Maintenance Technology December 2012 by Applied Technology Publications

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Contents

DECEMBER 2012 • VOL 25, NO 12 • www.MT-ONLINE.com

YOUR SOURCE FOR CAPACITY ASSURANCE SOLUTIONS

©PAVEL TIMOFEEV — FOTOLIA.COM ©TARAS LIVYY — FOTOLIA.COM ©TUULIJUMALA — FOTOLIA.COM

FEATURES CAPACITY ASSURANCE STRATEGIES 16

Small-Site Scheduling It’s an area where the one-size-fits-all CMMS approach doesn’t work. John Reeve, Cohesive Information Solutions, Inc.

THE CORPORATE REPORT 27

Proﬁles Of Leading Suppliers To Industry ■ Baldor Electric Company ■ Des-Case Corporation ■ Fluid Defense Systems ■ Fluke Corporation ■ Graybar ■ LUDECA, Inc. ■ Milwaukee Electric Tool ■ Nidec Motor Corporation ■ Scalewatcher North America, Inc. ■ SPM Instrument, Inc. ■ U.S. Tsubaki Power Transmission, LLC ■ ALL-TEST Pro, LLC (ATP) ■ American Trainco ■ Klüber Lubrication ■ NSK Corporation ■ PdMA Corporation ■ Predictive Service ■ Process Industry Practices (PIP) ■ Baker Instrument Co. (An SKF Group Company)

MAINTENANCE LOG 43

Oil Analysis Helps Keep The Trains Running A national railway system got a good look at what state-of-the-art condition monitoring can do for an operation. Special To MT From Spectro Inc.

DECEMBER 2012

DEPARTMENTS 6

My Take

Stuff Happens

10 13 14 25

Uptime

Motor Doc’s Hot Topics

Technology Showcase

Marketplace

Information Highway

Classiﬁed

Supplier Index

Viewpoint

Compressed Air Challenge For On The Floor Lubrication Checkup

MT-ONLINE.COM | 3

Dramatically extends equipment life!

December 2012 Volume 25, No. 12 Your Source For CAPACITY ASSURANCE SOLUTIONS

ARTHUR L. RICE President/CEO arice@atpnetwork.com

BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com

JANE ALEXANDER

Editor-In-Chief jalexander@atpnetwork.com

RICK CARTER

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ROBERT “BOB” WILLIAMSON KENNETH E. BANNISTER Contributing Editors

RANDY BUTTSTADT

Director of Creative Services rbuttstadt@atpnetwork.com

GREG PIETRAS

Editorial/Production Assistant gpietras@atpnetwork.com

ELLEN SANDKAM

Executive Editor rcarter@atpnetwork.com

Direct Mail 800-223-3423, ext. 110 esandkam@atplists.com

California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com m

JILL KALETHA

Reprint Manager 866-879-9144, ext. 168 jillk@fosterprinting.com

Editorial Office:

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1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 WWW.MT-ONLINE.COM

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Maintenance Technology® (ISSN 0899-5729) is published monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, 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 2012 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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MAINTENANCE TECHNOLOGY

DECEMBER 2012

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MY TAKE

Jane Alexander, Editor-In-Chief

Making It Home For The Holidays And More

s we get around to putting a bow on our December issue each year, I tend to cast about for some holiday-esque theme to put smiles on your faces. This year, I thought you might be interested in my year-end plans… I’m outta’ here (Chicagoland) soon, bound for the Rio Grande Valley of Texas to spend a couple of weeks with my little mamma and wonderful brothers. The family business is onions—and December is a busy month at the J.F. Palmer & Sons shed in San Juan. Big, beautiful, sweet Texas 1015s grown in Mexico will start coming north across the Pharr Bridge in mid-January to be run through my brothers’ operations and shipped to a wholesaler or retailer near you. Like any planned shutdown/turnaround/outage, there will be plenty to do in getting the machinery and facilities ready for what is expected to be a great 2013 season. As anyone who has visited the Valley lately will tell you, though, food production (farming and ranching) and other agriculture-related activities aren’t the primary drivers of the economy these days. The manufacturing sector (in this case, maquiladoras on the Mexican side of the river), oil & gas production and health-care facilities with their complex, mission-critical physical plants are booming— and demanding increasingly skilled workers. Like other regions, business and educational leaders in the Valley are now banding together to meet that need. I’m putting a spotlight on one such collaboration as an example of a success story in the works (or, let’s hope, many success stories in the works). Only time will tell, but Texas State Technical College (TSTC) seems to be on the right track— with no less than Texas Governor Rick Perry singing its praises. According to a November 27, 2012, article in Valley Morning Star by Allen Essex, which was also carried in The McAllen Monitor (www.themonitor.com), TSTC’s skilled-workforce efforts hope to reduce the time to prepare workers for jobs by focusing only on skills they need. As Governor Perry noted, that translates into cutting by 50% the time necessary for a student fresh out of high school to enter a technical field. But that’s not all. Having written so often in MT about the challenges we face in preparing a skilled workforce, a couple of other stated goals of the TSTC program were like music to my eyes and ears: According to TSTC Chancellor Mike Reeser, returning veterans will receive credit for their military training and be able to move directly to the courses they need to prepare for civilian jobs. The program also aims to benefit students who might have entered a conventional college program but can’t return because of low grade points—or because they didn’t want to go to a conventional college to begin with. As the Essex article characterized it, those students may have been pushed by parents to attend a fouryear college, or enrolled because their friends were going. (Imagine that!) I’m looking forward to visiting with the TSTC program organizers when I’m in the Valley and letting you in on what I learn. For now, let me wish you a glorious holiday of your own. You can count on me to be toasting all of our readers as I spend a little downtime in Nuevo Progresso! MT jalexander@atpnetwork.com

maintenance technology

DECEMBER 2012

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NEWS STUFF HAPPENS

A Winning Partnership SKF & Penske Racing Celebrate Big It was just over a year ago that SKF and Penske Racing finalized their partnership agreement related to Penske’s NASCAR and IndyCar teams, a relationship they defined as somewhat different from the traditional one between a sponsor and team. The recipe must have worked. This year, the two partners have plenty to celebrate: delivery of the first-ever Sprint Cup Championship for Driver Brad Keselowski, Crew Chief Paul Wolfe and Team Owner Roger Penske. Unlike many companies involved with racing teams, SKF brought years of racing experience and customer-event marketing to the table in its participation with Penske. Since last November, SKF and Penske Racing have engaged in more than 25 different application and development projects, drawing from all five of SKF’s technology competence areas (i.e., bearings, seals, lubrication, mechatronics and services). This collaboration helped the No. 2 Penske/SKF Dodge build a reputation as one of the most fuel-efficient machines on the track during the 2012 season, something that played a key role in Keselowski’s September 30th victory at Dover Speedway, As Penske moves to the Ford Platform for the 2013 season, SKF’s knowledge, experience and innovations in frictionreducing technologies (on and off the track) should be just as important, if not more.

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

Is your company planning to make major investments in 2013 (i.e., new hires, capital improvements, etc.)? Go to MT-online.com/question with your answer. 8|

MAINTENANCE TECHNOLOGY

PEOPLE PEOPLE...

Gardner Denver’s Board of Directors has voted to appoint Michael M. Larsen as the corporation’s President and CEO. Larsen, who had served as Vice President and Chief Financial Officer of the corporation since 2010, and as its Interim Chief Executive Officer since July of this year, was also appointed to the Board of Directors. He will continue to serve as CFO until a successor is named for that position. Prior to joining Gardner Denver, Larsen spent 15 years with General Electric, where he held a number of finance roles, including CFO of GE Water & Process Technologies.

GREAT APPS

Global water-business leader Xylem, Inc., has introduced another mobile app for its Bell & Gossett brand. Suitable for all iPad, iPhone and Android devices, it provides onetouch access to brochures, submittals, performance curves, drawings, specifications, part lists and installation and operation manuals. The second Bell & Gossett iOS app rolled out this year (following the launch of the company’s ESP-Syzer® app last January), it’s free and available for download from the iTunes App Store® or Google Play Store™.

The 17th Annual ARC World Industry Forum is just around the corner (February 11-14, 2013, in Orlando, FL). As the conference theme would suggest, if your operations have any interest in “Achieving Breakthrough Performance with New Processes and Technologies,” it’s the place to be. To review the schedule and register, visit www.arcweb.com.

ARC Advisory

DECEMBER 2012

STUFF HAPPENS NEWS

â&#x20AC;&#x2122; N I T S D FIGH R O W 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 â&#x20AC;&#x153;fightinâ&#x20AC;&#x2122; wordsâ&#x20AC;? for the maintenance and reliability community? Send your favorites to quotes@atpnetwork.com. Weâ&#x20AC;&#x2122;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. Donâ&#x20AC;&#x2122;t forget to include your complete contact info.

With a new year on the horizon, these words attributed to an ancient Roman statesman are something to chew on:

â&#x20AC;&#x153;If one does not know to which port one is sailing, no wind is favorable.â&#x20AC;? â&#x20AC;Ś Lucius Annaeus Seneca

T H E U LT I M AT E P O W E R T R A N S M I S S I O N T E C H N O L O G Y

7HEN YOU RE ON A ROLL YOU SHOULDN T HAVE TO STOP FOR ANYTHING

BIZ BUZZ...

Acquiring minds and checkbooks at Parker Hannifin got quite a workout last month. In early November, the motion and control technology giant closed on its previously announced acquisition of Velcon Filters, LLC, from The Sterling Group LP, a private equity firm. Velcon makes fluid-filtration systems, including vessels and replacement cartridges, for a variety of domestic and international end-market applications. With sales of approximately $115M and a global workforce of 300, it will become part of the Parker Filtration Group. Later in November, Parker announced that it was expanding its position in the oil & gas arena by acquiring PGI International. This Houston-based designer and manufacturer of specialized, high-pressure flow-control components and systems for oil & gas, agricultural and petrochemical applications has sales of about $100M and 550 employees. It becomes part of Parkerâ&#x20AC;&#x2122;s Instrumentation Group. Terms of the two transactions were not disclosed.

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DECEMBER 2012

MT-ONLINE.COM | 9

UPTIME

Bob Williamson, Contributing Editor

A Visit from St. Nicholas (2012 Asset Management Version) With another year drawing to a close, I’ve updated my version of this holiday treasure by weaving in themes from my 2012 columns: Asset management, PAS-55, reliability, work instructions and training, to name a few. Keep in mind that the underlying story is a fantasy (despite many readers’ experiences with some of the incidents cited in it) and, as St. Nicholas points out in the end, that there’s hope for all of us. Most readers will be familiar with the poem that begins ’Twas the night before Christmas, when all through the house, not a creature was stirring, not even a mouse. This poem has been part of a holiday tradition for many of us over the years. But what if this most famous workshop of all had some of the same problems we see in our plants and facilities just a week before Christmas… ’Twas the week before Christmas and all through the place, Not a person was loafing, one week to the race. The boxes were moving down the conveyors to load, While the elves all had visions of hitting the road. The machines were all humming, to the max they could go, With all parts and all motors producing the flow Of goodies and toys and clothing and games, All running and churning the presents with names.

10 |

From their perches above, on rooftops and cranes From their shops and their projects and work underway, Came mechanics and technicians with bright shiny tools And electricians and fitters from all the best schools. They pounced on the motors, the valves and the seals With their tools and their meters, were all startled to see The machines were all shot. They were down for the count! “Give maintenance a call!” was the solution to mount. “Give maintenance a call!” was the fix all had seen. But maintenance alone could not fix these machines. The budget was planned for maintenance last year With much less for the bearings, for spindles and gears. The machines, robots and conveyors all ran With little to none of a maintenance plan. There was tightening and scrimping on every new part, And cutbacks on time to check, lube and chart. The numbers looked good. All the schedules were met. The warehouse and shelves were filled with no debt. But all is not lost ’cause the sleigh has a load, Albeit lots less than was planned for the road. Some presents with names would surely be missed, But bad news like this clearly could not persist. Then back in the shop, the sleigh gave a groan. Its load and its driver could now not be flown.

When all of a sudden, there came a huge clatter Announcing the schedule was ready to shatter. Machines and the robots, the conveyors and all, They clattered and sputtered and went into a stall.

“Give maintenance a call! The sleigh fell apart. The runners are rusted and loose from the cart!” “Give maintenance a call!” was all that was heard. “Give maintenance a call!” for what was deferred.

The bearings and spindles all suffered from heat. The worst folks imagined was ’bout to be seen. All loading was stopped, but the sleigh was not full. All leaders and workers gave maintenance a call!

Soon after last year’s long late-night sortie, The maintenance was cut to ten dollars forty. So it sat there all year, while nothing was done, Just rusting and failing. PM? There was none.

“Give maintenance a call!” was the cry from the shop. “Give maintenance a call!” was spread from the top. “Give maintenance a call!” was heard all around. “Give maintenance a call!” Their feet hit the ground.

Now Dasher and Dancer and Prancer and Vixen, And Comet and Cupid and Donner and Blitzen All heard the bad news from the shops over there. Should jolly old St. Nick be told of the scare?

MAINTENANCE TECHNOLOGY

DECEMBER 2012

UPTIME

What better way to wrap up our 12-month celebration of MAINTENANCE TECHNOLOGY’S 25th Anniversary than to run this slightly updated Uptime classic? Enjoy!

That presents with names were about to be stopped? And children whose wishes were about to be chopped? Oh, what would we do if our mission should fail Or to deliver the gifts with the speed of a snail?

He got up and he dressed in his brightest new clothes, Then he wandered the shops and the plant to disclose: His bad dreams were a warning that all had to hear. “Give maintenance a call. We’ll tell them right here.”

Then all of a sudden, St. Nicholas appears, Aroused from his sleep by the shouts and the tears. He looked at machines, the robots and all. He looked at the bearings and things that had stalled.

“We’ll give up machines each month for a check To be sure that our plans don’t turn into a wreck.” He told workers and leaders, “’Tis not a wild dream! We win this or lose this as one great big team.”

“Give maintenance a call!” was all that he heard. “Give maintenance a call!” for what was deferred. He pondered destruction, the sorry state that he saw. He wandered the mess: “This IS the last straw!”

“Asset management’s our future and more than a fix Every one of us commits to be part of the mix. From the day we design them to the day they are done Our machines will be flawless, we won’t be outdone.”

His fears had come true. It had come down to the worst. All the presents with names could not be disbursed. The merry old soul grew sad and he cried, “’Tis the season to be jolly,” he sneered at his ride.

“So, look at your habits, your checklists, your plans. Find new ways to stop machine failures and scams. Beware of all parts that come from low bids, Part quality that’s suspect we all must forbid.”

The sleigh, it just sat there, rusted, tilted and broke Then suddenly St. Nicholas really awoke! The cobwebs of sleep and nightmares he knew Were all a bad dream, one not to come true.

“Our elves they are working but greying with age, So write what they know with great care on a page. Instructions in detail are the way it should be For training and qualifying each new trainee.”

DECEMBER 2012

MT-ONLINE.COM | 11

Although many of the incidents cited here may sound as if they could have come from your operations, as St. Nicholas notes in the end, there is hope for all.

‘Twas the week before Christmas and all through the shops All lines should be humming. There’ll be no big flops. PMs, they seem pricey but failures are worse. Breakdowns stop flow and their cost’s a big curse. A lesson was learned, even though in a dream That maintenance is shared, and that’s a new scheme. You plan all the work and work all you plan, For reliability’s our goal, and we know you all can. Deploy all new tasks, new lists and techniques. Give your attention to noises, to rattles and leaks. Assuring capacity is the name of our game, For assets, our people, our customers, our name.

May your holidays be blessed with good tidings and cheer… The next time you’ll see us, it’ll be a whole brand new year! MT RobertMW2@cs.com

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MAINTENANCE TECHNOLOGY

DECEMBER 2012

Overcoming Your Challenges

Efficiency Loss Due To Lack Of Maintenance By Ron Marshall, for the Compressed Air Challenge

hen times are tight, it can be tempting to skimp on the maintenance associated with your compressed air system. Replacement of parts and consumables associated with compressor lubrication, filtration and belt-drives are items that are sometimes put on hold if budgets are stretched. Ignoring maintenance on your compressors, dryers and filters, however, can cost you more than you think. The Compressed Air Challenge’s comprehensive Best Practices for Compressed Air Systems Manual discusses this subject, indicating that, like all electromechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and to minimize unscheduled downtime. Inadequate maintenance can have a significant impact on energy consumption through lower compressor efficiency, air leakage or pressure variability. This can also lead to high operating temperatures, poor moisture control and excessive contamination of any product that comes in contact with wet, contaminated compressed air. Fortunately, most problems are minor and can be corrected by simple adjustments, cleaning, parts replacement and elimination of the adverse conditions. Compressed air maintenance is similar to that performed on automobiles: filters and fluids are replaced, cooling medium inspected, belts adjusted and leaks identified and repaired. All equipment should be maintained in accordance with its manufacturer’s specifications. OEMs provide inspection, maintenance and service schedules that should be followed strictly. In many cases, it makes sense from efficiency and economic standpoints to maintain equipment more frequently than the intervals recommended by manufacturers—which are developed primarily to protect the equipment. One way to tell if a system is being well maintained and operating properly is to periodically baseline it by tracking power, pressure, flow and temperature. If power use at a given pressure and flow rate goes up, the system’s efficiency is degrading. This baseline will also let you know if

the compressor is operating at full capacity and if the capacity is decreasing over time. On new systems all appropriate measurements should be initially recorded once the system is set up and operating properly to establish a reference against which all other baselines can be compared. Proper maintenance is essential for compressed air system efficiency and reliability. The key is for compressor operators to be trained on the specific requirements for each piece of equipment, necessary resources and maintenance scheduling based on manufacturer recommendations and trend analysis of recorded data. All observations and meter readings should be recorded for compressors, dryers, filters and any other important components within the compressor room. A combination of equipment control-panel data backed up by frequent inspections and log sheets is mandatory for avoiding unscheduled system shutdowns and leveraging best-practice preventive and predictive maintenance. It’s critical to record the dates of all maintenance and repairs and to include a list of all parts that are replaced and/or all services that are performed. An example of the cost of poor maintenance involves filter differential. On a typical system with a continuously operating 100 hp compressor, it would cost about $1500 per year in additional energy to overcome an extra 4 PSI of main-filter differential caused by poor maintenance. MT 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: info@compressedairchallenge.org.

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MT-ONLINE .COM | 13

FOR ON THE FLOOR An outlet for the views of today’s capacity assurance professionals Rick Carter, Executive Editor

2012 In Review: Accent On The Positive If we had to pluck one theme from the recent elections and apply it to this month’s year-end review column, it might be the “Are you better off?” question. For the record, I didn’t ask our Reader Panelists to assess 2012 using this particular yardstick. If I had, it appears the predominant answer would have been “yes.” Panelists’ responses to questions about how they rank 2012 for themselves professionally and for their companies clearly skewed toward the positive. This was despite expected and ongoing issues like the skilled-labor shortage and job-related challenges that exist no matter what. Here’s our group’s view of a generally good year and their hopes for the one waiting in the wings: Rating 2012… “We have been going strong all year and our numbers continue to rise. We have seen work come back into our site from out of the country, which has added to our production numbers. With production being higher, we are adding a large amount of tradespeople, which has been a real challenge.” … PM Leader, Midwest “We saw a huge uptick in our production and maintenance due to acquiring another company. A lot of their equipment was in poor shape and their plant philosophy had been ‘run to failure.’ This put a great burden on us as we tried to change their culture to focus on reliability. We still have challenges, but have come a long way.” … Corporate Support Mgr., Maintenance & Reliability, Midwest “This year, we had to complete our normal duties, as well as prepare ourselves for expansions to our facility. This includes extra training as well as working with construction crews, which added challenges, but I happily accept them as opposed to working for a struggling company.” … Senior Maintenance Mechanic, South

14 |

MAINTENANCE TECHNOLOGY

“As years go, our challenges were about the same in number, just different in substance. This keeps you on your toes and improves your ability to handle crisis situations and practice good decision-making skills. This was definitely a year that brought that home. I feel that I grew more as a person and decision-maker because of these challenges.” … Maintenance Coordinator, Mid-Atlantic The year’s defining event… “Design issues on our turbines made it necessary to have extended downtime three extra times this year, which really hurts the bottom line! Our workforce responded professionally to these challenges and accomplished the needed repairs in record time, safely and event-free. Considering the stress this puts on your employees, this is saying a great deal.” … Maintenance Coordinator, Mid-Atlantic “I found it very strange that with 5 million people unemployed, we could not find qualified maintenance people to hire.” ... Corporate Engineer, New England “The most defining event for me and my company was the second acquisition of a major company in two years. We just wound down the first integration and then another acquisition was announced. The amount of effort needed to complete the first integration was tremendous. Now we are looking to do it all over again. It’s great to be busy, but sometimes people get burned out and don’t perform to the best of their abilities.” … Corporate Support Mgr., Maintenance & Reliability, Midwest “Construction has been our defining event of 2012. We are doubling the horsepower capacity at my [energy-related] location and installing new compression to one of our smaller facilities. This

DECEMBER 2012

FOR ON THE FLOOR

is the largest project our station has experienced in more than 30 years.” … Senior Maintenance Mechanic, South “The event for me was turning 67 and being forced to retire from my company. The forced retirement was company policy [even though] I was still able to do my duties. Being an old timer, I pride myself on professionalism, including honesty, integrity, loyalty and maintaining a high level of knowledge in my professional area. I completed 22 CEUs in the field of maintenance and management in 2012. To fill my position, the company had to hire two people to cover all the duties I performed and it cost them more money.” … Former Senior Maintenance Engineer, now a Teacher, West What they expect for next year. . . “Our production numbers are expected to continue to go up. We were just told that our sales team is aggressively going after new business, and by 2014 we are looking at doubling our business.” … PM Leader, Midwest “My goals for the coming year are to organize a user’s group with my peers to promote the exchange of ideas and resources, and to aid in problem-solving in our specialized field. [I also want to] increase our use of Radio Frequency Identifying Devices (RFID) to lower cost and increase profits, as well as to continue to be the subject-matter expert in my profession.” … Maintenance Coordinator, Mid-Atlantic “My goal is to get as many of our new plants [as possible] focusing on reliability. As for the company, our goal is to integrate the new plants into our current culture and strive for the best results we can.” … Corporate Support Mgr., Maintenance & Reliability, Midwest “We plan to complete our expansion projects and commission the new equipment in the first quarter of the new year. One of our priorities for

DECEMBER 2012

the latter half of 2013 is to comply with new emission standards. Our company has already started preparing for these new standards, so I expect everything to go as planned.” … Senior Maintenance Mechanic, South “I am working on many projects that should allow a company to increase the bottom line without impacting the workforce. [Some of these involve] reducing utility cost by using more of the renewable-energy programs in our state, adding newer automated equipment and changing many of the power eaters to high-efficiency equipment. The best part is to train every employee on newer methods of doing their job functions in a more effective manner. This makes them a valuable asset to the company and improves the profit line.” … Former Senior Maintenance Engineer, now a Teacher, West “My goal is to get a raise. I haven’t had one since the bottom dropped out three years ago, yet my responsibilities continue to expand. Perhaps now that the Presidential election is over, things will get better. I hope so!” ... Corporate Engineer, New England MT

About the MT Reader Panel The Maintenance Technology Reader Panel is comprised of working maintenance practitioners who have volunteered to answer bimonthly questions prepared by our editorial staff. Panelist identities are purposely not revealed, and their responses are not necessarily projectable. The Panel welcomes new members: Have your comments and observations included in this column by joining the Reader Panel at www.mt-online. com. Click on “Reader Panel” under the “MT Resources” header, and follow the instructions. If accepted, you will automatically be entered into a drawing for a cash prize after one year of active participation.

MT-ONLINE.COM | 15

CAPACITY ASSURANCE STRATEGIES

Overcoming a CMMS challenge…

Small-Site Scheduling

It's an area where the one-size-fits-all approach doesn't work. John Reeve Cohesive Information Solutions, Inc.

ave you ever walked into a local business and noticed a big whiteboard mounted on a wall (Fig. 1) indicating what the employees are supposed to do and when? If so, you were looking at a classic example of “small-site scheduling.” This concept could also be referred to as “call-center dispatching” (although that term is typically associated only with urgent or emergency work).

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MAINTENANCE TECHNOLOGY

DECEMBER 2012

CAPACITY ASSURANCE STRATEGIES

Small-site scheduling includes both routine and urgent work—and involves key operational activities, as well as maintenance work. The goal is to provide a level of coordination into the near future and sometimes a week or more out. Does small-site scheduling software, in fact, exist within the CMMS community? Many systems work beautifully for large, multi-craft organizations, but they may not offer an easy-to-use solution for mid- to small-size sites. Consequently, companies that might have spent many dollars on best-ofbreed systems may still find themselves struggling to make the scheduling process work at their smaller sites. CMMS systems commonly offer two approaches:

the task; 2) place it on a calendar; and 3) assign a crew. This must be done day-in and day-out without the luxury of job Planners or Schedulers. For those tasked with scheduling at small sites, is there a solution between planning-in-your-head and resourceintensive, computerized maintenance management systems, and, what should this design look like?

■ Direct entry of schedule start dates

on the maintenance work order (which is like driving in the dark): Could users be over-scheduling staff and not know it? ■ Manipulation of logic-based bar

charts: But does the user really need to create logic ties and see resource histograms to manage work at his/ her small site? The primary focus of small-site scheduling is what are we doing today, tomorrow and, perhaps, next week. The priorities are, therefore: 1) identify

Fig. 1. This whiteboard calendar from a countertop supplier’s shop is representative of one of the most basic approaches to small-site scheduling. (Source: Tops Solid Surface Co.)

How Does A Small Site Even Afford A CMMS? The company that buys a CMMS product may have a large O&M organization—and budget—but many smaller, geographically dispersed sites. Sometimes, upper management will purchase software and assume it is just what the Maintenance teams at each plant needs. The total head-count at some of those sites, however, could be fewer than six workers. DECEMBER 2012

Maintenance personnel want to do the right thing (within reason). They understand the importance of planning/ scheduling, but are often overwhelmed by high clickcount and screen complexity. They're willing to change processes and learn new technologies, but don’t want to spend extensive time trying to finagle work orders if they are going to reap no real benefit from doing so. MT-ONLINE.COM | 17

CAPACITY ASSURANCE STRATEGIES

Steps in planning/scheduling Table I below details the steps in a formal work-order process for a full-sizeâ&#x20AC;&#x201D; i.e., substantial head-countâ&#x20AC;&#x201D;Maintenance organization. Table I. Formal Work-Order Process in a Full-Size Maintenance Organization

Small-site priorities are to identify tasks, put them on a calendar and assign crews, and to do so day-in and day-out without the luxury of full-time job planners and schedulers.

A work request needs to be created. Requestor identifies problem and asset/location.

5-10 minutes (per WO)

Work request is reviewed by management, prioritized and then given to Planning.

5-10 minutes (all new)

Planner position looks for duplicates and begins the Planning function (enters duration and applies craft estimate). Offsite material requests are processed as applicable. The Supervisor or Lead is assigned.

15-30 minutes (per WO)

Scheduler reviews crew availability for next week, checks open backlog and selects work for week.

15-30 minutes (per WO)

Scheduler takes proposed schedule to Weekly Schedule meeting for review and approval.

45-60 minutes (all WOs)

Supervisor prints scheduled work for next week and starts identifying who is to do what, on what day.

30-60 minutes (all WOs)

Daily plan is created night before. Crew is briefed at the start of day. Work is performed. Actuals are captured. Work order is closed.

30-60 minutes (all WOs)

Total time: 2.5 hours minimum 18 |

MAINTENANCE TECHNOLOGY

DECEMBER 2012

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CAPACITY ASSURANCE STRATEGIES

Things can be quite different in a small-site Maintenance department: The Supervisor/Lead does everything. He/she creates the work request, reviews it, approves it, assigns a date/time and picks the worker. He/she needs to make sure that workers aren’t double-booked or that operational schedules aren’t impacted. These steps are all done at roughly the same time. In some cases, work needs to be quickly shuffled around. To the Supervisor/Lead, this is the definition of scheduling. The total elapsed time might be 5-10 minutes per WO. So, the question is, how much time should he/she spend managing O&M staff within the confines of the CMMS? And can the software be configured differently to combine functions? Other peculiarities of small-site scheduling… Quite often, the maintenance backlogs are small in size. Plus, most of the work is similar in terms of duration. This work may be preventive or corrective in nature, but neither will take more than one to two hours to perform. The only Maintenance craft at a small site typically goes by one name: “Operations/Technician.” With this understanding, the craft estimate could be defaulted. Thus, the Supervisor/Lead (i.e., Planner) can very easily start lining out morning and afternoon jobs for the coming days. This process could be applied to either emergency maintenance or routine work. With today’s technology you can do anything If your small site is one among many that are struggling with a one-size-fits-all CMMS, now is the time to imagine future perfect and ask "why not" of your chosen vendor (or other vendors). Designing an ideal small site-scheduling tool. . . If I were a Supervisor at a small site, I would want a visual display—such as a calendar-type format—similar to MS Outlook, from which I could manage all work. An ideal design would allow for quick insertion of new tasks on the calendar screen. (Note the reference to the word “task,” not “work-order number.” It may be that a work-order number is created later.) It would also be advantageous to include other activities like operational events that impact maintenance work and staff. The design should display worker schedules, as well as planned absences. Where work is assigned to a crew or person, color shading could clearly denote (visually) who does what. In the event more work is identified than is possible to display, an “overflow arrow” would point to the complete list. This type of CMMS calendar view would let the organization quickly see what work is scheduled where and which crew is assigned. Moreover, it could provide that information for an entire month or just a week. 20 |

MAINTENANCE TECHNOLOGY

Fig. 2. Incorporated into a CMMS, this simple type of calendar view could be an effective tool for a small-site maintenance operation.

Developing a calendar view. . . Given the fact that it is a principal feature of their email systems, a calendar format (like that shown in Fig. 2) is familiar to most employees. Incorporated in a small-site CMMS system, this type of calendar could show upcoming meetings, crew shift changes, training activities, etc.—and could be used by a supervisor to keep track of his entire staff. More important, it could also show maintenance work. Building an ‘add task’ screen. . . An example input dialog—which could appear when the user right-clicks on a specific date—is shown in Fig. 3. To keep the system simple, it is important to make the work-order insert from the calendar itself (as opposed to going back to the main WO application). The typical small-site user would probably prefer one application that allows him/her to do everything. Keep in mind the constraints of small-site scheduling: wherein the Supervisor/Lead position must do it all. He/she must be aware of all needed maintenance work as well as staff availability and operational events. The Add-Task screen would allow the user to specify the “type of record” and, if desired, enter a description without a work-order number. In addition, when linked to a workorder number, this action would directly update the CMMS (i.e., schedule start date). Based on a setup screen, activities would automatically be color-shaded, or the user could override. Alternatively, he/she could elect to show either a truncated description or the work-order number itself. Operational events would be stored as records outside the work-order table. Moreover, worker schedule changes (as in the case of crew rotations) would only show on the first date of the change. DECEMBER 2012

Plant-wide Safety Assessments

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CAPACITY ASSURANCE STRATEGIES

they might see that the problem is probably due to a poorly prioritized backlog and inaccurate job statuses. When data is bad, no automated program can help. If “bad data” were cleaned up, however, it would be technologically feasible for this advanced feature to be run. Prerequisites for this program to work would include:

Note(1): Operational events would be stored as records outside of the work order table. Note(2): Worker schedule changes (as in the case of crew rotations) would only show on the first date of the change. Fig. 3. In the Add-Task screen, an input dialog would appear when the user right-clicks on a speciﬁc calendar date.

Managing planned absences. . . It would seem that the best place to manage “planned absences” is from the calendar screen itself. A planned absence is where a worker plans to go on vacation for 1-2 weeks, or, perhaps, requests a day off. This entry should be a simple screen that captures the worker’s name, start date of absence, duration (or end date) and reason for absence. Note that there could be multiple absence reasons within one day. These planned absences would subtract from overall craft availability. Designing reports. . . When the user prints the calendar, additional information pertaining to the work order would appear. Specialized reports could be designed to show worker calendars/availability, resource usage, weekly schedules and daily plans. By making this external to the screen-entry system, unnecessary complexity is removed from the display. Plus, with the power of business analytics, users have more flexibility in terms of entering numerous combinations (variables) and extracting desired results and formats. Automatic resource leveling In the 1970s, automated resource leveling features existed within scheduling products (i.e., Project Software & Development, Inc.). To date, no CMMS or ERP system has been created that includes a built-in resource leveling feature to create a weekly maintenance schedule. Although this knowledge/capability exists, it’s never been incorporated in CMMS products. Imagine how empowered small sites would be if it were: A Supervisor/Lead could single-click “Generate Schedule” and out would come the report. Some users might be skeptical and believe that an accurate schedule would never be possible. Looking deeper into the database, though, 22 |

MAINTENANCE TECHNOLOGY

1. Internally stored craft resource availability 2. Properly prioritized/estimated backlog, and 3. The “Leveling” algorithm. This type of overall solution would demonstrate the real power of technology and enable any size organization to increase workforce productivity and effectively manage backlogs. Without this type of tool, small sites will never be able to successfully create an automated weekly schedule. The need for the right tools There is a reason why so many smaller-sized organizations are struggling to perform planning/scheduling for day-to-day maintenance: They don’t have the right tools. A nuclear power plant may have 10-15 Planner/Scheduler positions, but with that head-count you could make any software package work. The reality is that the majority of CMMS user sites fall into the small- to mid-size range. Giving them a product that is easy to use and adds real value can help create a positive attitude about the CMMS and positions them for the future—i.e., automated resource leveling. While best-of-breed CMMS products with their outstanding enterprise-wide capabilities and configurability are vitally important, they should also be able to support small-site scheduling. These goals are not unrealistic. We just need vendors to fully understand the CMMS-user community and realize that different-size customers have different needs. MT Acknowledgements The author wishes to thank Valerie Teters, President and Designer of Tops Solid Surface Co., in Lacy, WA, and Rick Smith, Supervisor Offshore Operations, with Williams Energy, in Bay City, TX, for their assistance with the images used in this article. John Reeve has spent 25 years supporting CMMS/ EAM users across a wide range of industries. Now, as Manager and Senior Consultant for Cohesive Information Solutions, Inc., he serves as Practice Leader for Maintenance & Reliability Solutions. Email: jreeve@cohe sivesolutions.com. For more info, enter 01 at www.MT-freeinfo.com DECEMBER 2012

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Next-Generation, Extended-Life Contamination Control Products

Specialty lubricants for sustainable efficiency

ir Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside vessels like gearboxes that hold lubricants, greases, hydraulic fluids and fuels. This extends the life of critical machinery and equipment, and significantly reduces lifecycle costs. The company’s innovative products have been the gold standard in contamination control since 1997. Its line includes nine series of desiccant breathers, anodized color-coded closed system adapter kits that prevent cross-contamination, manifold adapters and pressure-vacuum-indicating gauges. Air Sentry has recently introduced a revolutionary new line of desiccant breathers called Guardian™. These “next-generation” contamination control products are the first breathers constructed of Tritan™. This patented material provides the most chemical-, temperature- and impact-resistant casing on the market. Guardian also is the first desiccant breather to incorporate an isolation check valve that protects the adsorbent from exhaust air and volatile splashing fluids. This lengthens the desiccant’s service life and reduces replacement frequency. Learn more about how Guardian increases fluid life, improves lubrication and lowers maintenance costs by visiting www.airsentry.com/air-sentry-breathers/guardian.htm.

“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: Innovation for ecologically and economically efficient solutions. Klüber Lubrication North America L.P. info@us.kluber.com www.klubersolutions.com/sustainability2 your global specialist

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DECEMBER 2012

MAINTENANCE TECHNOLOGY

klu643-01sustHpvtMT-D3c.indd 1

3/12/12 2:08 PM

Lubrication Checkup Extending Lubricant Life By Dr. Lube, aka Ken Bannister

Symptom: “Dear Dr. Lube, we’re looking for ways to reduce the significant purchase and disposal costs of lubricants used in our plant. Can you suggest some strategies for extending lubricant life?

Diagnosis: If a lubricant is to lead a long, productive, healthy life, it must combat dirt, heat, moisture and apathy. Heat directly affects the oxidative (useful) life of the lubricant, and for every 18 F degree temperature rise, the oil life expectancy is halved. Moisture attacks the base oil and prematurely strips out the additive package, causing sludge and oxidation. Dirt clogs filters, creates sludge and destroys machined surfaces. The prescription below can enhance your lube program, reduce operating and maintenance costs and improve your energy efficiency and carbon footprint.

Prescription: ■ Work with a Lubricant Management Specialist and perform a Lubrication

Operation Effectiveness Review (LOER) to establish improvement opportunities in the applying, purchasing, storing, transferring, dispensing/metering and disposing of your lubricants. ■ Work with your supplier to implement a Lubricant Consolidation Program that reduces/optimizes the number of lubricant SKUs used in your plant. ■ Use professional-grade, dedicated transfer and delivery equipment to combat cross-lubricant contamination and dirt contamination. ■ Implement a condition-based approach to managing lubricant application (engineering your lubricant delivery, i.e., when and how much?) and changeout requirements (performing oil analysis, i.e., how often?) ■ Implement a Machine Cleanliness Program to quickly identify leaks and moisture invasion, and to prevent dirt from contaminating the lubricant and forming a thermal blanket that raises lube temperature. ■ Review your filtration methods and look for opportunities. ■ Take a 5R approach in tuning up your methods and systems to ensure that the Right person applies the Right amount of the Right lubricant in the Right place at the Right time. ■ Train and certify your maintenance personnel, engineers and lube technicians to recognize the impact and cost of poor lubrication practices. MT

.LHY VPSZ [OH[ KYP]L LMÄ JPLUJ` Higher revenues, increased reliability: special oils made by Klüber Lubrication help you achieve these goals through long maintenance intervals, high efficiency and lasting component protection — even at the gear’s performance limit. Together we can increase the efficiency and reliability of your mechanical systems. Klüber Lubrication North America L.P. info@us.kluber.com www.klubersolutions.com/ wind3 your global specialist

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: doctorlube@atpnetwork.com. For more info, enter 03 at www.MT-freeinfo.com DECEMBER 2012

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7/23/12 11:45 AM

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Corporate Report 2012

Profiles Of Leading Suppliers To Industry MAINTENANCE TECHNOLOGY Special Advertising Section

CORPORATE REPORT 2012

BALDOR ELECTRIC COMPANY

aldor Electric Company, based in Fort Smith, AR, is a leading marketer, designer and manufacturer of energysaving industrial electric motors, mechanical power transmission products, drives and generators. It was was founded in 1920 on the premise that a better motor is one that uses less electricity— and that belief holds true today. Baldor products have exceptionally strong brand recognition for quality and value with our customers. In January 2011, Baldor was acquired by ABB and is now a proud member of the ABB Group.

manufactures a complete line of gensets for industrial standby, portable and backup power needs. Baldor offers strong support and solutions for the mining, food & beverage, oil & gas, paper & forest, aggregate & cement, unit & airhandling, water and power-generation

as perceived by the customer) in relation to Cost and Time (both of which are measurable). The result is our “Value Formula,” which has become a part of our culture. It guides our thinking and directs our work every day.

Providing a Wealth of Solutions and Support Baldor is the largest motor and mechanicalpower transmission company in North America. Baldor•Reliance® motors range in size from 1/50th through 15,000 horse- Baldor’s industrial electric motors, mechanical power transmission products, drives and generators are power and have leading recognized around the world for their quality and value. customer preference and market share. Baldor sells and supports industries. We provide reliable, applithe entire line of ABB IEC motors and cation-specific products and expert medium-voltage motors, along with knowledge for each of these markets. the full range of ABB industrial drives. Installed Base Evaluations are also Customers can now create packaged available to aid end users in reducing solutions of Baldor and ABB industrial Baldor Electric Company energy consumption with the right motors and drives for most industrial 5711 R.S. Boreham, Jr. St. mix of industrial motors, drives and applications. Fort Smith, AR 72901 gearing in a single application or We are a leading producer of Ph: 479.646.4711 throughout an entire facility. mechanical power transmission prodwww.baldor.com ucts, including Baldor•Dodge® engDefining a Solid Value Formula ineered mounted bearings, enclosed More than 30 years ago, Baldor caregear products and power transmission fully defined “Value” as it is perceived components, as well as Baldor•Maska® by our customers. Value is defined in For more info, enter 260 at www.MT-freeinfo.com pulleys and couplings. Baldor also terms of Quality and Service (both

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CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

DES-CASE CORPORATION

es-Case understands the importance of fluid cleanliness and the role it plays in helping to ensure that equipment investments last longer. For more than 25 years, we’ve pioneered solutions to help maintain lubricant quality specific to customer applications. Featuring designs unparalleled in the marketplace, Des-Case products are used wherever lubricant life and performance are essential to daily operations. Count on Des-Case Why do many of the world’s leading companies, distributors and OEMs trust Des-Case to help keep their equipment and plants running smoothly? 1. Detection: Our Lubrication Transformation Services (consulting and training) help companies detect reliability problems and identify steps to address them, including implementation of practical machinery lubrication-management practices and cost-benefit analysis that support comprehensive programs. 2. Prevention: Getting clean, dry oil into machines (and keeping it that way) is one of the most fundamental elements of precision lubrication. Upgrading vent caps to high-quality Des-Case desiccant breathers and using lubricant storage systems and oil transfer/ filtration systems helps machines achieve optimum reliability and production uptime. 3. Removal: High-quality Des-Case fluid-handling devices remove dirt and water, helping equipment run at peak capacity. From small, portable machines to full-featured vacuum dehydration systems, customizable filtration devices are an integral component of proactive maintenance in unique environments.

DECEMBER 2012 / CORPORATE REPORT

Des-Case invented the desiccant breather and has continued to lead and innovate in products and services for precision lubrication ever since.

Industry-Leading Manufacturer of Desiccant Breathers ■ Continuous innovation. We invented the desiccant breather and continue to design new innovations. ■ Widest variety of high-value solutions. From small gearboxes to large hydraulic systems or storage tanks, Des-Case breathers are engineered to last and matched with your specific needs. Full Line of Fluid-Handling Products & Adapters ■ Easily customizable. Des-Case ﬁltration systems can be easily configured to your exact needs. Larger systems are also designed to your specs. ■ Rugged designs/thousands of options. Des-Case systems incorporate smart technology to make contaminant filtration a simple task, requiring less equipment and labor, while reducing system contamination. Lubrication TransformationSM: Putting Best Practices Into Practice ■ Consulting services & in-depth training. We specialize in helping companies

pinpoint lubrication issues and identify ways to address them, such as plant surveys, one-day best practice overviews and intensive training classes with ICML certiﬁcation options. ■ Knowledgeable team. Our Lubrication Transformation program is managed by lubrication engineers with years of in-plant experience. Whenever you need contamination control, you can count on Des-Case to provide the right products and services to keep you up and running. Visit www.descase.com to learn more about how we can help you take the next step in your best practice journey.

Des-Case Corporation 675 N. Main St. Goodlettsville, TN 37072 Ph: 615.672.8800 www.descase.com For more info, enter 261 at www.MT-freeinfo.com

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CORPORATE REPORT 2012

FLUID DEFENSE SYSTEMS

he OilSafe® Visual Lubrication Management System from Fluid Defense Systems is the company’s easy-to-implement, flagship innovation that helps users keep their storage areas clean and safe and prove their commitment to best practices. Providing a Range of Benefits Customizable, visually intuitive labels ensure consistent fluid identification throughout the manufacturing environment. The OilSafe Work Center provides safe, compact bulk storage and contamination control to promote best practices for lean manufacturing, 5Rs, 5S and OSHA® right-to-know compliance. In-line filtration and precise-pour transfer containers simplify maintenance and safeguard workflow. As a result, plants benefit from a complete system that covers the entire process loop and works with any existing maintenance process. “Our OilSafe transfer containers and labels have long been the industry standard to reduce contamination and spills. We recognized a need in the market to add bulk storage and dispensing to create a fully integrated system for managing lubrication from delivery to point of application,” explains John Gillian, Chief Executive Ofﬁcer for Fluid Defense. “That’s why we’re proud to introduce the OilSafe Work Center.” The OilSafe Work Center is the only modular, scalable bulk system of its kind. Each tank has its own pump and built-in filtration to prevent fluid crosscontamination and keep fluid storage areas organized, clean and free of the 55-gallon drums that are commonly used. According to Gillian, “It’s a safe and reliable solution that helps companies across the world instantly establish bulk-storage best practices on the plant

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The only modular, scalable, bulk-fluid storage solution of its kind, Fluid Defense’s OilSafe® Work Center can prevent costly inefficiencies, downtime and lost production.

floor and prevent the inefficiencies, downtime and lost production that can cost hundreds of thousands of dollars.” Serving a Range of Applications The OilSafe Work Center has been successfully implemented in applications such as manufacturing, mining, food and beverage, defense and more. Available in multiple configurations, each system is customizable to suit the application and budget. The scalable, plug-and-play design extends the life of the Work Center, minimizing downtime and increasing efficiency. In addition, the palletized, fully assembled pods allow for quick set-up and efficient transport. After years of delivering strong results, OilSafe has become the recognized standard in several key industries. Fluid Defense’s dealer network has a

distribution reach into more than 45 countries and is partnered with worldclass suppliers. For more information about the OilSafe Work Center and the OilSafe Visual Lubrication Management System, please visit www.fluiddefense.com.

Fluid Defense Systems 2001 Greenfield Rd. Montgomery, IL 60538 Ph: 630.280.8930 www.fluiddefense.com For more info, enter 262 at www.MT-freeinfo.com

CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

TROUBLESHOOT

SAFELY

FROM A DISTANCE Fluke 233 Remote Display Multimeter

The problem is inside. You have to be outside. Now you can ﬁx live machinery safely from a distance. The new Fluke 233 Wireless Remote Display Multimeter lets you connect to the measurement points and monitor the results safely from a distance. Stay away from moving machinery, energized panels and high voltage components.

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4239816A_EN_233_MaintTech.indd 1 DECEMBER 2012 / CORPORATE REPORT

9/24/12 4:14 | PM

CORPORATE REPORT 2012

GRAYBAR

raybar, a Fortune 500 corporation and one of the largest employee-owned companies in North America, is a leader in the distribution of high-quality electrical, communications and data networking products, and specializes in related supply chain management and logistics services. Through its network of more than 240 North American distribution facilities, it stocks and sells products from thousands of manufacturers. For decades, Graybar has helped industrial customers power, network and secure their facilities with speed, intelligence and efficiency. Buildings ■ Solutions for maintaining and upgrading facilities ■ MRO supplies ■ Industrial wire and cable ■ Electrical infrastructure ■ Plant and personnel safety Intelligence ■ Industrial automation and control

solutions that enable consistent and efficient production ■ Industrial Ethernet solutions that include structured cabling and wireless ■ Applications that connect people, systems and information ■ Security and access control solutions that protect facilities and people

Graybar Solutions for Industrial Customers

Energy ■ Lighting solutions that deliver high quality and energy efficiency ■ Power solutions that provide reliability and improved energy management ■ Power quality and power factor correction

■ Safety audits ■ Graybar ESP® ■ Graybar Financial Services® ■ Technical specialists (networking,

Emerging ■ Renewable energy ■ Electric vehicle charging stations

■ In-building wireless (DAS)

Services ■ Vendor-managed inventory

(Graybar SmartStock ) ■ Industrial vending machines and

systems

printing and publishing, pulp and paper and water/wastewater. We also provide solutions speciﬁc to OEMs—machine builders, panel builders and other equipment manufacturers. To learn more about Graybar industrial solutions, visit graybar.com/industrial, or contact your local Graybar representative at 1-800-GRAYBAR (472-9227).

energy, automation and control specialists) Through our specialized sales team, Graybar serves customers in automotive, chemical processing, food and beverage, metals, mining, oil and gas, pharmaceutical and biotech, power generation,

Graybar 34 N. Meramec Ave. St. Louis, MO 63105 Ph: 800.472.9227 (1-800-GRAYBAR) www.graybar.com For more info, enter 264 at www.MT-freeinfo.com

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CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

LUDECA, INC.

ts founding partners established LUDECA in 1953. In 1982, we became the exclusive representative of Prüftechnik AG for the United States, the Caribbean and Venezuela. Today, this representation includes marketing and support responsibilities for the entire Alignment and Condition Monitoring Divisions. LUDECA pioneered laser shaft alignment technology in the U.S. market with the introduction of its legendary OPTALIGN® system, manufactured by Prüftechnik in Germany in 1984. OPTALIGN’s newly-patented reflectedlaser technology was, at that point, years ahead of its time, revolutionizing the field of shaft alignment and saving plants untold thousands of dollars in downtime and repairs. Today, with a lineup headed by our globally respected ROTALIGN® ULTRA IS and OPTALIGN® SMART and SHAFTALIGN® tools, LUDECA remains America’s leading vendor of laser shaft alignment technology. We also offer geometric measurement systems, bearing heaters, shims and laser pulley alignment tools. LUDECA services the vibration analysis field with state-of-the-art portable and online condition monitoring systems, featuring the award-winning VIBXPERT® II vibration analyzer and balancer with the powerful OMNITREND® software as well as VIBNODE® and VIBCONNECT® RF online condition monitoring systems. We also provide alignment, vibration and balancing training (onsite and at our state-ofthe-art Miami Training Center), as well as repair, NIST calibration and high-end engineering consultation services. It’s What We Do: ‘Keep It Running’ LUDECA proudly announces the recent launch of a new logo, slogan and Mission Statement backed by the same fundamental values on which the company was built.

LUDECA’S New Mission Statement “LUDECA’s goal is to be the premier provider of reliability solutions and technologies to industry. Our years of experience and wealth of knowledge make it possible to offer the very best service and support to our customers. We are, and seek to remain, the leading suppliers of laser shaft and geometric alignment systems, laser sheave alignment tools, and vibration and condition monitoring systems to industry. LUDECA’s commitment to our customers strengthens our reputation as the very best in our fields, thereby creating and maintaining long-term customer partnerships.” Visit www.ludeca.com to learn how we can help you achieve your reliability goals.

According to Frank Seidenthal, President, LUDECA, Inc., “Our new slogan —‘Keep It Running’—is indicative of what our condition-monitoring solutions are committed to doing: keeping manufacturing running and productive. It’s what we’ve been doing all these years, and it was time to put it in writing.” But that’s not the whole story. As Seidenthal explains it, “We wanted a look and feel that was fresh and modern to reflect our growth and core company focus. Not only do we sell state-of-the-art cutting-edge products, we also improve our customers’ equipment reliability. Our new Mission Statement emphasizes this priority to our employees and our

customers that, at LUDECA, we maintain a high standard of ethics, service and customer support by always striving to exceed customer expectations. The proof is in our growth and high rate of repeat business.”

LUDECA, Inc. 1425 NW 88th Ave. Doral, FL 33172 Ph: 305.591.8935 info@ludeca.com www.ludeca.com For more info, enter 265 at www.MT-freeinfo.com

DECEMBER 2012 / CORPORATE REPORT

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CORPORATE REPORT 2012

MILWAUKEE ELECTRIC TOOL

or over 85 years, Milwaukee Electric Tool has led the industry in both durability and performance by providing the best in professional, heavy-duty power tools and accessories. Today, we continue to revolutionize the power-tool industry by focusing on our core professional users and providing new technologies, such as Milwaukee’s REDLITHIUM™ battery technology, that lead to greater efficiency on the jobsite. In a crowded marketplace, success requires innovation. This year, Milwaukee introduced the new M12 FUEL™ line, expanding the industry’s largest sub-compact battery system to the next level of performance and durability. Six unique drilling and fastening tools will feature Milwaukee’s POWERSTATE™ brushless motor, REDLINK PLUS™ intelligence and REDLITHIUM™ battery technology, resulting in superior application performance. “Our innovative M12™ lineup gives users new options, providing compact and lightweight power tool solutions for what was previously performed with hand tools,” says Mark Senske, Goup Product Manager, Milwaukee Tool. “Bringing our popular FUEL™ design into the mix of available 12-volt tools gives users even more options that deliver unmatched power, runtime and durability on the jobsite.” Not stopping there, the M12 FUEL™ line will feature Milwaukee’s other big news of the year—the introduction of their next generation of Lithium-Ion with REDLITHIUM™ 2.0 and XC4.0 batteries. “Milwaukee Tool,” Senske explains, “is dedicated to providing the best tool and battery technology to our users. With up to twice the run-time, 20% more power, two times more recharges than standard Lithium-Ion batteries and the ability to operate in climates below 0° F, this next generation of

Lithium-Ion will allow our users to focus more on getting jobs done and less on charging their batteries.” In addition, with more buildings implementing complex process-control automation equipment to manage new systems, measuring tools that identify problems before they occur, and in a time-efficient manner, have never been more important and needed. At Milwaukee Tool, this provides a window of opportunity. “Our focus is on providing users with innovative, high-performance solutions that increase productivity on the jobsite,” says Ernie Racenet, the Marketing Director of Milwaukee Tool. “An The M12™ 160x120 example of this is a new Thermal Imager is just Milliamp Clamp Meter one of many innovative launching soon that will products that Milwaukee allow facility engineers Tool launched this year. to measure 4-20 milliamp signals without Milwaukee Tool understands the breaking the loop, saving the user a importance of streamlining operations tremendous amount of time and money. no matter what the company size, and What used to take minutes can now be having the right tool to do the job can done in seconds.” Another example of an innovative, make a big difference. high-performance solution is Milwaukee’s M12™ 160x120 Thermal Imager. Launch-ed earlier this year, it’s the ultimate predictive maintenance tool. A display features high-resolution thermal images for simplified diagnostics, while a visual camera captures photos right on Milwaukee Electric Tool Corp. the device. This provides users with the 13135 W. Lisbon Rd. best information available, every time, no Brookfield, WI 53005 matter where they are, allowing them to Ph: 800.729.3878 (1.800.SAWDUST) schedule maintenance during downtimes. www.milwaukeetool.com For more info, enter 266 at www.MT-freeinfo.com

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CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

NIDEC MOTOR CORPORATION

idec Motor Corporation (NMC) is a leading manufacturer of commercial, industrial and appliance motors and controls. NMC’s product portfolio features a full line of highefficiency motors, large and small, that serve industrial, residential and commercial markets in applications ranging from water treatment, mining, oil & gas and power generation to pool and spa motors, air conditioning condensers, rooftop cooling towers and commercial refrigeration. The Nidec flagship brand, U.S. MOTORS®, has a 100-year history and a strong reputation in industrial motors. The U.S. MOTORS brand is a bridge from a rich, solid past to a bright and expanded future. Today, Nidec Motor Corporation is committed to developing new technologies and products that help our customers solve problems, improve efficiencies and protect the environment. Leading with a New Line of Inverter Duty Motors A perfect example of how Nidec is leading the vertical motor industry is the recent introduction of a new line of stock Vertical HOLLOSHAFT® inverter duty motors with a bearing protection system to help mitigate bearing problems caused by shaft voltage. The use of inverters in pumping applications has increased dramatically over the past few years. The combination of an inverter and induction motor with a pump produces an economical variable speed drive system that has the potential to provide energy savings and process optimization. It may also lead to improved system reliability. Unfortunately, inverters can be tough on electric motors. Those used to supply adjustable frequency power to induction motors do not produce sinusoidal output voltage waveforms.

Geared toward the pump industry, this U.S. Motors 5813 Frame Vertical Titan II is part of Nidec’s innovative inverter-duty line that incorporates an upgraded insulation system with a first-of-its-kind bearing-protection feature.

Most inverters use a control topology called Pulse Width Modulation (PWM) to change the voltage and frequency of the power applied to the motor. The switching frequency of the PWM control system generates steep-fronted voltage spikes that can damage motor insulation. U.S. MOTORS was the ﬁrst to recognize the need for special inverter duty insulation system and introduced our Inverter Grade® Insulation system. This system meets NEMA MG1 Part 31 insulation requirements for inverter–fed motors. PWM inverters also generate common mode voltage, which may produce a shaft voltage. Shaft voltage can result in bearing currents that may damage motor bearings. Motors 40 horsepower and larger now include a shaft ground ring to short-circuit current that can damage bearings.

While the number of occurrences of bearing damage due to shaft voltage is small, the cost to replace failed bearings is high. Reducing these types of field issues not only benefits the end user, but the pump OEM as well. Its new inverter duty motors are just one example of how Nidec Motor Corporation continues to reinforce its reputation as a true innovator in the motor industry.

Nidec Motor Corporation 8050 West Florissant Ave. St. Louis, MO 63136 Ph: 888.637.7333 www.nidec-motor.com For more info, enter 267 at www.MT-freeinfo.com

DECEMBER 2012 / CORPORATE REPORT

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CORPORATE REPORT 2012

Developed and patented in the Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher technology was introduced to the European market in the 1980s. With immediate market success, Mr. Doelman brought the technology to the United States and applied for and received a patent in 1991. From that moment, Scalewatcher North America has been on the forefront of environmentally sensitive water treatment. Located in Oxford, Pennsylvania, Scalewatcher North America continues to lead the industry in descaling products that do no harm to the environment. Scalewatcher North America focuses on the elimination of scale and the problems associated with scale build-up. Industries know the costs involved in keeping their capital investments running smoothly. Scalewatcher is there to help. Scaled cooling towers, chillers and associated equipment can negatively impact a company’s bottom line, and not just in cash. The caustic chemicals used to remove scale only create more problems with the environment. Your company can “GO GREEN” and stay within your budget.

If our product does not work for your application, we will buy it back! With our “Performance Guarantee,” you never have to worry about losing cash on a product that does not work.

For more info, enter 268 at www.MT-freeinfo.com

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CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

SPM INSTRUMENT, INC

PM Instrument, inventor of the original Shock Pulse Method and the patented SPM-HD® measuring technique, continues to broaden the scope of condition monitoring to include more machinery than ever before. Examples include: SPM Leonova® Diamond The portable Leonova Diamond was designed for rough industrial environments with a carbon-fiber-reinforced housing. Lightweight, yet sophisticated, it provides a powerful combination of well-proven measuring techniques for every situation, all in one instrument.

Bearing Monitoring as You’ve Never Seen It Where established methods fail, SPM-HD® detects deteriorating bearing condition and incipient failures with impressive accuracy and exceptional pre-warning times. Ultra-Low-Speed Bearing Monitoring Low-RPM applications have been beyond the limits of established monitoring techniques—until now. SPM-HD® is able to accurately measure rolling element bearings rotating from 1 RPM to 20,000 RPM. Advanced and patent-pending digital algorithms provide very high measuring dynamics with results presented in never-beforeseen detail. Razor-sharp spectrums and time signals bring root cause analysis to a new level of understanding. High-Definition Order Tracking Careful engineering and optimal use of digital technology in the design of SPM’s HD Order Tracking product allow for more precise measurements and more detailed spectrums than ever before. 3-Channel High-Performance Vibration Analysis Leonova® Diamond provides razor-sharp spectrums—even if signals are weak and

DECEMBER 2012 / CORPORATE REPORT

low in energy content. It will measure vibration severity for general machine condition, as well as velocity, acceleration and displacement according to ISO 10816 standards. In addition to RMS vibration readings, the instrument displays an FFT spectrum. Enveloping with band and highpass filters can be selected to optimize analysis. The EVAM® measuring technique provides pre-programmed evaluation models for time and frequency domain parameters. 25600-line FFTs to 40 kHz spectrums with true zoom makes the Leonova Diamond a powerful portable analytical tool for every industry.

SPM Instrument continues as a world leader in developing condition monitoring solutions. The Leonova® Diamond is just the latest proof of this commitment.

Corrective Techniques Leonova® Diamond provides sophisticated tools for root cause analysis and corrective maintenance. In addition to standard functions such as an Electronic Stethoscope, Laser Tachometer with Temperature, there are a number of modular functions, including Motor Current Analysis, Run Up/Coast Down, Bump Test, Laser Shaft Alignment and Dynamic Balancing, that can be added to the instrument at any time. Power-Packed Software Containing the expert knowledge needed to evaluate machine condition, Condmaster® Ruby collects and stores results from all SPM handheld and online measuring devices for evaluation and presentation—and does it all by way of a single powerful software package.

SPM Instrument, Inc. 780 Bailey Hill Road Eugene, OR 97402 Ph: 541.687.6869 www.leonovabyspm.com

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CORPORATE REPORT 2012

U.S. TSUBAKI POWER TRANSMISSION, LLC

.S. Tsubaki Power Transmission is a leading manufacturer and supplier of state-of-the-art power transmission and motion control products and a global leader in roller and conveyor chain production. U.S. Tsubaki is the largest global subsidiary of Japan’s Tsubakimoto Chain Company, which was founded in 1917. Today, Tsubaki products are marketed in over 70 countries. U.S. Tsubaki’s corporate headquarters and main distribution warehouse are just outside Chicago, in Wheeling, IL, and it runs full manufacturing facilities in Holyoke, MA, and Sandusky, OH. It also has strategically located service centers: in Los Angeles, CA, Dallas, TX, Atlanta, GA, Philadelphia, PA, Charlotte, NC, and Anoka, MN. The TSUBAKI name is synonymous with excellence in quality, dependability and customer service. An intense focus on research and development, along with constant modernization of its production facilities, are among the key components in Tsubaki’s ability to successfully meet the ever-changing needs of the marketplace. Leveraging its vast, international network of corporate and industrial resources, U.S. Tsubaki offers customers the finest power transmission products in the world. According to the company, it is well positioned to meet the challenges of the 21st century and beyond as it strives to be the “Best Value” supplier in the industry. Tsubaki’s global presence affords the company with unprecedented opportunities to market advanced new products and technologies, and to utilize the intellectual assets of what it characterizes as “some of the brightest minds in business and engineering from around the world.” This strength, combined with its continuous improvement of

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quality and processes, has U.S. Tsubaki poised for lasting growth now, and well into the future.

U.S. Tsubaki’s industrial group is currently comprised of four business units: the Roller Chain Division; Engineering Chain Division; Power Transmission Components Division (which includes Sprockets); and KabelSchlepp Cable & Hose Carrier Division. The Roller Chain Division provides some of the most versatile products on the market. Tsubaki innovations have yielded popular problem solvers such as self-lube Lambda® series chain, corrosion-resistant Neptune® chain, fatigue-resistant Super Chains and rugged Energy Series™ oilﬁeld chains and attachment chains. The Engineering Chain Division offers heavy-duty chains designed specifically to meet the demanding needs of a vast array of industries and prolong wear life under rigorous operating conditions. These products use various grades of steel, heat-treated to precise specifications and assembled with accurate press-fits to withstand

the requirements of today’s powerful, high-production equipment. Tsubaki Sprockets are built from top-grade, heat-treated carbon steel to offer long wear life, resist abrasion and withstand heavy shock loads. Precision manufacturing at our ISO-certified* facilities ensures that every U.S. Tsubaki sprocket stands up to critical design specifications and meets the highest quality standards. Tsubaki’s Power Transmission Components line includes all Tsubakimoto products other than chain and sprockets. A partial list includes belts, cam clutches, actuators, dampers, overload protection and reducers. The KabelSchlepp Division produces world-class cable and hose carriers in a wide range of sizes and types for a variety of environments. From our light-weight micro-sized mono cable carriers to our enormous super-duty steel chain designs, Tsubaki KabelSchlepp has the perfect solution for any application. Wherever shorter production times, faster installation, higher machine cycles, longer service life and better overall value are desired, Tsubaki KabelSchlepp can help. *Tsubaki is an ISO 9001:2000 and ISO 14000 registered company.

U.S. Tsubaki Power Transmission, LLC. 301 E. Marquardt Dr. Wheeling, IL 60090 Ph: 800.323.7790 www.ustsubaki.com

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CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

ALL-TEST PRO, LLC (ATP)

LL-TEST Pro, LLC (ATP), a subsidiary of BJM CORP, CT, is a privately held company established in 1983. The company manufactures handheld, battery-operated, portable instruments for the testing of motors, generators, transformers and other coil-based devices. Product family includes instruments for De-Energized testing (Motor Circuit Analysis-MCA), Energized testing (Electrical Signature Analysis-ESA), and Power Quality Analysis used for Predictive Maintenance testing, Quality Control, and Trouble-Shooting. We offer worldwide sales, service and training. The Power Quality Analysis includes an easy-to-use energy-saving calculation report. Versatility By being able to choose the particular ATP instrument for a customer’s need—be it just Troubleshooting or

more demanding Predictive Maintenance—the initial investment is very low and will produce a rapid Return on Investment for the contractor.

program. We know that contractors are perfectly positioned to offer these services, which will bring a new revenue stream to their businesses.

More than 12,000 instruments Sold ATP has sold over 12,000 instruments worldwide to be used daily in improving rotating equipment reliability, reducing energy consumption and lowering overall plant operating costs. Several instruments have received “Best Product” awards worldwide by distinguished associations and magazines.

ALL-TEST Pro Training ATP has been accredited as an “Authorized Provider” by the International Association for Continuing Education and Training (IACET), in McLean, VA.

Network of Contractors Electrical Motor System testing has become an important part of a successful rotating equipment reliability testing program but in fact, many potential customers are not capable of supporting an internal motor testing

ALL-TEST Pro, LLC P.O Box 1139 121 Spencer Plain Rd. Old Saybrook, CT 06475 Ph: 860.399.4222 or 800.952.8776 Fax: 860.399.3180 For more info, enter 271 at www.MT-freeinfo.com

AMERICAN TRAINCO

merican Trainco offers handson training in public-seminar and private on-site formats for maintenance personnel across industry. We cover hundreds of cities around the U.S. and Canada and will conduct more than 1500 sessions next year—making us the largest provider of this type of training in the world today. Since 2002, our expert staff has trained more than 135,000 maintenance workers. Among our most popular topics are “Basic Electricity for the Non-Electrician,” “Arc Flash Electrical Safety NFPA 70E,” “Electrical Troubleshooting,” “Air Conditioning & Refrigeration,” “Boiler Operation, Maintenance & Safety,” “Programmable Logic Controllers,” “Variable Frequency Drives,” “Pumps and Pump Systems,” “National Electrical Code,” “HVAC,” “Electrical Schematics and Drawings” and many more.

DECEMBER 2012 / CORPORATE REPORT

At American Trainco, we approach our students as if they were our own employees. We instruct and guide them in practical knowledge that allows them to immediately return to their workplaces and apply what they have learned. We make sure they can keep their plants or facilities up and running—and we make sure they can do it safely. For example, American Trainco doesn’t just provide textbook information and downloads about the National Electrical Code and NFPA 70E updates: Our instructors help our students apply that information to their own workplace and facility needs.

By providing exceptional learning experiences for our students and a positive work culture for our employees, American Trainco empowers individuals to become caring, competent and responsible citizens who value the positive contributions they make toward keeping our world running. American Trainco P.O. Box 3397 Englewood, CO 80155 Ph: 303.531.4560 Fax: 303.531.4565 www.AmericanTrainco.com For more info, enter 272 at www.MT-freeinfo.com

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CORPORATE REPORT 2012

KLUBER LUBRICATION

lüber Lubrication is one of the world’s leading manufacturers of specialty lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Klüber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which have earned it an excellent reputation in the market. The company holds all common industrial certifications and houses a test facility hardly rivaled in the lubricants industry. At Klüber, we continue to pioneer advances in order to translate previously inconceivable concepts into fully functional reality. We make these crucial contributions with over 2000

special lubricants that can be used in extreme operating or environmental conditions in vehicles, machinery or plant manufacturing, and in industrial engineering or production technology where conventional lubricants fail. When stringent technical and ecological requirements coincide, that’s where Klüber Lubrication’s special lubricants have the leading edge. For example, our specialty oils for ship-propulsion systems are classified as readily biodegradable and can be used in one of the world’s most sensitive ecosystems—the Arctic. Klüber Lubrication, set up as a retail company for mineral-oil products in Munich, in 1929, is part of Freudenberg Chemical Specialities KG, a Business Unit of the Freudenberg Group, Weinheim.

In 2011, Klüber Lubrication had approximately 1900 employees in more than 30 countries.

Klüber Lubrication North America L.P. 32 Industrial Dr. Londonderry, NH 03053 Ph: 603.647.4104 www.klubersolutions.com

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NSK CORPORATION

SK is a world-class manufacturer of motion and control products that help industrial customers maximize productivity, improve efficiency and overall performance. Through our 60 global manufacturing facilities and 12 global technology centers, we produce and distribute a wide range of bearing, linear-motion and automotive-component products for a variety of applications. NSK’s in-depth industry knowledge backs the design of products that address specific industry challenges. NSK’s HPS™ (High Performance Standard) Spherical Roller Bearing is one example of an innovative product that delivers unmatched quality and provides superior performance. Devel-

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oped using state-of-the-art materials and advanced production technologies, HPS Spherical Roller Bearings deliver 20% higher limiting speeds and approximately twice the operating life of conventional products. While NSK believes it is important to deliver exceptional performance for its customers, we also believe in strong corporate social responsibility (CSR). CSR activities impact the community and environment in which NSK conducts business. Our Quality and Environmental team ensures that the environmentally friendly products are used, chemical substance waste is managed, and reduce, reuse and recycle efforts are in place to offer energy and resource conservation. With these efforts,

NSK can continue to offer the best in quality products and performance to our customers, to our community and to the world. When it comes to maximizing performance, “Think NSK.”

NSK Corporation 4200 Goss Rd. Ann Arbor, MI 48105 Ph: 800.675.9930 www.nskamericas.com For more info, enter 274 at www.MT-freeinfo.com

CORPORATE REPORT / DECEMBER 2012

CORPORATE REPORT 2012

PdMA CORPORATION

hen you think of predictive maintenance, electric motor testing, condition monitoring, energy cost analysis or motor-circuit analysis training, if you don’t think of PdMA Corporation, you should! An industry leader and innovator, PdMA has over 20 years experience in the predictive maintenance and condition monitoring field. Our MCE™ (offline), Emax (online) and MCEmax™ (offline/ online) testers are utilized by a variety of industries around the world. All testers are designed to monitor and trend the condition of AC induction, synchronous, wound-rotor and DC motors and their circuits. Among the testing capabilities are: power quality, power circuit, stator, rotor, insulation and air gap. Designed to increase safety (PPE not required) and reduce connection time for

Group Meetings and free workshops are conducted throughout the year in locations around the world. Free video tutorials on the Six Fault Zones and other predictive-maintenance-related topics are available on the PdMA website (www.pdma.com).

A Leader In Electric Motor Testing

online motor testing, the MTAP2 TAP2 and MTAP3, MTAP3 motor test ports, allow you to capture data quickly to determine motor health. PdMA offers a variety of training courses, both at the user’s site and in our state-of-the-art-training facility in Tampa, FL. In addition to these training opportunities, Regional User

PdMA Corporation 5909-C Hampton Oaks Parkway Tampa, FL 33610 Ph: 800.476.6463 www.pdma.com

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PREDICTIVE SERVICE

redictive Service provides solutions for maintenance, reliability and sustainability to facility owners, operators and manufacturers around the world. We accomplish this by deploying unique technologies, thought processes, people, products and services, utilizing a collaborative and customized approach to maximize our clients’ results. A Global Team, Delivering Services Locally Predictive Service focuses on a complete spectrum of engineering and consulting services, predictive maintenance technologies, equipment efficiency and reliability, energy management and repair solutions. Our products and services are supported by patented technology and

DECEMBER 2012 / CORPORATE REPORT

a highly skilled, global team of professionals, delivering services locally. This combination of resources and methods ensures superior program management and actionable knowledge, thus enabling our clients to operate their facilities and equipment efficiently, maximizing their value, and thereby sustaining long-term partnership relationships. Why Clients Choose Predictive Service: ■ Broad range of product offerings and expertise ■ Integrated, customized solutions from highly-skilled professionals ■ Unique, patented technology to support our collaborative and customized approach ■ Superior program management with actionable knowledge and solutions

■ Documented KPI’s supported by true

Return on Investment ■ Dedication to long-term partnership

relationships

Predictive Service 25200 Chagrin Blvd. Cleveland, OH 44122 Ph: 866.772.6770 www.predictiveservice.com

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CORPORATE REPORT 2012

PROCESS INDUSTRY PRACTICES (PIP) process industry e are a consortium of process membership encompasses 67 companies,practices ■ Process Control & Analyzers plant owners and engineerplus 63 additional subscriber and licensee ■ Vessels/Exchangers/Tanks inga construction PIP members2009 share PIP’s the goal e are consortiumcontractors of process companies. As of November active Specific Practices include design, plant owners and engineering membership encompasses 55 compa-Specifi selection, specification, and installaharmonizing member companies’ internal of reducing total installed costs of process c Practices include design, selection, construction contractors harmonizing nies plus 46 additional subscriber and tion information. PIP has published standards for design, procurement, plants by up to 6% through the implemenspecification and installation information. member companies’ internal licensee companies. PIP Members over 460 Practices. A current listing of construction and design, maintenance into a set tation of common industry published over 475isPractices. standards for procurement, share the goal of practices. reducing totalPIP has published Practices available at of industry-wideand practices for voluntary listing of published Practices is construction, maintenance into a installed costs of process plants by upA current www.pip.org. set As of ofindustry six percent through the implemen-available at www.pip.org. use. Novemberwide 2012,practices PIP’s activefor Ourto Practices voluntary use. tation practices. Organized of in common 1993, PIPindustry is a separately Process Industry Practices funded, non-profit initiative operating 3925 West Braker Lane (R4500) Our Practices Austin, TX 78759 Organized in 1993, is a separately under the umbrella of thePIP Construction 512.232.3041 funded non-profit initiative operating Industry Institute at The University of Texas www.pip.org under the umbrella of the Construcat Austin. PIP publishes andatmaintains tion Industry Institute The Univerrecommended Practices for the sity of Texas at Austin. PIPprocess publishes and in the maintains recommended industry following disciplines: Practices in the following disciplines: ■ Civil/Structural/Architectural • Civil/Structural/Architectural ■ Coatings/Insulation/Refractory Process Industry Practices • Coatings/Insulation/Refractory Adopting ■ Document Management 3925 West Braker Lane (R4500) • Electrical • Machinery ■ Electrical Austin, TX 78759 Process Industry • Piping & Instrument Diagrams Engineering ■ Machinery Ph: 512.232.3041 Procurement • Piping ■ Piping & Instrumentation Diagrams www.pip.org Construction Process • Process Control & Analyzers • Vessels/Exchangers/Tanks For more info, enter 277 at www.MT-freeinfo.com ■ Piping

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PIP Practices

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BAKER INSTRUMENT CO.

otors drive industry and, ultimately, drive the success of corporations and organizations all over the world. Maintenance professionals need to ensure that the motors their companies depend upon are running optimally. To make good decisions about maintenance or repair, they need the best information they can obtain about their motors’ condition. Baker Instrument Co. (an SKF Group Company) designs, manufactures and markets electric-motortesting equipment that helps maintenance professionals, repair shops and motor-manufacturing operations maintain and repair equipment at a minimum of cost and effort. For example, the Baker AWA-IV and Baker DX series of instruments

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perform a comprehensive array of insulation and circuit tests on off-line (powered-down, or static) motors to discern any problems that would cause motor failure and unplanned downtime. The SKF Dynamic Motor Analyzer – EXP4000 is the latest in a line of motor-monitoring equipment pioneered by Baker in the late 1990s. The EXP4000 helps troubleshoot motor/machine systems by monitoring the quality of power fed to a motor, the unit’s performance and the quality of the load placed upon it. Another example, the SKF Online Motor Monitoring System – NetEP/iNet, provides continuous visibility into motor/machine health 24/7/365 from the comfort of an office or any location with an Internet-accessible computer.

For rock-solid quality assurance and condition monitoring of the electric motors and generators that your operations depend on, there’s an electricmotor test or monitoring instrument to acquire and analyze vital information. Baker Instrument and SKF have just what you need to keep your equipment up and running properly.

Baker Instrument Co. An SKF Group Company 4812 McMurry Ave. Fort Collins, CO 80525 Ph: 800.752.8272 www.skf.com For more info, enter 278 at www.MT-freeinfo.com

CORPORATE REPORT / DECEMBER 2012

MAINTENANCE LOG

Oil Analysis Helps Keep The Trains Running A national railway system got a good look at what state-of-the-art condition monitoring can do for an operation.

MEXRIX窶認OTOLIA.COM

Special To MT From Spectro, Inc.

DECEMBER 2012

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MAINTENANCE LOG

ased in Tullow, Ireland, T.E. Laboratories ("the Laboratories"), provides oil, fuel and environmental analysis services for a variety of customers, including Irish Rail, Ireland's national railway system. It regularly uses equipment from Spectro, Inc., including the Spectroil Q100 spectrometer. When the analysis of oil samples from a main locomotive showed a large amount of severe wear particles–– indicating that a catastrophic failure was imminent––Irish Rail took the Laboratories’ advice and brought the engine in for repair. An overhaul showed chunks of metal visible to the naked eye in the sump and that the bearings were about to fail. In this case, oil analysis saved the railroad both the expense of a more extensive engine overhaul and potential expenses associated with a breakdown. The tally of these avoided costs more than paid for the cost of oil analysis for Irish Rail’s entire fleet for a year.

The power of oil analysis From a custom, 40,000-sq.-ft. facility, T.E. Laboratories provides a machine-care predictive-maintenance system based on condition monitoring through oil analysis. For machine operators, the process is easy: They need spend only a few minutes to obtain an oil sample and ship it to the lab for identification of potential problems. These include abnormal wear in lubricated metallic components, dirty fuel and coolant contamination. Using oil analysis, machinery can be analyzed over a period of time to identify trends that can be used to plan maintenance based on actual need as opposed to simple intervals of time. The Laboratories’ services include transformer oil analysis, fuel analysis for microbial contamination and water and soil analysis. Regular customers include trucking, rail and marine shipping fleets; mining, quarrying and construction operators; industrial units; manufacturing plants and heavy-equipment operators. 44 |

MAINTENANCE TECHNOLOGY

Visible chunks of metal in the sump of the disassembled engine

DECEMBER 2012

MAINTENANCE LOG

“As the only oil analysis lab in Ireland, we handle a large number of samples and must deal with them efficiently,” says Mark Bowkett, T.E. Laboratories’ General Manager. Recent upgrades at the company include implementation of the SpectroTrack laboratory information management system that replaced the company’s former “home-grown” system. SpectroTrack offers the built-in ability to interface with the Spectro, Inc., line of viscometers and spectrometers. It can also integrate with instruments from other suppliers for vibration, thermographic and performance data. The database is configured to track asset information relating to service intervals, maintenance actions, locations, status and other issues. SpectroTrack also provides the Laboratories’ customers with security-protected access to their sample results. “The railroad makes extensive use of SpectroTrack Web access to obtain their test reports and to plan maintenance,” says Bowkett. “However, we don’t wait for customers to notice a problem. When we see something bad, we immediately notify them.” For example, a recent analysis of 18 different wear metals on a liquid-cooled diesel locomotive engine revealed several warning signs. According to the Laboratories’ report, the analysis uncovered “the presence of large sliding wear steel particles and some dark metallooxides,” which indicates “a transition from normal to severe sliding wear and likely due to insufficient lubrication.” Additional problems were also noted. These results “were worrisome, but not necessarily cause for immediate action,” says John McGrath, Sales Manager for T.E. Laboratories. But a closer look at the sample was ordered using the SpectroT2FM Q500 analytical ferrography laboratory. This technology uses a bichromatic microscope, video camera and image capture software for the separation and interpretation of wear and contaminant particles in used oils, hydraulic fluids, coolants and fuels. A bichromatic microscope equipped with both reflected (red) and transmitted (green) light sources was used to view and examine ferrograms so that the ferrogram could be illuminated from both above and below the microscope stage. With bichromatic illumination, metal particles that

reflect light appeared bright red, while nonmetallic particles appeared green (because light transmits through them). The ferrogram indicated that the problem had, in fact, reached an urgent stage. It showed a moderate to heavy amount of severe copper and white metal wear particles and a moderate amount of dark-metalloxides. These elements indicate lubricant starvation and abnormal wear. Red oxides

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were also present, which indicates water ingress. The analysis also showed large abnormal sliding wear particles in excess of 20 microns, copper chunks in excess of 20 microns, nonmetallic crystalline particles including silica and rust, low alloy steel fatigue particles and cast iron fatigue chunks from a case-hardened part. “The particles seen in the ferrogram were quite large and of a critical nature,” says McGrath. “The engine was on the verge of destroying itself. It needed to be brought in for an immediate overhaul.” When the engine was disassembled, he says, “It was obviously on the verge of a breakdown.” MT-ONLINE.COM | 45

MAINTENANCE LOG

Ferrogram image showing dark metallo-oxides indicative of abnormal wear

A bearing from the engine on the verge of failure Large copper chunk seen in ferrogram image

Bowkett believes in the use of cost-efficient oil analysis to prioritize maintenance by avoiding spending money on units that have reached a scheduled milestone, but don’t need maintenance. At the same time, he observes, regularly scheduled oil analysis can point out units like the one described above that urgently need maintenance, even though they’re not due for service. According to Bowkett, while it may not be possible to estimate the total amount of money saved in the above case by oil analysis, “It’s clearly well above the cost of the company’s oil-analysis program for its entire fleet.” MT Spectro, Inc. Chelmsford, MA For more info, enter 04 at www.MT-freeinfo.com

Cast iron fatigue chunk seen in ferrogram image

46 |

MAINTENANCE TECHNOLOGY

DECEMBER 2012

Go For It!

Are your innovative juices flowing? Are your light bulbs going off? They better be!

Categories: ÂŠ

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Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources

Presented By

Applied Technology Publications

Details & Entry Forms Available At www.reliabilityinnovator.com

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Hidden Failures In Synchronous Motors Howard W. Penrose, Ph.D., CMRP Vice President, Dreisilker Electric Motors, Inc.

MOTOR DOC’S HOT TOPICS

ou’d think that a common testing method (i.e., in practice for well over a century and referenced in testing standards) shouldn’t have to be identified as something you need to verify through repair and troubleshooting. But it is. Slight torsional vibration causing problems in machines attached to a synchronous motor, trouble starting, cracked amortisseur windings, broken couplings and the inability to maintain synchronous speed should signify potential problems in a rotor circuit. These may include problems in the excitation circuit, failed/failing diodes in the rotating rectifier or rotating fields that are shorted, open or grounded. For purposes of this article, we’ll discuss a simple method for evaluating rotating fields. The unbalance test must be performed with power to the stator tagged-out and—preferably—the rotor out of the stator and isolated from other coils or large metal objects that could influence test results. The rotor should be insulation-resistance tested and must be over 100 MegOhms at either 500Vdc or 1000Vdc applied. A 120 Volt source is applied to the rotor leads, and voltage is read across each of the field coils. The values should be actual supply voltage divided by the number of coils. If there are six coils at 120 Vac, the voltage drop across each coil should be 20 Vac. The maximum unbalance is +/- 5% with coils that are showing a significant unbalance being shorted and coils showing no voltage drop being open. Why AC Voltage applied? Most rotating fields will degrade from the inside of the coil toward the outside. Basic insulation breakdown will leave air gaps and resistances high enough that they can’t be detected by simple DC resistance or applied DC Voltage: You need an alternating current to “jump the gap” and show the short. This test, and others, must be insisted on during the repair process (and all can be referenced to IEEE Standard 115-1995, “IEEE Guide: Test Procedure for Synchronous Machines”). Don’t assume your repair center is following this standard or the common test procedures for synchronous machines. Ask to see the data. I’ve done this myself—when a machine operated no differently than when it was originally pulled from service—and discovered even a manufacturer’s repair shop had not performed these tests after a salient pole generator was returned to service for a life-critical system! MT Dr. Howard Penrose is VP of Engineering and Reliability Services for Dreisilker, Webmaster of the IEEE Dielectrics and Electrical Insulation Society, and Director of Outreach of the Society for Maintenance & Reliability Professionals (SMRP). For more info, enter 05 at www.MT-freeinfo.com

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TECHNOLOGY SHOWCASE

Electrical Equipment Solutions Energy-Monitoring For Motor Control Centers Energy-Saving Solutions Platform

ockwell Automation has announced the addition of new energy intelligence capabilities in several of its software applications to help users monitor resource consumption by specific units, lines and machines. Among them is IntelliCENTER Energy that offers a preconfigured setup of FactoryTalk EnergyMetrix software for intelligent devices in motor control centers (MCCs), including variable speed drives, overload relays and SMC controllers. Users can view real-time energy consumption and historical trending at the device level directly from IntelliCENTER software, which in turn can simplify the tasks of monitoring and managing energy usage and help integrate motor control centers into plant-wide energy-management systems. Rockwell Automation Milwaukee, WI For more info, enter 06 at www.MT-freeinfo.com

raybar’s comprehensive set of energy-saving solutions can help facility owners reduce costs and meet environmental goals. Known as Graybar PowerSmart, the platform’s five components include building automation and controls; power management and critical power; lighting and lighting controls; renewables and Graybar services. Across these categories, Graybar has relationships with leading manufacturers to provide products and solutions to meet customer needs. Graybar Services, Inc. St. Louis, MO

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UPS Optimizes IT System Availability

aton has launched the 9PX uninterruptible power system (UPS) for 5 to 11 kilovolt-ampere (kVA) applications. Providing approximately 28% more power than traditional UPSs, the 9PX is bundled with a network card and Eaton’s Intelligent Power Software Suite™, which lets users monitor/manage an entire power system from a single dashboard or via several major virtualization platforms. Eaton’s ABM® technology optimizes battery recharge time, eliminates overcharging and continuously monitors battery condition to extend service life by 50%. A two-year warranty covers all Eaton 9PX UPS units and batteries.

Avoid Arc Flash Accidents Safety is serious, but it doesn’t have to be complicated. Look to Graybar for: Plant-Wide Safety Audit Provisions Lockout/Tagout Provisions Arc Flash Analysis Personal Protective Equipment Plant Safety MRO Supplies Learn more at graybar.com/MT-6.

Eaton Corp. Raleigh, NC For more info, enter 08 at www.MT-freeinfo.com

50 |

MAINTENANCE TECHNOLOGY

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TECHNOLOGY SHOWCASE

Advanced, Easy-To-Install Overvoltage Protection

ersen’s Surge-Trap® Pluggable Surge Protection Device (SPD) provides advanced overvoltage protection by utilizing the company’s patented TPMOV® technology. According to the manufacturer, the product requires no fuses, fuse holder or additional wiring to meet the UL 1449 Third Edition standards, thus providing substantial cost savings and reduced installation times. The Surge-Trap Pluggable SPD base has been designed for mounting on 35mm DIN-rail. Plugs can be easily replaced upon failure without touching the base or rewiring. The fail-safe/self-protected/IP20 finger-safe design incorporates a visual indicator, mechanical coding and remote monitoring capabilities. Applications include AC/DC distribution, industrial automation, power supplies and power-transfer equipment, motor control centers and starter systems and HVAC operations, among others. Mersen Newburyport, MA For more info, enter 09 at www.MT-freeinfo.com

MAXIMUM LONGEVITY. MAXIMUM PRODUCTIVITY. MAXIMUM PERFORMANCE.

HPS SPHERICAL™ ROLLER BEARINGS NSK’s HPS Spherical™ Roller Bearings are engineered with an optimum raceway design and strengthened steel cage to offer 20% higher limiting speeds, and approximately twice the operating life of conventional products. Their state-of-the-art material technology offers the highest load rating and makes them ideal for a wide variety of applications. For maximum longevity, maximum productivity and maximum performance, Think NSK. 1.88ThinkNSK (888.446.5675) BALL BEARINGS

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MT-ONLINE.COM | 51

It Takes One...

An Innovator That Is!

The Innovators At Presented By

Applied Technology Publications

Scalewatcher North America, Inc. Oxford, PA www.scalewatcher.com

Developed and patented in the Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher™ technology was introduced to the European market in the 1980s. Based on its immediate market success, Mr. Doelman brought the technology to the United States, whereupon he applied for and received a patent in 1991. From that point on, Scalewatcher North America has been on the forefront of environmentally sensitive water treatment. Scalewatcher’s innovative products are no-maintenance, environmentally friendly descalers that do not change water composition. Scales and stains disappear gradually and completely, without further action required, guaranteed. The units work by way of magnetic and electric fields and a continuously changing frequency. The process forces dissolved minerals such as calcium and magnesium to crystallize before mineral ions (the cause of hard scale) can settle on surfaces. This stops or reduces buildup of hard scale, and because the water is better able to dissolve minerals, existing hard-scale layers are softened and eventually disappear. Scalewatcher technology has been used by more than 250,000 satisfied customers worldwide. These maintenance-free products prevent corrosion in pipework; prevent settlement of zebra mussels in plants using sea or river water for cooling; reduce bacterial counts in cooling systems; reduce water and energy bills; extend the life of water-using equipment (especially boilers); can be installed without plant shutdown; and last 20+ years.

The Innovators At Scalewatcher will award individual water-treatment units to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 83 at www.MT-freeinfo.com

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To Know One

Are You One? You Could Win An All-Expense Paid Trip To MARTS 2013 & More

The Innovators At Presented By

Dreisilker Electric Motors, Inc. Glen Ellyn, IL www.dreisilker.com

Applied Technology Publications

Henry Dreisilker came to America from Germany in 1954 seeking opportunity and gainful employment. Hard work and integrity landed him his first job in a small motor repair and appliance business. Seven months later, he purchased the business, founded Henry Dreisilker Electric Motors and Appliance Service and began by specializing in commercial motor repair and sales. Combining old-world craftsmanship with advanced technology, the company grew steadily from three employees to over 120. Today, Dreisilker Electric Motors, Inc. provides complete electric motor solutions to commercial, industrial and municipal customers nationwide. It distributes new electric motors, parts, accessories and controls from major OEMs and offers a range of value-added, reliability-related services. Among its many offerings is Dreisilker Total Motor Management (DTM2), a comprehensive program that incorporates expert technical coordination of an operation’s motor database, inventory recommendations, energy analysis, repairversus-replacement decisions, exchange motor options and maintenance training on motor systems. Expert field technicians are available for scheduled maintenance or to respond quickly to emergencies 24/7/365. The company’s innovative and exclusive Motor-Safe™ Repair 2.0 process uses special induction technology stripping, accurate and precise rewinding, advanced varnishing, dynamic balancing and thorough testing. Dreisilker never uses the “burnout oven” methods practiced by other motor shops. Motors repaired by Dreisilker improve reliability, increase uptime and save energy. The reliability of your motors, in turn, translates directly into productivity and profitability.

The Innovators At Dreisilker will award individual iPads to the 2012 Maintenance & Reliability Innovator of the Year and 3 Runners-Up For more info, enter 84 at www.MT-freeinfo.com

Get Details & Entry Forms At www.ReliabilityInnovator.com

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CAPACITY ASSURANCE MARKETPLACE

Oxygen Sensor For Flue Gas Analyzers

he OXeco LP sensor from City Technology was developed to improve accuracy, operational life and resistance to cross-contamination in flue gas analyzers. The 4OXeco LP low-power version is for use in portable equipment, and is produced in an industry-standard 4 Series form factor to ensure mechanical compatibility with existing instrument designs. According to the company, its lead-free toxic gas sensor technology reduces response and recovery times, and can eliminate field failures. City Technology Ltd. A Honeywell brand Des Plaines, IL

Portable Speed-Lathe Platform

he “Building Block” platform Model 30DC-BB from Crozier Machine Tool Co. can be mated with the company’s Model 30DC Speed Lathe to become a mini-machining cell suited for many second operations. Using a rigid T-slotted base for mounting, the portable platform is ideal for deburring, gauging, finish sanding, inspection, lapping, turning, assembly or light dry machining of any part that can be held by a collet. Crozier Machine Tool Co. Gardena, CA

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A Leader in Electric Motor Testing

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56 | MAINTENANCE TECHNOLOGY

DECEMBER 2012

CAPACITY ASSURANCE MARKETPLACE

Guide To Preventing Environmental Degradation

he Handbook of Environmental Degradation of Materials explains how to measure, analyze and control environmental degradation for a range of industrial materials, including metals, polymers, ceramics, concrete, wood and textiles. Environmental factors such as weather, seawater and fire are explained using case studies from pipeline operations, tankers, packaging and chemical processing. For each material, the book describes the kinds of degradation that affect it and how to best protect it. Research and Markets Ltd. Dublin, Ireland

Wireless Vibration Monitoring With Cloud Capabilities

martDiagnosticsÂŽ from KCF Technologies is a low-cost suite of wireless sensors for vibration monitoring of industrial machinery. With the release of version 1.2, KCF has added Cloud capabilities to the suite. The functionality adds a pre-configured collection server to deliver data to the user from a centrally located system in the Cloud, allowing implementation with minimal training and expertise. Also new is the ability to set up e-mail or text alerts to warn users of potential failures.

KCF Technologies State College, PA

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C^ [TPa] \âT PQ^dc bcPcXR \^câ cTbc T`dX_\T]c Ua^\ B:5 RP[[ B:5 2^]SXcX^] <^]XcâX]V 2T]cTa 5âc 2^[[X]b Pc ' &$! '!&! â eXbXc db ^][X]T Pc Wcc_) fff QPZTaX]bc R^\

CWT ?^fTa ^U :]^f[TSVT 4]VX]TTaX]V For more info, enter 87 at www.MT-freeinfo.com

DECEMBER 2012

MT-ONLINE.COM | 57

CAPACITY ASSURANCE MARKETPLACE

Air-Filtration Systems That Capture Oil Mist

Bio-Based Grinding Oil

astrol Performance Biolubes NuCut Grind is a light viscosity, high-performance cutting oil specifically designed for the grinding of ferrous and non-ferrous metals. Formulated with high-quality, plantbased oils and select additives, the product’s high levels of lubricity help it outperform conventional mineralbased grinding oils, according to the company. Intended for general-purpose surface and centerless grinding, it offers reduced levels of mist and improved centricity, accuracy and part run-out.

lean Air America’s ScandMist air-filtration systems are intended for the capture and removal of oil mist from manufacturing facilities. The most recent additions to the line, the ScandMist 70D and 100D, are compact solutions for keeping air clean in any size plant. The systems feature fiber-bed technology that allows oil mist to condense on filter fibers, where it collects to drain into a reservoir for future collection. An optional variable frequency drive measures air speed through the filters and helps boost efficiency. Clean Air America, Inc. Rome, GA

Castrol Industrial Naperville, IL

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Training for Industrial, Facility & Building Maintenance Go Online and See Our Entire 2013 Training Schedule! Arc Flash Electrical Safety NFPA 70E®

Air Conditioning & Refrigeration

PLCs for Non-Programmers

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Boiler Operation, Maintenance & Safety

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58 | MAINTENANCE TECHNOLOGY

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DECEMBER 2012

Heavy-Duty Lubricant For Drawing And Stamping

oughto-DrawÂŽ 7060-B from Houghton International, Inc., is a heavyduty, bio-stable lubricant that can be used for drawing and stamping a variety of metals such as high- and low-carbon steel and alloy steels. Formulated for use on yellow metals, the lubricant is water-soluble, protects metals without staining and provides corrosion protection with in-process protection of machinery parts. It can also increase tool and die life and improve surface finish.

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Houghton International, Inc. Valley Forge, PA For more info, enter 37 at www.MT-freeinfo.com

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CAPACITY ASSURANCE MARKETPLACE

Portable Cooling Unit

he Port-A-Cool® Hurricane portable evaporative cooling unit uses high-efficiency cooling pads and water to cool up to 3500 square feet and lower temperatures by up to 30 degrees F. Its design provides 67-gallon water capacity and 14,500 CFM which the company claims is the largest airflow delivery of any 36-inch evaporative cooler offered. It requires 11.4 amps for pump and motor operation. Additional features include a digital control panel with touch buttons for operation and status displays. Port-A-Cool, LLC Center, TX

DIN Rail And Head-Mounted Temperature Transmitters

el-Tru’s line of factorycalibrated analog temperature transmitters is available in configurations for RTD Pt100 or J, K, T, or E Thermocouple inputs, all with linear loop-powered 4-20mA output. Precision 20-turn potentiometers allow fine adjustment of zero and span. Available in a variety of configurations to meet demanding applications, the transmitters can be DIN-rail-mounted or mounted into industry-standard connection heads. Tel-Tru Manufacturing Co. Rochester, NY

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*Call for details.

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60 | MAINTENANCE TECHNOLOGY

info@atplists.com esandkam@atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 For more info, enter 87 at www.MT-freeinfo.com For more info, enter 92 at www.MT-freeinfo.com

DECEMBER 2012

CAPACITY ASSURANCE MARKETPLACE

Wiring Devices For Extreme Environments

Mobile App For AODD Pump Users

new Versa-Matic mobile application supports its Air Operated Double Diaphragm (AODD) pumps. It can help pump owners find the tools needed to support pumps installed in the field, as well as pumps currently being built and shipped. Information related to a specific pump can be found through bar-scanning or by manual entry. Additional features include an interactive guide to chemical compatibility, the latest full-line catalogs, service and repair training videos and more. Versa-Matic A Warren Rupp, Inc., Brand Mansfield, OH For more info, enter 40 at www.MT-freeinfo.com

oodhead’s Watertite® WetLocation Wiring Devices are intended for extreme and wet environments, and meet NEMA type 4, 4X, 6, 6P, IP65, IP66 and IP67. Products include closure caps, compression-type cord grips and single, duplex receptacles. The devices can withstand high-pressure hose-downs up to 1000 PSI, making them suited for use in processing and water-treatment plants. They include multiple ring seals that lock snugly to protect against moisture and contaminants. Woodhead Electrical Products A Molex Industrial Products Group Brand Lincolnshire, IL For more info, enter 41 at www.MT-freeinfo.com

“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 info@engtechindustries.com

For more info, enter 82 at www.MT-freeinfo.com

DECEMBER 2012

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MT-ONLINE.COM | 61

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: jpreston@atpnetwork.com Web Spotlight: Ludeca

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 95 at www.MT-freeinfo.com www.airsentry.com

LUDECA, INC. - Preventive, Predictive and Corrective Maintenance Solutions including laser shaft alignment, pulley alignment, bore alignment, straightness and flatness measurement, monitoring of thermal growth, online condition monitoring, vibration analysis and balancing equipment as well as software, services and training. For more info, enter 94 at www.MT-freeinfo.com www.ludeca.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 97 at www.MT-freeinfo.com www.graceport.com/3mt_informationhighway

CLASSIFIED

RENEW

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

For more info, enter 98 at www.MT-freeinfo.com www.kabelschlepp.com

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 96 at www.MT-freeinfo.com www.pip.org

The Maintenance & Reliability Technology Summit is the #1 learning venue and source of practical solutions for anyone concerned with the reliability, maintenance and the overall capacity assurance of critical equipment systems in a plant or facility. Mark your calendars! MARTS 2013 is taking place April 30-May 3, 2013 at the Hyatt Regency O’Hare in Rosemont, IL. For more info, enter 99 at www.MT-freeinfo.com www.MARTSConference.com

For rate information on advertising in the Classified Section contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: jpreston@atpnetwork.com

ATP List Services

In order for us to send

Customized, Targeted Lists For Your Marketing Needs

to you FREE,

www.atplists.com

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

MAINTENANCE TECHNOLOGY

You may renew online at

www.mt-online.com 62 | MAINTENANCE TECHNOLOGY

info@atplists.com esandkam@atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010

DECEMBER 2012

Index ADVERTISER

December 2012 Volume 25, No. 12

DECEMBER 2012 Volume 25, No. 12 •

WEB ADDRESS

Your Source For CAPACITY ASSURANCE SOLUTIONS

RS #

PAGE #

Air Sentry .....................................................................www.airsentry.com ................................................ 95 .............................62 ALL-TEST Pro, LLC...................................................www.alltestpro.com/c/247 .................................... 69 .............................12 ALL-TEST Pro, LLC...................................................www.alltestpro.com ............................................... 271 ...........................39 American Trainco.......................................................www.americantrainco.com .................................. 88,272................58,39 ATP Lists.......................................................................www.atplists.com ................................................... 92 .............................60 Baldor Electric Company..........................................www.baldor.com .................................................... 61,260..............IFC,28 Des-Case Corporation...............................................www.descase.com................................................... 63,261...................2,29 Dreisilker Electric Motors Inc...................................www.dreisilker.com................................................ 79,84..................49,53 Engtech Industries Inc. ..............................................www.engtechindustries.com ................................ 93 .............................61 Fluid Defense...............................................................www.oilsafe.com/workflow.................................. 66 ...............................5 Fluid Defense...............................................................www.fluiddefense.com.......................................... 262 ...........................30 Fluke..............................................................................www.fluke.com/vibrationmeter .......................... 70 .............................19 Fluke..............................................................................www.fluke.com/233............................................... 263 ...........................31 General Electric Company - Energy .......................www.ge-mcs.com/bently ...................................... 62 ...............................1 General Electric Company - Energy .......................www.ge-mcs.com/scout........................................ 100 ........................IBC Grace Engineered Products. Inc...............................info.graceport.com/mt_evolv .............................. 76 .............................45 Grace Engineered Products. Inc...............................info.graceport.com................................................. 97 .............................62 Graybar Electric Company .......................................www.graybar.com/mt-5 ........................................ 71 .............................21 Graybar Electric Company .......................................www.graybar.com/mt-6 ........................................ 81 .............................50 Graybar Electric Company .......................................www.graybar.com .................................................. 264 ...........................32 Innovator Of The Year Award ..................................www.reliabilityinnovator.com ............................. 77 .............................47 Kluber Lubrication North America ........................www.klubersolutions.com/sustainability2 ........ 73 .............................24 Kluber Lubrication North America ........................www.klubersolutions.com/wind3....................... 74 .............................25 Kluber Lubrication North America ........................www.klubersolutions.com.................................... 273 ...........................40 Ludeca Inc....................................................................www.ludeca.com .................................................... 75,94,265, ....26,62,33 MARTS-Applied Technology...................................www.martsconference.com.................................. 85,99..................54,62 Meltric Corporation ..................................................www.meltric.com................................................... 80 .............................50 Miller-Stephenson Chemical Co. ............................www.miller-stephenson.com ............................... 64 ...............................4 Milwaukee Electric Tool Corporation ....................www.milwaukeetool.com/thermal-imaging..... 67 ...............................7 Milwaukee Electric Tool Corporation ....................www.milwaukeetool.com ..................................... 266 ...........................34 Nidec Motors ..............................................................www.usmotors.com............................................... 72,267................23,35 NSK Corporation.......................................................www.nskamericas.com.......................................... 82,274................51,40 Palmer Wahl Instrumentation Group ....................www.palmerwahl.com .......................................... 91 .............................60 PdMA Corporation ...................................................www.pdma.com ..................................................... 86,275................56,41 Predictive Service ........................................................www.predictiveservice.com.................................. 90,276................59,41 Process Industry Practices.........................................www.pip.org ............................................................ 89,96,277 .....59,62,42 Scalewatcher ................................................................www.scalewatcher.com ......................................... 78,83,268 .....48,52,36 SKF CMC-Fort Collins .............................................www.bakerinst.com ............................................... 87,278................57,42 SPM Instrument, Inc. ................................................http://www.spmhd.com........................................ 101 .........................BC SPM Instrument, Inc. ................................................www.spminstrument.com.................................... 269 ...........................37 Strategic Work Systems, Inc......................................www.swspitcrew.com ............................................ 65 ...............................4 U.S. Tsubaki Power Transmission, LLC ..................time4lambda.com .................................................. 68 ...............................9 U.S. Tsubaki Power Transmission, LLC ..................www.ustsubaki.com............................................... 270 ...........................38 U.S. Tsubaki Power Transmission, LLC ..................www.kabelschlepp.com......................................... 98 .............................62 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.

DECEMBER 2012

1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603

SALES STAFF OH, KY, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com AL, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com IA, MN, NE, ND, SD 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x116; Fax 847-304-8603 BILL KIESEL bkiesel@atpnetwork.com CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059 Osterville, MA 02655 508-428-3331; Fax 508-428-2545 VINCENT LeGENDRE vlegendre@atpnetwork.com IL, IN, MI, WI 1173 S. Summit Street Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-3534; Fax 972-767-4442 GERRY MAYER gmayer@atpnetwork.com AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com CLASSIFIED ADVERTISING 3605 N. Tuscany Mesa, AZ 85207 480-396-9585 JERRY PRESTON jpreston@atpnetwork.com

MT-ONLINE.COM | 63

viewpoint Jeff Eger, Executive Director, Water Environment Federation (WEF)

Rebuilding Our Water Infrastructure

s members of the water profession—or simply as water users—I believe we can all agree that we are at a critical point for water. We can no longer afford to ignore or push aside the state of our water and wastewater infrastructure as every American company, job and citizen is dependent on this vital resource and the vast network of pipes, utilities and reservoirs that supports it. More than 800,000 miles of water pipes and 600,000 miles of sewer lines support America’s private and public water consumption. Major renovations are needed in water and wastewater infrastructure across the United States. Much of this infrastructure was created a century ago and is no longer operating at an efficient level. Aged pipes and plants are fast approaching a critical point where immediate action needs to be taken. If money and time fails to be committed toward our water and wastewater utilities, Americans are likely to face service disruptions, water main breaks and threats to public health. With millions of Americans out of work, now is the perfect time to focus on our water infrastructure. The National Association of Utility Contractors (NAUC) estimates that every $1 billion invested in water infrastructure represents 26,000 possible jobs. The NAUC also estimates that every public dollar invested in America’s water structure produces a $6.35 private long-term GDP. The value of job creation in water infrastructure has been seen by the Department of Commerce (DOC), as well. The DOC recently said that each job created in the local wastewater industry contributes 3.68 jobs to the national economy and economic value across multiple industries. Clean water and wastewater services support $50 billion per year in the recreation industry, $300 billion in coastal tourism and $45 billion in the fishing industry, among others. We cannot deny the impact that investment in our water infrastructure has on job creation. Public safety depends heavily on well-functioning water and wastewater utilities. Clean water and

sanitation have saved countless lives in the U.S. While water-related diseases like cholera and dysentery may no longer pose a significant threat to our nation’s health, spills from aging, underfunded infrastructure are a growing problem. Severe, “new normal” weather events—such as Hurricane Sandy—further demonstrate the necessity of a reliable water infrastructure.

It’s been estimated that each job created in the local wastewater industry contributes 3.68 jobs to the national economy. If there is a single issue on which all political platforms should agree, I believe water safety is it. The quality of life our nation is dependent upon demands the preservation of clean, safe drinking water that is accessible to all. Furthermore, innovative technologies are fueled by resilient infrastructure and serve to keep America competitive. As our leaders look to the future, please keep in mind the promises made during this last campaign cycle. In their 2012 election platforms, both the Democratic and Republican parties promised to attend to the nation’s water supply and ensure that it remains clean and dependable. I urge you to hold our leaders accountable for keeping rural water and sewer infrastructure front and center. The Obama Administration’s investment in rural water and wastewater infrastructure projects thus far has already safeguarded the health of 18 million residents and resulted in job creation. Let’s keep this momentum going and continue to move America forward. For more information on this topic, please visit www.waterforjobs.org. MT

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.

64 | MAINTENANCE TECHNOLOGY

DECEMBER 2012

GE Measurement & Control

Take a walk with us. With improved ergonomics for faster and easier walk-around data collection, GEâ&#x20AC;&#x2122;s Bently Nevada* line introduces the SCOUT series, an amazing new lineup of portable vibration analyzers. Based on a design with a proven track record of quality and innovation, the SCOUT platform has been engineered from the ground up to deliver better reliability, accuracy, and usability. Its powerful combination of intuitive operation, ease of use, up-to-the-minute data collection, and outstanding storage capacity ensures a premium return on investment and one of the industryâ&#x20AC;&#x2122;s lowest total costs of ownership. SCOUT portables bring our industry-leading Bently Nevada condition monitoring expertise to the world of portable data collection and analysis. Backed by the powerful Ascent* software platform, they can be used in conjunction with other Bently Nevada technologies to provide dependable, efficient, and cost-effective condition monitoring across your entire plant. Portable data collection has never been easier. Visit our website at:

www.ge-mcs.com/scout

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*Trademark of the General Electric Company.

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