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TECHNOLOGY & ASSET PERFORMANCE
OCTOBER 2013 • VOL 26, NO 10 • www.MT-ONLINE.com
FEATURES CAPACITY ASSURANCE STRATEGIES 20
Enhance Power Equipment Reliability With Predictive Maintenance Technologies ©SERGEY NIVENS — FOTOLIA.COM
Trending is crucial. Condition monitoring of your electrical equipment provides the type of data that helps you anticipate and plan future maintenance activities. S. Frank Waterer, Schneider Electric USA, Inc.
ON THE ROAD TO SUSTAINABILITY 30
It Also Takes A Little TCO According to automation and controls giant Honeywell Process Solutions, true sustainability can’t be realized without factoring in total cost of ownership. Rick Carter, Executive Editor
CAPACITY ASSURANCE STRATEGIES
15 16 18 28 46 48
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Augmenting your human senses with advanced technologies is truly a PdM best practice. Consider all of your options.
Next-Gen Power: Reliability-Centered Maintenance Delivers Savings The power industry is investing heavily in new technologies to harvest energy from renewables. New technologies, though, can introduce new, perhaps massive, maintenance costs. Special to MT
THE RELIABILITY FILES 39
Protect Your Gearbox With The Right Lubricant Compared to past models, today’s gearboxes typically call for more comprehensive protection from their lubricants.
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& ASSET PERFORMANCE
October 2013 • Volume 26, No. 10 ARTHUR L. RICE
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“Visual systems, when applied to equipment, can reduce training time by 60 to 70% and eliminate errors.” —Robert Williamson, lean equipment specialist
Our Visual Supplies Can Improve Your Equipment’s Performance! Colored gauge marking labels Problem and Opportunity Tags in English or Spanish Red Move Tags Colored paint pens Colored grease fitting caps and lube point labels Vibration analysis pickup discs and labels Proven Tips for Equipment Troubleshooting handbook Lean Machines instructional book for applying visuals Temperature indicating strips and more
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Maintenance Technology® (ISSN 0899-5729) is published monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodicals postage paid at Barrington, Illinois and additional offices. Arthur L. Rice, III, President. Circulation records are maintained at Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Maintenance Technology® copyright 2013 by Applied Technology Publications, Inc. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@ wdsmail.com. Submissions Policy: Maintenance Technology® gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc. permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. “Maintenance Technology®” is a registered trademark of Applied Technology Publications, Inc. Printed in U.S.A.
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Jane Alexander, Editor-In-Chief
Regarding Reliability: Enlightenment Matters
he Texas A&M Turbomachinery and Pump Symposia in Houston was full of it: the “R” word, that is. It showed up, in some shape, form or fashion, in technical sessions, networking affairs, casual conversations, printed and electronic materials, exhibitor-booth signage, you name it. Whether or not the event organizers planned it that way, “reliability” (or, more precisely, the endless quest for it) seemed to be an underlying theme among this year’s attendees and exhibiting companies—just as it is in your plants, day in and day out. As an editor, I attend industry events like the Symposia for two main reasons: 1) to learn about and report on our readers’ concerns, problems and successes; and 2) to learn about and report on technologies and services that can address those concerns, solve those problems and lead to those successes. The good news, from what I gathered in Houston, is that suppliers are on the same wavelength. The marketplace is flush with offerings to help you achieve reliability across your operations. They’re the types of groundbreaking/game-changing technologies and services that we regularly feature in this magazine. Alas, I also have some bad news to report (although it’s probably not real news to you). Allow me to explain… My favorite hangouts at technical conferences are the Discussion Groups. They’re where I key in on some of the most pressing issues you face. The Symposia program always offers several such sessions. One that I sat in on this year focused on “Monitoring Vibration and Other Critical Conditions.” Led by Bill Marscher, President of Mechanical Solutions, Inc., it opened up several cans of worms, including one I’ve heard debated again and again. As described by a long-time maintenance pro from a big—real big—company, it involved the selling of predictive maintenance to management (or, as he put it, the need to constantly be reselling the value of these programs to new managers). You would think, with so much involved in keeping critical equipment and processes humming these days, that maintenance and reliability teams would have something better to do than stay in a continuous selling mode. It’s a real conundrum, isn’t it? Why do some new managers cut predictive maintenance programs and others buy in to them? As one veteran of the equipment-reliability wars later suggested to me, the real danger comes from unenlightened managers. What we need, he asserted, are more of the enlightened variety. How do you get them? That’s a problem in itself. If you wish to start or keep the enlightenment ball rolling around your site, feel free to share this little nugget I picked up in the Discussion Group: As one rotating-equipment vendor in attendance volunteered (he didn’t represent a predictive-maintenance solution supplier), his company would be delighted to regularly sell new units to attendee companies that cut their maintenance budgets. Laughter rippled around the room, but it sounded like the nervous kind. MT firstname.lastname@example.org
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NEWS STUFF HAPPENS
Prepare To Vote On Engineering Our Future Rockwell Automation has announced the launch of an Engineering Our Future video contest, designed to excite and inspire elementary-, middle- and highschool students about future careers in science, technology, engineering and math (STEM). To participate in the contest, FIRST* teams will produce videos answering the question: “What could your team engineer that would have a positive impact on your community and our world?” Rockwell Automation will award up to $10,000 in team grants for winning entries. According to Ninveh Neuman, Vice President of Global Commercial Marketing for the corporation, “As Rockwell Automation celebrates the 110th anniversary of its Allen-Bradley brand, a milestone achieved thanks to the commitment of countless innovators, we wanted to look to the future. The Engineering Our Future contest engages our world’s future innovators and asks them to consider how they could create a more productive and sustainable world.” Teams participating in FIRST LEGO League (FLL), FIRST Tech Challenge (FTC) and FIRST Robotics Competition (FRC) are eligible to enter the contest by creating and submitting a video that’s 60 seconds or less in length. All entries must first be uploaded to YouTube or Vimeo, and teams will be asked to provide a link to their respective submissions as part of the entry process. Video entries will be accepted through Oct. 31, 2013. Participating teams will compete in a public vote to win team grants. Voting runs from Nov. 5 through Nov. 29. People can vote once per day by visiting the Engineering Our Future contest Website (http:// www.rockwellautomation.com/rockwellautomation/news/110-anniversary/ engineering-our-future.page). Teams with the most votes will receive grants that can be applied to the 2013-2014 season for FTC and FRC teams or the 2014-2015 season for FLL teams.
*About FIRST Inventor Dean Kamen founded FIRST (“For Inspiration and Recognition of Science and Technology”) in 1989 to inspire an appreciation of science and technology in young people. Based in Manchester, NH, it designs accessible, innovative programs to build self-confidence, knowledge and life skills, while motivating young people to pursue opportunities in science, technology and engineering. With support from over 200 of the Fortune 500 companies and more than $16 million in college scholarships, the not-forprofit organization hosts the First Robotics Competition (FRC) for students in grades 9-12; FIRST Tech Challenge (FTC) for grades 7-12; FIRST LEGO League (FFL) for grades 4-8; and Junior FIRST LEGO League (Jr. FLL) for grades K-3. Gracious Professionalism is a way of doing things that encourages high-quality work, emphasizes the value of others, and respects individuals and the community. To learn more, go to http://www.usfirst.org.
In Memoriam: Ralph Buscarello Vibration analysis pioneer and industry icon Ralph Buscarello died Sept. 5, 2013, at the age of 87, in Castle Rock, CO. The founder and CEO of Update International, he spent more than 50 years working in the area of practical vibrationrelated machinery improvement, including several decades teaching those best practices to others in more than 40 countries around the world. Although Buscarello had engineering degrees, both mechanical and administrative, from the University of Denver, he was best known for his down-toearth approach that made vibration-analysis principles and methods easy to understand and apply. Those who knew, worked with and learned from him over the years, including the editors of this magazine, will greatly miss being on the receiving end of his special wisdom and wit.
STUFF HAPPENS NEWS
Invensys has acquired InduSoft. Founded in 1997 and headquartered in Austin, TX, InduSoft has delivered more than 250,000 HMI software licenses to more than 700 customers worldwide. Clients are primarily industrial computer manufacturers and machine and system builders, who embed the company’s software into their products. According to Norm Thorlakson, Vice President, HMI and Supervisory Software and Solutions for Invensys, this acquisition means that Wonderware® users will now be able to buy industrial devices, machines and computers with InduSoft software, while companies using InduSoft software will be able to expand their solutions with Wonderware supervisory, historian and manufacturing operations management software. Allied Reliability Group (ARG) has announced a new partnership with Pfingsten Partners, LLC. Pfingsten is a longestablished private equity group with decades of experience building services companies. Since its founding in 1997, ARG has provided a wide range of reliability and maintenance services and products, including condition-based monitoring, consulting, training, staffing and integrated software solutions. According to ARG Partner and co-founder John Schultz, “With Pfingsten’s operational expertise, global capabilities and financial support, we will have the resources to embark on our next stage of growth by investing in a broader service offering and expanding our reach internationally.”
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Pump-maker Grundfos has appointed Duncan Cooper as President and Chief Executive Officer of the company’s North American region. He succeeds Jes Munk Hansen, who leaves the company to pursue other interests after having led the region for the past five years. In his new position, Cooper will oversee and direct all operations in the U.S., Canada and Mexico with continued emphasis on residential and commercial buildings services, as well as the industry, water utility, irrigation and agriculture and wastewater businesses. He’s been with the company since 1997, and most recently served as Regional Managing Director of Grundfos Western Europe. Going forward, he will continue in his role as Group Senior Vice President. (BTW: This year, Grundfos celebrates its 40th anniversary in the U.S. The company opened new North American headquarters in the Chicago area [Downers Grove, IL] in August 2013.)
N’ I T H FIG WORDS The great Winston Churchill could always be
counted on to inspire those fighting the good fight. This one seems particularly appropriate for those in the maintenance and reliability arena:
“Success is not final, failure is not fatal: It is the courage to continue that counts.” Inspiration For Those Battling The Enemies Of Reliability & Productivity
Have you read, heard, seen, thought or written down something that falls into the realm of “fightin’ words” for the maintenance and reliability community?
Send your favorites to firstname.lastname@example.org. We’ll be selecting one or two (maybe even three) to feature each month. Be sure to give full credit to the individual (dead, alive, real or fictional) that uttered or wrote the words, and why those words inspire you. Don’t forget to include your complete contact info.
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NEWS STUFF HAPPENS Got items for Stuff Happens? Send your news to email@example.com
n o i t a ci
Francis J. Kuhn, CFM, CFMJ WorleyParsons Azusa, CA Thomas L. Mitchell, Jr., CFM, CFMJ Booz | Allen | Hamilton San Antonio, TX Curtis L. Slife, CFM, NCARB, AIA FM Solutions, Inc. Phoenix, AZ
Title: The Innovator’s Path Author: Madge M. Meyer Reviewed By: Jane Alexander, Editor
In this new book, business executive/thought leader Madge Meyer puts an easy-to-read roadmap to “business as usual” innovative thinking and doing in our hands. She points readers in the right direction by focusing on the eight essential disciplines of innovation: listen; lead; position; promote; connect; commit; execute; evolve. Individuals, teams and organizations seeking to nurture innovating corporate cultures should check this one out. . . . JA
Have you read a book that could be of value to other readers of MT? Tell us why in 100 words or less. Visit www.mt-online.com/bookclub for Book Club Rules and submission forms. Or, after reading those rules, send your reviews directly to firstname.lastname@example.org.
Showcasing In-Depth Technical Articles From Your Suppliers
The International Facility Management Association (IFMA) has announced its 2013 class of Fellows. The association’s fellowship program was established to recognize members dedicated to IFMA and the facility management profession. Over the years, it has become an elite core of respected leaders who act as advisors to and ambassadors of the organization. Being named a Fellow is the highest honor that IFMA can bestow on a member. This year’s class of four includes:
MT’s Book Club
Recommended Reading For Maintenance & Reliability Pros
TOPIC: “Save Time and Costs with Intelligent P&IDs and Smart 3D Model-Based Management Information System for Operating Industrial Plants “ A fundamental deficiency in the current life-cycle management of a plant is that any “intelligence” (i.e., data, drawings and documents) entered during any activity for any object in the plant (i.e, equipment or a valve etc.) doesn’t automatically flow to all downstream activities involving that object. This type of information gap can cause bottlenecks. A White Paper from SST India discusses how the company’s integrated plant asset management system can help users deal with this situation and reduce time and costs for their operations through, among other things: • Rapid, accurate retrieval of information;
Ondrej Strup, Ing. Hein Consulting Prague, Czech Republic
• Decisions in case of equipment failures;
For more information, go to www.ifma.org.
To download this free White Paper, go to: www.mt-online.com/SST
• Responses to plant emergencies; • Sequencing/scheduling construction activities and more. For more info, enter 01 at www.MT-freeinfo.com Sponsored Information OCTOBER 2013
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UPTIME This column is the first in a series discussing the ins and outs of the new ISO 55000 Asset Management Standard. Look for others intermittently over the next several months.
Bob Williamson, Contributing Editor
ISO 55000: Management Systems For Asset Management, Part I Facilities and equipment management is about to be taken to a whole new level with the release of ISO 55000 Asset Management Standard scheduled for early 2014. Or is it? The long-awaited rollout of this new global standard might not be what many are assuming it will be. Then again, maybe it will. That’s the way it is with the introduction of global standards. Remember the launch of ISO 9000 and ISO 14001? Regardless, even if ISO 55000 isn’t perfect when it rolls out, it will still provide a very sound foundation for organization-wide life-cycle asset “ownership.” Readers will soon recognize that the ISO standard is NOT solely about fixed assets, either: Instead, it identifies assets as items having “potential or actual value to an organization.” It would have been simpler if it were focused on “physical” or “fixed” assets alone. However, this new definition of an “Asset Management System” will serve as a framework that has long been missing in our fixed/physical asset-based business and industry. The push for ISO 55000 I expect that the directive to conform to ISO 55000 requirements will come from outsiders (i.e., owners, investors, insurance underwriters and regulators)—and it won’t be optional. For the most part, these entities want an assurance that the organization is systematically addressing risks associated with unreliable assets: high costs, lagging ROI, catastrophic damage, and safety, health and environmental incidents. Compliance with this new global standard goes a long way to assuring that the value assets bring to the business increases. But ISO 55000 does not specify HOW to manage the assets. What, then, is this Asset Management Standard all about? Simply stated, the intent of the new ISO 55000 Asset Management Standard is to provide a framework that specifies and links life-cycle asset decision making and actions to the strategic goals of the business. Unfortunately, it’s not as simple as that. Let’s review the recent history of Asset Management. The precursor to ISO 55000 was PAS 55 Asset Management Specifications, issued in 2008 by the British Standards Institution as a “publicly available specification for the management of physical assets.” 12 |
While PAS 55 has been evolving since 2004 and has developed a significant body of knowledge and track record, the ISO 55000 suite of standards is mostly new content with no track record yet. A committee of committees The global committee work devoted to developing the ISO 55000 structures and language took on a Herculean task. It eventually involved representatives from 31 participating countries and 13 observing countries under the guidance of the International Organization for Standardization (ISO) located in Geneva, Switzerland. The primary players in the ISO 55000 project included PC/251 (ISO Project Committee 251), The British Standards Institution and Technical Advisory Groups (TAGs) from around the world (for the United States, they were ASTM International, ANSI [American National Standards Institute] and the US/ TAG [U.S. Technical Advisory Group]). Visualize a “committee of committees” structure that pulled all of the pieces together. No doubt, the big challenge was combining all the various perceptions, beliefs and assumptions about “asset management” into a cohesive working document. Turning such a working document into a draft standard is yet another huge challenge. Ultimately, the international organization must compile, format and publish the new Asset Management Standard conforming to their standard format and style. As you can imagine, there were many compromises and disagreements along the way. But once ISO 55000 is released, it will provide one of the most comprehensive global guidelines for improving the fixed assets (and more) for a wide variety of businesses around the world. Expect a steep learning curve leading up to informed discussions regarding the ISO 55000 revision and updating process in about five years. Deﬁning ISO 55000 Let’s review the elements. ISO 55000 is a “suite” of international standards developed and published by the International Organization for Standardization (ISO). These include ISO 55000, 55001 and 55002. Each of these various elements has a specific purpose OCTOBER 2013
The definition of ‘asset management system’ will provide a framework that’s been missing from our fixed/physical asset-based operations. in the development and deployment of Asset Management Systems: n ISO 55000: Asset Management Overview,
Principles and Terminology n ISO 55001: Asset Management Systems —
Requirements n ISO 55002: Asset Management Systems —
Guidelines for the Application of ISO 55001 The ISO 55001 Standard describes the elements of an Asset Management SYSTEM—it doesn’t specify the process, programs or best practices for actual management of assets. It is NOT a “standard for the management of assets” but rather a “standard for asset management systems.” And though maintenance and reliability processes, programs and best practices fit within ISO 55001, the new standard is NOT about maintenance and reliability. But there’s more… ISO 55002, on the other hand, reflects “guidelines” for the design and operation of an Asset Management System. Here is where recommendations and examples that support development and implementation of ISO 55001 are discussed. Again, it stops short of discussing HOW to manage specific types of assets. That, of course, is left up to the various asset management stakeholders and experts in the organization seeking to conform to ISO 55001. Interpreting the terminology Asset management is more than maintenance management—a whole lot more. When reading the draft documents, one could easily become confused and conflicted with some of the terminology. Accordingly, let’s sort through some basic terms related to Asset Management and the ISO 55000 series. (Notice how the focus of each term changes.) n Asset—A tangible (or intangible) mechanism that
adds value to the organization. (The Focal Point) (Note: At this point, the term “asset” hasn’t been fully defined in the ISO document. The Standard was intended to include physical assets, as well as OCTOBER 2013
intangible ones like value-adding intellectual property, software, etc.) n Maintenance Management (My Own Definition)—
Structured work processes for the purpose of caring for fixed assets (i.e. equipment and facilities), coordinating the efforts of people and achieving maintenance goals and objectives in support of overarching strategic business goals. (Asset-Care focus) n Asset Management—Coordinated asset-related
decisions, plans and activities, using a risk-based approach of an organization to realize value from assets throughout the asset’s life-cycle stages. (Value-Adding Focus) n Asset Management System—A set of interde-
pendent elements of an organization, to establish the asset management policy and asset management objectives and the processes for the development, coordination and control of asset activities over different life-cycle stages, aligned with the strategic goals of the organization. (Organizational-Behavior Focus) Look to ISO 55000 for the official definitions of applicable terms and concepts. Critical asset-management success factors Asset Management, as described in the ISO 55000 documents is NOT about “maintenance and reliability management”—barely a word is spoken about maintenance. But we don’t have to reflect on the basics of fixed asset management very long to recognize that maintenance and reliability practices play a huge role. “Asset Management” (AM) in general covers the life cycle of physical/fixed assets, and there are numerous critical success factors. At the top if the list, I would suggest the following: n Connecting life-cycle “asset” decision-making about
acquisition, operation, maintenance and decommissioning to the strategic business goals is the most important factor. mt-online.com | 13
Don’t be caught off guard. Now is the time to study this emerging standard. Let’s all be prepared for its expected roll-out early next year. n Engage
ALL stakeholders in “asset” decision-making from the early stages and throughout the remaining life-cycle phases.
n Continuous improvement of asset
performance and reliability to 1) extend asset life (as needed); 2) improve reliability; 3) lower operating costs; and 4) strategically manage asset-related risks. n Leadership and teamwork within
and outside the organization is essential. Since successful AM starts at the “policy level,” it represents a major culture change for most fixed asset-intensive businesses. n Maintenance and reliability profes-
sionals must lead the way to weaving in what we already know about “lifecycle asset management,” and all of the maintenance and reliability best practices that go with it. Now’s the time to study the emerging Asset Management Standard. There’s no need to wait on this. Let us position ourselves ASAP to become engaged in the rollout of ISO 55000 across our plants, facilities and organizations. MT
Robert Williamson, CMRP, CPMM and member of the Institute of Asset Management, is in his fourth decade of focusing on the “people side” of world-class maintenance and reliability in plants and facilities across North America. Email: RobertMW2@cs.com. For more info, enter 70 at www.MT-freeinfo.com
Overcoming Your Challenges
Dry Compressed Air Efficiently By Ron Marshall, for the Compressed Air Challenge (CAC)
ir is like a sponge: It soaks up as much moisture as it can hold. When moisture-laden air is sucked into the intake of an air compressor and squeezed, like a sponge, it releases the moisture it has absorbed. If left untreated, this moisture will flow downstream with the compressed air. As it flows, it will gather the dust, rust and lubricant that exist on the compressed air piping walls and form a soupy mix that contaminates downstream equipment. In an effort to prevent this contamination from occurring, compressed air is normally dried and filtered at various strategic points before it’s sent to plant end-uses. The type of air dryer and level of filtration varies, depending on the quality of compressed air required. (In general, the better the quality of air required, the more expensive it is to produce.) Refrigerated air dryers and desiccant air dryers are two of the most common types. Refrigerated air dryers… These types of dryers cool air to near the freezing point of water using a refrigeration circuit and a heat exchanger. As the air cools, water condenses out of it and is removed via a water separator. This produces a dew point (the temperature at which the moisture within air starts to condense) of between 35 and 40 F. It is the refrigeration circuit in these dryers that consumes most of the energy; a smaller amount of energy is lost due to pressure differential. Rated specific power on these units is about 0.8 kW/100 cfm. Desiccant dryers… These types of dryers use a moisture-adsorbing material, such as activated alumina, to remove water molecules from the air stream. Most models incorporate two separate vessels containing desiccant: When one vessel is drying, the other is regenerating to remove adsorbed moisture. Once regeneration is finished, the dryer automatically switches sides. The regeneration process consumes
most of the energy in desiccant dryers; a small amount of energy is lost due to pressure differential. These types of units typically produce compressed air with dew points of -40 F. Rated power consumed ranges from 2.0 to 3.0 kW per 100 cfm. The key to energy efficiency of compressed air dryers is realizing that standard units consume near full power—even at light (or zero) loads. Because such dryers are usually sized for the worst-case scenario (i.e., the hottest, most humid day, when the compressor is at full load), the average loading at normal conditions is typically much less than the dryer rating. Thus, it’s desirable to select a dryer that can turn its energy down with reduced loading. A second benefit can be gained if the dryer has a low-pressure differential. Cycling or thermal-mass refrigerated dryers reduce energy with reduced loading. For desiccant dryers, the use of dew-point controls or capacitive sensing of the desiccant moisture content will reduce wasted energy from unnecessary regeneration cycles. Often, the choice of these strategies will pay for themselves very quickly. More information on this topic and others can be found in the Library section of the CAC Website, or in our Best Practices for Compressed Air Systems Manual. MT For more info, enter 02 at www.MT-freeinfo.com
The Compressed Air Challenge® is a partner of the U.S. Department of Energy’s Industrial Technology programs. To learn more about its many offerings, log on to www.compressedairchallenge.org, or email: email@example.com.
MT-ONLINE .COM | 15
FOR ON THE FLOOR An outlet for the views of today’s capacity assurance professionals Rick Carter, Executive Editor
Skills Shortage As Real As Ever We’re told to embrace change because it’s coming (like it or not). But for those affected by the U.S. skills shortage, change has so far been a no-show. Consistently ranked a top challenge for industry, the shortage of skilled labor for key manufacturing positions has received a lot of coverage and well-meaning attention in the past half-decade, yet still shows little improvement. Our Reader Panelists confirm this disturbing fact—again. Three years have passed since they were last asked about their skills-shortage problems. With few exceptions, the new responses on the subject, below, virtually match the old ones. I regret the repetition. I also hope another three years won’t pass before the news improves.
Q: How does your current skills-shortage issue compare to the situation you had three years ago? “The skills shortage continues to worsen. Very few young people are encouraged to pursue a career in the skilled trades.” … Reliability/Maintenance Engineer, South
Q: Does your company still have trouble filling skilled positions?
“I can’t see much difference. This has been a growing problem for several years.” … Senior Maintenance Mechanic, South
“Yes, we are having a very difficult time hiring qualified maintenance technicians, especially those with PLC knowledge.” … Senior Facilities Engineer, South
“Our situation is about the same. We have been trying to grow and improve our maintenance staff for more than two years.” … Senior Facilities Engineer, South
“We continue our struggle to find experienced maintenance technicians. We have been relegated to hiring young people right out of vocational maintenance programs with little or no experience.” … Reliability/Maintenance Engineer, South
“It hasn’t proven to be a problem, now nor then. That doesn’t mean it couldn’t become one.” … Maintenance Engineer, West
“It is becoming increasingly hard to find people. Most who seek higher education aren’t interested in this type of work and many who are consider it ‘just a job’ and don’t want to develop skills.” … Senior Maintenance Mechanic, South “With few exceptions we’re not refilling positions, skilled or otherwise. But when we do, we are finding a lot of qualified people.” … Maintenance Engineer, West
“We are still having trouble filling trades positions, particularly electricians. Most have experience only in construction or home building. We have hired some of them and they generally are not able to catch on with the logic or the programming.” … PM Leader, Midwest
“It’s much worse. Hiring is brisk in our area, and we lose personnel as fast as we can fill positions due to demand from local manufacturers with openings that pay higher starting rates.” … Maintenance Supervisor, South Q: What does your company do to mitigate skills-shortage problems? “I cannot convince my company to do anything [in this area]. I’m told there has to be somebody out there.” … Senior Facilities Engineer, South
FOR ON THE FLOOR
“Our company has established maintenance training centers at each of our U.S. locations, and we have established vocational school scholarships for kids with interest in maintenance at local high schools.” … Reliability/Maintenance Engineer, South “Our company spends a lot of time and money on training, both in-house and outside. Most of the in-house training is mandatory, but we have many opportunities for specialized training outside. This is voluntary and many don’t take advantage of it.” … Senior Maintenance Mechanic, South “We have discontinued [most] training due to budgeting issues and lack of time due to understaffing.” … Maintenance Supervisor, South Q: What, if anything, do you think government could do to address the skills shortage? “This is not the government’s issue. If people are not willing to work for the skill sets and companies are not willing to assist developing them, why should the government be involved?” … Senior Facilities Engineer, South “The government should stay out of it. The private sector will sort this out. It is the government’s steering of every child to pursue a college education that has created the problem in the first place.” … Reliability/Maintenance Engineer, South “They could offer grants specifically for technical schools.” … Senior Maintenance Mechanic, South “Considering there are at least 47 federal employment and training programs, I think the government is doing too much already.” … Maintenance Engineer, West “Link trade schools with high schools and junior colleges.” … Maintenance Supervisor, South
The jobs are there, but… In a country where unemployment figures are a regular component of daily news, it can be hard for some to believe that manufacturing has jobs to be filled. “The jobs are there,” notes a Panelist from the West, “but no one seems to want them.” He agrees with other Panelists that the nation’s emphasis on a four-year college education is part of the problem. “We do not see a PhD repairing your car or processing your food,” he says. “It’s the skilled laborers that keep this country going.” But this concept may be foreign to younger workers. As another Panelist notes, when his operation does find qualified workers, “many of our young hires don’t stick around. The hours are too long and they don’t like the call-outs on weekends and nights.” He adds that his company has been reluctant “to put extra people on the payroll for them to learn, so we now have a pending crisis.” This view suggests that industry itself must share at least partial blame for the skills shortage. A consultant from the Midwest concurs. Not only are certain companies reluctant to hire, he says, some are too quick to release older, experienced workers without tapping their knowledge. Coupled with “the low esteem many organizations have for their maintenance departments,” he says, such practices will put companies in a bind. World-class organizations operate differently, he says, “by hiring the right people—who are not the cheapest—and developing their own internal apprentice and mentoring programs.” Solutions to the skills shortage will be more obvious and simpler to enact, predicts this Panelist, when “CEOs and CFOs become less concerned with the cost of maintaining their equipment and more concerned with the cost of not maintaining it.” MT The Maintenance Technology Reader Panel is comprised of working maintenance practitioners who volunteer to answer bimonthly questions from our editorial staff. Panelist identities are not revealed, and their responses are not necessarily projectable. The Panel welcomes new members: Have your observations included in this column by joining the Reader Panel at www.mt-online.com. Click on “Reader Panel” under the “Info” tab, and follow the instructions. If accepted, you’ll be entered into a drawing for a cash prize after one year of active participation.
MT-ONLINE.COM | 17
Flexible, Scalable Fieldbus For Asset Performance Gary Mintchell, Editorial Director
elcome to the fourth column in this series covering industrial networking and how these networks benefit maintenance, reliability and operations functions in a plant. I have previously covered HART Communication Protocol, Foundation Fieldbus and the FDT standard for displaying status and diagnostic information from the field. This month’s topic is “all things Profi.” Profibus is a device-level fieldbus for connecting various devices, primarily in factory automation. Profibus PA extends the standard into process automation applications. Profinet is the Ethernet implementation of the standard. Similar to HART and Foundation Fieldbus, Profi networks are digital networks featuring simplified wiring among devices and controllers. Via a single cable, Profibus links controllers or control systems with decentralized field devices (sensors and actuators) on the field level and also enables consistent data exchange with higher-ranking communication systems. The consistency of Profibus is enabled through a single, standardized, application-independent communication protocol that supports fieldbus solutions in factory and process automation, as well as in motion-control and safety-related tasks. Part of the Profibus value proposition is its ability to cut costs and improve operations across the life cycle of a plant— from design though ongoing maintenance and even revamps. It does this in many ways: At the engineering stage, it simplifies plant design, eliminates hard wiring and requires less hardware, leading to faster commissioning and lowered costs. It supports better diagnostics, so commissioning is much faster. Profibus also helps achieve improved productivity and higher product quality through the delivery of better, moretimely data to operations and management staff. In addition, it supports advanced strategies that allow plants and equipment to be better managed and maintained. A huge number of vendor companies have developed Profibus-capable devices for discrete and process automation, so system integrators have plenty of choices. This leads not only to security and flexibility of supply, it also means healthy competition among vendors—and pricing that is highly favorable to end-users. The applications coverage has been
continuously extended to include new and relevant functionality, such as integrated Functional Safety and advanced Motion Control. Users have made substantial investments in training, tools, inventories and plants. Benefits of using a digital fieldbus include: ■ Plant asset management. Information from process instruments,
sensors and actuators are available in the controller. ■ Engineering and documentation. Engineering is simpler, and the
documentation is far less complicated as hundreds of separate wires are reduced to just a single cable. ■ Installation. With less hardware, installation is easier and faster. ■ Commissioning. Devices can sequentially be brought online, one
by one, with startup initiated from a central location. ■ Process variables. The diagnostic information and status bytes
available tell the user if they can trust the process variable or not. ■ Manufacturing flexibility. As demand shifts, manufacturing
changes can be implemented rapidly. ■ Maintenance and operations. With the powerful diagnostics of a
fieldbus come improved availability and reduced downtime. I’m still stung by the question posed to me during a presentation at the last MARTS Conference: “Do these things really work?” The answer is yes. I’ve talked with many engineers who have implemented these networks, plant and division managers who have seen the benefits and maintenance professionals who have saved countless hours figuring out a problem. Are you moving into the digital era? Let me know your results and frustrations, if any. MT Gary Mintchell, firstname.lastname@example.org, is Executive Director and Editorial Director of Applied Technology Publications. He also writes at www.themanufacturingconnection.com. For more info, enter 03 at www.MT-freeinfo.com
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Enhance Power Equipment Reliability With Predictive Maintenance Technologies Trending is crucial. Condition monitoring of your electrical equipment provides the type of data that helps you anticipate and plan future maintenance activities.
S. Frank Waterer Schneider Electric USA, Inc.
very facility manager should know what the monetary impact of an unplanned outage means to his/her respective operations. When an event occurs, however, the focus is usually on restoring power as fast as possible and at all costs. Often, the tangible and intangible costs are not accounted for during the event. The best way to avoid this financial impact is to reduce the risk of an unplanned outage, which requires time, effort, planning and the funding of an effective maintenance program.
CAPACITY ASSURANCE STRATEGIES
A comprehensive maintenance and testing program should cover all of your electrical-power-distribution systems— regardless of manufacturer—to ensure that all equipment and components operate safely and reliably as originally designed and intended. The ultimate goal is to minimize equipment malfunction, power outages or interruptions to operations or service. Approaches to electrical-equipment maintenance Depending on the process, operating environment or age of equipment, companies may adopt one or more of the following maintenance strategies: Reactive maintenance… ■ Repair work conducted after a failure or breakdown,
often completed as an emergency
The value of predictive maintenance Predictive maintenance (PdM) technologies enable companies to perform an effective amount of maintenance at an appropriate or practical time. Often referred to as conditionbased maintenance, predictive maintenance tools monitor the conditions of in-service equipment, either continuously (online) or at periodic intervals. Since many predictive maintenance technologies are utilized on in-service equipment, disruptions to facility operations can be reduced. Having regular access to the current state of the equipment provides valuable information to determine when maintenance should be performed. From a cost-effective standpoint, it should take place before the equipment loses optimum performance. Conditions that can be monitored on “in-service” electrical equipment include the following: Transformer
Temperatures, liquid levels, nitrogen blanket, insulating-fluid deterioration, gas analysis
Operating time, voltage bandwidths, insulating-fluid deterioration
Opening, closing time, available magnitudes of l2t energy
Temperature of connections, insulation condition
Starting time, number of operations, power, insulation breakdown
■ The most costly of all maintenance strategies
Preventive maintenance… ■ Routinely performed maintenance, regardless of
the equipment's condition ♦May be unnecessary, based upon condition of the equipment ■ Specified list of inspections, cleaning, testing and
part replacement ■ Less expensive than reactive maintenance, but more
costly than predictive maintenance Predictive maintenance (or periodic diagnosis)… ■ Scheduled, based on diagnostic evaluations
♦ Factors like equipment age, environmental stresses, criticality of equipment, utilization, etc., affect decisions concerning maintenance schedule ■ Provides significant reduction in equipment-related
incidents ■ Least expensive of all maintenance strategies
An efficient maintenance strategy will identify the type and amount of maintenance to be performed as well as the frequency for maintenance activities on each piece of electrical-distribution equipment. OCTOBER 2013
Cable Connections Insulation breakdown
Specific PdM technologies Power-system assessments. . . Power-system assessments are often the first necessary inspections to be performed after the equipment was originally installed. Completed by professional electrical engineers trained in power-system analyses, power-system assessments provide for visual inspections of portions or all of the existing power-distribution system. Power-system assessments determine the present electrical and mechanical “health” of the electrical equipment and power-distribution system, and how long they will likely continue to function as originally designed and intended. Defects, deficiencies, deteriorations, hazards or weaknesses in existing electricalpower-distribution system installations are also identified as part of a power-system assessment. Issues discovered as a result of the assessment are prioritized based upon one of four factors: 1. The safety hazard to electrical workers 2. The impact of the occurrence on key process elements MT-ONLINE.COM | 21
CAPACITY ASSURANCE STRATEGIES
3. The probability of an occurrence 4. The ability to respond quickly to correct the negative effects of the occurrence (vulnerability) Power-system assessments can be customized based upon the need to reduce risk to your facility from reliability issues, process disruptions, code violations and/or outdated workplace safety requirements. Infrared (thermographic) inspections. . . Infrared inspections use an infrared (IR) camera to detect anomalies not noticeable to the naked eye. In an electrical setting, infrared inspections identify hot spots that can be a precursor to equipment malfunction, which leads to unplanned downtime. Heat rise in electrical equipment can be the result of:
How it works: During a planned outage, wireless temperature sensors are installed in low-voltage and medium-voltage equipment* in areas usually not accessible with an infrared camera. Utilizing wireless technology eliminates the need for special cables and provides lower installation costs than other types of online condition-monitoring equipment. Temperature data is transmitted from the sensors to a nearby receiver via radio frequency signals. The receiver is connected to a computer via serial or Ethernet. The data can be collected, compiled, analyzed and reported by a dedicated software package or via a SCADA program with Modbus TCP connectivity. Desired or specific alarm set points can also be programmed. (*Sensors can also be installed on equipment with high arc-flash ratings, allowing equipment condition to be monitored without a risk of danger to personnel or equipment.)
■ Poor or loose electrical contacts or connections ■ Unbalanced electrical loads ■ Defective components
Having infrared inspections routinely performed may qualify a company for reduced insurance premiums.
Infrared Windows Enhance Safety Since infrared inspections are performed while equipment is in service and under load, equipment covers typically need to be removed. Infrared windows installed in equipment panels permit permanent access for inspection of electrical components without disturbing operations or removing covers. These window are made of a glass-like material that is transparent to infrared rays and allows hot spots to be registered by a thermographic camera. Online temperature monitoring. . . Online temperature-monitoring technology provides 24/7 access to critical connection points where traditional thermography cannot be used. Continuous monitoring provides the means to evaluate the equipment’s current condition and detect abnormalities at an early stage. Conduction problems caused by loose connections or deterioration of contact surfaces result in a local temperature rise, which contributes to a deterioration of insulation properties and the reduction of the contact quality. Thermal runaways induced by conduction problems also deteriorate the insulating material and cause disruptive dielectric discharges, resulting in arcing faults. 22 |
Insulating-fluid analysis. . . This predictive maintenance technology measures the physical and chemical properties of insulating fluids within liquid-filled transformers and load tap changers. Since transformers represent a substantial investment in a company’s electrical-distribution system, they must be maintained properly to maximize their reliability and useful life. An insulating-fluid analysis can detect the breakdown of the internal insulating systems along with a variety of other potential issues. Common tests performed on electrical insulating fluids include: ■ Clarity: Evaluates the clearness level and discoloration
of insulating fluids and checks for suspended or settled particulates. ■ Viscosity: Evaluates the density of the insulating fluid
relative to the manufacturer’s product data sheets and inspects for breakdown or contamination ■ Moisture Content: Increased moisture content can
negatively affect the insulating properties of the insulating fluid and cause dielectric breakdown. ■ Acid Number: As oil degrades, it produces charged
by-products—including acids and hydroperoxides— that adversely affect the fluid’s insulating properties. ■ Dielectric Strength: This is the maximum voltage that
can be applied across the fluid without electrical breakdown or flashover. A substantial reduction in dielectric strength may indicate that the insulating fluid can no longer perform as intended. OCTOBER 2013
CAPACITY ASSURANCE STRATEGIES
Reducing the risk of an unplanned outage requires time, effort, planning and the funding of an effective maintenance program. ■ Power Factor: In transformers, a high power factor is an
indicator that the insulating fluid has a significant power loss, usually caused by contaminants (water, oxidized oil or degrading cellulose paper). ■ Dissolved Gas Analysis (DGA): Concentrations and ratios
of certain gases in the insulating fluid may be indicators of operational problems with the transformer. Three DGA examples are: ♦ High levels of carbon monoxide in relation to other gases may be a symptom of thermal breakdown of cellulose paper. ♦ High hydrogen levels, in conjunction with methane, may point to a corona discharge in the transformer.
♦ Acetylene levels may indicate arcing within the transformer tank. Possible issues can be discovered in time, and outages can potentially be avoided. In addition, an efficient approach to maintenance can be adopted and the optimum intervals determined for insulating-fluid processing, repairs or replacement. Partial-discharge monitoring. . . Partial discharge is a leading indicator of insulation breakdown and occurs in electrical equipment under high voltage stress, usually greater than 2000 V. Higher system voltage and greater amounts of leakage current correspond to a higher potential for damages or downtime. Specifically, partial discharge is a localized electrical discharge in an insulation system that does not completely bridge the electrodes. As insulation systems age,
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MT-ONLINE.COM | 23
CAPACITY ASSURANCE STRATEGIES
Predictive maintenance technologies offer the types of cost-effective solutions that maximize reliability and increase workplace safety.
they become more susceptible to breakdown. Continuous monitoring provides early warning alarms to help prevent extensive damage to electrical equipment and downtime before it occurs. Technology is available to detect and notify facility engineers or maintenance and operations personnel of impending insulation breakdown. Partial-discharge monitoring is applicable on equipment rated 5kV to 500kV, where the age of the insulation could be cause for concern. Specific equipment applications include: ■ Metalclad switchgear and switches: 5kV and 15kV ■ Motors and generators > 2.4kV ■ Large power transformers and bushings ■ Substation yard structure-mounted voltage transformers and
current transformers ■ Generator step-up transformers and bushings
How it works: Sensors are installed on equipment during a planned outage. They are wired to a monitoring unit, which can be tied into an existing SCADA system via open protocol (Web hosting is also available). The sensors monitor: ■ Magnitude (mV or pC) - Size or volume of the deficiency ■ Pulse Count (PS) - Number or growth of deficiency ■ Intensity/Power (mW) - Destructive power of the partial
discharge events ■ Signature - Both phase and type of deficiency
Monitored results are evaluated and compared against an existing database. Trending data helps anticipate problems so that engineering and operations personnel can plan future maintenance activities. Circuit-monitor analysis Circuit monitors (CM) record data relating to system voltages, current magnitudes and power consumption. CMs also offer a full range of power-quality features to help facility managers and engineers understand where and when dangerous and destructive transients, sags and swells occur. These include: ■ Waveform capture and wave shape analysis ■ Disturbance recording ■ Disturbance direction detection ■ Transient analysis
Some circuit-monitor models can provide data on other utilities—including gas, compressed air, water and steam—to help management control operating costs. Whether they are addressing operational or power quality, circuit monitors have the ability to diagnose potential problems and minimize downtime. Intelligent protective devices Circuit breakers. . . ■ Electronic trip units or separate monitors can provide
intelligent information regarding an individual circuit breaker’s status, which includes: ♦ General condition: Identification, position, number of operations, cumulative interrupted currents, integrity of interrupting medium for medium-voltage (SF6 or vacuum) ♦ Mechanical condition: Operating times, charging time, travel-time curve, excess closing energy, wear of contacts ♦ Control circuit/auxiliaries: Supply voltage, supervision of trip coil circuit or sensors circuit
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■ Provides advanced planning ability as “condition-
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toring of motor current and power: ♦ Motor control centers are upgraded and networked into a centralized or distributed control scheme.
Resistance Stator Rotor Contamination
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♦ Digital display can be mounted on the door to minimize the need to open/close. ♦ Motor run time can be easily tracked. ■ Intelligent monitoring functions include:
♦ Current: Thermal capacity, line currents, average current, ground current, motor temperature (sensor) and current phase imbalance ♦ Voltage: Frequency, line-to-line voltage, line voltage imbalance ♦ Power: Active and reactive power, power factor, active and reactive energy OCTOBER 2013
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■ Electrical-signature analysis can detect:
♦ Rotor-bar damage ♦ Stator electrical faults ♦ Defective bearings ■ Maintenance can be scheduled on an as-needed basis.
Typical Identifiable Root Causes of Motor Control Center Outages: ♦ Power Quality
♦ Voltage and Current Waveforms
♦ Harmonic Voltage Factor
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Benefits of a predictive maintenance program Industry trends point to reduced maintenance staffs and budgets coupled with aging electrical equipment. Predictive maintenance technologies offer the types of cost-effective solutions that maximize reliability and increase workplace safety. Incorporating them into a company’s maintenance strategy enhance's the operation's ability to successfully: ■ Determine the operational status of equipment ■ Evaluate present condition of equipment ■ Detect abnormal conditions in a timely manner ■ Initiate actions to prevent possible forced outages
In short, monitoring your equipment condition and analyzing trending data to help anticipate and plan future maintenance will help you save time and money. MT (Note: Electrical equipment should be installed, operated, serviced and maintained only by properly trained and qualified personnel.) Frank Waterer is an Electrical Engineering Fellow with Schneider Electric USA, Inc. In addition to his many years in various engineering and R&D roles with Square D, he served, among other things, as Chair of the PES/IEEE Committee responsible for the design, development and installation of IEEE Standards relating to all surge-protective devices.
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Lubrication Checkup Single-Point Lubricators By Dr. Lube, aka Ken Bannister
Symptom: “We’ve begun using a variety of single-point lubricators for remote plant bearings on HVAC rooftop units, cranes, conveyor drives, etc. While our bearing failure rate has decreased drastically, we still experience failures. Is that normal for this type of automated lubricator?”
Diagnosis: Automatic single-point lubrication (SPL) devices are relatively inexpensive, compact and easy to operate when engineered and set up correctly. They can continuously deliver full-film lubrication to single or multiple bearing points for up to two years on one lubricant charge. There are four major SPL types:
Specialty lubricants for sustainable efficiency “Sustainable industrial production” means long-term, holistic thinking. Key examples include minimal unplanned downtime, less friction and reduced lubricant consumption. The effect: lower energy consumption, less CO2 emission, longer maintenance intervals and longer component lifetime. To keep up with your sustainability goals, we are continually improving our environmentally-friendly lubricants. Klüber Lubrication North America L.P. email@example.com www.klubersolutions.com/ sustainability4
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1. Mechanical: Grease-gun-filled and reusable, spring-actuated; relies on atmospheric and system backpressure to slow lubricant release. 2. Chemical: Pre-filled single-use; employs a chemical reaction to generate expandable gas acting on a flexible diaphragm to push the lubricant into the bearing; once invoked, can’t be stopped or influenced until all lubricant is discharged. 3. Electro-Chemical: Pre-filled single-use; employs a battery-operated programmable timer that sends an electrical charge into an electrolyte to produce an inert expandable gas that acts against an expandable bellows to push out lubricant. 4. Electro-Mechanical: Battery-operated, motor-driven device attached to a small positive-displacement piston pump; fully controllable and refillable; higher discharge pressure allows coupling to “splitter” devices and lubrication of numerous points simultaneously with one pump. Each type demands different set-up and maintenance procedures. Their success relies on the user understanding exactly how to install and operate the chosen type, compensating for ambient condition factors and performing regular preventive checks while the SPL is in operation. Lack of discipline in this area can easily lead to incorrect use and bearing failure. A second reason for bearing failure can be attributed to use of the wrong grease. Many SPLs come pre-filled with a specified lubricant that can easily be mixed and/or mismatched when units are taken from inventory. Be careful.
Prescription: Keep your approach toward SPLs simple and consistent: Choose a design that best suits the application and use only that type of lubricator. Closely read and follow the OEM’s instructions for setting up, operating and maintaining the unit. Then train all staff on its use. Good luck! MT Lube questions? Ask Dr. Lube, aka Ken Bannister, author of the book Lubrication for Industry and the Lubrication section of the 28th edition Machinery’s Handbook. He’s also a Contributing Editor for Maintenance Technology and Lubrication Management & Technology. E-mail: firstname.lastname@example.org.
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It Also Takes A Little TCO According to automation and controls giant Honeywell Process Solutions, true sustainability can’t be realized without factoring total cost of ownership into the calculation. Rick Carter Executive Editor
ith nearly half of its products linked to energy efficiency, Honeywell is a leader in promoting sustainable operations for manufacturers and facility operators worldwide. But the respected New Jersey-based company doesn’t limit its discussion of sustainability to energy efficiency. To achieve the highest level of sustainability, it recommends also putting on a green visor to study the numbers—all of them. Most important, say its experts, are those tied to the total cost of equipment ownership, an accounting procedure that enables managers to calculate any system’s true cost (based on all related factors, direct and indirect) over an actual or projected lifetime.
ON THE ROAD TO SUSTAINABILITY
Honeywell’s Doug Bach says TCO and sustainability can be “both parallel and overlapping.”
“TCO and sustainability can be both parallel and overlapping,” says Doug Bach, a Honeywell Process Solutions Customer Marketing Manager based in Phoenix, AZ. Plants seeking to integrate sustainable principles into their operation typically focus on reducing costs related to energy and maintenance, he says, expecting to move forward with the same or greater reliability and less environmental impact. But other equipment costs and expenses affect this goal as well, such as those related to acquisition, upgrades and ongoing support. For this reason, says Bach, “There needs to be an equation that considers the benefits and justification of doing many different things to the equipment over time. The total cost of ownership is never just about the cost of buying equipment,” he explains. “It’s everything else.” Honeywell’s TCO-based approach includes what Bach calls a “migration path forward” that involves “having a written plan to stay on that path and understanding the useful life of a system.” A system’s “useful life” is a key term with regard to TCO. Applied correctly, TCO covers the necessary details about the support needed to reach a calculated useful life and, consequently, to prevent dollars being spent on systems that have become obsolete. TCO calculations can be applied to any type of equipment or capital purchase. Bach’s frame of reference centers on the automated distribution control system (DCS) hardware and software for which Honeywell is known. His customers are largely process manufacturers that use DCSs to digitally control continuous and/or batch output at multiple locations through hundreds or thousands of I/O (input/output) devices. DCSs are also used to control equipment, such as variable speed drives. The job of maintaining and supporting such systems is usually entrusted to highly trained in-plant specialists, vendor implementers or both. It’s at this point, Bach suggests, where attainment of true sustainability can be missed if the type of written automation plan he refers to is not in place. Without one, it’s too easy to assume a DCS (or any other system) is humming along as designed, when in fact it could be wasting money, which fits no one’s definition of sustainability.
Industry Trends That Impact TCO TCO (total cost of ownership) comes into play whether equipment owners calculate it as a real number, see it as an abstraction or don’t recognize it at all. Numerous broad-based factors impact it, including the aging workforce, the skills shortage and aging plant infrastructures. Others are more focused, such as those uncovered in a 2008* survey of process automation system operators conducted by the ARC Advisory Group. Their responses indicated that: ■ 84% planned to run their installed
systems up to 10 years beyond the
suppliers’ stated obsolescence date (the date after which repair of components and technical support is no longer offered by the supplier).
■ 58% did not have a written life-
■ 64%, in fact, operated installed
*Honeywell process automation experts believe that the 2008 figures continue to represent current conditions accurately.
process automation systems 11 to 20 years beyond their system’s calculated useful life. ■ 69% did not believe that passing
their system’s obsolescence date was a reason to fund a system upgrade as long as it continues to operate reliably.
cycle management policy that would incorporate TCO calculations and strategies to keep TCO at an assigned level.
Source: ARC Advisory Group, “Trends in Process Automation System Lifecycle Management & Operational Services” report, 2008.
MT-ONLINE.COM | 31
Road TO System support reduces TCO Bach makes clear that his job is not to make the case for what he calls “rip and replace” projects for systems that have reached a certain age. It’s about providing customer education and support for systems, almost regardless of age. “I deal with DCS hardware that might be anywhere from 11 to 16 years older than the initial calculated useful life. We also have 35-year-old equipment that is still running and we have programs to wrap a level of support around those customers. But at some point,” he adds, “an aging system does become a risk and a potential downtime situation, so we work to help customers understand when they need to make decisions about useful life and keep their systems supportable.” That level of advice can only result after in-depth customer/vendor interaction. Sample questions Bach might ask to create a TCO profile include: ■ How willing is the company to maintain a system at levels
needed to reach its calculated useful life? ■ What level of accountability exists among key roles at the
company? ■ Are metrics being used, tracked and reported? Are they
linked to goals? ■ Are best practices written and shared? ■ How comfortable is the company adopting new tech-
nology? ■ Are the company’s systems proprietary or open? ■ Is maintenance of the installed DCS a core competency? ■ What types of long-term support partnerships does the
company currently have? A structured assessment is undertaken to provide such details and create “a baseline of where the customer is,” says Bach. “This will include a discussion around risk, unplanned downtime and problem resolution. For example, we’ll find out if procedures have been created for when a problem arises or if the site has a talent-succession plan. If someone retires and a skillset goes missing, we’ll identify that.” Bach says he often finds “the opposite of a total-costof-ownership mindset” in plants, especially those that lack basics like system back-ups. “One client had to restore and didn’t have up-to-date back-ups,” he says. “They also had no written disaster-recovery plan and lacked critical spare 32 |
parts that would be needed if a failure occurred. Maybe they were trying to cut back and decided they didn’t need to have certain parts onsite. But at this point, their total cost of ownership goes way up because they would most likely have to expedite a part, potentially pay extra for it and probably wait a couple of days to get back on line.” Even more costly to operate can be plants that lack an overarching strategy. “Nearly half of the customers we talk to don’t have written, well-communicated life-cycle management plans,” says Bach. “This means they don’t have that link between business strategy and support strategy. So if they’re not managing cost across multiple sites and getting into integrated-service agreements and really looking into managing an installed system with an eye on five years down the road, they’re potentially spending too much to keep their systems running.” Post-assessment solutions are, naturally, as varied as each client’s specific needs. Bach pinpoints training, however, as a common major concern among the many plants that face the double challenge of aging equipment and retiring workers. The new open-technology platforms for automated systems, he says, add to that challenge because they require a different skillset than older, proprietary systems. “So from a maintenance perspective, I’m talking to people who are thinking about retiring and I’m talking to the people who are replacing them,” says Bach. “The new people may be IT-savvy and welleducated, but lack process-control experience, so our training programs are likely to include components like remote-technology to help them do their job better. All of this is part of total cost of ownership in the Honeywell world,” he adds. “It’s driven by our customers having to do more with less, and our goal to have them lean on us for guidance.” Not a ‘flavor of the month’ Honeywell’s emphasis on TCO is not new, says Shawn Gold, Global Program Manager for Honeywell’s Services Marketing Group, based in Vancouver, Canada. “We are talking about it now,” he says, “but more importantly, we’ve been practicing it for years.” He refers to the company’s longtime focus on supported product evolution, which helps keep TCO low and is the opposite of planned product obsolescence. Plant owners naturally want to get as much value from their investment as possible, he says, and they fear obsolescence, but often lack the knowledge, time and resources to take full advantage of what they have. According to Gold, Honeywell has emphasized long-term value since the mid-1980s, when a technological leap over its DCS offering from a decade earlier convinced the company “that we had to ensure customers could keep their systems current and have access to all necessary services: that rip-and-replace was not necessary with Honeywell. This has been ingrained in our actions, if not always our words.” OCTOBER 2013
ON THE ROAD TO SUSTAINABILITY
requirements of maintaining open-technology equipment. “Open systems are more work,” he says. “They will require a periodic technology refresh, for example, and you’ll have to deal with cybersecurity management.” Because open technology opens the door to viruses and other cyber events, including cyber attacks, there’s little room for complacency when it comes to system management. “Any plant using open technology needs to know what a cyber event would cost,” says Gold. This must include the probability such an event would cause a production loss and a certain amount of time to repair. “We do that kind of analysis for our customers,” he says. “We can also predict the probability of that happening, based on the industry they’re in.” Gold says plant operators should realize that if they do come under a targeted cyber attack, “there is little chance of stopping it. You must invest in an appropriate level of security and hope the attackers go after an easier target. Based on your knowledge of what a cyber attack would cost if it happened to you, you can determine what you might be willing to spend to stop it from happening or reduce the risk significantly. That is what an effective TCO analysis has to include.” TCO isn’t a new focus at Honeywell, says Shawn Gold, but is receiving more emphasis as a way to help customers tame the growing complexity of automated systems.
With the growing acceptance of open-technology platforms, Honeywell now predicts that the TCO approach is poised to play a far more important role in manufacturing. “If you’re getting into a world with more change,” says Bach, “you need to take a look at the impact that’s going to have. How much needs to be changed, and how quickly? That is a key component of TCO that I don’t think users or manufacturers always understand. Open technology can create additional challenges and risk, like shorter component life cycles for one, even though much of the core equipment includes lower-cost, off-the-shelf products. When you get to the actual core products that you can extend the life on and find a step-wise migration rather than rip-and-replace, you can manage it cost-effectively. But you must have a written plan to manage the open-system life cycle, which is different than the life cycle of a proprietary system. Nearly all of what you already have invested in engineering costs and wiring as well as knowledge and intelligence—which is usually more than the cost of the control products themselves—can be retained.” Gold notes that when strong system support is a given, an accurate TCO calculation helps keep the focus on long-term, sustainable goals and the path to reach them. “Once you know your equipment is supportable, that opens a discussion about how you make sure it stays supportable and sustains its value,” he says. This means following procedures outlined with a TCObased plan. These naturally include basic maintenance (like filter replacement), says Gold, along with the more-challenging OCTOBER 2013
You need help Even without the threat of a cyber attack, it makes sense that today’s plant professional would welcome reliable guidance and support on the automated-technology front. To this end, Honeywell is taking what Bach terms “a more proactive posture toward providing holistic system care.” This includes services like remote patch management and its new Assurance 360 services program, which is designed to better balance the risk-exposure/service-cost equation between Honeywell and its customers. “For other things, like troubleshooting,” he says, “we’ve been telling customers to allow us to observe system behavior while its happening and not just tell us over the phone what they think is happening. The ability to articulate a problem over the phone versus allowing us to see it will enable us to solve things 50% faster, and we’ll be able to identify a problem faster without having to swap files and send things through e-mail.” Gold calls remote capability “a real game changer.” He has similar expectations for an upcoming new product that will help customers better manage cybersecurity. Other areas of emphasis for the company will include change-management and best-practice strategies as Honeywell strengthens its efforts to help plant operators understand an increasingly complicated big picture. “The fact is, manufacturers have become overwhelmed with too much technology,” says Gold, “and they don’t have enough resources to handle it all. Helping them better understand TCO and how to manage their systems effectively is clearly in their best interest,” he adds, “as well as in the best long-term interest for Honeywell.” MT For more info, enter 05 at www.MT-freeinfo.com MT-ONLINE.COM | 33
CAPACITY ASSURANCE STRATEGIES
Next-Gen Power: Reliability-Centered Maintenance Delivers Savings
The power industry is investing heavily in new technologies to harvest energy from renewables. New technologies, though, can introduce new, perhaps massive, maintenance costs. What to do? Special To MT
s we march further into the 21st century, the power sector is undergoing a massive shift. With climate change high on the global agenda, the industry as a whole is committed to finding alternatives to conventional fossil fuels. Low-carbon power sources like wind, solar and hydro are being pursued by even the most traditional power companies.
CAPACITY ASSURANCE STRATEGIES
To meet this commitment to produce a certain amount of power from renewable energies, operators must invest significant amounts of money in new technologies and new assets, which, in turn, bring a raft of other costs impacting the bottom line: Maintenance is a big one. Consider this scenario: ACME Power is a global power generation and distribution company. It recently committed to generating 25% of its total power using renewables, and has invested $X in purchasing 250 wind turbines and siting them in an ideal, windswept location. Each turbine is capable of producing 2.3MW with a typical efficiency of 30%. The entire wind farm will contribute to 8% of the total power generation for ACME Power, which at its most efficient is 450MW. While it looks like a great investment on paper, ACME Power is concerned that maintenance—as yet an unknown entity for the new technology—will prove a costly blow. For example, in the event that significant repairs are required to one of the massive wind turbines, the crane needed to maneuver the turbine is very hard to come by. It can take months for a crane to become available, and the costs for transport and hourly hire are huge. What is the risk of a crane not being available? Is ACME Power better off buying one outright, sharing the cost with neighboring companies or shouldering the occasional, yet very expensive, hire cost? This is a typical scenario, and just one of the many factors that need to be considered when new technologies like wind turbines are introduced into existing operations.
New technology typically can present a host of unknowns when it comes to operations and maintenance. Even with strong support from the OEM and the provision of thorough training for the operations team, it’s still hard to quantify costs and, more important, identify ways to save on maintenance at this early stage. RCM: Early mapping of maintenance plans Proven reliability engineering techniques are used to plot a clear path for maintenance of new assets, and to provide management with reassurance around ongoing costs. Reliability Centered Maintenance (RCM) is one of the most beneficial techniques to use at this point. An RCM study will determine the optimal maintenance strategy for the new assets, as well as predicting the maintenance budget and spares usage over a 20-odd-year lifetime. It will also model different maintenance strategy scenarios to compare risks and improvements over this lifetime, to enable the better long-term management of the assets. Here’s how RCM would work for the hypothetical ACME Power wind-turbine project. First, failure data would be gathered from a variety of sources—such as work-order history, spares usage rates and interviews with the personnel responsible for maintaining the equipment. Given that ACME Power hasn’t been using wind turbines for long, the failure data may not be all that comprehensive. This shouldn’t be seen as a stumbling block. Fig. 1. Average annual cost comparison over 20 years of the two maintenance strategies referenced in the hypothetical ACME Power example
$150,000 Spares Labor
Optimized MT-ONLINE.COM | 35
CAPACITY ASSURANCE STRATEGIES
$10,000 $0 Equipment Labor Spares Effects
Existing Strategy - 4909.1.1.A.1-Yaw Clamp Cracked Due To Fatigue 0 238.08 1227.6 310290
Optimized Strategy - 4909.1.1.A.1-Yaw Clamp Cracked Due To Fatigue 0 294.018 1425.6 0
Using this data, along with OEM maintenance manuals and spares catalogs, a preliminary RCM model is built (with the intention of fleshing out the model during facilitations with staff). During the process, technicians and engineers can have direct input into the maintenance activities that are included—which, importantly, creates a sense of ongoing ownership of the maintenance strategy. From the facilitation process, the RCM model is validated and then optimized by assessing each failure mode by the cost, safety, environmental and operational contributions to reduce cost and risk. For example, at this point, ACME Power may identify that maintenance of the main gearbox used to power the wind turbine is problematic (given the fact that the main gearboxes cost $300,000 and the aforementioned cranes add significantly to their repair costs). It’s here that further reliability engineering techniques—like Root-Cause Analysis (RCA)—may be deemed necessary to make further improvements to the maintenance strategy. Figure 1 shows the outcome of the RCM report for ACME Power. The first column shows what the operation’s existing strategy will cost per year; the second shows the optimized model. The latter delivers $46,000 savings annually, or close to $1 million over 20 years for each turbine. Figure 2 shows the actual impacts of a specific failure mode where we can see that the optimized strategy has dramatically reduced the effects and costs associated with this failure mode. 36 |
Fig. 2. Average annual impact comparison of a failure mode over 20 years
Long-lasting benefits An RCM study will deliver long-lasting benefits for any organization that has invested in significant new technologies. Tangible savings are generated through the reduction in unplanned downtime, the avoidance of production losses and a fall in risk-based costs. This type of study will reveal any gaps in the existing maintenance strategy, not to mention provide peace of mind that existing maintenance strategies are working. Using the right technologies and the right facilitators, an RCM study has broader benefits for operations and maintenance teams. It can boost overall capabilities by providing training and development, and by integrating RCM software tools with other processes for continuous improvement. These tools can be used for long-term forecasting of entire fleets of assets, and to empower companies to be on the front foot when it comes to contract negotiations with OEMs for maintenance. In short, an RCM study is a powerful technique for optimizing maintenance strategies for new and existing assets alike—and for delivering real savings in the long term. MT This information was supplied by ARMS Reliability, a global team of consultants specializing in reliability methods. For more info, enter 06 at www.MT-freeinfo.com
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WHERE THE PROCESS INDUSTRIES COME TOGETHER to
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Volume 2 Number 10
RELIABILITY F I L E S TECHNOLOGY M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
RELIABILITY F I L E S TECHNOLOGY M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
Protect Your Gearbox With The Right Lubricant Problem For many industrial businesses, gearboxes represent the heart of production. Today, advancements in technology have enabled equipment manufacturers to decrease the footprint of gearboxes, while maintaining the same—or even higher—power transmission capabilities. Compared to previous models, these newer, higher-performing units typically require lubricants that offer more comprehensive protection. If a gearbox isn’t properly maintained with the appropriate lubricant, there’s a potential for the equipment to experience a condition known as “micropitting.” A common sign of excessive load, torques and stress placed on operating components, micropitting is surface fatigue that’s mainly seen in gears— but which also can be found in rolling element bearings. Micropitting causes destructive wear that can occur within the first few hours of operation. One measure of micropitting is profile deviation, which is the modification of the in-service gear tooth profile by tens of microns versus its starting profile. When small amounts of material are worn away from the pitch line, it results in changes to the tooth profile. This can be detected through increased vibration and a change in load distribution across the tooth surface. The combination of higher local loading on the tooth surface due to these changes in tooth profile and the existence of micropitting as a surface flaw can lead to the initiation of macropitting and spalling on the gear teeth. Both of these conditions can greatly impact equipment performance and reliability. Solution To help mitigate wear such as micropitting, companies should select a highperformance synthetic lubricant that features a balanced formulation and is designed to deliver exceptional, longlasting wear and corrosion protection.
This chart shows that some competitive synthetic gear oils are formulated specifically to deliver exceptional results in one area but may sacrifice performance in many other areas. Only by selecting an oil that has a balanced formulation can operators look toward maximizing productivity. (Source: ExxonMobil Research)
The Mobil SHC™ Gear Series, a family of outstanding-performance, fully synthetic industrial gear oils, represents the latest innovation from ExxonMobil that pushes the boundaries of what’s possible in gearbox lubrication technology. Mobil SHC Gear Series lubricants are developed with ExxonMobil’s proprietary balanced formulation approach, which stresses well-rounded equipment protection in all critical performance areas for a targeted application. Approved by Siemens for use in Flender gearboxes, Mobil SHC Gear Series lubricants meet or exceed nearly every other major industry and Original Equipment Manufacturers (OEM) specification for industrial gearbox applications. Return On Investment As shown in the chart above, oil in the Mobil SHC Gear Series meet or exceed the capabilities of competing synthetic and conventional mineral-based fluids across a wide spectrum of performance parameters, including: ◆ Micropitting Protection ◆ Oxidative Stability ◆ Foam and Air Release ◆ Rust and Corrosion Protection ◆ Low-Temperature Fluidity
In addition, Mobil SHC Gear Series lubricants offer potential energyefficiency benefits. Across a range of statistically validated tests, they exhibited energy savings of up to 3.6% compared with conventional oils.* And, when compared with competitive mineral oil–based gear lubricants, Mobil SHC Gear Series oils deliver a service life of up to six times longer, helping to reduce oil consumption and staff time needed for lubricants changes. MT Exxon Mobil Corporation Fairfax, VA
* The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6 percent efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and applications. For more info, enter 260 at www.MT-freeinfo.com
THE RELIABILITY FILES / OCTOBER 2013
If you’re thinking productivity, upgrade to a smarter grease. Our greases are engineered smart, right from the start. With an advanced formulation designed to provide all-around, balanced performance for the severe conditions experienced by today’s equipment. What’s more, our high-technology greases offer a controlled release of oil and additives. They know just the right amount to release, lubricating for optimum protection. Providing greases that stay exactly where they’re needed — making them easy to use, which can help control maintenance and replacement costs. Adding up to outstanding productivity. Learn more about our advanced engineered greases for advanced productivity at mobilindustrial.com.
© 2013 Exxon Mobil Corporation. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.
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As your workforce continues to turn over, are your new hires prepared to avoid the hazards of electricity?
A Perspective On Electrical Training By Ron Spataro
f there is an electrical accident in your facility, or you are in a highrisk industry, you’ve got pretty good chances of getting a visit from OSHA. In a one-year period, OSHA issued $26,460,902 in penalties for violations of electrical requirements. Because OSHA regulations are not updated with industry standards, when a violation of a recognized hazard occurs, OSHA’s inspectors will issue citations under the General Duty Clause. This clause requires employers to provide a workplace free from “recognized hazards,” as identified by industry consensus standards such as the NEC, NFPA 70E and IEEE. On-the-job apprentice training is a proven, effective method of growing your staff. The new technician can learn a lot from the experienced ones, but what do you do when veteran electrical maintenance personnel are leaving the job market in waves? Burdening your experienced technician with a “less experienced” apprentice can lead to gaps in the knowledge transfer and can be dangerous. When your experienced technician starts with a new apprentice, do they skip right to application? What’s the procedure for this, where to find it and what to do when this happens, etc.? While this type of focus is essential to continuing work during training, as a starting point for apprentices, it is fundamentally flawed.
To grow an effective electrical maintenance technician, you must start by building a foundation of fundamental knowledge—those things veterans take for granted and may not adequately pass on. The following fundamental subjects should be covered in your apprentice program: ■ What is the difference between AC and DC
electricity? ■ How do you calculate voltage, wattage,
resistance and current? ■ How do you interpret the readings on a
multimeter? A technician cannot fully understand the implications of changes he/she makes to a circuit without this fundamental knowledge. All electrical maintenance boils down to one essential question: “It’s not working; why?” Each technician relies on troubleshooting procedures to locate the causes of failure—and there is a logical way to locate those causes without “chasing the voltage.” Inadequate troubleshooting skills can cost your organization. Staying compliant is very important, but worker safety is essential. Ron Spataro is Director of Marketing, AVO Training Institute. For more info, enter 07 at www.MT-freeinfo.com
Sponsored Information 42 ||
MAINTENANCE MAINTENANCE TECHNOLOGY TECHNOLOGY
OCTOBER OCTOBER 2007 2013
MAINTENANCE LOG Editor’s Note: This article is based on one that ﬁrst ran in the June 2013 issue of Maintenance Technology
Consider the alternatives...
Methods For Monitoring Bearing Performance A range of traditional and advanced options are available to help you monitor your bearings. Don’t disregard any of them. Leveraging instrumentation to augment our human senses is very much a predictive maintenance best practice.
he health of your bearings is critical to the health of your equipment and processes. With proper performance monitoring, imminent failures can be identified and corrected. Conversely, without a sound monitoring program in place and subsequent corrective actions not being taken when needed, a single bearing failure can result in full machine shutdown and countless hours of lost production.
Galen Burdeshaw Baldor Electric Co.
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Bearing monitoring is guided by three main human senses: sight, sound and touch. Basic monitoring has typically been conducted through elemental observations. Fortunately, there are a number of highly sensitive tools that can amplify these observations—making them more noticeable and recordable. They also include basic logic to assist with warning identification. Keep these technologies in mind as you seek to augment your bearing sense(s): #1. Visual monitoring: Looking Monitoring bearings visually through classical methods includes observing lubricant condition, corrosion and deterioration. Mounted bearings that are lubricated properly will purge grease from their seals. The condition of the grease upon purging can indicate improper relubrication intervals and/or contamination. Dark, cakey or milky grease are visual signs that relubrication intervals and procedures may be improved. Evidence of corrosion is a valuable monitoring tool as well. High levels of corrosion can degrade material strength and performance. Deterioration of the surface, seals or obvious physical dimensional characteristics should also warrant further investigation. These observations are often signals of wear, heat and other abnormal performance prior to total bearing failure. Sight-gauge bearings and thermal imaging guns are among the readily available monitoring tools that leverage visual observations. Bearings that are lubricated by oil rather than grease are often fitted with sight gauges to indicate the presence and quantity of oil available to the bearing. These types of gauges aren’t just practical—they’re inexpensive. #2. Audible monitoring: Listening Traditionally, audible monitoring is one of the most common methods of machinery monitoring. That’s because odd noises are obvious indicators of improper operation, even to the untrained user. This type of monitoring is conducted quickly—through an operator’s daily routines. After all, if a machine bearing doesn’t sound well, it usually isn’t. There can be two problems with a bystander’s audible observations: (1) Such observations usually identify the later stages of bearing failure, when planning downtime for bearing replacement is impractical; and (2) audible feedback of a single bearing can be masked by the overall noise of its environment. This is where instruments such as stethoscopes (with amplification) and decibel-level meters are advantageous. Both are available with a wide range of features, including quantified readings and recording capabilities that allow users to trend bearing performance. These 44 |
tools are also more useful at identifying improper operation at a less-threatening stage of failure. Bearings should run quietly and smoothly—anything different likely will reﬂect a ﬂaw in or problem with the bearing itself. Noises such as grinding or banging should be investigated quickly. These noises may indicate complete bearing failure and continued use may lead to catastrophic failure and/or damage to neighboring equipment. Bearing noises like light clicking and squealing may indicate looseness, faults or skidding, and should be inspected for cause and remedy. Audible evaluation is not as sensitive as other monitoring techniques. It’s really more of a method of identifying failure than identifying poor performance. One more thing to keep in mind: Audible monitoring in the early stages of failure is more noticeable at higher operating speeds than lower speeds. #3. Physical monitoring: Touching Monitoring bearings by touch—and then trending the observations against historical performance—is by far the most useful and accurate means for assessing bearing condition and predicting failure. The touch method can be used to monitor temperature, vibration and lubrication parameters. Temperature. . . Operating temperature is the most practical and beneficial monitoring method for bearings because expensive tools are not required. It’s also appropriate to all types of applications (i.e., slow to high speeds and light to heavy loads). For example, the average threshold of pain for humans is approximately 130 F. Thus, if it’s difficult to maintain handto-bearing contact for several seconds, the temperature probably exceeds 130 F. (A related method, wherein water droplets that are placed on a bearing housing quickly boil, will indicate that bearing temperature has exceeded 212 F.) Monitoring bearing temperatures is crucial: As these components fail, they get hotter. Trending their temperatures over time will help identify the early stages of failure. The most common tools for doing this include thermocouples and resistance temperature detectors (RTDs)—both of which can be permanently mounted to locations on the bearing housing for continuous real-time monitoring. Temperature switches that can be utilized for warning and/or shutdown at dangerous operating temperatures are also available. Many bearing manufacturers offer permanently mounted sensors that are pre-installed in bearing housings (in areas that accurately reﬂect the true bearing temperature, not just the housing-skin temperature). OCTOBER 2013
You may also consider vibration-measurement instruments to not only identify stages of bearing failure, but to also identify overall machine performance and problems. Sensors mounted to the bearing may include permanently mounted or portable magnetic-base accelerometers, displacement probes or velocity pickups. Sensor selection is dependent upon the bearing speed, sensitivity requirements and the application. Although vibration feedback is highly desirable, proper training is important due to the complexity in data collection and interpretation. Lubrication. . . Simple tests can also be conducted on purged grease to detect hard-particle contaminants. After re-lubrication, the technician should rub some freshly purged grease between his/her fingertips. Gritty grease may indicate a need for more frequent lubrication—or wear from a failing bearing. MT Galen Burdeshaw is Baldor’s Customer Order Engineering Manager for DODGE Bearings and PT Components. For more info, enter 08 at www.MT-freeinfo.com
Many bearing manufacturers offer various permanently mounted sensors pre-installed on bearings that provide online, real-time monitoring of temperature and speed.
Portable thermal imaging tools offer a quick and efficient means of monitoring bearing performance. These devices use infrared (IR) thermography to visually identify variations in temperature—the most common being the infrared thermometer. Although portable thermal imaging tools typically can’t measure temperatures over a broad area, they’re inexpensive and easy to use. Vibration. . . Vibration analysis is the most information-rich method available for bearing analysis—and touch is a good way to distinguish between smooth and rough operation. As safety permits, feel the bearing housing during operation. Rough operation, jostling or grinding may indicate a bearing problem. Utilizing a portable temperature-measuring tool, like a thermal imaging gun, will help you accurately monitor bearing temperature. As a bearing fails, its temperature will continually increase. Trending temperature over time will help identify a bearing in the early stages of failure. OCTOBER 2013
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Automation Solutions PLC Boiler Controls
layton Compusteam PLC Control Systems are standard on all modulating models of the company’s boilers. They are available in three basic levels (I, II & III) with various options for expanding system capabilities. Compatible with Modbus, Ethernet/ IP and Bacnet protocols, these PLC controls increase system reliability by making operating parameters readily available. PLC interface capability also improves communications between the steam-generator controls and total plant monitoring systems, and enhances control for multiple-unit installations.
Clayton Industries El Monte, CA For more info, enter 09 at www.MT-freeinfo.com
Power, Safety Features Added To Next-Gen Automation System
oxboro Evo is a new, next-generation process automation system from Invensys that features advanced tools and applications delivered across a high-speed, fault-tolerant, cyber-secure hardware platform. A leading supplier of state-of-the-art industrial software, systems and control equipment, Invensys has integrated the new system with its Triconex safety system, which is designed to improve operational insight and integrity. The Foxboro Evo system can undergo major upgrades without halting operations. According to Invensys, because users can upgrade at their own pace, Foxboro Evo delivers the lowest total cost of automation and highest return on assets, compared with other systems. Its new applications also enable plant personnel to contribute toward the success of the business by streamlining and contextualizing the information they need to make the right business decisions at the right time. Invensys Sharon, MA For more info, enter 10 at www.MT-freeinfo.com
Make Asset Health More Predictable
he recently released update to Meridium Asset Performance Management (APM) software (v3.5.1) is designed to help users improve efficiency while reducing risk. Enhancements include new work-process dashboards for the end-to-end management of performanceimprovement opportunities, as well as expanded monitoring policies that address process excursions and enhanced integration capabilities that enable machine-to-machine communications. It also includes a new analytical model that lets users visualize the impact performing an inspection has on an asset’s risk ranking. This functionality is expected to improve efficiency by optimizing inspection intervals. Dashboards in the new v3.5.1 are mapped to each of the five Meridium APM Work Processes: APM Foundation, Failure Elimination, Asset Strategy, Mechanical Integrity and Asset Safety. Key measurements are displayed in an easy-to-use format for rapid information delivery across a wide range of computing platforms and mobile devices. This functionality allows users to have a 360-degree view of critical assets and their associated goals to increase equipment availability. Meridium® Inc. Roanoke, VA
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Advanced Packaging-Line Integration
ew packaging-line integration technology from Rockwell Automation called RAPID Line Integration uses Packaging Machine Language (PackML) to enable easier linkage between machinery across an entire packaging operation. This allows plant managers to monitor machines in a connected and standardized format, giving them visibility into the throughput of each machine and a centralized view of overall line performance. Because packaging machines often are acquired from different OEMs, intermachine communication can be complex. RAPID is designed to simplify communication, as well as reduce startup time and integration costs. RAPID does this by using a flexible approach to integrating packaging machines and lines by allowing a single location to set up, control and analyze the performance of an entire line. Users benefit from a configurable solution that provides instantaneous overall equipment effectiveness (OEE) reports and actionable error reporting. Unlike legacy systems that require lines to be stopped for each changeover, line-integration systems also allow operators to make seamless changes. Rockwell Automation Milwaukee, WI For more info, enter 12 at www.MT-freeinfo.com
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AIR SAVING BLOWOFF IS SUPER QUIET
The low cost Super Air Knife速 dramatically reduces compressed air usage and noise when compared to other blowoffs. It delivers a uniform sheet of laminar airflow with hard-hitting force across the entire length. Energy use is comparable to a blower without the maintenance or downtime. Many sizes in aluminum or stainless steel. Applications include blowing liquid, chips, and contaminant from parts and conveyors, cooling hot parts, and air screening.
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Beyond Snapshots: Motor/Machine Monitoring System Improves Maintenance Decision-Making
he SKF Online Motor Analysis System — NetEP is a permanent motor/machine system monitoring solution that works continuously to acquire health and performance data on electric motors and the rotating machinery with which they operate. With NetEP, maintenance professionals can monitor motor-system health and performance 24/7/365 from virtually anywhere in the world, via the product’s Web-accessible interface. Reflecting a new predictive-maintenance paradigm, the system effectively provides critical motor assets with the ability to communicate that they are malfunctioning or experiencing problems. According to SKF, motor-maintenance programs are too often characterized by reactive approaches to failures. They also typically rely on testing to troubleshoot a given motor’s condition. While these types of snapshots can help determine if a unit needs to be repaired or replaced, the acquired data frequently doesn’t reveal serious system issues that can impact motor performance or cause failure. The NetEP goes beyond what portable snapshot testing does to provide a continuous timeline of trend data that maximizes visibility into motor-system health and performance. As the company explains, this system isn’t designed to replace route-based maintenance tests using portable equipment, but complements use of portable motor analyzers such as SKF’s Baker AWA-IV or EXP4000 to minimize catastrophic motor failures and costly unplanned downtime. It can also be used to supply motor-system data into an OPC standard server for use with a site’s unique maintenancemanagement and asset-analysis systems. This system can monitor up to 32 motors over as many as seven voltage busses from a single motor-control cabinet. It acquires data on power quality, distortion peak levels, unbalances, crest factor and symmetrical component data.
It gathers spectral data for current, torque and voltage, and monitors motor speed, rotor bar, eccentricity, power out, percent load, percent efficiency, effective service factor, input power, power factor and torque time waveforms. It employs a sequential data acquisition method to record information from each motor connected to the system.
Monitor up to 32 motors over as many as seven voltage busses from a single motor-control cabinet. The NetEP cabinet is the permanently installed measurement engine; the NetEP server (connected via Ethernet to a secure computer network) manages data storage and communication to an organization’s computer network resources, including the Internet. The system’s Surveyor NetEP software is the user interface and application navigation system for viewing condition status of all connected motors and machinery. It all adds up to continuous visibility into the health and performance of critical motor systems that businesses and organizations depend upon for revenue and profitability. MT SKF CMC-Fort Collins Fort Collins, CO For more info, enter 30 at www.MT-freeinfo.com OCTOBER 2013
Advanced Welding Systems: A Key To Piping Durability For Renewable Energy
renewable energy provider faced significant challenges on a geothermal project due to extreme degradation in critical piping. The heat and the highly corrosive nature of the geothermal liquids present at the steam source critically reduced the anticipated life of the originally specified carbon steel steam-supply system. Extensive research and testing prompted the plant managers to specify the replacement of the carbon steel with “Super Duplex” stainless steel pipe and Alloy 59 filler metal to achieve maximum corrosion resistance and piping-system life expectancy. Both materials have proven to be challenging to machine and weld, a factor that has limited their utilization despite superior corrosion resistance. Proper fusion of these materials requires precisely machined symmetrical weld joints, a scrupulously clean environment and a carefully tested and controlled heat input that can only be achieved with advanced computer-controlled welding equipment. Conventional welding methods that had been previously implemented at the plant had yielded poor results in terms of low deposition rates and a high number of rejected welds. Even with extensive experience with the proposed base and filler materials, project supervisors remained highly skeptical of weld processes other than conventional GTAW, and required a definitive welding solution with consistent proven results. Prior working experiences led to a request for Tri Tool to design a comprehensive field-machining and welding solution centered on those unique materials. In response, the company’s welding-research team developed specialized procedures leveraging the latest AdaptARC mechanized, multi-process equipment, such as the GMAW Pulsed Spray delivery platform for the exacting control
Welders work with advanced multi-process equipment to develop weld procedures for “Super Duplex” stainless steel pipe and fittings that will be used in a geothermal renewableenergy project.
of heat input required to consistently deliver 100% X-ray-qualified welds. Weld coupons were produced in the project materials and third-party testing validated the successful implementation of welding procedures and equipment. Sixteen critical steam-supply system welds were performed on 20” O.D. x .390” wall and 24” O.D. x .435” wall Super Duplex pipe, elbows and saddle branches using Alloy 59 filler material and a GMAW-P process with dramatically higher deposition rates and reduced weld-out times relative to conventional methods—with zero defects—vastly exceeding project managers’ expectations. In summary, the improved performance and technological and procedural advancements offered by today’s programmable, multi-process welding systems can provide major benefits for project and maintenance management. Whether working with exotic and difficult materials or implementing custom procedures for maximum efficiency and reliability, welders have an incredible level of control and unprecedented operational advantages. Their flexibility and configuration make these systems a serious consideration for maintenance or fabrication work when procedural compliance planning, dependability, quality results and increased productivity are priorities. MT Tri Tool, Inc. Rancho Cordova, CA For more info, enter 31 at www.MT-freeinfo.com MT-ONLINE.COM | 49
Calling All Innovators! Don’t just leave it to ‘the other guy’ to show off his/her innovation. You Could Be Our Next Grand-Prize Winner! Enter Now.
Categories: Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources Honoring the essence of innovation in maintenance and reliability, entries will be judged on the following elements:
Practicality. . . Can it be adopted across industry? Can it be easily replicated, manufactured or sold?
Simplicity. . . Is the ROI less than 3 months? Is the idea intuitive and easily understood?
Applied Technology Publications
Deadline for Entries is Midnight, December 31, 2013. Our Grand-Prize Winner & Runners-Up Will Be Announced Early 2014.
Details & Entry Forms Available At www.reliabilityinnovator.com
Impact. . . Reliability Ergonomics (operator, maintainer) Safety Energy reduction Environmental Maintainability (reduces maintenance)
Sponsored By The Innovators At
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CAPACITY ASSURANCE MARKETPLACE
Web-Based Dashboard Solution Monitors Equipment Health From Machine To Fleet Levels
Respirator for Harsh Environments
E’s Measurement & Control business has introduced Bently Nevada System 1 Fleet Management, a Webbased dashboard providing a single, secure access point for monitoring equipment and instrument health from the machine to fleet levels across industrial users. The conditionmonitoring solution, a part of GE Predictivity Industrial Internet Solutions, allows operators to effectively monitor each connected plant asset for an all-in-one view of operational health. System 1 Fleet Management applies Advanced Analytics, combining physics-based analytics, predictive algorithms and deep domain expertise, to instrument and software alarms. With an intuitive user interface, the dashboard requires little training for use and maintenance.
M’s 6500 Series Rugged Comfort Half Facepiece Reusable Respirator is designed for comfort and built to withstand long hours under extreme conditions. The over-molded design of the 6500 series respirator is easy to clean and compatible with other personal protective equipment. It includes a valve-cover feature that directs exhaled breath and moisture downward to reduce fogging.
GE Measurement & Control Boston, MA
3M Co. St. Paul, MN
For more info, enter 32 at www.MT-freeinfo.com
Three-Phase Electrical Energy Logger
For more info, enter 34 at www.MT-freeinfo.com
Portable Gas Detector
he Fluke 1730 Three-Phase Energy Logger is an intuitive, easyto-use tool for energy-data gathering. With the accompanying Fluke Energy Analyze software, the logger helps maintenance pros analyze and report on energy use right out of the box. Results help users identify and prioritize energy-saving projects. All measured values are logged automatically and can be reviewed during logging.
rowcon’s Gas-Pro portable gas detector is designed to ensure worker safety in confined spaces. Compact for personal use, it detects multiple gases, is reliable and features a bright, easy-toread display and long battery life. In alarm conditions, warnings include a loud alarm, vibration and a two-color backlight. The detector can be customized for use in various industries.
Fluke Corp. Everett, WA
Crowcon Detection Instruments Erlanger, KY
For more info, enter 33 at www.MT-freeinfo.com OCTOBER 2013
For more info, enter 35 at www.MT-freeinfo.com MT-ONLINE.COM | 51
CAPACITY ASSURANCE MARKETPLACE
Automated On-Off Valves
Thermal Imaging Cameras
he VA Series combines a pneumatic actuator and fast on-off control valve into one body, eliminating packing glands, actuators and mounting kits. There are no exposed moving parts, eliminating pinch points and increasing operator safety. Because the actuator is part of the valve, it costs less than standard actuated valves. According to the company, operating life has been tested to well over 1,000,000 cycles due to a balanced design that reduces friction and wear.
eneral Tools & Instrumentsâ€™ expanded line of Predator thermal imaging cameras includes nine extended-temperature-range models. The GTi10, GTi20 and GTi50 now offer models with temperature-measurement ranges up to 600 C (1112 F), 1000 C (1832 F) and 1500 C (2732 F), respectively. The units detect small temperature differences from a distance and convert an objectâ€™s invisible infrared radiation to a visible color image. Each model is powered by two rechargeable Li-ion batteries (included) for up to six hours of operation.
Assured Automation Clark, NJ
General Tools & Instruments New York, NY
For more info, enter 36 at www.MT-freeinfo.com
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ENGINEERED TO SERVE YOUR MAINTENANCE NEEDS, YOUR PLANT & YOUR BUSINESS
ATP List Services
At Revere, we engineer controls for an incredible range of industrial applications. From conveyor controls to 15 kV switchgear and plant wide SCADA systems for municipal, industrial and energy applications. Arc flash studies and control systen network security. Legacy migration. System upgrades, expansions, and maintenance. Control your systems. Control your business.
Customized, Targeted Lists For Your Marketing Needs www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110
CONTROL SYSTEMS T 1.205.824.0004
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52 | MAINTENANCE TECHNOLOGY
firstname.lastname@example.org email@example.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 Formore more info, info, enter enter 85 For 83atatwww.MT-freeinfo.com www.MT-freeinfo.com OCTOBER 2013
CAPACITY ASSURANCE MARKETPLACE
Multipurpose NSF H1 Greases
Steam-Turbine Sealing Solution
he ALLPLEX FMG Series of greases from Klüber offers multi-purpose, NSF H1 registered products for the food processing, beverage and pharmaceutical industries. A special additive package provides anti-wear and extreme pressure protection from corrosion. Equipment in wash-down environments benefit from the aluminum complex thickener system, which adds water resistance and a broad temperature range. ALLPLEX is available in multiple standard packaging options from drums to cartridges, and can be used as a single-point lubricator.
he Sentinel Floating Brush Seal (FBS) for Elliott YR process steam turbines was developed as a drop-in replacement to carbon rings. The manufacturer claims it can extend seal life by three times normal maintenance intervals. Its brush-seal technology comprises densely packed, flexible metallic bristles that bend with changing clearances between rotating and stationary surfaces. The brush serves as the primary shaft seal while a carbon element provides face sealing in the turbine casing.
Klüber Lubrication Londonderry, NH
Inpro/Seal Rock Island, IL
For more info, enter 38 at www.MT-freeinfo.com
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“Industrial Lubrication Fundamentals” 3-Day, On Site, Certification Preparation Training Program
With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certified lubrication personnel working on your reliability efforts!
Unlock the Secrets that let you Tap your True Maintenance Potential and Maximize Asset Reliability! World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprint all commence with a best practice lubrication program! Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certification exams. Exams can be arranged to take place at your site immediately following the training. For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certification Domain of Knowledge Content. Contact ENGTECH Industries Inc at 519.469.9173 or email firstname.lastname@example.org For more info, enter 86 at www.MT-freeinfo.com
MT-ONLINE.COM | 53
INFORMATION HIGHWAY For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: email@example.com Web Spotlight: U.S. Tsubaki
Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fluids, and fuels. Air Sentry breathers and adapters ensure longer fluid life, better lubrication and lower maintenance costs. For more info, enter 90 at www.MT-freeinfo.com www.airsentry.com
U.S. Tsubaki is a leading manufacturer and supplier of Roller Chains, Engineering Class Chains, Power Transmission Products and KabelSchlepp Cable & Hose Carrier Systems. The Tsubaki name is synonymous with excellence in quality, dependability and customer service and support. An intense focus on research and development, along with continuously modernized production facilities and highly trained engineers allows Tsubaki to provide you with the right solutions for all of your application needs. For more info, enter 87 at www.MT-freeinfo.com www.ustsubaki.com
Increase reliability while decreasing costs with Inpro/Seal application solutions. The inventor of the original bearing isolator, Inpro/Seal’s technologies increase the reliability of rotating equipment and provide real cost savings by improving MTBR. Our superior customer service and streamlined production processes allow for same-day shipments on most products, even new designs. For more info, enter 88 at www.MT-freeinfo.com www.inpro-seal.com
The ability to identify, verify and locate every voltage source from the outside of electrical panels greatly reduces electrical risks. That’s why we’ve incorporated two of our most popular products - ChekVolt® and VoltageVision® - into one unique, exclusive product called The Combo Unit.. For more info, enter 89 at www.MT-freeinfo.com www.graceport.com/3mt_informationhighway
PIP is a consortium of process plant owners and engineering construction contractors harmonizing member’s internal standards for design, procurement, construction and maintenance into industry-wide Practices. PIP has published over 450 Practices. A current listing of published Practices is available on the PIP website at: http://pip.org/practices/index.asp. For more info, enter 91 at www.MT-freeinfo.com www.pip.org
Need an air compressor with proven performance? Whether you’re a large manufacturer or a shade tree mechanic, we have the right oil-lubricated or oil-free, fixed or variable speed compressor for you. Right away. Learn more about FS-Curtis products and distributors, and see the compressors in stock at our St. Louis headquarters, where we’ve been located since 1854, by visiting www.RightCompressorRightNow.com For more info, enter 92 at www.MT-freeinfo.com www.RightCompressorRightNow.com
For rate information on advertising in the Classified Section contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: firstname.lastname@example.org
ATP List Services
In order for us to send
Customized, Targeted Lists For Your Marketing Needs
to you FREE,
we are required by the US Post Office to have a completed and signed renewal form once a year.
Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110
You may renew online at
www.mt-online.com 54 | MAINTENANCE TECHNOLOGY
email@example.com firstname.lastname@example.org 1300 S. Grove Ave., Suite 105, Barrington, IL 60010
TECHNOLOGY & ASSET PERFORMANCE
OCTOBER 2013 Volume 26, No. 10 •
OCTOBER 2013 • Volume 26, No. 10 RS #
Air Sentry ...................................................www.airsentry.com...............................................................90 .................54 ALL-TEST Pro, LLC..................................296.alltestpro.com ................................................................73 .................25 Allied Reliability Group............................www.alliedreliability.com ....................................................70 .................14 ARC Advisory Group ...............................www.arcweb.com/events/arc-industry-forum-orlando/....77 .................37 ATP Lists ....................................................www.atplists.com..................................................................85 .................52 Baldor Electric Company.........................www.baldor.com...................................................................94 ................BC Des-Case Corporation .............................www.descase.com .................................................................63 ...................2 Emerson Process Management ...............www.emersonprocess.com/workfaster ..............................93 ..............IBC Engtech Industries Inc..............................www.engtechindustries.com ...............................................86 .................53 Exair Corporation.....................................www.exair.com/48/123.htm ................................................81 .................47 Fluid Defense.............................................www.oilsafe.com/provenchoice ..........................................76 .................29 Fluke ...........................................................www.fluke.com/try-cnx .......................................................62 ...................1 Foster Printing Services ............................www.fosterprinting.com......................................................95 .................26 FS-Curtis Air Compressors......................www.rightcompressorrightnow.com .................................92 .................54 Grace Engineered Products, Inc. .............www.pesd.com......................................................................71 .................19 Grace Engineered Products, Inc. .............www.graceport.com .............................................................89 .................54 Honeywell Process Solutions ...................www.becybersecure.com .....................................................67 ...................7 Innovator Of The Year Award..................www.reliabilityinnovator.com.............................................83 .................50 Inpro/Seal, LLC C/O Waukesha Bearing, Inc .www.inpro-seal.com ............................................................88 .................54 IRISS, Inc....................................................www.iriss.com/mt ................................................................66 ...................5 Kluber Lubrication North America L.P. .www.klubersolutions.com/sustainability4 ........................75 .................28 Ludeca Inc..................................................www.ludeca.com ..................................................................69 .................11 Meltric Corporation .................................www.meltric.com .................................................................82 .................47 Miller-Stephenson Chemical Co. ............www.miller-stephenson.com ..............................................64 ...................4 Mobil Industrial Lubricants.....................www.mobilindustrial.com...................................................260,261 ...40,41 Process Industry Practices........................www.pip.org ..........................................................................68,91 .........9,54 Revere Control Systems............................www.reverecontrol.com.......................................................84 .................52 Royal Purple, Inc. ......................................www.royalpurpleindustrial.com .........................................74 .................27 Strategic Work Systems, Inc. ....................www.swspitcrew.com ...........................................................65 ...................4 Test Products International .....................www.testproductsintl.com ..................................................79,80 ............47 The Chem Show........................................www.chemshow.com/visit14...............................................78 .................38 Tri Tool, Inc................................................www.tritool.com...................................................................72 .................23 U.S. Tsubaki Power Transmission, LLC ..ustsubaki.com/mt.................................................................61 .............. IFC U.S. Tsubaki Power Transmission, LLC ..ustsubaki.com .......................................................................87 .................54
Access MT-freeinfo.com and enter the reader service number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Maintenance Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Reproduction of Materials: Materials produced by Maintenance Technology may not be reproduced in any form for any purpose without permission. For Reprints: Contact the publisher, Bill Kiesel (847) 382-8100 ext. 116.
TECHNOLOGY & ASSET PERFORMANCE
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viewpoint Michael “Mic” Callanan, Executive Director National Joint Apprenticeship & Training Committee (NJATC)
Reopening The Gates To Apprenticeship Opportunities
bout five years ago, in the weeks following the historic election of President Barack Obama, the Federal Advisory Committee on Apprenticeship (ACA) developed a briefing paper entitled “The Future of National Registered Apprenticeship System: A Workforce Strategy for Main Street America.” The ACA proposed a $1 billion annual investment to support the expansion of the National Registered Apprenticeship System. The ACA’s goal was to expand the apprenticeship model by up to one million apprentices each year. At that time, the briefing paper reported that we had over 468,000 active apprentices in the United States. Unfortunately, neither of those recommendations has been enacted. At the close of fiscal year 2012, our total number of apprentices—nationwide—had fallen to 358,000 (www.doleta.gov/OA/data_statistics.cfm). Over an approximate four-year period, we had lost 110,000 apprentices! Admittedly, these have been very difficult times for many of our industries and our nation. It should be noted, however, that many of the trends on this workforce data began well before the Great Recession of 2008. In my opinion, much of the problem stems from the inability of our National Registered Apprenticeship System, as presently structured, to meet the needs of the construction and maintenance sectors. This is largely due to the fact that during periods of economic downturn, the apprenticeship gates close and apprenticeship openings vanish. In the years leading up to 2008, magazines like Maintenance Technology warned of the “perfect storm” that was gathering as projections for demand of skilled workers far exceeded the anticipated supply. The Great Recession of 2008 (and its lingering effects) only postponed, to some degree, the full onslaught of that storm. Today, we once again find ourselves facing an imminent shortage. I believe there are three important steps that we can take—immediately—to mitigate the damage that has occurred over the past five years. First, the federal
investment in Registered Apprenticeship must increase significantly. In 2008, that investment was only $23 million. I would suspect that five years later, in the age of “sequestration,” it remains under $30 million. Our National Registered Apprenticeship System is simply not sustainable with such a limited investment.
The Great Recession of 2008 only postponed the full onslaught of that skills-crisis ‘perfect storm’ we now face. Second, the principal reason the federal government can get away with a $30 million investment in apprenticeship is because private industry invests over $2 billion in education and training each year from apprenticeship-program sponsors. We need to provide incentives to program sponsors and employers that hire apprentices to increase the total number of apprenticeship opportunities. Third, we need a comprehensive workforce development strategy for industry. Currently, we operate in silos with community colleges, union training programs (like mine at the NJATC), Workforce Investment Boards and employers—all going in different directions. Our challenge is large enough that each of these entities can play an important role in helping grow the pool of skilled workers. We need to get everyone on the same page, committed and driven to meeting the needs of our customers and our everchanging industries. MT The National Joint Apprenticeship and Training Committee (NJATC) for the Electrical Industry is the training arm of the IBEW and NECA. It oversees 300 program sponsors and 40,000 apprentices in the electrical industry. In addition to serving as NJATC’s Executive Director, Mic Callanan is a member of the Federal ACA. For more info, enter 13 at www.MT-freeinfo.com
The opinions expressed in this Viewpoint section are those of the author, and don’t necessarily reflect those of the staff and management of Maintenance Technology magazine.
56 | MAINTENANCE TECHNOLOGY
My vibration routes seem endless. I need to collect data faster, so I can spend more time fixing problems.
YOU CAN DO THAT Spend time on high impact tasks with faster data collection. The CSI 2140 is the fastest vibration analyzer available. With triaxial accelerometer and four-channel monitoring capabilities, you can finish your route in half the time. Use your valuable time to solve problems instead of collecting data. Scan the code below or visit EmersonProcess.com/WorkFaster to learn more.
The Emerson logo is a trademark and a service mark of Emerson Electric Co. ÂŠ 2013 Emerson Electric Co.
For more info, enter 93 at www.MT-freeinfo.com
Baldor UL 2200
Gensets UL Verified Components Tested as a Complete System Not every UL 2200 genset on the market is fully tested as a complete system. Many are open units that are upgraded with third party components and shipped to customers without a complete system test to verify performance and reliability. Every Baldor UL 2200 genset is a complete system designed, manufactured AND tested at our plant. We use only UL verified components and every genset is tested as a complete system before it leaves our factory. Once each genset passes rainwater ingress tests, hipot alternator tests, air blockage and flammability tests, proper safety shutdown checks and verification that component temperatures are below combustion levels, then and only then will we apply the UL label and the Baldor name.
ÂŠ2012 Baldor Electric Company
For more info, enter 94 at www.MT-freeinfo.com
Published on Oct 16, 2013
Maintenance Technology & Asset Performance October 2013 Magazine maintenance, innovation, automation, capacity assurance, reliability, indu...