a high enough con-
centration of airborne particulate
in an enclosed space. Additionally,
long-term health concerns exist for
employees working where airborne
particulate is present. The issue of
Summit air quality is both a short-term and
long-term issue for any controlled
Ultima® environment.
Series
Controlling particulate
contamination
The most common methods used to
prevent particulate from one space
contaminating another are exhaust
Extended Life separation and barrier separation.
Exhaust separation methods rely on
Rotary Screw moving a volume of air containing
the contaminate particles through
Compressor Oil exhaust fans through ducts to create
a negative air pressure environment.
In a clean space that generates no
particulates but is adjacent to a par-
Up to ticulate-intensive area, a positive air
12,000 hours of pressure environment is desired. To
achieve this, filtered air is pumped
Dependable Service into the clean space, preventing the
inward flow of air that might contain
Summit Ultima is a high performance lubricant formulated foreign particulate matter.
to outperform other synthetic compressor lubricants on In some cases, a simple partition
today’s market. Ultima’s unique formulation allows for better or wall between a clean space and
compressor performance, and it is compatible with existing an uncontrolled ambient space (such
as between a processing area and a
O.E.M. lubricants. Summit Ultima Series synthetic rotary loading dock) is an effective means
screw air compressor lubricant benefits include: ur of separation. If a negative air pres-
sure differential exists across the wall
• Better thermal conductivity for lower operating temps between the clean and ambient space,
• Superior protection against mechanical stress the wall acts as a physical barrier,
• Reduces power consumption through reduced friction blocking most of the foreign matter
• Eliminates varnish, sludge and carbon deposits from crossing the barrier. Depending
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• Protects against shear & viscosity loss under heavy loads required, and the need and frequency
• Product consolidation by application for traffic to move through the parti-
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ume of the space to be exhausted across them. lation standards in local building
means smaller fans can be used, codes; however, many systems are
which reduces total air movement. HVLS fans can play a role not operated or maintained in a way
Lower air velocity through filter Increasing ventilation rates and air that ensures these design ventilation
media increases the effective particle distribution often can be a cost- rates are achieved.
separation of the device. Addition- effective way to reduce indoor pol- In operations that do not produce
ally, lower airflow through the filter lutant levels, as well. HVAC systems abu nd ant ai r p ar t i c u l ate matte r,
reduces the frequency required for
change out or cleaning.
However, plants with frequently STATE-OF-THE-ART SOLUTIONS FOR DEMANDING APPLICATIONS
changing layouts will find permanent
walls are rarely a good option.
The value of fabric curtain walls

Fabric curtain walls also allow sepa-
ration between processing areas and
clean rooms or finishing areas. Cur-
tain walls also can be reconfigured if
the facility layout changes.
In a situation where a positive
pressure space is desired, some sort
of enclosure (or “box”) around the
space would be optimal to maintain
the pressure differential. Fabric cur-
tain walls are less expensive to install
than hard walls and create a compa-
rable enclosure seal to a hard wall.
The inclusion of standalone, high-
speed roll-up doors in the curtain
wall allows for efficient thoroughfare
while minimizing time the interior
is open to the processing area. In
the same way as a permanent wall,
fabric curtain walls act as a physical
barrier, blocking particle transfer.
Because they are made of flexible
fabric, they also are relatively easy
to reconfigure if a space needs to be
enlarged, reduced, or the shape of Every one an original masterpiece.
the space footprint needs to change. Drawing from a palette that includes the industry’s widest selection of cable
Fabric curtain walls can be trimmed
and hose carriers and paying attention to every detail, Tsubaki cable & hose
to fit around conduit, piping, duct-
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ture and can be anchored to the floor concept to masterpiece.
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will be more effective in input #32 at www.plantengineering.com/information
specific work areas or

where installation space
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© 2015 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.
NYLON • STEEL • HYBRID • TUBE • 3D • SILENT

plant engineering July/August 2016 • 57
mechanicalSOLUTIONS
Curtain walls offer a flexible solution when plants need either a temporary closed space or because planned expansion would
preclude the construction of permanent walls.
high-velocity, low-speed (HVLS) fans space is limited. However, fans up to 24

can provide constant air movement that feet in diameter can cover areas up to
disperses concentrations of these airborne 22,000 square feet and can move air over
contaminants. obstructions.
This gentle mixing of air also offers
workers relief from the heat. HVLS fans Maximizing air particulate
can keep workers cool and more produc- control efficiencies
tive. Slight breezes of only 2 to 3 mph can Plants requiring air particulate control
provide a cooling sensation of up to 11 F, stand to benefit from curtain walls. As a
which can provide significant relief for flexible and economical way to partition
workers operating in hot welding, cutting, space, curtain walls can be effective for
or production areas. exhaust, supply, and separation systems,
When considering HVLS fans, issues regardless of the application. HVLS fans
such as including the location of pallet are a cost-effective way to provide optimal
racks, machinery, product staging areas, airflow and particulate dispersion in the
personnel work areas, and overall build- large open spaces that exist in most plants. PE
ing layout should be considered. Small-
diameter fans will be more effective in Chuck Ashelin is an engineering manager
specific work areas or where installation for Zoneworks.

Four causes of water hammer,
and how to prevent damage
It’s a safety and maintenance issue—and it is preventable.
W
By Kelly Paffel ater hammer is never normal in systems but this statement is entirely false.
Inveno Engineering the steam and condensate system If the system is properly designed and cor-
and must be always considered rectly operated, water hammer in any form
extremely abnormal and totally will not occur. It is possible to have high-
unacceptable in today’s plant operation. pressure steam systems operating without
Water hammer is not only a system issue; water hammer and enjoy a long operational
it is primarily a safety issue. Understand- life from the steam components.
ing the nature and severity of water ham- In Figure 1, the red circles show improper
mer in a steam and condensate system will connection to the condensate header, which
allow plants to avoid it’s the safety issue generates a thermal shock type of water ham-
and destructive forces. mer. Instead of connecting into the side of
A greater understanding of steam system the condensate header, the returns should
water hammer will help the plant to imple- enter in the top of the manifold (condensate
ment the necessary changes in steam system header).
design, start-up, maintenance, operation and
installation to eliminate water hammer. This Where water hammer occurs
will additionally help provide maximum Water hammer can occur in any steam or
safety for plant personnel, reduce mainte- condensate line. The steam system is greatly
nance cost, and reduce system downtime. at risk of water hammer during startup of
In its most severe form, water hammer the steam system when the highest level of
can injure or even cause fatalities to plant condensate is generated during the warm up
personnel. of the steam line. If the steam line is ener-
Figure 1: The red circles Unfortunately, 82% of the steam systems gized too quickly without proper warm-up
show improper connection in North America are experiencing some time, and if the condensate created during
to the condensate header. type of water hammer. Many mistakenly the start-up is not being properly removed,
All images courtesy: Kelly believe that water hammer is unavoidable water hammer will result.
Paffel and a natural part of steam and condensate The other risk of water hammer in the
steam system is when the condensate is not
properly removed from the steam line dur-
ing operation.
Its effects can be even more pronounced in
heterogeneous or condensate bi-phase (flash
steam and liquid condensate) systems. Con-
densate bi-phase systems contain two states:
the liquid (condensate) and a vapor (flash
or generated steam). The bi-phase condition
exists in a steam system where condensate
coexists with generated flash steam.
Typical examples include heat exchangers,
tracer lines, steam mains, condensate return
lines, and sometimes pump discharge lines.
Results of water hammer

The effect of water hammer cannot be under-
estimated, as its forces have been documented
to be capable of the following results:
• Rupturing pipe fittings
• Causing valve failures
www.plantengineering.com plant engineering July/August 2016 • 59

mechanicalSOLUTIONS
human hearing. However, the dam-
age to steam and condensate system
is still occurring.
The continuing banging or audible
sound accompanying water hammer
should be interpreted as the way the
steam system is trying to commu-
nicate with plant personnel. This
audible noise should be an alarm
meaning “please correct the system
errors to eliminate the water hammer
problem, or damage will occur.” This
water hammer sound means some-
thing in the system is wrong and
needs to be corrected.
Evidence gathered while conduct-
ing root cause analysis on steam
component failure suggested that
Figure 2: An example of • Causing heat exchanger equipment failures water hammer causes 67% of premature
incorrect condensate piping: • Breaking pipe welds and even rupturing component failures.
A branch line from a steam piping systems
trap station is piped to the • Causing the failure of pipe supports and Water hammer: four causes
bottom of a condensate guides There are four typical conditions have been
main header. • Bending internal system mechanisms identified as causes of the violent reactions
• Flange failures known as water hammer. These conditions are:
• Overstressing pressure gauges • Hydraulic shock
• Cracking steam trap bodies. • Thermal shock
• Flow shock
When water hammer is severe, it can result • Differential shock.
not only in damage to equipment but also in Here’s a more thorough look at each one.
significant injury to plant personnel.
Water hammer may be occurring and yet be Hydraulic shock
silent to personnel. This means water ham- A small percentage of the water hammer
mer is not always accompanied by audible problems found in a steam system are
noise that the human ear can hear. For exam- caused by hydraulic shock. This type can
ple, a steam bubble from flash steam that is be easily described by using the example of
Figure 3: All condensate delivered into a condensate line under the a home faucet. When the faucet in a home
system branch lines must be condensate level in the piping system may opens, a solid shaft of water is moving
connected into the top of the be small, yet the collapsing bubble creates through the pipes from the point where it
main condensate header. a thermal shock that is beyond the range of enters the house to the outlet of the faucet.
This could be 200 lb of water moving at
10 ft/s or about 7 mph. When the faucet
is suddenly shut, it could be compared to
a 200-lb hammer coming to a stop. There
is a noticeable “bang” heard in the system
when the faucet is closed. This shockwave
sound is similar to a hammer hitting a piece
of steel. The shock pressure wave of about
300-psi is reflected back and forth from end
to end until the energy is dissipated in the
piping system.
This is the same action that can take
place in the discharge piping in a conden-
sate pump system when pumps (electric or
steam motive) are used in an on/off opera-
tion with large condensate pumping capa-
bilities. The pumping system normally has

check valves installed on the pump
outlet. As the pump starts and stops,
hydraulic shock can occur as the con-
densate flow rapidly stops and the
check valves restrict the flow in one
direction.
Solutions:
1. Condensate capacities above
12,000 lb/h use a continuous
flow pumping system that incor-
porates a variable speed drive
motor or a level control valve
in the discharge line of the con-
densate pump (pump operates
continuously).
2. Use disk type check valves on
the pump discharge instead of
the common swing type. main condensate header: there is no excep- Figure 4: A graphic example
tion. The condensate connection is at the top of proper piping for a con-
Thermal shock on the horizontal condensate main header densate system branch.
One pound of steam at 0 psig occupies 1,600 and never into a vertical condensate header.
times the volume of a pound of water at
atmospheric conditions. This ratio drops Flow shock
proportionately as the condensate line pres- Flow shock is most commonly caused by
sure increases. When the steam collapses, lack of proper drainage ahead of a steam line
water is accelerated into the resulting vacu- isolation valve or steam control valve. For
um from all directions at great speed. example, consider a steam line isolation valve
In bi-phase condensate systems, steam (typically used with pipe of 3 in. or larger)
bubbles may be introduced below the level of opened without the use of a warm-up. When
condensate in a condensate line. For example, the large valve is opened, steam rushes down
a branch line from a steam trap station may a cold pipe, producing a large quantity of con-
be piped to the bottom of a condensate main densate at high velocity. This condensate will
header, as shown in Figure 2. continue to build in mass as it travels along
For example: Steam is introduced into the the pipe, and a large wave of condensate is
heat exchanger (P2) at 100 psig or 338oF and created. The wave will travel at a high veloc- Figure 5: Flow shock is most
condensate at P3 will be 338oF. When the con- ity until there is a sudden change in direction, commonly caused by lack of
densate passes through the steam trap station possibly an elbow or valve in the line. When proper drainage ahead of a
at P4, which at a lower pressure a percentage the condensate changes direction, the sudden steam line isolation valve or
of the liquid will flash to steam due to the low stop will generate water hammer. steam control valve.
pressure/temperature relationship. When
the flash steam bubble flows to P5 and is
introduce below the condensate level in
the condensate piping, the thermal dif-
ferences will cause the flash steam bubble
to collapse. During the collapsing, the
water is accelerated an extremely high
speed due to the vacuum that occurred
when the bubble collapsed. The result is
a pinging sound or when there is large
quantity of flash steam (bubble is large)
a very sharp banging sound.
Solutions: Connect into the condensate

header
All condensate system branch lines
must be connected into the top of the

mechanicalSOLUTIONS
ing condensate return lines becomes essential.
Condensate normally flows at the bottom of
a return line with the assistance of gravity.
Condensate flows naturally because of the
pitch in the pipe and also because the higher-
velocity flash steam above it pulls it along.
The flash steam moves at a higher velocity
because it moves by differential pressure.
Flash steam occurs in the condensate
return lines when condensate discharges into
these lines that are operating at a lower pres-
sure. The lower pressure causes a percentage
of the condensate to flash back to steam at
Figure 6: An example of dif- When a steam control valve opens, a slug the given saturation pressure. If the lines are
ferential shock. of condensate enters the equipment at a high also undersized, additional pressure is created
velocity. Water hammer is produced when the in the line. This pressure pushes the flash
condensate impinges on the heat exchanger steam at relatively higher velocities toward
tubes or walls. the condensate receiver, where it is vented to
the atmosphere.
Solutions: Heat loss of the flash steam while moving
1. Installation and use of a warm-up valve in the line causes some of the flash steam to
that is shown in Figure 3. condense, which contributes to this pressure
2. Installation of a steam line drip leg pocket difference and amplifies the velocity. Because
with a steam trap station ahead of the the flash steam moves faster than the conden-
isolation valve. sate, it makes waves. As long as these waves
These recommendations will prevent water are not high enough to touch the top of the
hammer during start-up, but it will also pro- pipe and do not close off the flash steam’s
mote long valve life. passageway, there is no problem. This is why
larger condensate return lines are preferred.
Differential shock To control differential shock, the condensate
Like flow shock, differential shock occurs in seal must be prevented from forming in a
bi-phase systems or the condensate system. bi-phase system.
It occurs whenever steam and condensate Condensate line velocities (two-phase flow)
flow in the condensate line but at different should never exceed 4,500 fpm. If the con-
velocities. In bi-phase systems, the velocity densate line is properly sized for the liquid
of the steam is often 10 times the velocity of and flash steam, but the plant does not have
the liquid. If condensate waves rise and fill a a proper steam trap management program
pipe, a seal is formed temporarily between and steam traps are failed and blowing steam
the upstream and downstream side of the into the condensate line, this will contribute
condensate wave. Since the steam cannot to increase velocities above 4,500 fpm and
flow through the condensate seal, pressure water hammer will occur in the system.
drops on the downstream side. The pressure
differential now drives the condensate seal Solutions:
at a high velocity downstream, accelerating 1. Condensate lines sized for 4,500 fpm
it like a piston. As it is driven downstream, or less
it picks up more liquid, which adds to the 2. Steam trap station management pro-
existing mass of the slug, and the velocity gram to eliminate unnecessary steam
increases. being introduced into the condensate
Just as in the example above, the slug of line. PE
condensate gains high momentum and will be
forced to change direction due to an elbow or Kelly Paffel is technical manager at Inveno
a valve in the line. The result is usually great Engineering Inc. He is a recognized author-
damage when the condensate slug pounds ity in steam and condensate systems and is
into the wall of a valve or fitting while chang- a frequent lecturer and instructor on the
ing direction. technical aspects of steam systems. In addi-
Since having a bi-phase mixture is possible tion, Paffel has published many papers on the
in most condensate return lines, correctly siz- topics of steam system design and operation.

FIFTEEN wAyS TO PREvENT wATER HAmmER
A variety of design or system changes can be implemented to prevent or eliminate water hammer:
1. Implement proper training for plant personnel.
2. Ensure correct steam and condensate design.
3. Have documented standard operating procedures (SOPs) for steam system start-ups and shutdowns.
4. Have installation standards for steam components.
5. Specify and place steam line drip steam traps on the steam system properly.
6. Correct condensate connections of branch lines to the main condensate line and enter only on the top.
7. Use steam traps that are properly sized and appropriate for the application.
8. Use warm-up valves on steam line isolation valves larger than 2 inches. Do not crack open large steam isolation valves
with the hope of avoiding condensation-induced water hammer. This will not guarantee safe operation.
9. Check or repair the pipe insulation. It saves energy and reduces accumulation of condensate in the piping system.
10. Condensate line sizing is crucial to ensure proper operation of the steam system. Undersizing the condensate lines is
one of the largest contributors to water hammer.
11. All steam valves that can be in the closed position must have proper drip legs on the steam line (see Figure 7) to remove
any condensate build up during the close position.
12. Always direct condensate gravity drainage away from the process applications with a modulating control valve.
13. Condensate can be drained into a pressurized condensate return line only if the proper differential is maintained.
14. Properly label the steam and condensate lines.
15. Remove abandoned steam and condensate lines from the system.
Figure 7: An example of a standard drip leg installation.

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MAINTENANCESOLUTIONS
Figure 1: Loss of material
in the metal-sheet com-
ponents of a superheater
caused by sigma phase
embrittlement, which
resulted from using the
wrong material. All images
courtesy: TÜV SÜD
Choosing the right strategy

to stay on the safe side
There’s no ‘one-size-fits-all’ approach on maintenance.
I
By Hans Christian Schröder n recent years, the testing techniques is the right maintenance strategy. However,
TÜV SÜD and models for calculating and forecast- as the operating performance of each plant
ing component behavior have grown in is unique, and particularly as complexity
numbers and improved in reliability. Nev- increases, there is no “one-size-fits-all” in
ertheless, power stations repeatedly suffer maintenance strategies. What is important
failures and defects, sometimes of major is that the strategy is customised to fit the
proportions. One of the leading causes is plant and that the maintenance experts ask
inadequate maintenance. Buzzwords and the right questions. Which maintenance
acronyms are no solution in these cases; strategies fit the company, the plant, and
only strategies tailored to the special fea- the maintenance organization? And which
tures of the plants will be able to balance strategy is suitable at what times and for
safety, costs, and benefits. which service parameters?
Whether leakage, cracks, wear, or opera-
tion and design errors, early identification Future-oriented...
of weak points in plants and systems and Maintenance has long evolved from purely
appropriate assessment can prevent many reactive failure recovery and remediation
defects and unscheduled downtime and thus into a future-oriented service. Mainte-
unnecessary costs. A requirement for this nance objectives include a high level of

mAINTENANCESOLUTIONS
Figure 2: Slag formation in plant availability and operational safety maintenance work. However, monitoring
the combustion chamber of while ensuring profitability. Obstacles to causes higher efforts and costs.
a wood-fired boiler caused these objectives are increasing cost pressure Predictive maintenance is a proactive form
by temperatures above the and a lack of future strategies. Fundamental of maintenance which includes a conceptual
deformation temperature. approaches are preventive, condition-based, framework. Possible defects are localised at an
predictive, and risk-based maintenance. early stage and corrected as soon as possible.
Preventive maintenance refers to anticipa- However, the strategy and its implementation
tory servicing without a conceptual frame- are time-intensive and make high demands
work, in which scheduled and standardized on the maintenance team.
maintenance activities are carried out at fixed
intervals. This form of maintenance reduces …or risk-based?
unexpected shutdowns but also replaces many Risk-based strategies, such as risk-based
components before they actually reach the maintenance (RBM) or reliability-centered
wear limit. Preventive maintenance thus maintenance (RCM), focus on failure prob-
results in “excessive maintenance,” which abilities. Risk-based maintenance identifies
drives maintenance costs. the potential risks that may lead to plant
breakdown and ranks them in order. Plant
...and condition-based… units or components that involve the high-
Condition-based maintenance monitors est risk of failure are addressed with prior-
component condition to ensure timely iden- ity. As complex technical structures, plants
tification of potential defects. This approach require systematic and practice-focused
allows for timely planning of the necessary analysis.

For reliability-centered maintenance,
all plant components must be analyzed
for potential malfunctions and the con-
“Management needs to be able to motivate their personnel.
sequences of these malfunctions defined.
This is only possible in an organization based on division
This approach enables the experts to of labor, which leaves staff scope for action and for taking
select and implement the necessary
maintenance measures and thus allows on an appropriate level of responsibility. Acceptance of tol-
the best possible use to be made of dif-
ferent strategies while reducing costs. erable risks is also part of the deal. Given this, the working
Continuous improvement atmosphere should be based on clarity, consistency, trust,
Total productive maintenance (TPM)
makes sensible use of production per-
sonnel. By carrying out routine main-
and appreciation. ”
tenance and servicing of “their” equip- is one of the fundamental questions in Probabilistic strategies, by contrast,
ment, they can identify possible wear maintenance. Deterministic approaches are based on probabilities. They quan-
or other weak points at an early stage. focus on the cause and follow the “if-then tify potential risks according to their
Preventive maintenance measures then principle”: If x happens, y will result. frequencies of occurrence and the
avoid breakdowns and quality losses. Maintenance following this principle has severity of their consequences to pri-
This results in a continual improvement proved effective from the point of safety oritise maintenance measures. This
process and eases the workload of the technology, and deterministic methods reduces the costs of maintenance.
maintenance team. form the basis of Germany’s technology However, the input data determined
laws. On the downside, these approaches may be fraught with lack of precision,
Deterministic or probabilistic? result time and again in excessive main- and in case of complex events, the
The question of whether deterministic tenance measures because of the safety approaches involve high efforts and
or probabilistic approaches are better factors that must be observed in design. fault-tree analyses.
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Systematic and practice-oriented... decisions. Practice in general engineer- creates the basis for practice-focused
When choosing the overall maintenance ing, experience, and in-depth knowl- hazard assessment. This also means that
strategy, the responsible parties must take edge of plants and systems are therefore “defects” need not be repaired in every
into consideration the special features of important. The role of a maintenance case. Inhomogeneities in materials or
the company and of the plant in question. professional today is that of a system ana- incipient cracking that are detected with
The maintenance professionals should be lyst who keeps an eye on the full picture. the help of non-destructive testing may
aware of the conditions of operations and A carefully coordinated combina- not necessarily have to be repaired if
of the plant and include them in all their tion of individual strategies and tools fracture mechanics and risk assessments
show such findings to be tolerable under
the defined service parameters. Within
Performance
the scope of high-quality analysis of the
total system, the principle of “living with
defects” is quite acceptable. Likewise,
Meets Peace
safe operation of plants of an advanced
age can be continued with the help of a
dedicated asset analysis and customized
of Mind.
refurbishment and maintenance mea-
sures. This also applies to process con-
trol systems and, in particular, process
Guaranteed.
control systems that are no longer pro-
duced. As long as these are functioning
and their use can be continued with the
help of repair strategies, these systems
Engineered for precision and power, the Model 850 picks up even do not have to be replaced.
the finest powders, anywhere in your plant. With clean, HEPA-filtered
exhaust air, a streamlined filter cleaning system, a continuous bagging
system, and a performance guarantee—it’s more than a cleaning ...as well as creative and
system; it’s a business asset. solution-focused
To deliver maximum benefits for the
VAC-U-MAX MDL-850 Continuous-Duty company and ensuring profitability,
Industrial Vacuum qualified maintenance needs to find
• Continuous-bagging system creative solutions on any given day.
• Eliminates manual dumping of drums & collection containers Recruitment of committed and highly
• Available in 2.5HP, 5HP and 8.5HP
• Features PTFE-coated primary filter & standard
qualified maintenance personnel is
HEPA secondary filter therefore of crucial importance.
• Faster discharge time of collected dust & debris. Management needs to be able to moti-
• Closed bags prevent fugitive dust clouds vate their personnel. This is only pos-
sible in an organization based on divi-
Let us solve your industrial sion of labor, which leaves staff scope for
vacuum cleaning challenges. action and for taking on an appropriate
Visit vac-u-max.com/vacuum level of responsibility. Acceptance of tol-
or call 800-VAC-U-MAX. erable risks is also part of the deal. Given
this, the working atmosphere should be
based on clarity, consistency, trust, and
appreciation.
In the future, maintenance will
increasingly focus on the prevention
of failure and continual improvement
of plants and systems. Systematic knowl-
edge and practice-focused approaches
will come together to ensure the best
possible plant management, offering
long-term operational safety and reli-
ability as well as maximum availability. PE
Hans Christian Schröder is a senior

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Wireless sensors allow
plant managers to add
more nodes to the
process points where
needed, increasing the
amount of information
available. All images
courtesy: Parker Hannifin
Sensors drive intelligence

into maintenance
Data-driven analysis can create a roadmap to find problems early.
I
By Mario Calvo t seems like everything we buy today breakdown. When examining the potential
Parker Hannifin Corporation is intelligent. Thermostats that adjust disadvantages of this reactive approach—
themselves based on weather condi- downtime, production delays, inefficien-
tions. Cars that alert us to upcoming cies, added costs, poor quality, increased
maintenance needs. Alarm systems that scrap, warranty issues, or product recalls—
can be armed or disarmed from a mobile it’s easy to see why it’s not a best practice.
phone. Wristbands that track fitness prog- On the other end of the spectrum, pre-
ress. dictive maintenance employs ongoing
Thanks to the Internet of Things (IoT), analysis to determine the condition of
the same technologies that have revolu- equipment and predict when maintenance
tionized the way consumers do everyday will be needed. The more compelling sell-
things can now enhance the way we man- ing points of this sophisticated approach
age maintenance in the plant environment. are its role in preventing unexp ected
And it doesn’t take a brand new plant or equipment failures as well as its ability
the latest equipment to derive benefit. to identify precisely when maintenance
The spectrum of maintenance ranges should be executed.
from passive to predictive. On the passive Somewhere in the middle is condition
end, maintenance is approached primarily monitoring. A practice that is quickly
as a fix–a reaction to a problem, issue, or becoming fundamental to maintenance

“According to the U.S. Department of Energy, minimizing

downtime has been shown to drive up asset availability
by as much as 30% as well as increase production by as
much as 25%. By identifying issues before they escalate,
organizations can also decrease maintenance costs and
avoid potentially dangerous situations. ”
management, it utilizes periodic assess- in a variety of applications. In fluid power,
ments to analyze the health of equipment. for example, sensors can be applied for
When executed consistently, it enables an condition monitoring of injection mold-
understanding of a more periodic state of ing units, metal forming and fabrication
the equipment—a heartbeat of its condi- equipment, conveyor systems, dispensing
tion, if you will—to help inform mainte- systems, robotic assembly, and hydraulic
nance planning. power units, to name a few.
Condition monitoring identifies trends In the fluid power example, sensors can
that may indicate a change in the way assess systems that use oil, water, or gas
equipment is performing. Such changes to either transfer liquid or gas from one
often serve as early warnings of impending point to another or as a means to generate
issues. Recognizing them can be the key to power. Pressure, temperature, and humid-
triggering action that prevents failure— ity are absolutely critical in these systems,
and its consequences. especially when it comes to quality. Too
It wasn’t that long ago that the only much or too little pressure can wreak havoc
option for monitoring the condition of on production. And if temperatures don’t
equipment was to do it manually. Anyone remain consistent—in the tool, lines, and
who has spent any time in a plant knows atmosphere—it can be to the detriment of
the process can be arduous, especially for quality. Sensors can provide enough data
operations with significant equipment to enable the identification of trends that
inventory. Visually reviewing gauges, enter- show the condition of a piece of equipment
ing data into spreadsheets, traversing into is changing. This insight can trigger correc-
hard-to-reach or dangerous areas–the tra- tive action, before the catastrophic occurs.
ditional approach is time consuming and Sensor-driven condition monitoring is
vulnerable to human error. And, oftentimes, especially useful in hard-to-reach or inac-
it’s not proactive enough to prevent a fault cessible areas where on-board gauges may
or failure. be hard to reach or view. It’s also valuable
Sensors are making over this historically in hazardous environments, enabling the
manual process. Deploying them to monitor user to keep a safe distance and eliminate
different elements of equipment—pressure, the need for special safety-related clear-
temperature, humidity—can pinpoint con- ance or process.
ditions that may be indicative of a specific Because replacing manual monitoring
problem. with sensor technology enables the optimi-
zation of assets and processes, productivity
Sensing maintenance needs is arguably its biggest benefactor. The first
Sensors are a cost-effective way to take productivity gains come with the elimina-
a snapshot of what’s happening with a tion of the need for staff to perform manual
piece of equipment–down to the second, reads of equipment conditions, which can
if that’s what an organization needs. The net a significant improvement in labor effi-
technology is fast and efficient, enabling ciency. The second gains, and likely even
the monitoring of more process points and more significant, come with the prevention
more machines. And it’s suitable for use of downtime.

Combined with wireless technology and mobile devices such as smartphones, sensors are giving maintenance workers a new
insight into what’s happening on their plant floor at any moment.
According to the U.S. Department of technologies have pushed wireless into the
Energy, minimizing downtime has been mainstream, it has driven down the cost
shown to drive up asset availability by as of the bill of materials needed for wireless
much as 30% as well as increase produc- sensor acquisition, especially components
tion by as much as 25%. By identifying like Bluetooth radios. And because wire-
issues before they escalate, organizations less doesn’t require strenuous installation
can also decrease maintenance costs and or specialized skills, implementation is
avoid potentially dangerous situations. more affordable.
The accessibility and ease of implemen-
Going wireless tation makes wireless sensors ideal for
When organizations learn about how sen- placement in many types of production
sors can be applied for maintenance man- machines to monitor a variety of oper-
agement and condition monitoring, they ating parameters. Reduced cost isn’t the
can’t deny the benefits. But the added- only benefit of going wireless. The sens-
on, and often high, investment in the ing technology is easier to install than its
installation and use of traditional wired stringing wired counterparts, and it elimi-
sensors can make implementation cost- nates risk of physical connection faults.
prohibitive. Wireless technology is a via- The addition of access points is simplified,
ble alternative. and the commissioning routine doesn’t
Wireless options make sensor solutions require laborious programming and data-
sur prisingly af ford abl e. As c onsu me r collection devices, such as a programmable

logic controller (PLC). Once installed, a
wireless sensor allows for instant and easy
access to data for a variety of stakeholders
via user-friendly software and apps.
“Thanks to the Internet of
Things (IoT), the same
Enhancing equipment—new and old technologies that have
Some of today’s newest equipment comes
with on-board sensor technology. But it’s revolutionized the way
safe to assume that older equipment—
which still accounts for the vast majority consumers do everyday
of the assets found in plants around the
world today—doesn’t have the same bells things can now enhance
and whistles.
It doesn’t take a new asset to implement
the way we manage
sensor-based condition monitoring. Sen- maintenance in the plant
sor technology is so flexible and adaptable
that it can be implemented for maintenance
management throughout the lifespan of
environment. ”
equipment. Even for new technology, orga-
nizations can consider aftermarket appli-
cation of additional test nodes to increase a predictive approach. For organizations
their monitoring potential. that aspire to move along the maintenance
Wireless condition monitoring tech- management spectrum, a sensor-driven
nology can readily supplement an exist- condition monitoring program can be part
ing wired system without being directly of a deliberate roadmap to achieving pre-
integrated into it. More importantly, cost- dictive maintenance.
effective wireless sensors provide users with In the near term, the options for how
the flexibility to add more nodes to the condition monitoring data can be used are
process points that make the most sense becoming more robust. For example, orga-
to their specific applications—a capability nizations may be gathering maintenance
not available to industrial organizations as data from a variety of systems. But it’s
little as three years ago. likely those systems aren’t interconnected
and their dashboards are exclusive. Incre-
Putting data to work mental improvements in technology will
The collection of data through sensor tech- help marry data sets. An organization can
nology is just the beginning. The data overlay what’s happening with its hydrau-
mean nothing if they aren’t utilized. lic equipment, for instance, with weather
The other critical element of a sensor- data or information about the utilization
based condition monitoring system is the of energy. This enables the optimization of
software application that houses and pro- various factors that can affect production,
vides access to the data. These applications such as ambient temperature conditions of
make information available on multiple the production floor that impact produc-
devices. And they can be configured to tion equipment or energy-saving discounts
generate dashboards that transform data offered by utility suppliers when energy
into insights that drive maintenance man- utilization during peak times can be mini-
agement decisions. Additional support for mized and validated.
decision making can be provided by fea- It’s possible to make maintenance man-
tures such as alarms or e-mail alerts that agement as intelligent as some of the con-
notify users of certain conditions in real sumer technology that’s become so com-
time and allow them to act. monplace today. Sensor technology is the
powerhouse that can make it happen. PE
Taking intelligence to the next level
Effective, disciplined, condition monitor- Mario Calvo holds three patents and has
ing lays the groundwork for—and is the been with Parker Hannifin Corp. for 22
precursor to—predictive maintenance. In years, currently as business unit manager
fact, the data generated through condi- for its diversified technologies group focusing
tion monitoring are mission-critical for on life sciences and IoT.

Education and personal development are vital to the advancement
of the engineering community. We invite you to explore and celebrate
the educational efforts of the following companies participating in our
innaugural Educating Engineers program:
AutomationDirect Fluke
AVO Training Institute FORCAM
Baldor GTI Spindle Technology
Camfil APC Kaeser Compressors
Dynatect Lubriplate
ErectaStep MovinCool
Flexicon Vac-U-Max
S ince 1994,
AutomationDirect has
been saving customers money
by fighting on their behalf!
Saving you money is what we do!

Our tens of thousands of high-value
industrial automation products include
everything from cable ties, wire and tools, AutomationDirect campus, located 40 miles north of Atlanta, GA, USA
to pneumatics, HMIs, SCADA software
and PLCs.
you can take for a spin. We also offer a 30 day money back
Our name-brand products come from guarantee on most products and orders made before 6pm
multi-billion dollar companies, such as will ship out the same day, with orders over $49 shipping
Fuji Electric, Cutler-Hammer, and Hubbell/ (2-day) free of charge.
Wiegmann, that we work with in order to
provide world-class quality products at the Our technical support specialists are always ready to
lowest prices possible. assist over the phone, no matter how big or small the
issue or product, at no cost to you. Our learning library
We also co-engineer many of our private- (http://library.automationdirect.com) has tons of informative
labeled products with the manufacturer content including articles, eBooks, whitepapers, app stories,
to ensure you are getting the features you blogs, newsletters, and supplier profiles. If it is PLC training
need at prices you can afford. that’s needed, we partner with Interconnecting Automation
(http://www.interconnectingautomation.com) to provide
On top of that, our volume purchases and PLC training courses both online and onsite.
streamlined operation allow us to pass
even more savings on to you. Our 24/7 So if you are looking for a one-stop supplier with your best
online store (www.automationdirect.com) interest in mind, take a look at AutomationDirect!
has tons of free goodies including, product
documentation (manuals, comprehensive
help files, price list, and CAD files), tutorial
and how-to videos, tech forums, example
programs, FAQs, firmware updates, and sales@automationdirect.com • 1-800-633-0405
full package (no demo) PLC software that automationdirect.com

N ew Baldor
Customer Education
Course Announced
The Baldor Advanced

Motor Academy
The Baldor Customer Education team
is pleased to offer the Baldor Advanced Baldor Advanced Motor Academy at the Baldor Electric
training center in Ft. Smith, Arkansas
Motor Academy at the Baldor Electric
training center Ft. Smith, Arkansas.
The new course is part of the customer This class will be scheduled to run twice per year for 3.5
education classes that we offer to assist days per session. Baldor Education classes at the Ft. Smith
you, our customers. campus include: hotel, food, transportation (from hotel to
class and return) and class materials. Transportation to and
In this program, students will gain from Ft. Smith is the responsibility of the student.
in-depth knowledge of the Features and
Benefits of Baldor’s motor products. Please check the Customer Education section of the
baldor.com website to review dates and descriptions of all
Students will also learn how to properly available classes and register for the next Advanced Motor
select and apply the correct product to Academy session.
specific applications. Included in the
course agenda are tours of two motor For further information please contact:
plants and a test lab. Chris Whitfield
Training Specialist - Electrical
Enrolled students are expected to have Chris.Whitfield@baldor.abb.com
3-5 years of experience in the industrial
motor field. Each student will need to
provide their own laptop computer to
access and utilize the motor selection
tools taught in the class. www.baldor.com

C amfil APC Offers Training
Programs, Videos and
White Papers on Dust, Mist
and Fume Collection and
Combustible Dust Topics
To educate engineers on dust collection

and combustible dust topics, Camfil Air
Pollution Control (APC) conducts Camfil APC offers training programs on dust collection and
combustible dust topics.
seminars at the company training center in
Jonesboro, Arkansas. Programs include
NFPA standards training to help engineers Additional Camfil APC programs for engineers include:
understand safety and compliance issues
• Educational white papers cover a wide range of subjects
with combustible dust. NFPA standards
including combustible dust, welding fume control, mist
trainees receive a certificate of completion
collection, dust collector safety, the new OSHA silica rule
for 14 Professional Development Hours
and more. The downloadable white papers are offered
(PRH). Operation and maintenance training
free with registration.
for Farr Gold Series® cartridge dust
collectors is also available. • An APC Video Center, accessed via the company
website, features a selection of videos including customer
For engineers who cannot travel to case studies, product demonstration and installation
Jonesboro, the company maintains a fleet videos, and industry-specific dust collection topics.
of more than 60 mobile dust and fume
collection systems for training and • Company experts also participate regularly in online
education. The trailer-mounted units are webinars conducted by industry associations and
available on request and may be used engineering publications. Topics include the latest NFPA
for dust collection seminars or for more standards, OSHA compliance, and other timely subjects.
informal training on basic principles of dust
collector design, selection and operation. Contact the company for a current list of white papers and
upcoming training sessions and webinars.
They are also used to demonstrate the
dust collectors at professional meetings,
trade shows and “Learn over Lunch” onsite filterman@camfil.com • 1-800-479-6801
customer events. www.camfilapc.com

S afety in
Smaller Numbers.
An Innovative Line of Work

Platforms and Crossovers
Do More With Less.
When they say there’s safety in numbers,

they’re usually referring to vast quantity.
Something with at least one comma in it.
But, occasionally, there’s an exception to
that rule. Occasionally, there’s safety in a
much a smaller number. A number like five. As you’d imagine—given the small number of parts—
assembly is simple. In many cases, it can be accomplished in
After all, five is the number of components a few hours. There’s no welding and no waiting. You’re just a
that make up an ErectaStep crossover or wrench away from a safety-enhancing, fine-avoiding solution.
work platform. Five standard, prefabricated
parts. But don’t let that simplicity fool you: And here’s another small number with big implications: one.
these systems are incredibly advanced. As in your crossover or work platform can be delivered to
you in one day. That’s right. Not only are the systems safe,
The engineering is built into each part and, but they’re also in stock. And that’s important because, just
in turn, built into every conceivable as they say safety comes in numbers, they also say time is
configuration of the parts. So no matter money. And they happen to be right on both counts.
how you assemble your platform or cross-
over—and they can be configured and Learn how you can increase safety and boost productivity
reconfigured over and over again—it will with ErectaStep’s five easy components by visiting
be strong, safe and, most importantly, erectastep.com/PEM or calling 888-878-1839 for your
OSHA-compliant. free quote.
Call us toll free: 1.888.878.1839 • internationally +1.843.485.0630

Visit us online: ErectAStep.com/PEM
input #39at www.plantengineering.com/information

M oving bulk material?
Understand the fundamental
differences between Flexicon
Flexible Screw Conveyors,
Tubular Cable Conveyors and
Pneumatic Conveying Systems Flexible Screw Conveyors, Pneumatic Conveying Systems and Tubular Cable
Conveyors from Flexicon offer unique attributes relative to individual requirements.
Several conveyors can move your bulk separation of blends and evacuate material from the tubing
material, but only one is likely to offer the circuit, preventing waste and allowing rapid cleaning.
greatest efficiency, dependability and cost
effectiveness for your requirement. Dilute-Phase Pneumatic Conveying Systems with single or
multiple inlets and outlets move bulk materials vertically and
Flexible Screw Conveyors can move the horizontally in low to high capacities over short to long
greatest diversity of bulk materials, including distances using pressure or vacuum generated by a blower.
those that pack, cake or smear, with no Material enters the system through rotary airlock valves,
separation of blends. Economical to pick-up adapters and wands (vacuum systems), and is
purchase and maintain, they convey at any separated from the airstream using filter receivers or cyclone
angle over short to medium distances in low separators. Material exits the system through rotary airlock
to medium capacities. The removable inner valves or fill/pass valves, or discharges directly into process
screw is the only moving part contacting vessels--with no residual.
material, and is driven above the point at
which material exits the conveyor, eliminating While these generalizations may help narrow your conveyor
contact with seals. choices, Flexicon recommends running your material in its test
laboratories equipped with full-size conveying systems and
Tubular Cable Conveyors gently slide fragile upstream/downstream equipment to simulate your process.
food and non-food products through smooth
stainless steel tubing routed at any angle
over short or long distances in low to high
capacities using low-friction polymer discs
attached to stainless steel cable.
These conveyors are available with single +1 888 353 9426 • sales@flexicon.com
or multiple inlets and outlets, prevent the www.flexicon.com

M ake better
energy consumption
decisions with Fluke
Power quality analysis and energy

studies are ideal methods to assess
overall electrical system health, but they
require special tools that can log multiple
parameters over time to capture dips,
swells, and inrush currents.
The Fluke 1738 Advanced Three-Phase As part of the Fluke Connect® system of software and more
Power Logger automatically captures than 30 wireless test tools, the 1738 allows technicians to
and logs more than 500 power quality access and share data remotely with the entire team via the
parameters to give electricians and Fluke Connect app, or access the logger through the
technicians more visibility into the data facilities’ Wi-Fi infrastructure.
needed to make better power quality and
energy consumption decisions. With the included Fluke Energy Analyze Plus software
package, measurements can be quickly and easily graphed
The Fluke 1738 is the ideal tool to conduct: to help identify issues and create detailed reports. Optionally,
• Load studies — verify electrical system IEEE519 reports can be created to provide more insight into
capacity before adding loads. harmonic levels, voltage and current distortion, and load
The 1738 is also suitable for NEC 220 current (license required).
load studies.
• Energy assessments — quantify The Fluke 1738 also allows engineers or technicians to
energy consumption before and after perform advanced analysis with an enhanced Power
improvements to justify energy Quality Health Summary (EN50160) function that provides
saving expenditures. fast insight into overall electrical system health. For more
• Harmonic measurements — uncover information visit fluke.com/1738
harmonic issues that can damage or
disrupt critical equipment.
• Voltage and current event capture —
monitor for dips, swells, and inrush
currents that cause false resets or 1-800-44-FLUKE • fluke-info@fluke.com
nuisance circuit breaker trips. www.fluke.com

S MART FACTORY brings End to
Shop Floor Disconnectivity
Cutting-edge Shop Floor Management

technology eliminates the “disconnectivity” in
the manufacturing value chain. Manufacturers
need a concrete action plan to deliver better
products and improve bottom line results.
SMART FACTORY 7-Step Checklist:

Step-1 Acceptance: Success of a Smart
Factory requires management support. Must “Strategically, the biggest risk of NOT having FORCAM’s
be a top priority and accompanied by modern Shop Floor Management Technology is that we would
change management processes. be out performed by our competitors.”
Martin Thorden, President, GKN Aerospace Newington, CT
Step-2 Step-by-Step: Plan well, set small
goals, and achievable milestones.
Cross-functional teams should gather best SMART FACTORY Starter Kit: Simple, Fast, and Economical
practices and create an achievable action plan. SMART Shop Floor Reports to proactively drive productivity
DATA:
Step-3 Select High-Performance Technology:
REAL TIME: Visualize 3 machines. Real-time reports with
Only the best features memory-based and light
In-Memory + Complex Event Processing technology
speed processing power.
TRAINING: Learn how to use smart data to drive productivity
Step-4 Test Pilot: Test smart manufacturing
technologies in a critical manufacturing SMART FACTORY features these Benefits:
area, on select troubled machine assets, for a EASY: Consulting, implementation and training for the pilot
set time. FAST: Machine connection to our
FORCAM FORCE™ solution
Step-5 Metrics: Define metrics to control prog-
ress and generated data through smart ratios. See us at IMTS: booth E-4421 in the EAST BUILDING.
FORCAM provides analytical solutions to complex manufacturing
Step-6 Communicate: Hold regular meetings
industries through innovative Shop Floor Management technology.
to inform stakeholders on outcomes and
We Deliver Results in Productivity.
opportunities for improvement.
Step-7 Rollout: Broaden communication. +1 (513) 878-2780

Involve all stakeholders and customers by info@forcam-usa.com
using mobile devices and shop floor monitors. www.forcam.com

A ttend Pressure & Profit:
Find Out How to Design,
Optimize, and Monetize
Compressed Air Systems
for Manufacturing
In nearly all manufacturing facilities,

compressed air is the single largest
contributor to energy costs. When you
combine this with the Department of
Energy’s estimate that roughly 50% of all
compressed air is wasted, the potential for
increasing profitability is enormous. But the
only way to realize this potential is to deepen
your understanding and application of
compressed air systems best practices. Who are the Speakers? Compressed air experts Gerald
Baron of Kaeser Compressors and Joe Ghislain of Ford Motor
What is Pressure & Profit? We will show Company will help you put theory into practice with real world
you ways to improve your system so you examples you can directly apply in your context. Seating is
can reduce downtime, scrap rates, and limited, so you’ll have plenty of time to ask about your
maintenance and lower production costs. specific application.
We’ll talk to you about new DOE efficiency
standards, variable frequency drive, leaks, What’s the Schedule? We’ll provide breakfast and start at
controls, and a lot more. It’s not a sales 8:00 am with a welcome session. You’ll have your pick of two
pitch. We won’t try and sell you anything. learning tracks. Then it’s time for a Q&A session over lunch.
After a quick wrap-up, the conference ends at 1:00 pm.
With conference locations in St. Louis,
Boston, and San Francisco, there are ample How Can I Register? Visit www.kaeser.com/conferences to
opportunities to join us. register. Tickets are $99. Early bird and discounts for bringing
a colleague are available. Contact conference organizer
Who Should Attend? Energy managers, Bob Glenn (bob.glenn@kaeser.com) for more information.
plant and production managers, consulting
and plant engineers or anyone responsible
for compressed air system design customer.us@kaeser.com • 866-516-6888
or maintenance. www.us.kaeser.com

I nformation on Industrial
lubricants for your
plant operations at…
www.lubriplate.com... FREE
Log on to our website and find all the

information you need about industrial
lubricants. From mineral based greases
and oils to the latest high grade synthetic
fluids, the data is compiled in our
Lubriplate Lubrication Data Book that
you can download at no cost to you.
Also available in digital format are

important specification and product
information sheets on H1 Food Machinery
Lubricants, Environmental Lubricants
and more.
Complete data on drop points, cold

tests, viscosity indexes, ISO grades,
AGMA numbers, etc. is included.
There is lubricant information available
regarding compressor fluids, hydraulic
fluids, bearing lubricants, power
transmission fluids, specialty lubricants,
high grade greases and more.
If you have a specific question you

may also talk with a lubricant
representative at 1-800 733-4755 or LUBRIPLATE LUBRICANTS CO.
e-mail lubeXpert@lubriplate.com Newark, NJ 07105 / Toledo, OH 43605

P ortable Air Conditioners
Outshine Other
Methods of Spot Cooling in
Industrial Facilities and
Office Environments
MovinCool educates engineers with

its expert field support team. Plus, on In addition to cooling people and equipment, MovinCool provides
MovinCool.com engineers can learn first- process cooling to reduce production time.
hand with videos, whitepapers, case studies
of how industrial cooling units bring cool, Evaporative coolers aren’t much better. They provide
refrigerated air to production lines without cooling, but don’t perform well in humid climates and throw
the need to spend hundreds of thousands moisture into the air, which, again, is detrimental to equipment
on 100 or more tons of cooling. life cycles and employee comfort.
Do you find that certain areas of your plant Through years of experience and training, MovinCool
or facility are often fitted with fans or local educates engineers on how to measure, manage, and
evaporative coolers even though your facility maintain a comfortable work environment. The company
is equipped with a large-capacity central air has found that portable spot air conditioners specifically
conditioning system? If so, something needs developed to meet the needs of the application will solve
to be done about it. the problem. Portable spot air conditioners are compact,
self-contained units that combine a compressor, condenser,
When excessive heat builds up in local- and evaporator in a single cabinet.
ized areas, it lowers employee productivity,
which causes product quality and cycle Industrial engineers will easily learn the quick and easy
times to suffer and the performance of installation, compact size, cost-effectiveness, and flexibility of
equipment to suffer, shortening life cycles— portable spot air conditioners— they are customizable. When-
in some cases OSHA violations can occur. ever a change is needed the cold-air duct can be extended
up to 80 feet long, allowing easy installation on crowded
Fans or cross-ventilating windows seldom factory floors or for remote cooling of difficult-to-reach areas.
provide adequate cooling, plus can blow
dust, grit, and other foreign matter through
the air, contributing to possible eye injuries info@movincool.com
or equipment wear. movincool.com/industrial-cooling

Avo Training Courses Advance Job Skills
Avo offers the following Engineering Courses:

• Protective Device Coordination for Utilities
• Protective Device Coordination for Industry
• Short Circuit Analysis
• Power Quality & Harmonics
Also our Electrical Engineering Division works with all types

of utilities, industrial facilities, levels of government, as well
as data centers and a wide variety of commercial industries.
We aren’t industry or equipment specific and are qualified to
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We use industry preferred software, the most current IEEE

standards, the National Electrical Safety Code, and the Tel: 877-594-3156
Ralph Lee papers for our engineering calculations. www.avotraining.com

pe201608_eduEngHLF_AVO.indd 1 7/20/2016 12:30:16 PM
Dynatect presents machine protection and safety

at the 2016 International Manufacturing Technology
Show in Chicago (IMTS).
Dynatect’s 2,100 square-foot exhibit will present products used
to protect machinery and enhance safety. Visit our booth # NC-300
within the dedicated Pavilion for Machine Components & Accessories,
Safety and Environmental in the North C Hall.
Dynatect’s brand family includes: Gortite®, Gortrac®, and LSI (ball

screws). Product demos will feature: protective bellows for linear ways
and hydraulic cylinders, roll up covers, safety pit covers, cable carriers,
way wipers, automated roll up doors, safe machine door actuators,
and precision ball screws. We’ll also unveil our expanded capabilities
to manufacture a customized ball screw in virtually any combination
of lead and screw diameter. A custom roll-up door highlighting over 25
years of experience designing and manufacturing industrial doors for www.dynatect.com • 800-298-2066
automation and machine tool applications will also be presented. jessica.mallinus@dynatect.com

Changing Predictive Technology
GTI Predictive Technology has been at the cutting edge of

predictive maintenance technology for several years now. Our
iPad based platform has grown over the past 6 years to include all
of the essential tools on a single device. GTI’s iPads can be outfit-
ted with vibration analysis, field balancing, laser shaft alignment,
thermography, ultrasound, and many other specialized tools.
GTI empowers our users by providing in-depth training.

We offer our users both Skype training and on-site training. Every tool right on your iPad
Our intuitive software allows training to get to our more advanced
features very quickly.
Modern technology, putting the user first, and a passion for

info@gtipredictive.com
predictive maintenance are just some of the reasons how GTI is 603.669.5993
changing predictive technology. Call or email to find out more. www.gtipredictive.com

pe201608_eduEngHLF_gti.indd 1 7/18/2016 8:53:44 AM
Top 10 Must-Have’s When Designing

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As all processes vary, so does the pneumatic conveying tech-
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When properly defining pneumatic conveying technologies, it is
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including the heart of the system, the vacuum receivers.
Consider the advantages and disadvantages of dilute vs. dense

phase conveying, and respective dilute phase positive pressure
conveying vs. dense phase positive pressure conveying. To learn
more about the top ten design considerations for the dust-free
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info@vac-u-max.com
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section of www.vac-u-max.com and download the whitepaper. or (800) VAC-U-MAX

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IN NOVATIONS
Digital panels
ProSense digital panel meters are designed to display
analog process signals, including +/-10 V and +/-20 mA.
The 4-digit red LED display is easily scaled into any engi-
neering units from -1999 to 9999 with a selectable deci-
mal point location. Non-linear processes can be scaled
by entering up to 16 scaling points. It offers two SPST
relay outputs that can be set to activate on an increasing
or decreasing input signal with hysteresis or time delay
operation, retention and reset of minimum and maximum
display values, a tare function, filtering to minimize dis-
play bounce, and display brightness adjustment.
AutomationDirect
www.automationdirect.com
Input #200 at www.plantengineering.com/information
Electric chain hoist

The EDV mini electric hoist is a single phase, single speed hoist that features Smart Speed
Technology which allows users to change the factory set speed to a higher speed by mak-
ing a simple adjustment inside the hoist when necessary. It handles loads by providing the
speed flexibility and precise load positioning needed for a variety of lifting requirements.
It is a lightweight, low-headroom hoist that is easy to install, transport and store and is
available in four capacities of 250, 350, 500, and 1000 lbs.
Harrington Hoists Inc.
www.harringtonhoists.com
Circuit monitor panelboard

The Pow-R-Line PXBCM Branch Circuit Monitor Panelboard delivers remote energy usage
monitoring and improved compliance. It monitors up to 84 branch circuits and provides facil-
ity managers across industries with remote access to live energy readings. This panelboard is
ideal for end users to help track power usage and maintain compliance with emerging energy
codes. The solution combines monitoring capabilities of branch circuits with overload alerts
that indicate when circuits are close to exceeding thresholds, enabling facility managers to
proactively mitigate events and minimize downtime.
Eaton
www.eaton.com

Send new product releases to: peproducts@cfemedia.com
Shaft collar
The Easylock shaft collars, for high speed converting and
winding applications, allows users to adjust the holding force
from 90 to 1,124 pounds. Easylock shaft collars with positive
release are designed to reduce downtime to help maintain
consistent production rates. The quick-release feature makes
Easylock collars well suited to high volume production where
frequent changeovers of shaft-mounted tools, reels/spools and
other objects are required.
Amacoil
www.amacoil.com
Pedestal platforms
GREEN insta-rack pedestal platforms
provide safe access to the tops of
single-dome tank/bulk trucks, tanks
cars, and hopper cars. They feature
single or double-sided access, static,
pivot or slide-track mounting, custom
design to meet your application. There
are various integration options with
loading arms and pumping stations.
Benko Products Inc.
www.benkoproducts.com
Electromagnetic flowmeter
The OPTIFLUX 4100 electromagnetic flowmeter is demanding
and harsh applications including liquid manure applications,
dragline pump safety, and billing for commercial applicators.
The meter can provide an accurate record of the fluid that
was moved. It can be independently verified to validate the
measurements. It features bi-directional flow metering and a
wide range of approvals for hazardous areas. The OPTIFLUX
4100 also provides extensive diagnostic capabilities.
KROHNE
www.us.krohne.com

IN NOVATIONS
Hybrid laser analyzer
The Rosemount CT5100 is a hybrid gas analyzer that
combines Tunable Diode Laser (TDL) and Quantum
Cascade Laser (QCL) measurement technologies
for process gas analysis and emissions monitoring.
It can detect down to sub ppm level for a range of
components, while simplifying operation and signifi-
cantly reducing costs.The CT5100 can measure up to
12 critical component gases and potential pollutants
simultaneously within a single system-meeting local,
state, national, and international regulatory require-
ments.
The CT5100’s laser chirp technique expands gas
analysis in both the near-and mid-infrared range,
enhancing process insight, improving overall gas
analysis sensitivity and selectivity, removing cross
interference, and reducing response time. The laser
chirp technique produces sharp, well-defined peaks
from high-resolution spectroscopy that enable
specificity of identified components with minimum
interference and without filtration, reference cells, or
chemometric manipulations. Air-driven linear pump
Emerson Process Management The Flex-I-Liner pump is designed for use in remote
www.EmersonProcess.com areas where electricity is unavailable or when a spark
Input #206 at www.plantengineering.com/information may ignite the substance being pumped. Providing
gentle pumping action, it operates wet or dry and can
be supplied with rotary vane air motors. Designed to
eliminate shaft seals, stuffing boxes and other common
sources of leakage, this pump can be supplied with
reversible operation to allow for changing flow direc-
tion. Its motors develop up to 2000 rpm on 90 psi and
control of the air motor drive allows for varying flow
rates within +/-5%. No special tools are needed for
maintenance.
Vanton Pumps
www.vanton.com

Send new product releases to: peproducts@cfemedia.com
Vortex flow transmitter

The Huba 210 Series Vortex Flow Transmitter is designed for water and
water/glycol based heat exchange systems and other fluids compatible
with the materials of construction. Featuring a number of sizes and signal
outputs, these transmitters provide an economical option for OEM flow
measurement applications. The 210 Series Transmitter offers <1% fs accu-
racy and media resistance. Easy insertion and removal of fittings for pipe
sizes to 1in. allows them to accommodate any system. The temperature
measurement range is -40 F to +302 F (- 40 to +150 C).
Clark Solutions
www.clarksol.com
Laser marking system

The MP2 is a diode pumped solid state (DPSS) laser marking sys-
tem that is ideal for applications that require high resolution and
where speed throughput is not required. It features a DPSS laser,
laser beam scanning optics (galvanometer), control electronics,
and marking software. The laser provides a pulse duration of 3
nsec, high peak power of 30 kW, and runs on 24 VDC (6 Amps).
The 1064 nm infrared wavelength is well suited for laser mark-
ing a wide range of materials such as: metals, plastics and some
organics and can be used in a variety of industries.
LNA Laser
www.lnalaser.com
Multi-channel controllers
The Zen RTU and the Zen Datalogger are ideal in a range or heavyweight
industrial monitoring and control applications. The Zen RTU is ideal for
applications which require collation of multiple signals routed directly to
a master console such as for connecting directly to a PLC and SCADA
system. It has four digital inputs and a RS485 Modbus/RTU port. The Zen
Datalogger is appropriate for applications that require acquisition and
visualization of data from multiple sources. It has two analog outputs and
two relay contact outputs for control and alarm applications.
Define Instruments
www.defineinstruments.com

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Place next to your computer as a reference or go online to www.plantengineering.com for hot links to these companies.
For more information on how to advertise in Plant Engineering’s
Internet Connection, call Jim Langhenry at 630-571-4070 x2203
alliedelec.com erectastep.com newellrubbermaid.com
Allied Electronics is a small order, high service level dis- Modular work platforms and aluminum stairs pre-engi- Newell Rubbermaid is a global marketer of consumer
tributor of electronic components and electromechanical neered for unlimited configurations. Platforms and metal and commercial products with a strong portfolio of lead-
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Allied Electronics ErectaStep
orival.com
atlascopco.us flexicon.com Orival is a leading manufacturer of self-cleaning water
Atlas Copco produces and markets compressed air equip- Flexicon designs and manufactures bulk handling equip- filters, automatic water filters and strainers, for use as
ment and generators, construction and mining equipment, ment and custom-engineered and integrated plant-wide industrial water filters, irrigation filters, cooling tower fil-
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Atlas Copco Flexicon Corp. Orival Inc.
automationdirect.com fluke.com seweurodrive.com

AutomationDirect offers over 16,000+ industrial automa- Fluke is the world leader in the manufacture, distribution, One of the largest global suppliers of drive technology,
tion products through their free catalog and online super- and service of electronic test tools and software. SEW-EURODRIVE specializes in gear reducers, motors
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FORCAM GmbH is a technology and consulting company soparts.com
avotraining.com with headquarters in Ravensburg at the Bodensee. SPECO provides premium replacement parts and oils for
For almost 50 years, AVO has been helping organizations FORCAM GmbH all major air compressor manufacturers.
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AVO Training Institute goodway.com
Goodway Technologies is a global manufacturer and mar- spminstrument.com
baldor.com keter of industrial maintenance solutions for commercial SPM offers a wide product range from high-tech portable
Baldor Electric designs, manufacturers, and markets a HVAC, facility management, manufacturing, power gen- instruments to online systems and comprehensive soft-
broad line of industrial energy-efficient electric motors, eration, maritime, and other industrial applications. ware.
mechanical power transmission products, and more. Goodway Technologies SPM
Baldor Electric Co.
gtispindle.com klsummit.com
camfilapc.com GTI Spindle Technology provides the highest quality and Industry leader in synthetic lubricant technology with a line
Camfil Air Pollution Control (APC) is a leading global most extensive range of machine tool spindle repair ser- of over 200 products that can service almost any industrial
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equipment and is part of Camfil, the world’s largest air fil- GTI Spindle Technology Summit Industrial Products
tration company.
Camfil APC harvardcorp.com ustsubaki.com
Harvard Corp. develops, manufactures, and markets filter U.S. Tsubaki is a leading manufacturer and supplier of
centuryspring.com and filtration systems. power transmission and motion control products and is the
Century Spring has been supplying quality stock and cus- Harvard Corp. world’s market share leader in roller chains.
tom springs, metal stampings, and wire forms for MRO U.S. Tsubaki Inc.
and OEM applications since 1927. us.kaeser.com
Century Spring Corp. Manufacturer of air system products, including rotary vac-u-max.com
screw compressors, portable compressors, rotary lobe VAC-U-MAX specializes in design and manufacture of
cemanet.org blowers, vacuum packages, refrigerated and desiccant pneumatic systems and support equipment for conveying,
CEMA is a trade association serving the manufacturers dryers, filters, and condensate management systems. weighing and batching of dry materials.
and designers of conveyor equipment worldwide since Kaeser Compressors Inc. VAC-U-MAX
1933.
Conveyor Equipment Manufacturers Assoc. lubriplate.com whitemores.com
Lubriplate manufactures more than 200 high quality lubri- Whitmore creates component protection technology
donaldson.com cants, including high performance synthetic lubricants and through the manufacturing of specialized lubricants, rail
Compressed air purifications solutions, compressed air NSF-H1 lubricants for food processing and beverage. equipment, coatings, sealants, and contamination control
filters, dryers and process water chillers. Lubriplate Lubricants Co. solutions.
Donaldson Company Inc. Whitmore Manufacturing Co.
mapcon.com
dynatect.com MAPCON Maintenance Software protects plant assets yaskawa.com
Dynatect designs and manufactures a complete line of from unscheduled downtime and costly maintenance Yaskawa is the world’s largest manufacturer of ac inverter
components to protect equipment and people. repairs. drives, servo and motion control, and robotics automation
Dynatect MAPCON Technologies Inc. systems.
Yaskawa America Inc.
est-static.com movincool.com
EST specializes in mitigating static charges, induced volt- The MovinCool division of DENSO has been responsible
ages and random discharges on rotating shafts, moving for pioneering the use of portable air conditioning solutions
surfaces, and all types of manufacturing equipment. for a wide variety of U.S. markets since 1982.
Electro Static Technology MovinCool

CONTACTS Advertiser Contacts
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Request more information about products and advertisers in this issue by using the
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Ph. 630-571-4070, Fax 630-214-4504 know you read about them in Plant Engineering.
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CONTENT SPECIALISTS/EDITORIAL Advertiser Page Service # Phone # Web site
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EMILY GUENTHER, Associate Content Manager Atlas Copco Compressors 19 16 866-688-9611 www.atlascopco.us
630-571-4070 x2220, EGuenther@CFEMedia.com
ATS IA15 24 www.advancedtech.com
AMANDA PELLICCIONE, Director of Research
631-320-0655, APelliccione@CFEMedia.com AutomationDirect C-2 1 800-633-0405 www.automationdirect.com
ERIN DUNNE, Production Coordinator Baldor Electric Company C-4 52 800-828-4920 www.baldor.com
630-571-4070 x2210, EDunne@CFEMedia.com
Beckhoff Automation LLC IA16 25 952-890-0000 www.beckhoff.com
PUBLICATION SERVICES Camfil APC 4 4 800-479-6801 www.camfilapc.com
JIM LANGHENRY, Co-Founder & Publisher Caterpillar - Northeast 22 19 www.NECatDealers.com/power
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630-571-4070 x2204, SRourke@CFEMedia.com CENTURY SPRING CORP 10 7 800-237-5225 www.centuryspring.com
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773-815-3795, EMYounger@CFEMedia.com ErectAStep C-1, 11 8 888-878-1839 www.ErectAStep.com
KRISTEN NIMMO, Marketing Manager Exair Corp 7 5 800-903-9247 www.exair.com
630-571-4070 x2215, KNimmo@CFEMedia.com
Flexicon Corp 8 6 888-353-9426 www.flexicon.com
MICHAEL SMITH, Creative Director
630-779-8910, MSmith@CFEMedia.com Fluke Corp 15 13 888-443-5853 www.fluke.com
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630-571-4070 x2208, PBrouch@CFEMedia.com Featured Integrators 45 630-571-4070 www.plantengineering.com/global-si-database
MICHAEL ROTZ, Print Production Manager Greenheck Fan Corp 13 11 715-359-6171 www.greenheck.com
717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com GTI Spindle Technology 48 29 603-669-5993 www.gtipredictive.com
MARIA BARTELL, Account Director, Infogroup Targeting Solutions IANA at IMTS 2016 IA4, IA12 23 www.industrialtechnology.events
847-378-2275, maria.bartell@infogroup.com
IIoT Webcasts 51 630-571-4070 www.plantengineering.com/IIoT
RICK ELLIS, Audience Management Director
303-246-1250, REllis@CFEMedia.com Kaeser Compressors, Inc 1 2 866-516-6888 www.us.kaeser.com/PE
LETTERS TO THE EDITOR LubricantPros.com 14 12 877-717-4242 www.LubricantPros.com
Please e-mail your opinions to BVavra@CFEMedia.com
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INFORMATION
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REPRINTS
For custom reprints or electronic usage, contact: MOVINCOOL 41 26 800-264-9573 www.movincool.com
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Plant Engineering 2016
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SPECO 13 10 888-793-4988 www.soparts.com
Richard A. Groth Jr., NJ/ E. PA RGroth@CFEMedia.com
12 Pine St. Tel. 774-277-7266 Sullair Industrial Products 18 15 219-879-5451 www.sullair.com
Franklin, MA 02038 Fax 508-590-0432
Summit Industrial Products 56 31 800-749-5823 www.klsummit.com
Jerry Preston, West Coast JPreston@CFEMedia.com
6746 E. Tyndall Circle Tel. 602-369-3037 U.S. Tsubaki 57 32 800-443-4216 www.ustsubaki.com
Mesa, AZ 85215
Vac-U-Max 68 35 973-759-4600 www.vac-u-max.com
Stuart Smith, International stuart.smith@ssm.co.uk
SSM Global Media Ltd. Tel. +44 208 464 5577 Wildeck, Inc. 67 34 800-325-6939 WWW.WILDECK.COM
Fax +44 208 464 5588 Yaskawa America, Inc C-3 51 800-927-5292 www.yaskawa.com

INCONCLUSION
Big Data shouldn’t be too big to manage
“
By William E. Amos, PhD
Meridium How do you know if you are effectively applying
smart technology to the right assets? Some as-
W
ith the massive sets may not need to be as `smart‘ as others or
amount of informa-
tion currently resid- outfitted with advanced sensors, and it’s critical
ing in existing enter- to understand which assets, data, and symptoms
prise asset management (EAM)
systems, real-time systems, his-
torians, devices, and condition monitor-
you need to be monitoring.
”
organization, they generate disparate data strategies.
ing systems, the promise of Big Data has sets and potentially cause hours of lost These strat-
yet to be fulfilled: using it to help your productivity through rework, overlap, and e g i e s are
company stay competitive, profitable, confusion. key to the
and innovative. Consolidating all of the data into a IIoT as they use both analytical and com-
The challenge with Big Data is making single, secured location, making it avail- parative analysis to provide a platform
sense of all the information and putting it able across all levels of an organization, to integrate asset data from existing and
in the proper context: using it for action- and in the desired form, is the first step new sources. Intelligent asset strategies
able analysis and predictive modeling to to wrestling control of your operating and are also a driver for the critical conversion
determine what, if anything should be production environment. A unified data of that data into actionable information
done to change the way the asset is man- set that pulls from every connected device to predict how and when an asset will
aged. Without a reliable and consistent can help businesses benchmark the per- fail and the recommendation of actions
ability to process, analyze, understand, formance of individual sites against that of to prevent that failure.
and make decisions on the information others in the organization and even against
contained within these massive unused industry peers around the globe to get a Embracing IIoT
data sets, expending resources to accu- true picture of how well they’re operating. To ensure that organizations are taking
mulate that data is questionable. The next step is figuring out how to full advantage of IIoT, making strategic
An effective approach implements an manage all that data. How do you man- business decisions, and seeing a return
asset performance management (APM) age those billions of bits of data from all on their investment, they must be able to
program that analyzes data across the those devices? How do you know if you draw insights from data within the plants
entire organization to understand asset are effectively applying smart technology across their facilities and against the
criticality and risk. By automating the to the right assets? Some assets may not performance of other organizations in
Big Data analysis, ranking asset needs by need to be as “smart” as others or outfitted their industry. APM programs can help
priority, and generating actionable plans, with advanced sensors, and it’s critical companies connect their disparate plant
APM programs can help plant operators to understand which assets, data, and systems and use all this data to create and
identify emerging trends and take imme- symptoms you need to be monitoring. manage the intelligent asset strategies
diate action to mitigate any risk of failure. More importantly, are you analyzing the that will predict and prevent failures as
right data to get the key insights to act well as drive improved asset performance
Understanding criticality and risk upon? With all this information, are you and reliability, reduce operational risk,
All operators understand that asset fail- bringing it together in context and with and optimize costs.
ure could result in the injury of people, a set of analytical tools to make sense of As organizations manage ever-growing
the environment, and business invest- it and drive action from that? groups and types of assets, the amount of
ments. It is therefore crucial to have the The promise of the Industrial Internet data created by connected devices will
technology needed to flag potential risk of Things (IIoT) is real, but for all this increase exponentially. But all that data
and proactively avoid it. Today many new, accurate data to have value, indus- will only provide value if integrated with
organizations are managing multiple try will require more than OEM-specific enterprise systems and used to enable
systems and solving one problem at a M2M platforms or standalone point solu- more informed business decisions. When
time rather than considering long-term tions. Enabling the IIoT requires con- accurately managed, Big Data generated
costs and strategic implications. In almost necting disparate information sources, by connected assets keeps facilities more
any manufacturing plant, you will find a creating storage capacity for exploding efficient and creates a safer environment. PE
menagerie of technology and processes to volumes of Big Data, comprehensive ana-
collect data on equipment assets. When lytics, expert content presented in context, William E. Amos, PhD, is Chief Tech-
systems are operating in silos across an and most importantly, intelligent asset nology Officer at Meridium.

READY FOR THE
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