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OCTOBER 2011 • VOL 24, NO 10 • www.MT-ONLINE.com
M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
FEATURES CLOUDS OVER POWER 16
Survival Of The Efﬁcient
©Guido Akster — FOTOLIA.COM
A power-industry “insider,” says it’s time for utilities to walk their talk. From an end-user perspective, if your operations require electricity, consider this timely update as a loud wake-up call. William C. “Bill” Livoti, Baldor Electric Co., A Business of ABB
ON THE ROAD TO SUSTAINABILITY 24
Listening To IBM’s ‘Building Whisperer’ A company veteran is helping the century-old global giant known as “Big Blue” boost its already strong environmental record. Rick Carter, Executive Editor
THE RELIABILITY FILES 34 36
8 11 12
CAPACITY ASSURANCE STRATEGIES
Maintenance As A Proﬁt Center: It’s The Only Way To See It
Despite great strides in maintenance techniques, management too often views the department as a cost center. That can be a very costly mistake.
Anthony M. “Mac” Smith, AMS Associates
Fewer Worries/More Beneﬁts With This New Generation Of Smart Meters Lubricants Are Not Commodities: Making The Case For Superior Lubrication
SUPPLY CHAIN LINKS 41
Expansion Joints: Growing The Technology Advanced materials and innovative technology have transformed a common product into something extraordinary, further raising industry standards.
Compressed Air Challenge For On The Floor
Jane Alexander, Editor, with Lloyd B. Aanonsen, P.E., General Rubber Corp.
MT-ONLINE.COM | 3
M A I N T E N A N C E
Reliability: Own It
Your Source For CAPACITY ASSURANCE SOLUTIONS
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ROBERT “BOB” WILLIAMSON KENNETH E. BANNISTER RAYMOND L. ATKINS Contributing Editors
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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 2011 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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All Fired Up About Phoenix
ere it is, the first week of October and I’ve already packed my bags for a trip out to Phoenix in early November. No, this unusual degree (at least for me) of early-bird/non-11th-hour prep isn’t related to the recent weather forecast that Chicagoland can expect to have the worst winter in the country. (Who, though, could blame me for hustling if it were? As a transplanted Texan, I’m convinced that “winter” actually kicks off in these parts on Halloween. . . ) I’m just very excited about attending SKF’s Asset Management 2011 Conference—“asset management” being the operative term. That’s one of my passions and, if you’re reading this magazine, I know it has to be one of yours. According to SKF, its Phoenix event (November 14-16, at the Sheraton Wild Horse Pass facilities) will showcase the latest thinking, concepts, trends and innovations in asset management, as well industryby-industry mega-trends and implications. Content will be delivered through presentations by leading industrial asset management practitioners from across North America, along with facilitated discussion panels, networking and one-on-one consultations with SKF’s asset management experts. Among those aforementioned “leading industrial asset management practitioners” taking the podium will be our own contributing editor Bob Williamson. He’ll be speaking on a topic near and dear to his heart (one he’s tackled in his “Uptime” columns multiple times): “In Pursuit of 100% Reliability.” Based on his work with NASCAR racing teams, it’s a spot-on focus for the type of cutting-edge asset management event SKF is sponsoring. Bob will be the first to tell you that motorsports racing is more than a fan event. As he points out, “Competing NASCAR racing teams depend on high-performing, 100%-reliable equipment to accomplish their business goals. And flawless human performance is the goal of their leadership, teams and individual employees.” He contends that maintenance and reliability professionals in industry can—and should—learn what will work in their plants from top NASCAR teams. “After all,” he wryly observes, “isn’t human performance and equipment reliability critical to OUR [YOUR] business?” Speaking of NASCAR, as part of their paid conference registrations, attendees are invited to be guests of SKF for the Sprint Cup Series race at Phoenix International Raceway on Sunday, November 13. Need I remind any of you racing fans out there that this race is the ninth—i.e., next-to-last— in The Chase? (Shouldn’t things be getting rather interesting about that time?) In addition to enjoying the race with SKF, conference registrants will, among other things, also be able to tour the pits and visit with members of the Richard Childress racing team. Doesn’t sound like too bad of a way for maintenance and reliability aficionados to while away a a few hours, does it? Given the fact I love fast cars and have enormous respect for the professionals who drive and maintain them, I’m really fired up about this opportunity (and hope you are, too). Why don’t you make plans to join us at Asset Management 2011? If you haven’t already, go immediately to http://secure.lenos.com/lenos/pcg/skfassetmanagement2011 and register. Then, start your packing. SKF, Bob Williamson and I are looking forward to seeing you in Phoenix this November! firstname.lastname@example.org
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A Tsunami Of Counterfeits: Electrical & Electronic Parts
Sound the alarms Hundreds of millions of dollars in counterfeit electrical and electronic parts are seized annually in the U.S. Manufacturers, trade groups and testing/certifying organizations are up in arms over the bogus products sold with their brand names, look-alike trademarks, labels and packaging. Even worse, counterfeits can kill! These fakes are being produced at alarming rates. Product performance and reliability may be disappointing, but the bigger issue is the SAFETY HAZARD these electrical/electronic parts create: electrical shock, fires, damaged equipment and burns. The risks they pose also create a huge liability problem for authorized manufacturers, distributors and retailers. Here’s a list of the most commonly detected and seized counterfeit electrical and electronic parts:
China’s underground economy Historically, in China, there have been huge individual, local and state revenue streams that come from counterfeit and knock-off products. In 2003, to comply with the World Trade Organization (WTO) foreign trade regulations, China changed its foreign trade laws to eliminate the monopoly that government-owned trading companies had on exports. Prior to this, all exports had to be processed through state-owned companies. Counterfeiters had to work through these state-approved distributors and brokers to get their bogus goods into the world marketplace. When the foreign trade laws were changed in December 2003, every counterfeiter could become a first-tier exporter of its own bogus parts. Let’s back up a bit. How did the Chinese get the ability to produce counterfeit parts in the first place? From 1980 through about 1992, China’s economy grew at unprecedented rates—from a poverty-stricken, seemingly backward, closed society to one of the fastestgrowing economic powerhouses in the world. This was made possible by massive amounts of “foreign direct investments” (FDI) from multinational enterprises. In the 1990s, China was the second-largest recipient of FDI in the world. (The U.S. was number one.) By 2002, though, China had become the largest FDI recipient. Along with multinational businesses investing in the Chinese market came the transfer of “intellectual property” (i.e., copyrights, patents, trademarks, proprietary business information) and advanced manufacturing technology: State-of-the-art technologies and manufacturing processes were purposely transferred to China’s shores. But there’s more…
n Circuit breakers and fuses n Dry-cell batteries (cell phones, cameras, PDAs, radios, toys, etc.) n Small electric motors n Control relays n Receptacles and switches n Lighting controls n Ground fault circuit interrupters (GFCIs) n Lamps and lamp ballasts n Extension cords and power strips n Conduit fittings n Microprocessors/microcircuits
Eight factors that promote counterfeiting There have been an increasing number of factors influencing the rapid and sustainable (yes, sustainable!) growth of counterfeiting in China since 2004. It started with the big three building blocks: relaxed foreign trade laws, technology transfer and little respect for intellectual property rights. Then came three local elements: lack of local enforcement of Chinese counterfeiting laws, organized crime networks and an economic boon to small communities in China. Linked together, the six factors above were the start of a deadly tidal wave of counterfeit, knock-off, fake
“What about counterfeit electrical and electronic repair parts? We’ve seen some really suspicious parts and packaging and some pretty scary failures.” Great question. Like the fake bearings covered in my September 2011 “Uptime” column, counterfeit electrical and electronic parts can be extremely dangerous. Incidents of these parts have been growing at a staggering pace since 2004. The supply chain for electrical and electronic parts used in our plants and facilities—not to mention in our homes— is tainted with substandard knock-offs (most of them from China). What is being counterfeited/what has made China the world’s largest source of counterfeit parts makes for a frightening story. What can we do to protect ourselves?
and bogus products hitting the Chinese marketplace, then flowing into the global supply chain. Two additional factors, though, combined to make the monster more dangerous: the Internet and low bid. Online sales have grown exponentially over the past 20 years. Anybody can set up a Website and hawk his/her wares to customers around the world. Company buyers and consumers—in their quest for low prices—are drawn to such sites and products like moths to porch lights. Together, these eight factors create a powerful synergy: The whole is truly greater than the sum of the parts! They work in tandem to generate a virtually unstoppable economic machine in China—and have created a counterfeit tsunami sweeping through every economy in the world, including China’s own! Yes, China has also become a victim of its own counterfeit machine (i.e., bogus automotive parts, electrical and electronics products, foodstuffs, medicines, etc.). An unintended consequence, to be sure, it’s estimated that over 90% of the consumer products used daily in China are counterfeit or trademark-infringing knock-offs. “China is considered by many to (be) the most serious counterfeiting problem in world history” according to testimony by Professor Daniel C.K. Chow of the Ohio State University College of Law. In 2004 Professor Chow also stated, “Counterfeiting is estimated to now account for approximately 8% of China’s gross domestic product.” Today, many small local Chinese economies depend on counterfeiting in both domestic and global export markets. So, if you think the problem can be controlled at its source, think again: It’s going to get worse before it gets worse! (You can quote me on that.) How counterfeit parts are made When you think about it, the manufacture of fake parts is not easy. Or is it? There are a number of ways counterfeiters produce their wares: Scrap materials: Asian countries, including China, are buying up much of the world’s electronic scrap (e-scrap) and “recycling” it. Components are removed from the equipment, cleaned up, re-packaged and sold as “new.” Substitute parts: A similar new, recycled, obsolete or knock-off part is re-labeled as a higher-end or newer part. (It may look right, but it won’t function properly.) Manufacturing defects: Legitimate manufacturers in China—and elsewhere—occasionally scrap out products because of defects. Rather than these parts being destroyed as directed, they’re stolen by employees and sold on the black market as first-quality parts. Brand new parts: Many counterfeit parts are made from scratch using similar-to-the-original manufacturing processes and equipment—thanks to decades of technology transfer. But shortcuts are taken in component selection quality and assembly methods. Often, these products OCTOBER 2011
contain high levels of toxic substances not allowed in most countries. There are also cases of authorized Chinese manufacturers making their own counterfeit lines of products on the same equipment as the authentic products. Fakes: These items may look authentic, but they’re nothing more than non-functional rip-offs. Caveat emptor Let the buyer beware! You simply can’t be too vigilant. Here are some suggestions to protect yourself, your facility, your operations and your home from counterfeit electrical/electronic parts. Check the price: If the price sounds too good to be true, it probably is. Beware of brokers, independent non-franchised distributors, exclusive Internet sources and individual sellers offering parts at a significantly lower price that your normal reputable suppliers. These sources may not be authorized by the original component manufacturers (OCMs). While the prices are attractive, the goods may be counterfeit. Check the country of origin: Carefully consider and inspect any critical component “made in China” or other countries/regions known for counterfeiting electrical/ electronic parts—i.e., Hong Kong, Taiwan, Malaysia and Singapore, to name a few. China heads this parade with more than seven times as many counterfeit products as the second in line. But the problem doesn’t stop there: Some Chinese counterfeiters are transshipping their bogus products through other countries, marking them as made in that country versus “made in China.” In some cases the sub-standard materials are shipped to the U.S. and assembled here to get the label “Assembled in the USA.” Check for improper packaging: Sometimes, the packaging of counterfeit parts just doesn’t look right. Look for fuzzy and unclear printing on products, labels and boxes. Spelling mistakes on packaging and instructions flyers are also common. Missing product-information sheets or the wrong instruction sheets are typical red flags. A discrepancy between the package and the contents may also be a sign of counterfeit parts. Check for authentic certification labels: Look for genuine, detailed and reputable certification marks on the packaging and on the product. When in doubt about authenticity, check the certifying organizations’ Websites for sample certification marks. Inspection laboratories and certifying organizations are starting to use more holographic labels and unique and permanent identification on the parts and the packaging of authentic parts to make counterfeiting more difficult. For end-users and consumers of electrical/electronic parts, look for recognized testing and certification labels and consult with the following organizations when something looks suspicious: mt-online.com | 9
n ESFi – Electrical Safety Foundation International (www.esfi.org) n ETL – Edison Testing Lab (www.Intertek.com) n NAED – National Association of Electrical Distributors (www.naed.org) n NEMA – National Electrical Manufacturers Association (www.nema.org) n UL – Underwriters Laboratories (www.ul.com) n CSA International – Canadian Standards Association (www.csa-international.org) Verify specific industry certification/registration: Look for evidence of quality-management systems’ certification such as ISO-9001: 2000 for manufactured components, or AS9120 for aerospace product distributors.
Visit www.CounterfeitsCanKill.com: There are a number of counterfeit-related news articles and resources here. Their purpose is to distribute an “anti-counterfeiting message” to professionals in the distribution, specification, purchasing and installation of electrical products. Sponsors of this Website include Alcan Cable, Eaton, Fluke, GE, Siemens and Square D (and it’s endorsed by NEMA, NAED, NECA, CSA and UL). Dealing with this ever-lurking danger The more I study and experience first-hand the impact of the growing incidents of counterfeit parts in American plants and facilities, the more I believe we as maintenance and reliability professionals must take a stand to seek out quality repair parts and speak out when we discover counterfeit, bogus and/or fake parts. Price has to be a secondary consideration from now on. In the meantime, we’re not done with this topic. It’s too big and poses too much danger. If you and/or your operations have had experience with counterfeit repair parts—of any type—please let us know. We’re very interested in your story. MT RobertMW2@cs.com
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Overcoming Your Challenges
Turning Down Pressure To Cut Operating Costs By Ron Marshall, for the Compressed Air Challenge®
he following is a question received by the Compressed Air Challenge (CAC) from a concerned electricalcontrols programmer. Queries such as these are commonly a result of someone participating in a CAC training event and learning about efficiency measures. Question: “We have a new maintenance supervisor that has turned down our shop air pressure to 86 psi, supposedly saving operating cost. My opinion is it should be set between 90 and 100 psi to accommodate surges. Is there really a significant savings by turning the supply down to 86 psi?” The CAC Answer: Yes indeed, lowering discharge pressure reduces the compressor motor power by about 1% for every two psi of lower pressure. Also, the lower pressure makes any unregulated uses in the “shop” reduce consumption (cfm) by almost 1% for every one psi of pressure reduction. You will achieve extra savings if your compressor-control systems can turn down compressor power in response to reduced flow or unload and possibly shut off unnecessary compressors. The best pressure at which to set your system is the level where your production can operate efficiently and effectively without waste: There is no right pressure—it depends on your machines. That being said, often you may have 90 to 100 psig at the compressor, but at the production machine, where the actual work is being done, you could have only 65 to 70 psig. In some cases, it may be even lower due to pressure drops in undersized piping, filters, regulators, lubricators and tubing and connectors. The goal is to lower compressor discharge pressure without affecting the endusers. The method is to address these pressure differentials and get the pressure to the machines with minimal loss; then the compressor discharge pressure may be reduced even more. This is typically a job for a controls programmer.
Having artificially high plant-pressure can help you deal with surges in compressed air demand that might occasionally cause lowpressure and affect production. The higher pressure acts to store reserve air in the various volumes made up of receivers, pipes and such in your system. However, the higher pressure costs more to produce and makes unregulated end uses consume more air, which is an expensive trade-off. Another strategy might be to use a pressure/flow controller and large storage receiver capacity in the compressor room. This will supply stored air for surges, but maintain lower plant pressures to reduce artificial demand caused by elevated pressures. Your compressed air service provider can assist with implementing this. To learn more about optimizing your system, download the free resource Improving Compressed Air Performance: A Sourcebook for Industry, written by the Compressed Air Challenge and the Department of Energy. Also check out the CAC’s Compressed Air Best Practices Manual. You also may be interested in learning about our upcoming November 7 Web-based “Compressed Air Fundamentals” seminar and/or the many in-person seminars that the CAC presents across the country. For additional information on all these items, go to www.compressedairchallenge.org. 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: email@example.com.
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MT-ONLINE .COM | 11
FOR ON THE FLOOR An outlet for the views of today’s capacity assurance professionals Rick Carter, Executive Editor
ISO-Lation Or ISO-Nation? In April, Maintenance Technology Reader Panelists offered their views on personal certifications such as CMRP and CLS. Here, they reflect on the value and impact of company certification to standards that address operational management issues, such as those from the International Organization for Standardization (ISO) and others. The topic takes on new meaning as ISO develops a new standard based on PAS55, a set of asset-management guidelines prepared by the British Standards Institution and the Institute of Asset Management. Cross-mapped against other ISO standards, this new standard—likely to be labeled ISO 55000—is expected to be of great value to asset-intensive operations. How will it be welcomed? Our Panelists’ acceptance and perception of existing standards may provide a clue. Slow domestic uptake Manufacturer acceptance of key ISO standards like 9000/9001 (for quality management) and 14000/14001 (for environmental management) has grown steadily in the past decade, but less quickly in the U.S. than in other countries. According to the latest ISO figures, the number of worldwide ISO 9001 certifications is estimated at over one million today among all business types. And while the U.S. just makes the top-10 list of countries with the most ISO 9000 certifications (in the ninth position), it’s surpassed by China, in the top position, Italy, Japan, Spain, Germany and the U.K., among others. This may explain our Panelists’ divided views. On the positive side, a facility-transition manager in the South says operational certifications are most definitely worth the effort. “The [facility’s] maintenance department now has set guidelines to allow all personnel to function in a set pattern by assigning key personnel to critical maintenance and breakdown areas.” He adds that under a former employer, he wrote the plant’s ISO 9000 maintenance plan and everything went smoothly. In both operations, he observes, the
process “had a very positive effect and improved the administration of maintenance significantly.” A reliability/maintenance engineer, also working in the South, agrees—but for a different reason. “Employers hire people with degrees, not because these people are more intelligent or more capable, but because they demonstrated that they have the discipline and determination to complete a degree program,” he says. “ISO certifications serve a similar purpose in a different way. When manufacturers are looking for suppliers or vendors, the status of a potential partner’s ISO certification can help to quickly identify companies with higher standards of performance.” He adds that at his ISO 9001- and 14001-certified operation, “These certifications have served to raise awareness among employees, with regard to quality and environmental responsibility.” A maintenance manager in New England recalls his positive ISO 9000 certification experience with a “very progressive” former employer whom he says “has probably moved on to ISO 14000 by now.” Over the last 20 years, he notes, this company also instituted Six Sigma, Kanban and just-in-time, “all of which has made them extremely efficient and competitive.” Acceptance not universal Several Panelists working in certified plants report dismay about the long-term results of certification. A production support manager at a company in the Midwest with ISO 9001 and LEED (green-building) certification, notes that “a lot of time is put in to achieve the certification, but after the initial surge of achieving the plaque on the wall, the effort is usually not sustained.” When his company followed ISO procedures to expand operations, he says the asset was built following the same procedures and documentation, but mistakes were copied over and over. “If you have a good process,” he theorizes, “you’ll have a good product, but if you have a bad process, your product won’t be so good,” regardless of certification.
FOR ON THE FLOOR
The topic of certification takes on new meaning with PAS55 sitting on the launch pad. Another Panelist calls the effectiveness of his company’s ISO 9001 certification “mixed.” While he believes that “forcing operations to document procedures is generally beneficial, there is a tendency to not follow the true intent of the certification and to just go through the motions. Like any program,” he says, “if you don’t give it some love on occasion, it tends to wither on the vine.” Even Panelists without experience in operational certification have opinions about the process. A corporate engineer in New England, for example, has concluded that his company “didn’t need certification,” but that if it did decide to pursue such designation, it would mean “more reporting and more internal audits.” A maintenance manager in Mexico says, “I don’t believe in them.” The work required to certify, he adds, represents a “non-standard model” for his operation, which would force workers “to fulfill documents only to accomplish what’s required [for] the audit.” Likewise, a Panelist in the upper Midwest says simply that taking an active energy-management approach has “no value for our organization.” Interestingly, several Panelists acknowledge that their companies are certified, but they’re not sure for what. The suggestion here is that their management may have missed the key “communication” steps required in most certification processes. Enlightened views Some Panelists (consultants in particular) understand the danger manufacturers face if they fall behind in adherence to internationally accepted operational standards. “They must consider certification if they want to sell products and services in a world-class arena,” states a consultant in the upper Midwest. Naturally, it’s in consultants’ best interest to support certification, but their argument makes sense: “Certification is very useful in times when our industries are facing so many challenges with global
competition,” says the Panelist above. “Those who decide to get ISO 55000-certified, for example, even before any of their customers or vendors may demand it, are in for a series of great achievements. Its purpose is to reduce the risk and breakdowns of critical equipment, mainly through root cause analysis. Two components—criticality and reliability—will come together,” he says, “reducing the cost of operations and maintenance, while boosting productivity.” Will manufacturers warm to 55000, considering that it may be the most manufacturing-specific of ISO standards? An East Coast consultant says no: “I must admit that in my client relationships I am not seeing any real push on newer certifications,” he says. “Most companies have already earned the certifications they need.” Another sees room for greater acceptance, but believes more education is needed. “Several of my clients have ISO 9000 [and other certifications],” says this Canada-based consultant, “but there is a significant amount of ignorance among maintenance workers about what certification can and cannot do.” When training clients, he says he takes “about an hour” explaining how adherence to the standards their companies have chosen to follow will help them see how “quality performance and reporting the truth are applied” to the overall good for both company and customers. 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 | 13
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Proud Sponsors Of The 2011 Maintenance & Reliability Innovator Of The Year Award About Our Monthly Winner For October Michelle Laramee, Founder & CEO of the small, Woman-Owned Business ByerSource, based in Smithﬁeld, RI, submitted our winning October entry. ByerSource was founded in 2007 by a small group of entrepreneurs who have an interest in improving products used in the electrical industry and bringing manufacturing back to the USA. The winning innovation is a newly patented product: a universal in-line mountable device that meets NEC speciﬁcation for earth grounds, supplementary grounding and grounding plurality. It can attach to any knock out or any threaded ﬁtting including emt, pvc, lmc, cord connectors, device boxes, panel boards, rigid pipe and imc pipe.
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l a v i rv
Clouds over power. . .
e h t of
i f Ef
t n e i c
It has been a couple of years since this industry insider last covered the future of power generation in depth. While you may have picked up bits and pieces about it in his quarterly “Big Money Talks” columns, here’s a wide-ranging, detailed update. If your operations use electricity, consider it a loud wake-up call.
William C. “Bill” Livoti Baldor Electric Co. A Business of ABB
CLOUDS OVER POWER
ew, emerging technology for cleaner electricity production will play a vital role in our economic growth. How and when this technology is implemented and at what cost will determine the future of our existing base load fleet. But what’s going to happen in the meantime? With the focus on renewable energy and the negative press surrounding fossil fuels and nuclear, the power industry has few options to meet growing demand. The answer to this dilemma is simple: Efficiency is the future of power generation.
A problem with our existing ﬂeet To put it kindly, the existing fleet of U.S. power plants has grown rather “long in the tooth.” As Fig. 1 shows, approximately 530 gigawatts of power—that’s 51% of all generating capacity—is now being produced by plants that were at least 30 years old as of 2010. The oldest plants tend to be hydropower. Then come our coal-fired operations—the majority of which went online before 1980—and our nuclear plants, which were constructed from the late 1960s into the 1980s. Figure 2 (see page 18) provides a breakdown by age, fuel source and capacity of the existing fleet. Many of the gasfired plants are less than 10 years old (65% being combined cycle as opposed to simple cycle). Approximately 73% of all
coal-fired capacity falls into that 30-years-or-older category as of 2010. (Note: The average efficiency of the entire coal fleet is only around 33%.) The “other” category includes solar, biomass and geothermal, as well as landfill gas, municipal solid waste, etc. Natural gas appears to be today’s fuel of choice. Gas production is at its highest level since 1971. Almost 237 gigawatts of gas-fired capacity (most of it in combinedcycle operations) has been added in this country since 2000—representing 81% of total generation-capacity additions from 2000 to 2010. The primary driver behind this surge is existing air-pollution restrictions and pending legislation. Investor-owned utilities (71% of the existing fleet in the U.S.) can’t risk investing in coal-fired plants.
60 Current U.S. Capacity
Nuclear Natural Gas
40 30 Hydro
20 10 0 1930
Fig. 1. More than half of our generating capacity is being produced by plants that were at least 30 years old as of 2010. (Source: U.S. Energy Information Administration) OCTOBER 2011
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CLOUDS OVER POWER
250 200 150 100 50 0 10 or fewer
11 to 20
21 to 30
31 to 40
41 to 50
51 to 60
Plant Age (Years) Coal
Fig 2. This breakdown by age, fuel and capacity of the existing U.S. power ﬂeet paints a troubling picture. (Source: U.S. Energy Information Administration)
In addition to generating capacity that began coming online via natural gas-fired units in the early 2000s, “renewable” units—primarily wind and solar (CSP and PV)—began coming online in the late 2000s. According to the June 16th edition of Today in Energy, the annual growth in U.S. wind capacity had been averaging 40%. Since 2006, 36% of total electric power industry capacity additions have been wind generators. The economic downturn, however, and an uncertain regulatory environment (particularly relating to the renewal of production and investment tax credits) led to fewer wind-capacity additions in 2010 and 2011—and seems to be on track for even lower levels in the future. Solar energy projects, though, are a different story. Compared with wind, solar seems robust— for now. That could change, depending on political winds. So what and what if So, what does the age of our power plants and plant energy sources (fuel type) have to do with efficiency, OUR economic growth and YOUR operation’s survival? If your facility is operating in the most efficient, most costeffective manner, it could mean reduced profit. On the other hand, if the overall efficiency of your facility can be improved (i.e., reduce energy consumption), you have the opportunity to maintain your profit margin. Where am I going with this? Utilities are being “attacked” from all sides. We’ve discussed this before: On one side, it’s special interest groups protesting coal (global warming, heavy metals, etc.); wind (noise and birds); solar (turtles and other desert creatures). On the flip side, it’s EPA restrictions, primarily directed at coal, and Washington’s failure to develop an energy plan. Case in point, according to the National Energy Technology 18 |
Laboratory, is the fact that 11 new coal plants totaling 6682 MW were commissioned in 2010 (the most in 25 years). Since December 2010, though, only 1599 MW of new capacity has been announced—and 6418 MW of planned coal power-generation projects have been canceled. As to those older, inefficient plants that the utilities have relied on for over 30 years… Roughly half of U.S. power plants still use once-through cooling and lack state-of-the-art emissions controls (scrubbers). Yet, in March 2011, EPA proposed Best Technology Available (BTA) regulations for existing facilities. What does that mean? Section 316(b) of the federal Clean Water Act requires plants to use the best technology available to minimize the adverse environmental impacts of cooling water intake structures. In 2001, EPA issued national regs identifying closed-cycle cooling as BTA for new plants. New and proposed EPA regulations include: ■ Proposed Clean Air Transport Rule ■ Proposed Coal Combustion Residuals rule ■ Proposed Tailoring Rule (covering greenhouse-
gas emissions) ■ Ozone NAAQS (National Ambient Air Quality
Standards) ■ Pending National Emission Standard for Hazard-
ous Air Pollutants and cooling water regs under Section 316(b) of the Clean Water Act OCTOBER 2011
CLOUDS OVER POWER
The agency will take final action on those regulations by July 2012. The impact could be considerable. For example, the EPA Cross-State Air Pollution Rule could close 20-50 GW of un-scrubbed coal plants: ■ Over 25 GW of retirements have already been
announced nationally. ■ Nearly 100 GW of un-scrubbed coal is in the
CSAPR-affected states. ■ Estimates indicate 20-30 GW may be retrofitted
for SO2. ■ An additional 40 GW will retrofit to meet NOx and
mercury requirements. ■ 20-30 GW more will retire due to SO2 reduction costs.
There's currently a lot of posturing going on in the power industry. Many large, coal-heavy producers are threatening to close plants if pending legislation passes. American Electric Power, Duke Energy and Progress Energy have announced old coal-fired plant retirements—placing an estimated 65 GW of capacity “at risk” when (if) these operations shut down. The million-dollar question: What do you replace them with? ■ Cleaner Coal? Unlikely, based on public sentiment and
the cost of meeting the above referenced regulations. ■ Solar? Great concept, plenty of federal incentives, unfor-
tunately the cost per kW is still high and overall plant efficiency is low.
■ Nuclear? Economics have jeopardized nuclear energy's
resurgence in the United States. Now, the potential for tougher safety requirements and regulatory scrutiny threatens to pile on more uncertainty and re-ignite a public backlash against a technology that until recently has been viewed by the power industry and others as a prime defense against global warming. ■ Wind? The low capacity factor of wind turbines relative
to coal and other fossil-fueled power plants limit wind’s viability as a primary source of power. (Note: "capacity factor" is simply the ratio of actual energy produced by a power plant to the energy that would be produced if it operated at rated capacity for an entire year.) Capacity factors of successful wind-farm operations range from 0.20 to 0.35. These can be compared with factors of more than 0.50 for fossil-fuel power plants and over 0.60 for some of the new gas turbines. That being said, wind advocates believe wind energy, in the near future, will be the most cost-effective source of electrical power we have. A good case can be made that it already has achieved such a status. The future outlook Looking ahead 15 to 20 years, the primary source of electricity, according to a new projection from consulting firm Black & Veatch, will be natural gas. Why? It’s the fossil fuel with the least greenhouse-gas impact on the atmosphere, releasing 43% less CO2 than coal. Add to the equation new, vast U.S. reserves of natural gas in places like the Marcellus Shale Formation. By 2034, according to Black & Veatch, nearly half of U.S. electricity will come from natural-gas combustion turbines
Many large, coal-heavy power producers are threatening to close plants if pending legislation passes. The million-dollar question: What do you replace them with?
MT-ONLINE.COM | 19
CLOUDS OVER POWER
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Fig. 3. A typical pulverized coal-ﬁred power plant S:9.5”
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(simple cycle) or combined-cycle units, whereas conventional coal-fired generation will shrink to just 23%. Nuclear will grow to provide nearly 150,000 megawatts of electricity as renewables jump from just 54,000 megawatts today (excluding hydroelectric dams) to more than 165,000 megawatts in 2034. Will this actually transpire? It’s anybody’s guess given the politics and world economy. Regardless, the trend of switching from coal to natural gas already exists, even with a moderate level of carbon-emission prices. If natural gas remains competitive as a fuel, it's unlikely that you'll see more “conventional” coal-fired power plants. That being said, even with demand-side management and energy efficiency, we still expect some growth in demand, requiring additional power generation— which will come at a price to both utilities and end-users. You’re probably already aware of the energy-efficiency programs (demand side) available to the end-user: Most utilities offer attractive incentives to cut consumption. It's too bad that “demand-side” energy-efficiency programs alone will not achieve the energy reduction necessary to control the cost of electricity. This is not to suggest that the following proposal is the answer to our rising energy however, serve as a common-sense approach to This mechanical prepared by pain. It Thiscan, mechanical should not be modified in any way without prior written direction from MRM Worldwide. MRM Worldwide minimizing the sticker shock we will all see as utilities are forced to upgrade Client: Exxon Mobil Job Number: EXOD0079 Safety: 2.125" x 9.5" their infrastructure. Trim: None
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An alternate solution to control energy costs Space: 4C 1/3 pg Production Contact: Linda Herskovic 1-646-865-6371 As noted previously, the average efficiency of a coal-fired power plant is 33%. Publications: Various Pubs - 2011 The losses are indicated in Fig. 3. Looking deep into their operations, utilities could realize savings through improving process/systems efficiency while reducing waste and EFOR risk. As an added bonus, efficiency also impacts reliability and increased workforce productivity. This would allow the power industry to achieve sustainability and minimize rate hikes. Although the industry hasn’t changed the way it
9/19/11 5:54 PM
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© 2011 Exxon Mobil Corporation The Mobil logotype and the Pegasus design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.
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CLOUDS OVER POWER
Several relatively inexpensive modifications can improve power-gen efficiency and reliability while reducing the financial impact on both the utility and end-users.
generates power in over 75 years, there is hope, as evidenced by the following quotes from a powerful industry leader: “To ensure a sustainable and secure energy future, I have two aspirations for this country—that we substantially de-carbonize our energy supply in this century and that we become the world’s most energy-efficient economy. “Practically speaking, the way we can begin to achieve these aspirations is to take an entirely new path—and change the way we think about and use energy in this country.” … James E. Rogers, chairman, CEO and president, Duke Energy Mr. Rogers goes on to say: “Challenges in the areas of energy and the environment can be met not by doing without technology, but rather by continuing to develop it to save energy and protect the environment—in other words, by developing more efficient technologies.” The average annual operating heat rate of the typical U.S. coal-fired power plant is approximately 10,400 Btu/kWh. Because operating units report heat rates that include performance at all levels (due to load swings), the numbers are usually significantly higher than the design heat rate. ■ Improving efficiencies of energy systems will play a major role in solving the
energy and environmental problems of the future. To improve efficiency, there must be a rapid technology transfer. This means using ultramodern technologies when building and/or upgrading power-supply systems, thereby using fuels more efficiently so that less damage is done to the climate and resources aren't used up. ■ Higher efficiency means lower fuel consumption and fewer pollutant emissions. ■ The most important indicator for the energy efficiency of a power plant is its
electrical efficiency. ■ For coal-fired power plants, further improvements in efficiency primarily depend
on two variables: ◆ Increasing the two steam parameters, pressure and temperature ◆ Reducing losses in the steam water cycle. ■ Target efficiency should exceed the 53% mark by 2020. Coal consumption per
kilowatt hour will be only 230 grams, with CO2 emissions of 620 grams. Several relatively inexpensive power-plant modifications/upgrades (as compared with new construction) can improve plant heat rate, reduce parasitic load and improve uptime availability and reliability while reducing the financial impact on end-users (as well as the utility). These, in turn, can help other U.S. industries survive. They include: ■ Control systems (digital, online performance monitoring, etc.) ■ High-efficiency motors on all major rotating equipment
■ Variable-frequency drive motors on
all major rotating equipment ■ FD/ID fans ■ Boiler feed pumps ■ Condensate pumps ■ Heater drain pumps ■ Mechanical draft cooling towers ■ VFD/PM technology ■ Circulating water pumps ■ Controlled start with gearmotor
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Walking the talk It’s time for the utilities to walk the talk. While we appreciate the demandside incentives they’ve been offering, such incentives won’t get the industrial sector where it needs to be. In short, the power generators need to do some serious housekeeping. As evidenced by his remarks quoted on page 22 of this article, Duke’s James Rogers seems to clearly understand the situation. Well said, Mr. Rogers. MT
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Sargent and Lundy Bill Livoti is senior principal engineer, Power Generation and Fluid Handling, with Baldor Electric Co., a business of ABB. Based in Greenville, SC, he also writes the quarterly “Utilities Manager” column entitled “Big Money Talks” for MAINTENANCE TECHNOLOGY. Email: firstname.lastname@example.org.
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8/4/11 2:04 PM
Listening To IBM’s ‘Building Whisperer’
Dave Bartlett, VP of Industry Solutions at IBM, understands and interprets the language of buildings.
This IBM veteran is helping the century-old global giant known as ‘Big Blue’ boost an already strong environmental record with a holistic approach to managing facility energy.
Rick Carter Executive Editor
ave Bartlett has a special rapport with buildings, especially those in need of an energy tune-up. To help wasteful facilities, he gathers and analyzes, in real time, everything that their energy-management systems tell him. In this holistic approach to solving problems, system inequities stand out and become targets for correction in new software IBM writes for system operation. Bartlett’s changes reduce energy use and cut maintenance costs. His ability to make them— even in buildings that are already considered to be relatively efficient—has earned him the memorable title of “building whisperer.” “I would argue that you will not find any campus or portfolio of buildings owned by mid- to large enterprises where anyone is taking a holistic approach,” says Bartlett. “People listen to pieces of it, and individual control systems are monitoring individual units. But if you listen to everything, you can make higher-level decisions based on that high-level knowledge. That’s why I came up with this analogy of the building whisperer because if you really listen to all of the data, the results we’re getting show that you can heal buildings of their wild energy- and water-wasting ways.” Bartlett, 58, hasn’t always been a building whisperer. After college, his plan was to pursue a career in ecology, which was—and is—his passion. But prospects in this field looked slim at the time, he says, especially when compared with the excitement being generated in the computer sector. So Bartlett returned to school for a graduate degree in computer science, and in so doing, created a skill-set tailor-made for the age of sustainability. Today, his balanced understanding of metrics, software and environmental issues enables this IBM vice president of Industry Solutions to fulfill the promise of his title for his company and its customers by helping them save energy in a vital new way. The big picture Now in his 28th year with IBM, Bartlett leads the development of global industry solutions under IBM’s “Smarter Planet”
initiative. He has held this position for several years, during which time the Armonk, NY-based technology company has racked up impressive figures for its own portfolio: ■ Since 2008, IBM has saved over $50 million in electricity expenses and conserved 523,000 megawatt hours of electricity, company-wide. This is enough energy to power 47,000 average U.S. homes for a year. The savings were the result of 3100 conservation projects at more than 350 IBM facilities in 49 countries. ■ From 1990 to 2010, IBM avoided 5.4 million megawatt hours in energy use and nearly $400 million in associated direct energy expense. Its continuing conservation efforts aim to eliminate 1.1 million megawatt hours of energy consumption by year-end 2012. Some of these savings are directly attributable to Dave Bartlett’s team and a program for IBM customers that was pitched to IBM CEO Sam Palmisano in 2009. Palmisano liked what he heard, but directed that the program be tried out at IBM’s own ’90s-era corporate headquarters building in Armonk, before being offered outside the company. It became the trial run for Bartlett’s holistic approach and, eventually, its showcase. The first thing IBM did was replace the building’s existing sensor network with one based on an
40 Years of Environmental Responsibility IBM was among the earliest large corporations to make environmental responsibility a part of company policy. Its Corporate Policy on Environmental Responsibilities, written in 1971, is now supported by the company’s global environmental management system, which calls for environmental leadership in all of the company’s business activities. These include addressing waste that results from producing its products as well as working to prevent pollution by considering the consequences of product-development processes. In the late 1990s, IBM became one of the first major companies to earn a single global registration to the ISO 14001 environmental management standard. And in October 2010, Newsweek magazine ranked IBM the top green company in the world.
MT-ONLINE.COM | 25
Hard-drive assembly is one of many activities at IBM’s Rochester facility, which, thanks to Bartlett, now uses 15% less electricity than it did two years ago.
Internet protocol (IP). The facility manager was immediately impressed with the new network’s ability to monitor the building’s 7600 data points in the blink of an eye. “‘Wow, that’s fast,’” Bartlett recalls him saying, which was music to his ears. Bartlett explains that in this first implementation of those IBM has done since, they do not reconfigure how equipment is monitored, but how data is analyzed and used. “We’re not replacing sensors,” he says. “We tie into all of that and take the data and warehouse it. And in real time, we correlate it, sort it, and run analytics and rules on it, so it’s a lot of data analytics at a high level. That’s the big differentiator: realtime sensing and real-time analytics to do real-time optimization of the performance. It also optimizes how we do maintenance,” he says, “because with real-time monitoring, it’s easier to pinpoint exactly where an outage is and what the part is and what skill level is needed, all of which lower maintenance cost.” IBM’s approach is also not about redesigning a building’s energy-management system. In most client projects, “they’ve made great advances in terms of the systems they’re running,” he says. “But we want to go beyond that. Without an intelligent system over the entire enterprise, managers are missing comparisons of how one building compares with 26 |
another, how one air-handling unit compares with another, and how one boiler compares with another.” The result, he says, is that program rules don’t reflect this data and fall short of what can be done to optimize energy use. “So we end up relying on the building-management systems to do local optimization as well as for all the higher-level decisions that have to be resolved.” This can open the door to unwanted scenarios, such as when two HVAC components work at cross purposes in the same building—one producing cold air and another heat, simultaneously. “Both systems may be doing it very efficiently,” says Bartlett, “but why are they opposing each other? In some cases, this is valid, but in many cases it isn’t, so coming up with rules to look at things like this is an example of the problems we address. We also monitor equipment to achieve more of a condition-based maintenance approach as opposed to a scheduled, preventive approach. So when the condition of a filter merits the filter being replaced, that’s when we replace it.” The Rochester challenge Bartlett’s team completed the Armonk project in time for Palmisano to display the results to board members who were gathering at headquarters. With the building starting OCTOBER 2011
to produce savings, Bartlett expected to begin working with customers, but instead received another IBMcentric assignment. In early 2010, the company’s real-estate team asked him to apply his methods at one of the corporation’s largest energy-using sites: the 35-building, 3 million-sq.-ft. manufacturing/R&D/laboratory campus in Rochester, MN. Though the site had recently undergone an energy overhaul using IBM’s Intelligent Building Management software—which produced a 7% energy savings—the real-estate team thought Bartlett’s approach could do better. Like Armonk, Rochester’s energymanagement practices followed the traditional route. Though it had a world-class energy-management system, “no one was listening to all the data across the campus,” says Bartlett. “No one knew what was the best- or worst-performing building or what was the best assembly area or the best air-handling unit.” Unlike Armonk, however, the number of data points to sample at Rochester topped 300,000. “It was a massive amount,” says Bartlett, “but this is where computer science comes in. Taking a lot of data and making sense of it very quickly, warehousing and running it, that’s what computer science is.” Without it, he adds, it would be essentially impossible to both collect, monitor and filter data in real-time as well as “take any type of event coming forward and enhance it with what you know from the asset-management systems that track maintenance history and service issues.” Despite having a green light to implement his approach at Rochester, Bartlett didn’t arrive as the big man on campus. “There were skeptics who thought we couldn’t do more than was already being done,” he says. “They told me they were already the best in the industry. But our chairman saying he wanted to do it provided the impetus to
‘If you really listen to all of the data, you can heal buildings of their wild energy- and water-wasting ways.’
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get these groups together who weren’t used to working together.” Everyone involved, he recalls, had to put aside the old role definitions and stop protecting their skill expertise. As he puts it, the facility guys had to jump more into the IT world and the IT world had to jump more into the facilities world. Those “jumpers” included Bartlett himself. “I was uncertain about the types of rules that make sense in a large building or manufacturing operation,” he admits. “So when we got all that data, I didn’t know how to prioritize it, how to sort it and how to set up rules for it. The facility guys were incredibly valuable helping me do that.” After tackling obvious targets, such as the buildings’ highest energy-using air handlers, Bartlett’s team pursued more complex issues like concurrent heating and cooling conditions. The opposing actions he found in one Rochester building were due to an air-handling maintenance mistake. “We learned that, as the guys make preventive maintenance checks on the units [in warm weather], they put them into override to check the heat. And after checking 400 air-handling units, somebody left one in override. In a facility that big, you wouldn’t notice it being too hot. With so many other air-handling units pumping out cold, the ambient temperature was achieved even in a competitive situation,” he says. “The only way they would have found it was by chance or on the next energy bill. But we picked it up immediately and corrected it.” 28 |
Opposing HVAC operations are most common in large office buildings, which are numerous at Rochester, says Bartlett. In these structures, south-side summer cooling often makes the north side too cold. When this happens, “if people have thermostats, they’ll put the heat on,” he says. “And if they can’t get heat, they put portable heaters under the desk.” The way around the conflict is to use biometric parameters— those based on actual climate conditions—rather than allowing individual preferences to rule. “Think of what the real objective of the building is, based on the season and the set points you have established,” says Bartlett. “You must also ask if you even need set points if people can override them or if the points are not readjusted for seasonal shifts.” The first and most important step, says Bartlett, “is to get the visibility—the data—and start to work on it.” In addition to the need to rapidly monitor data points, this can involve thermomapping of floors to determine hot and cold spots. “The idea of thermomapping is that, when you see a thermal layout, you can lay it over any of the modeling data you have for the building or any of the architectural drawings and understand how to achieve a more consistent temperature for each section,” says Bartlett. If a stuck valve or breach in ductwork is present, he continues, this [methodology] can help find it. According to Bartlett, as data poured into Rochester and was evaluated, maintenance work orders multiplied since “suddenly we had end-to-end visibility. There was a lot of low-hanging fruit, OCTOBER 2011
ON THE ROAD TO SUSTAINABILITY
‘I don’t feel like this is a job. It’s a mission, something you live and breathe, and I never leave it.’ based on the rules and what we were targeting.” After the initial surge, however, “the work orders went way below what they were for maintenance because we were ahead of the curve. Maintenance was not waiting for someone to call with a problem and sending someone out with a flashlight to figure out what it was.” As Bartlett had anticipated and IBM had hoped, the Rochester implementation resulted in even greater energy savings for the campus. “After nine months, we achieved 8% on top of their previous 7%,” says Bartlett. “The facility manager told us we taught them a whole new way to think about the space. And at the end of the 12-month period in January of this year, they were getting a lot fewer service orders and seeing a 200% return already on the investment. They also projected a 10% improvement in maintenance costs.” Ready for the world In June of this year, IBM offered its Smarter Planet software to customers. Underscoring the product’s universality, Bartlett
says he “bundled it differently because it’s not going to the traditional IT [data-center] target. I’ve pre-configured and pre-imaged it so it’s already installed and can be delivered on whatever hardware the customer has. We’re taking the best lessons we’ve learned about how you can configure and install it for this type of application and done that already. And we’ve priced it per square foot, which, for IBM software, is a big shift.” IBM is also expanding the system into more of the 1700 buildings it owns worldwide. “Next year, instead of doing one big site, we’ll do 10,” notes Bartlett. “The real-estate team has declared that, regardless of what happens to the price of energy, IBM’s energy bill cannot go up. So when you’ve already implemented all of the obvious things, you’re looking for new ways, and this gives them something for that.” Bartlett concedes that, with the growing need for sustainable approaches to energy management, he could, if he wanted, be on the job 24/7. “But I don’t feel like this is a job,” he says.
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MT-ONLINE.COM | 29
ON THE TO
Road Sustainability “It’s a mission, something you live and breathe, and I never leave it.” Bartlett says he fully expects IBM will make a substantial contribution to a more energy-efficient future. “In five years, I’ll show you a transformed IBM, and I’ll tell you the impact I’ve made reducing electricity, our carbon footprint and water usage. For just one company, it will be significant. I’ll also tell you about other companies that have implemented this and seen the same result. And if you extrapolate that to all the companies in the world or just the five million buildings in this country alone,” he says, “you’ll appreciate the impact this initiative can have on our planet. It’s going to be an exciting story.” MT
More About The ‘Building Whisperer’ As IBM’s vice president of Industry Solutions, Dave Bartlett leads the company’s development of global industry solutions for a Smarter Planet. He is responsible for the architecture, design and implementation of industry-focused solutions that include Smarter Buildings, Cities, Healthcare, Transport, Chemicals & Petroleum, Telco and Banking as well as Smart Grid and Smart Water. Prior to assuming his current role, Dave spent close to 10 years in Europe as IBM’s vice President of Europe, Middle East and Africa; director of Europe’s software development laboratory; and country site executive. Before joining IBM, Dave worked as a computer scientist and engineer for United Technologies and Univac. For additional details on Bartlett’s holistic approach to building energy management, visit www.ibm.com/smarterplanet. For more info, enter 02 at www.MT-freeinfo.com
Slightly used workhorse
Obtain results on efficiency estimation and torque analysis with the SKF Dynamic Motor Analyzer-EXP4000.
Verify the motor circuit and insulation with the Baker/SKF Static Motor Analyzer - AWA.
Monitor motors online from your office with the SKF Online Motor Analysis System - NetEP
Reliability, durability and longevity are properties worth looking for in test equipment.
Through the years Baker Instrument has been known for developing test instruments that hold up and saves money in the harshest environments. We pride ourselves in continually following that tradition and developing analyzers to provide maintenance professionals with the right tool to efficiently keep rotating electrical machinery operating without downtime.As we transition to SKF durability, reliability and longevity will continue to be our focus. To obtain more information on these instruments contact us at 800/752-8272 or at our website at www.bakerinst.com.
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LMT IS BUILDING A TEAM...
e b Know AnyL u z ? r a t S ©
LUBRICATION MANAGEMENT & TECHNOLOGY (LMT) magazine likes learning about its readers, including what they do in the field of lubrication and what they like about their jobs. Here’s what a recent addition to the team told us:
Steve Vaughan, MLT I Title: Maintenance Mechanic
Alcoa – Mt. Holly Goose Creek, SC Background: Steve Vaughan has been working
in the Alcoa – Mt. Holly operations for 28 years, including 24 in his current position as a maintenance/lubrication professional. He ranks his overall knowledge of industrial lubrication as “advanced,” and tells us that he received much of his lubrication-related education and training on the job and through live workshops and non-structured online opportunities (such as Webinars, company videos, etc.). Why He Became A Lubrication Professional: According to Steve, he viewed
professional development in the lubrication arena as an opportunity to focus on a part of a job that he had been doing for years. After all, as he points out, “There is a lot more to it [lubrication] than shooting grease and filtering oil.” What He Likes Most About His Work: Steve summed up the best part of his work
in one sentence: “I like the wealth of information on lubrication and figuring out the best way to apply that knowledge with resources available.”
Congratulations to Steve for being selected to our Lube Starz team! Our congratulations (and thanks) also go out to Alcoa – Mt. Holly for helping us put a spotlight on Steve, as well as for helping grow the maintenance/lubrication profession.
L utbaerz S
Our hats are off to all our hardworking Lube Starz, who’ll receive their own baseball caps for making this team. Up for the game? Go to www.lmtinfo.com/lubestarz or www.lubestarz.com to tell us about yourself!
Follow the instructions for submitting your own application and photo and you might find your work-related profile in a future LMT issue. We look forward to hearing from you !
Share This With The Lube Starz On Your Team. We Want Them On Our Team!
Don’t Get Boxed in by LOTO
The Benefits Of PESDs Phil Allen, President, Grace Engineered Products
ermanent electrical safety devices (PESDs) have had a marked impact on electrical safety practices. Because they are mounted on the outside of the electrical enclosure, these devices directly affect Lock-out Tag-out (LOTO) procedures. Let’s review them with regard to Article 120.1 of the NFPA 70E.
T h i n k Outside the Panel GRACE
Reduce the risk of arc flash while increasing employee productivity by incorporating PESDs from Grace
Products into your LOTO procedures. To learn more at please visit us at: www.graceport.com/pesd For more info, enter 78 at www.MT-freeinfo.com
Going above and beyond Article 120.1 of the NFPA 70E establishes the procedure for creating an electrically safe work condition. Since this standard was written, the day-to-day practice of electrical safety has changed dramatically. This is due to the increased utilization of PESDs in LOTO procedures. The relatively new concept of permanent electrical safety devices reflects a solution that actually improves a worker’s ability to safely isolate electrical energy over and above that which was originally conceived with Article 120.1. While PESDs go beyond the high standard set by Article 120.1, they still adhere to the core principles found in it. With PESDs incorporated into safety procedures and installed correctly into electrical enclosures, workers can transition the once-risky endeavors of verifying voltage into a less precarious undertaking that never exposes them to it. Every electrical incident has one required ingredient: voltage. Thus, electrical safety can be radically improved by eliminating exposure to it while still validating zero energy from outside the panel. That’s the focus of a new White Paper available for free from Grace Engineered Products. It’s entitled “Permanent Electrical Safety Devices Will Verify Zero Electrical Energy.” A sure way to reduce electrical risks Remember: To employees, all safety—especially electrical safety—is personal. Little else matters to them unless electrically safe work conditions can be created and maintained through their work environment. Article 120.1 of the NFPA 70E was, as its title suggests, penned with the important purpose of establishing the “gold standard” for creating that type of environment. Over time, innovation in the realm of electrical safety has surpassed the precise language of Article 120.1(1-6) because it does not speak directly to the value that PESDs have in achieving electrically safe work environments. With these devices incorporated into safety procedures and installed correctly into electrical enclosures, workers can transition the once-risky endeavor of verifying voltage into a less-precarious undertaking that never exposed them to voltage. You can read more about advances in PESD technology and how they can help protect your personnel and operations by downloading our new White Paper in its entirety at www.graceport.com/pesd. MT To learn more about specific recommendations and practices, visit: info.graceport.com/MT5; or email the author: email@example.com. For more info, enter 03 at www.MT-freeinfo.com
Volume 1 Number 10
RELIABILITY F I L E S TECHNOLOGY M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
RELIABILITY F I L E S TECHNOLOGY M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
Fewer Worries/More Benefits With This New Generation Of Smart Meters Problem Workloads continue to increase. Why shouldn’t tools be expected to do more? That includes your trusty multimeter, which should allow you to carry fewer tools and still get the job done faster and better. Solution Agilent Technologies—the world’s premier measurement company—has brought that type of tool to market specifically for you: The U1233A Handheld Digital Multimeter. Consider the potential benefits you’ll be able to reap if you purchase a U1233A today. How much are they worth to you in terms of time and resources? Less worry over unplanned replacements. The mechanical design of the U1233A’s flexible protective holster makes sure that you can drop this meter multiple times from any work site location with very little chance of damage. The hammerhead body shape helps provide an easy grip, even for gloved hands. The bright orange color makes sure that the tool is not left behind accidentally. All these design elements are key to ensuring a full service life. No flashlight to carry. The U1233A has an LED flashlight built in, aiming at the exact location where you would want to put your test leads. Saves you money, time and effort. No need for pencil and paper. Up to 10 independent readings can be stored and recalled at will in your U1233A. There’s no need to carry pencil and paper to write down readings as you go about your routine. No need for a voltage sensor. A non-contact voltage sensor allows
easy checking of live voltage without direct access through the protective insulation. Most operators carry one in addition to their handheld meters. Such a sensor is already built into the U1233A. No need for an analog meter. The induced “ghost” voltage indicated by sensitive digital multimeters can be confusing to operators. In the past, to safely disprove its presence, an operator would have to use an analog meter. The low input impedance loads down the induced voltage and the mystery is solved. Now, with the U1233A, an operator just switches to ZLOW and the device performs the same test as an analog meter. No wasted calibration. When an operator accidentally puts live voltage on the current function, the U1233A is protected with a high-energy fuse. Moreover, this fuse is easily accessible from the battery compartment. There’s no need to invalidate your calibration sticker by opening the case to access fuses on the circuit board, as found in many common meters. Less calibration cost. The U1233A, like all the handheld meters from Agilent, uses a closed-case calibration scheme. It is the most advanced, costefficient way to calibrate, eliminating most of the repetitive, unnecessary labor costs. No need to double-team. In the past, you may have needed a working partner to read the meter and relay that information back to you on a walkie-talkie. With the new Bluetooth adaptor accessory, you can easily read your Agilent U1233A from 10 meters away. Soon, you can add this to any of your Agilent meters.
Return On Investment The new generation of meters from Agilent is smarter and better thoughtout than what you may have been using up until now. They address many of the inconveniences that plague maintenance professionals. With these state-of-the-art tools, maintenance is becoming much more efficient and productive. For more information visit www. agilent.com/find/AgilentU1230. MT Agilent Technologies, Inc. Santa Clara, CA
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THE RELIABILITY FILES / OCTOBER 2011
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RELIABILITY F I L E S TECHNOLOGY M A I N T E N A N C E
Your Source For CAPACITY ASSURANCE SOLUTIONS
Lubricants Are Not Commodities: Making The Case For Superior Lubrication Problem Lubricant performance can vary greatly between competing mineral-based and synthetic oils. Because these quality differences directly and significantly impact the ultimate cost of operating and maintaining rotating equipment, your lubricant purchases can’t be managed the same way your organization manages its purchasing of commodity-type products. Lubricant excellence must always be the top priority, for even the most effective lubricant-management practices can’t impart properties to a lubricant that it doesn’t possess. Solution The primary job of a lubricant is to reduce friction and protect lubricated components. (Those reflect, respectively, energy- and wear-related issues.). Most rotating equipment repairs are due to the failure of lubricated components, mainly bearings. Therefore, it makes perfect sense that truly superior lubrication will deliver both energy and maintenance savings. That’s where Royal Purple comes in. Return On Investment Royal Purple lubricants consistently deliver a higher level of performance across a broader group of equipment than other industrial oils. The cost reductions achieved with these lubricants consistently exceed the total cost of the product, often within a few weeks. A number of real-world case examples back up these statements—based on actual data from paper mills, food processing facilities, refineries, chemical plants and more. They’re available for your review at http://royalpurpleindustrial.com/techi/whyrpi.html. These success stories have been categorized by the primary benefit reported from using Royal Purple products: energy savings, maintenance savings or improved production. In these cases, Royal Purple lubricants replaced major brand products that met all of the equipment manufacturer’s requirements. In multiple examples, Royal Purple replaced another synthetic oil. In most of the studies, the equipment involved didn’t suffer from mechanical defects, nor did it lack proper maintenance. The improved performance resulted because Royal Purple lubricants were able to mitigate effects of the conditions in which the equipment was required to operate. All of the energy studies are inclusive of every piece of machinery selected for evaluation so as to be representative of what might be expected across a broad population of equipment.
• Example is based on 36,000 hp (electrically driven) operating 8000 hours per year @$0.05 kwh power cost • Lubricant purchases are 3% of the maintenance costs • Lubricant purchases are 3/4% of the energy costs • Though conceptually accurate, expense ratios will vary from plant to plant
But don’t just take our word for it. Royal Purple encourages you to make an informed decision based on actual results in your own machinery. Ask your maintenance and operations departments to select equipment for an evaluation of what Royal Purple lubricants can do for you. To learn more, visit us at www.royalpurple.com. Royal Purple Porter, TX
REMEMBER: Most initiatives intended to reduce maintenance costs and improve rotating equipment reliability are very time- and people-intensive. Royal Purple offers substantial improvements and cost savings by simply replacing a product you already buy and use. It doesn’t get any easier than this.
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THE RELIABILITY FILES / OCTOBER 2011
“...we extended drain intervals from every 15 days to every three months AND reduced engine repairs and replacements.” Luis Garza Kingfisher Marine Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. Get your FREE copy of the ‘Lowest Total Cost of Ownership’ today by calling 866-447-5173 . . .
For more information on Royal Purple, visit royal-purple-industrial.com today. For more info, enter 280 at www.MT-freeinfo.com For more info, FILES enter 281 at www.MT-freeinfo.com For more info, /enter at www.MT-freeinfo.com JULY 2011 THE280 RELIABILITY
MT-ONLINE.COM | 37
CAPACITY ASSURANCE STRATEGIES
Maintenance As A Profit Center:
It’s The Only Way to See It Despite great strides in maintenance techniques, management too often views the department as a cost center. That can be a very costly mistake. Anthony M. “Mac” Smith AMS Associates
imes and thinking in the industrial world have changed dramatically in the past three decades. In maintenance, technical change and innovation have brought us predictive maintenance (PdM) technology, which has been, and continues to be, one of the foremost positive changes in the way we do business. It has provided the opportunity to measure and trend equipment health and avoid intrusive actions until absolutely necessary. It minimizes the well-documented risk of human error that might require another service call to fix.
CAPACITY ASSURANCE STRATEGIES
PM $1 Here
and Reduces $100 Saves $10 Here to $10,000 Here
AMS’ experience with “effective PM tasks”
A second important innovation is the widespread use of IT that has given us the CMMS and its capability to record, store and retrieve volumes of useful data and information at the touch of a keyboard button. While we have not yet learned how to best use all of this CMMS capability (such as developing useful equipment-history files), it has, nonetheless, advanced the automation of routine maintenance paperwork (work orders) that previously required many man-hours and file cabinets. A third important innovation, and one that has been paramount for me, is the widespread use of Reliability-Centered Maintenance (RCM) methodology. Introduced by United Airlines in the mid-1960s to address maintenance issues on the new Boeing 747-100 airplane, the RCM process shifted our attention from a mindset of “preserve equipment” to one of “preserve function.” This allowed us to concentrate resources on what really counted—functions—and away from efforts designed to simply keep everything running, regardless of importance. With all of the achievements industrial maintenance has made, however, it’s odd that we’re still dogged by something that has not changed (or changed little) in this time: the age-old management perception that maintenance is a necessary evil and unfortunate cost center. Maintenance today is still too often simply tolerated rather than appreciated or, worse, effectively used. Simply put, a properly managed and deployed maintenance organization is a BIG money generator! Let’s explore this further. It’s all about the money As a consultant, my first task when meeting with a client is to establish that there is only one reason for our meeting and discussion: money. I have discovered that once the initial focus is on money, perception of maintenance improvement can change from simply reducing Preventive Maintenance (PM) costs to increasing Return On Investment (ROI) from OCTOBER 2011
maintenance expenditures. The ROI factor is a significant, if not the dominant, element in forming any maintenance strategy. This is because PM costs are relatively small when compared with those that might be incurred through Corrective Maintenance (CM) actions and possible loss of revenue from downtime (DT). As illustrated in the accompanying figure, this concept can be used to drive a maintenance optimization strategy. Notice that the model shown recognizes the costs required by the PM and CM portions of the maintenance effort. Unfortunately, most organizations look only at these two elements and conclude that maintenance is strictly a cost center. They determine that the driving force behind maintenance improvement is to minimize maintenance costs in any way possible. The net result is frequently a reduction in PM activity. And if this is measured, the net effect is usually an increase in CM cost and an increase in lost revenue. Maintenance = profit These two unwanted results—an increase in CM costs and, especially, lost revenue—are key factors that can help define a maintenance organization’s true role. Specifically, when the emphasis is on spending needed funds to activate a meaningful PM effort, our measurements over 25 years of experience indicate that the multipliers shown in the figure are achieved. While an effective PM program can increase PM costs, each PM dollar spent and effectively focused on the bad-actor systems in place can actually preclude the necessity to spend $10 dollars on Corrective Maintenance. But the multiplier of particular interest is the reduction in output Downtime, where a multiplier of $100 to $10,000 can be achieved. This reduction translates directly to profit! The figure on this page makes a strong argument in support of our belief that maintenance is, in fact, a profit center for your operations. Although this may be a new notion to some readers, our experience has indicated it to be a key factor in producing dramatic bottom-line impact—and moving a maintenance organization toward what constitutes "World Class." MT Mac Smith has more than 50 years of technical and management experience in reliability/availability/maintainability (RAM), component and system design, hardware test and evaluation, data management, product assurance, and safety and plant maintenance optimization via RCM methodology. Widely regarded as a pioneer of RCM and advanced maintenance practices, he is the author of Reliability-Centered Maintenance, the highly regarded 1993 book on RCM, and RCM—Gateway To World Class Maintenance, published in 2004. Over the last 27 years, Smith has directed and contributed to a wide variety of consulting projects in the energy, aerospace and industrial sectors. Email: firstname.lastname@example.org. MT-ONLINE.COM | 39
PERFORMANCE IMPROVEMENT POINTS
Equipment Criticality Assessment For Reliability
quipment criticality assessment is a key process in the development of any maintenance and reliability process. It provides the basis for determining the value and impact that specific equipment has on the manufacturing or production process, as well as the level of attention that equipment requires in terms of maintenance strategy and tactics. A practical means of conducting such assessments is i-Quantum Solutions’ Visual Risk tool—which is being used by companies across the globe for equipment criticality reviews. This innovative software solution not only provides a structured and standard method for completing this critical activity, its approach is highly interactive and engages the operational and technical staff in the process. How Visual Risk Works An asset register or equipment list can be exported from any maintenance management system and uploaded via Microsoft Excel to the Visual Risk Tool. ISO 14224 equipment classes and types taxonomy is provided. The tool’s risk consequence and likely calibration scores and descriptions can be constructed easily for any plant (and for several risk criteria specific to an individual operation or corporation). The risk matrix display of equipment risk is viewed online for workshop reviews and interaction. The quality and data security of the criticality assessment is significantly improved—i.e., error-free—with the internal data checks that are performed. Typically, more than 200 equipment items can be reviewed in a day with the multidiscipline group (which makes the best use possible of personnel’s time and effort). Any applicable technical drawing or document of the equipment and system can be uploaded to the application and displayed during the review process. Reports are automatically generated in the following forms: risk matrix, risk pareto graph and criticality ranking tables. Data can be exported straight to Microsoft Excel for offline review or for upload of information into the client CMMS. Cloning of similar equipment and associated risk scores significantly reduces the time to perform the criticality review process. A maintenance ranking and prioritization matrix can be incorporated to provide a direct link from the criticality assessment to the maintenance activity. Visual Risk can directly interface with other available analysis modules such as FMEA, FMECA, Spares Criticality, Maintenance Tactics Review and Maintenance Task Selection. MT To learn about i-Quantum’s practical performance improvement processes and innovative solutions, visit www.i-qs.com, or email: email@example.com For more info, enter 04 at www.MT-freeinfo.com For more info, enter 81 at www.MT-freeinfo.com For more info, enter 79 at www.MT-freeinfo.com
SUPPLY CHAIN LINKS
Expansion Joints: Growing The Technology Advanced materials and innovative technology have transformed a common product into something extraordinary, further raising industry standards.
Jane Alexander, Editor with Lloyd B. Aanonsen, P.E. General Rubber Corp.
lastomeric (rubber) expansion joints have long been recognized for their ability to reduce noise and vibration and accept fluctuating thermal movements in piping systems. Recent advances in engineered elastomers and textiles have led to the development of expansion joints with improved performance and operating life that benefit both new and existing construction. Equally valuable are application-based ratings and design tolerances built to accommodate moderate misalignment and/or brief excursions outside design ratings. One of the best strategies users can leverage involves engineered (i.e., custom) expansion joints—unique products manufactured to spec for particular applications. Custom-engineered solutions are ideal for operations taking a condition-based replacement approach, as opposed to the more common, and at times inefficient, practice of time-based replacement. Technological resources such as computer-aided design provide the tools needed to create these types of products for the most complex applications. Advances in methods and materials of construction The most common expansion-joint fabric reinforcement used to be square-woven cotton or polyester. “Square-woven” means the fabric strands are intertwined perpendicular to each other
and have approximately the same strength in each direction. If greater strength were needed in one direction, engineers would have to increase the overall number of plies, thereby increasing the strength in both directions and—consequently—also increasing overall joint stiffness (which is loosely defined as the force needed to move the joint a fixed distance). Today’s expansion joints use modern engineering principles and materials developed largely in the tire industry— including tire cord plied up on a specified bias angle. General Rubber’s design reflects a wide-flowing arch reinforced with polyester tire cord in just that type of bias ply arrangement (Fig. 1). Coated with the advanced adhesive resourcinol formaldehyde latex (RFL), the tire cord also ensures a superior rubber-to-fabric bond. (This RFL was developed by MT-ONLINE.COM | 41
SUPPLY CHAIN LINKS
Resultant Bias Top & Bottom Ply Overlapped
Fig. 1. Bias ply angle detail
the tire industry to optimize bond strength between elastomer and fabric, preventing ply separation and delamination.) These advancements have resulted in higher expansion-joint tensile strength and increased all-directional movement. The bias angle can be adjusted to increase the strength in one direction versus the other—a significant benefit since the resultant forces in an expansion joint are typically greater in the axial and not radial direction. Bias-angle adjustment is even more important when a large arch is used for increased movement capabilities. Advancements in engineered elastomers have made it possible to design expansion joints for continuous exposure to elevated temperatures (400 F), pressures in excess of 350 psi and a high resistance to chemical erosion and abrasion. Many of these designs incorporate DuPont Viton, Teflon liners and Kevlar tirecord fabric reinforcement. The combination of advanced elastomerics, superior bond strength between plies and optimal number of angle plies creates a homogenous composite with consistent and predictable engineering capabilities. The larger arch form and reduced overall number of plies increase all-directional movement capabilities while minimizing stiffness. Increased flexibility, in turn, reduces stress on the piping system. Custom-engineered-application success Building expansion joints to exact field dimensions addresses another crucial problem in both replacement and retrofit projects. In the course of its life span—typically 20 years—piping settles and offsets at different rates. A largediameter condenser, for example, can develop non-parallel flanges and large lateral offsets. This was the problem in a Northeast nuclear power plant, where a 108”-diameter pipe had lateral offsets in excess of 2” (see Fig. 2). As the condenser and piping system still had many years of life left, the question of how to fit in this offset was resolved by building the lateral offset into the replacement expansion joint. While the adjacent valve would usually be replaced or refurbished at the same time, in such a replacement it’s often cost42 |
Fig. 2. Field measuring offsets and building replacement expansions joints to fit the application’s parameters not only minimizes installation time and expense, it ensures 100% of the joint’s allowable movement capabilities and operating life.
prohibitive to realign the piping. It’s also unrealistic to order a replacement valve with varying overall lengths and built-in lateral offsets. On the other hand, it’s relatively inexpensive for the expansion joint manufacturer to incorporate these field variances in the replacement expansion joint. Before this technique was developed, the installation crew could spend a great deal of time and effort forcing a straight standard product into an offset and misaligned position. After an exhausting installation process, the standard joint would have been substantially compromised, reducing the life due to permanent installation stresses. In many cases, the actual field-measured offsets exceed the allowable movement capability of the joint—practically ensuring an imminent failure. When the expansion joints are custom- built to fit the application parameters, it not only minimizes installation time and expense, it also ensures 100% of the allowable movement capabilities and operating life. The advanced features and improved safety factors actually increase reliability and life expectancy. Retrofit applications are slightly different in that a complete section of equipment and piping is often replaced. Problems arise when the new equipment doesn’t line up with old piping. (Center-lines of the pump’s suction and discharge may be different from the original equipment, etc.). An expansion joint can be used as a transition piece between new and old flanges. If a lateral offset is required, it can simply be manufactured into the expansion joint. This gives the design engineers greater flexibility when designing retrofit systems. Expanded capabilities New design features in piping expansion joints allow them to do more with less. Their expanded versatility includes the ability to accept greater all-directional thermal movements, plus more flexibility for reducing noise and vibration and excellent resistance to shock and fatigue. They also accommodate moderate misalignment and/or brief excursions outside design ratings with a longer useful life. Incorporating these advantages in OCTOBER 2011
SUPPLY CHAIN LINKS
custom expansion joints built to exact field dimensions offers greater opportunity for design engineers. Moreover, utilization of advanced engineered elastomers and textiles has made it possible for expansion joints to be used in a wider cross section of chemically abrasive and erosive mediums under higher system temperatures and pressures. MT
Lloyd Aanonsen is president of General Rubber Corp. A licensed professional engineer with an MBA, he’s been designing and developing non-metallic expansion joints and other mechanical rubber products since 1987, and has published several articles on the subject. Aanonsen has also completed multiple terms as chairperson of the Fluid Sealing Association’s (FSA’s) Expansion Joint Division. Email: firstname.lastname@example.org.
VFD-Induced Bearing Currents Kill Motors!
More About General Rubber…
From simple to simply amazing… General Rubber Corp. (www.generalrubber.com) has been designing and developing a wide range of mechanical rubber products for the most demanding applications since 1950. Customer commitment is evident in every aspect of its business. That includes maintaining a team of engineers who are prepared to discuss each application and identify the best solution at the best price. If an effective solution can’t be obtained from its extensive product line, the company will custom-design that “best” solution. This attitude is ingrained throughout the organization and lies behind its tradition of releasing new products each year. General Rubber is a founding (and active) member of the Fluid Sealing Association (FSA). The company’s leadership in technology and ability to consistently exceed customer expectations was validated when it became the first company in its industry to earn ISO-9001 certification. For more info, enter 05 at www.MT-freeinfo.com
Your motors may be at risk! Now, with the AEGIS™ Shaft Voltage Test Kit, you can measure voltages on the shafts of your motors to quickly and easily see if they are at risk of bearing damage.
Save your motors with
SGR BEARING PROTECTION RING
The AEGIS™ SGR protects motor bearings from damaging shaft currents, extending motor life and reducing downtime.
• Channels harmful currents safely to ground • Maintenance-free, lasts for life of motor • Easy to install — standard sizes and universal mounting kit simplify installation on any size or shape motor
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For a free in-plant motor shaft voltage test, fill out the form on our website: www.est-aegis.com/freetest.htm For more info, enter 80 at www.MT-freeinfo.com
11-343 Probe and O-Scope Isle hlf ad (MT).indd 1
MT-ONLINE.COM | 43
9/15/11 10:21 AM
TECHNOLOGY SHOWCASE Looking at trends in products and services in the area of...
Information Technology ...What’s up?
aintenance pros pulled unwillingly into the world of Information Technology (or IT) decades ago will probably now admit that without IT (and an on-call IT expert), most industrial operations could not compete in the 21st century. Though the benefits of IT-centric solutions were late in coming to maintenance, today there’s probably not a single medium- to large-scale operation whose maintenance teams have not integrated at least some IT-category components. Software programs and systems, computers and related hardware, as well as network components,* are all vital parts of today’s industrial environment. The computerized maintenance management system—CMMS—is the IT centerpiece of most maintenance organizations. Though many installed CMMS systems remain underutilized, CMMS has nonetheless revolutionized how maintenance is scheduled, work orders are prepared and accessed and how equipment condition is monitored. To counter complaints that the complexity of CMMS products makes them hard to implement and use (aided in part by a continuous, rapid rise in features and functions), vendors have begun to simplify many options. Web-based CMMS applications, for example, remove the need for on-site hosting and management and, at the same time, give users universal access to their information as well as higher-level options at less cost. Vendors have also made CMMS systems easier for users to customize (rather than require them to operate within set parameters), have improved analytic tools for condition-based maintenance efforts and made on-screen visuals more intuitive. Simplicity and ease-of-customization are expected to continue in the CMMS sector, as will the incorporation of CMMS functions into larger plant- and companywide EAM systems like those from SAP. Pricing flexibility will also increase as vendors offer greater purchase options, such as monthly software-as-a-service (SaaS) agreements that include installation, training and support. Worker access to computers for performing maintenance work is a key part of the IT evolution. Not only are maintenance job carts often PC-equipped today, maintenance teams benefit from other portable versions, such as tablet computers and PDAs, including smartphones. The enterprise digital assistant, probably bestsuited for in-plant maintenance work, resembles a rugged smartphone, but is equipped to capture data from barcodes, RFID transmitters and other sources. As our ability to electronically generate and analyze information grows, paperwork can be reduced, efficiencies improved and communication opportunities expanded. The trend to produce ever greater amounts of data, however, means that our systems to gather, manage and analyze it must match the pace if the data is to have value. While some new software programs can interpret large quantities of data in real time, especially for energy-system management, these could tax the resources of smaller operations. As a result, according to experts, database outsourcing will emerge as a growing, cost-effective solution. MT Rick Carter, Executive Editor *Definition determined by Maintenance Technology editorial staff.
MACHINING WITHOUT COOLANT The Cold Gun Aircoolant System™ increases tool life, tolerances and production rates by eliminating heat build-up. The quiet Cold Gun produces cold air at 20°F from compressed air to extend tool life, stop burning, and reduce wheel loading. No moving parts assures maintenance-free operation. The Cold Gun is ideal for dry machining or to replace messy mist systems. Applications include milling, tool and carbide grinding, drill sharpening, plastics machining. (800) 903-9247. E-mail: email@example.com. www.exair.com/48/199.htm
EXAIR CORPORATION Formore moreinfo, info, enter enter 00 81 at For at www.MT-freeinfo.com www.MT-freeinfo.com
Stop wasting time & money finding the right part. Mincom LinkOne can help.
Try The 30-Day Free TriaL www.mincom.com/free-trial Call Jennifer at 303-446-6338
For more info, enter 84 at www.MT-freeinfo.com
What’s Up With November’s
Arc Flash Protection & Electrical Safety 70E
Public Seminars or Training at Your Facility • Live, Instructor Led Training
We Look At Trends In The Area Of
• Identify Electrical Hazards
Testing & Analysis
• Safety Related Work Practices • Maintenance Requirements • Call or Visit for a Complete Schedule
Calling All Advertisers! Want to see your products and/or services featured here?
Creating a Better, Safer and More Efcient Maintenance Workforce
www.AmericanTrainco.com For more info, enter 82 at www.MT-freeinfo.com
Please contact your ad rep For more info, enter 83 at www.MT-freeinfo.com
OH, KY, TN JOHN DAVIS 440-463-0907; Fax 440-891-1254 firstname.lastname@example.org AL, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV JIM HANLEY 610-793-3093; Fax 610-793-3094 email@example.com CT, ME, MA, NH, NY, RI, VT, ON, QC VINCENT LeGENDRE 508-428-3331; Fax 508-428-2545 firstname.lastname@example.org IL, IN, IA, MI, MN, NE, ND, SD, WI TOM MADDING 847-382-8100 x108; Fax 847-304-8603 email@example.com AR, KS, LA, MO, NM, OK, TX GERRY MAYER 972-816-6745; Fax 972-767-4442 firstname.lastname@example.org AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK JERRY PRESTON 480-396-9585 email@example.com
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MT-ONLINE.COM | 45
Powered-Up Machinery Protection: The Highest Degree Of Reliability & Safety
A fully-redundant, vibration-based monitoring system is taking it to the max.
n the modernizing of PowerSouth Energy Cooperative’s McIntosh Power Plant, near McIntosh, AL (America’s only compressed air energy storage plant), safety and maximum availability were of the utmost importance. This called for a machinery protection system with a maximum degree of fail-safe reliability and reaction capabilities to help guarantee the safety of the machine and its surroundings— without any loss of availability due to spurious trips. During the upgrade of the plant’s existing I&C system to Siemens Power Plant Automation T3000 (SPPA-T3000), the McIntosh facility was also equipped with VIB3000 Machinery Protection from the SPPA-D3000 portfolio— the most modern and reliable protection system on the market today. An efficient combination of two essential machinery protection functions in VIB3000 (vibration and combustion chamber humming), replaced two obsolete instrumentation systems, while retaining the existing sensors, thus saving time and money. The system can be integrated fully into the I&C system and supports operations from the plants DCS. It combines I/O interfacing modules and machinery protection into one single system. According to PowerSouth Energy Cooperative’s project manager Robert Meyer, “The complete integration of the protection system into the I&C system was the winning argument for us. Schedule and budget targets were also consistently adhered to. This enables us to achieve the highest degree of reliability and availability while reducing costs at the same time. We are very satisfied with the results.”
Protection systems must guarantee security for the machine and for the environment at reasonable costs and preferably without any loss of availability. To achieve this, the protection system itself must be reliable and manufactured to the highest standards. It also must offer flexibility in its use and application—i.e., 2 out of 3 alarm voting, redundancy from the sensor level up to the communication level and user-friendly design and functions. The VIB3000 does all that. This innovative solution is the first-ever fully redundant, vibration-based monitoring system to simultaneously guarantee maximum safety and maximum availability of power plant assets. Benefits include… ■ Enhanced power plant component availability due to maximum fail-safe availability ■ Maximum safety and reliability attributed to rapid reaction time and ease of use ■ Full operability from control room ■ Low total cost of ownership (TCO) ■ Modern design ■ Flexibility of integration to I&C systems Siemens Energy, Inc. Alpharetta, GA
For more info, enter 30 at www.MT-freeinfo.com OCTOBER 2011
xtech’s durable HDV600 highdefinition borescope camera series features a 5.7” (145mm) color display for bright outdoor sites or poorly lit facilities. Optics include 4mm-6mm LED-illuminated camera probes. An SD memory stores 15,000 JPEGs or video (plus audio annotations). Glove-friendly controller handsets with 320˚ articulated probes and wireless connectivity (10 m range) simplify inspections. Extech Instruments A Flir Company Waltham, MA For more info, enter 32 at www.MT-freeinfo.com
Tool Vending Machines
astenal’s FAST 4000CT and FAST 2000CT cutting-tool vending machines are designed to provide point-of-use dispensing of individual inserts and round tools. With these compact, costeffective units, workers have secure, 24/7 access to tooling without having to leave the work cell. There’s no capital expenditure required since the local Fastenal store provides the machines and keeps them stocked. This helps eliminate inventory, improve productivity and reduce cuttingtool consumption. Fastenal Winona, MN For more info, enter 33 at www.MT-freeinfo.com
Upgraded Oil-Analysis Software
ingo’s Trakka® Web-based software system lets the company’s Condition Based Asset Management (CBAM) system track, store and analyze oilsample data to help identify maintenance issues early on. The software’s latest version allows easier dissemination of information and more detailed tracking. Other enhancements include the ability to integrate with existing CMMS/ERP systems. Dingo Software Pty. Ltd. Centennial, CO For more info, enter 34 at www.MT-freeinfo.com
G100/G120 Series Features:
• Panoramic Shot
Panoramic Thermal Imaging Function
• Vibration Alarm
Vibration Alarm Function for Noisy Environments
• Thermal Image Movie Direct Recording of Fully Radiometric Images on SD Card
• 3.5 Inch LCD Screen
Flexible 270 Display Supports Easy Shooting Posture
• Easy Operation
Joystick for Intuitive Operation, Auto Focus / Level Sense
• Image Fusion Function Allows for Parallel and Synthetic Display
• Data Storage Format 2GB SD Card Radiometric JPEG
Sales@NECAvioInfrared.com www.NECAvioInfrared.com Tel: (800) 423-2344 Ext. 411 For more info, enter 86 at www.MT-freeinfo.com
MT-ONLINE.COM | 47
CAPACITY ASSURANCE MARKETPLACE
Wireless Temperature Loggers
T Anti-Slip Metric Wrenches
rightGrip™, an innovative, high-strength, antislip design from Wright Tool is now available on the company’s open-end and combination wrenches in metric sizes from 7 to 24 millimeters. The WrightGrip feature ensures that the wrench fits snugly on the fastener, thus preventing the jaws from spreading and the wrench from slipping. Wright Tool Company Barberton, OH
he new TandD RTR-505Pt Wireless Temperature Logger works with industry standard 3-wire Pt-100 sensors and accepts industry standard 3-wire screw terminal attachments. The temperature range is from -199 C (-326.2 F) to +650 C (1202 F) depending on the sensor selected. It features a large LCD display, holds 16,000 readings and is IP64 water-resistant. Products in this series boast battery lives from 10 months up to four years (for the “L” version). A standard communication range of up to 500 feet can be extended with the use of repeaters. TandD Corp. Saratoga Springs, NY
For more info, enter 35 at www.MT-freeinfo.com
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Upgraded Ethernet Security
PIP IS SIMPLE. Let PIP’s harmonized engineering Practices simplify your next project.
www.pip.org For more info, enter 87 at www.MT-freeinfo.com
48 | MAINTENANCE TECHNOLOGY
chweitzer Engineering Laboratories has enhanced its SEL-3620 Ethernet Security Gateway, a firewall and access control solution for substations and industrial environments. The upgrade adds centralized, user-based access controls to serial intelligent electronic devices (IEDs), Ethernet IEDs and critical protection devices downstream of the gateway without disturbing existing configurations or requiring infrastructure upgrades. It generates complex passwords and adds automatic password management on a user-configurable schedule or triggered basis. Schweitzer Engineering Laboratories, Inc. Pullman, WA
For more info, enter 37 at www.MT-freeinfo.com OCTOBER 2011
100+ Maintenance Tips For Free
revised brochure featuring more than 100 tips from real-world maintenance and operations personnel is now available at no charge from Kano Laboratories. Included are ideas for handling frozen bearings, loosening corroded bolts and frozen brake cables, removing rust, improving belt power transfer, improving engine performance, increasing gas mileage and much more. Kano Laboratories, Inc. Nashville, TN For more info, enter 38 at www.MT-freeinfo.com
Mechanical Power-Relay Modules
pto 22’s SNAP-OMR6-A and SNAPOMR6-C mechanical relay modules provide a way to switch higher voltages and currents without the need for breakout boards, header cables or other interposing hardware. The company notes these modules offer three times the rated current switching capability of standard SNAP optically isolated outputs. Opto 22 Temecula, CA
Features: • High Performance
640 x 480 Pixel Array with 0.03C NETD
• Radiometric Movie Recording Simultaneous Thermal / Visual / Fusion Video Recording Feature (30fps)
• Large 5.6 Inch LCD Display For more info, enter 39 at www.MT-freeinfo.com
Multiple Technologies In One Lubricant Management System
es-Case’s FlowGuard LT Series Lubricant Management System (LT-LMS) incorporates multiple technologies in a single unit to keep lubricants clean before they enter your equipment. Sturdy, stackable and customizable storage pods free up valuable floor space, while features like quick-disconnects and desiccant breather filters help keep fluids clean and dry. High-density polyethylene and steel tanks are available in a range of sizes with a variety of hose-end connections. Each container features a dedicated pump and motor and allows for the management of a number of lubricant types. Des-Case Corp. Goodlettsville, TN
For more info, enter 40 at www.MT-freeinfo.com
Equipped with Glare Resistant LCD Screen and View Finder for Sunny Outdoor Conditions
• Superb Auxiliary Functions Built-In LED Illuminator and Laser Pointer
• Excellent for Field Work
Field Replaceable Optional Lenses and IP54 Environmental Protection
• Articulate Eyepiece
Sales@NECAvioInfrared.com www.NECAvioInfrared.com Tel: (800) 423-2344 Ext. 411 For more info, enter 88 at www.MT-freeinfo.com
MT-ONLINE.COM | 49
CAPACITY ASSURANCE MARKETPLACE
System For Complete, Uniform Lubrication Of Critical Areas
praying Systems says its AutoJet Electrostatic Lube System can provide complete, uniform lubrication of critical areas and is also well suited for oil-coating applications and other lube tasks calling for single-point delivery. Capable of accommodating up to four electrostatic nozzles with an injector pump for each, the system eliminates oil-mist concerns in the work environment, minimizes cleanup and reduces potential for product contamination. It can also help reduce oil consumption. Spraying Systems Co. Wheaton, IL For more info, enter 41 at www.MT-freeinfo.com
Asset Management Consulting and Training Services
Think you are
WORLD CLASS? Find out by using our maintenance benchmarking tool. FIND OUT Download our FREE Qwik Ratio Tool www.marshallinstitute.com/qwik
1-800-637-0120 For more info, enter 89 at www.MT-freeinfo.com
50 | MAINTENANCE TECHNOLOGY
Base Mounts That Dampen Shock & Vibration Concerns
onical antivibration base mounts from Advanced Antivibration Components are designed to dampen shock and vibration for compression loads up to 3598 lbf (1632 kgf). They feature zinc-plated steel metric housings and isolators made of a nitrile rubber compound that offers excellent pliability and elasticity. Typical applications include controllers, large pumps, fans, motors, compressors and other medium-load equipment. Advanced Antivibration Components New Hyde Park, NY For more info, enter 42 at www.MT-freeinfo.com
Revamped Line Of Extreme Service Greases
hell Lubricants has launched an improved range of Shell Gadus greases designed to meet the challenges of large, fast equipment operating in some of the most extreme conditions imaginable, including mining, steel-production, power-gen and marine applications, among others. The revamped lineup makes it simpler for customers to compare product benefits and performance while taking into account variables such as compatible thickeners, base oil viscosity, NLGI grade and other special performance characteristics. Shell Lubricants Houston, TX For more info, enter 43 at www.MT-freeinfo.com OCTOBER 2011
Heavy-Duty Peristaltic Pumps
lowrox’ heavy-duty LPP-T peristaltic pumps can be used in a range of difficult applications, including those handling abrasive, corrosive, viscous or crystallizing media. Their advanced design eliminates friction, maximizes hose life and lowers energy consumption. According to the company, its LPP-T pumps double the flow per hose compression compared with conventional peristaltic units. Flowrox, Inc. Linthicum, MD For more info, enter 44 at www.MT-freeinfo.com
Ultra-Small Drain Inspection
he RIGID SeeSnake nanoReel N85S industrial drain-inspection camera is designed for ultrasmall-diameter lines ranging from ¾ to 2 inches. The compact system let users push cable distances of up to 85 feet. At 9½ pounds, the product can easily be transported to and from jobsites. RIDGID Emerson Professional Tools Elyria, OH For more info, enter 45 at www.MT-freeinfo.com
• Panoramic Imaging
Vertical or Horizontal Panoramic Thermal Images are Captured without using a PC
• Close Focus Distance
Minimum Focus Distance of 10cm (3.9”) allows user to Image Small Targets without Additional Lens
• Thermal Image Movie
Simultaneous Thermal / Visual / Fusion Video Recording Feature (10fps)
• 3.5 Inch LCD Screen
Equipped with Glare Resistant LCD Screen and View Finder for Sunny Outdoor Conditions
Lightweight, Digitally Controlled, Mechanical Torque Multipliers
• High Sensitivity & Accuracy
• Unique Emissivity Features
dvanced Torque Products’ digitally controlled, all-mechanical torque multipliers have ranges from 600 to 40,000 ft./lbs., with accuracy to ±1%, even over extreme temperature fluctuations. These lightweight products need no external power and present a small, ergonomic footprint. According to the manufacturer, a host of drive adapters and mounting fixtures accommodate existing tooling for most applications.
Advanced Torque Products, LLC Berlin, CT For more info, enter 46 at www.MT-freeinfo.com OCTOBER 2011
320 x 240 Pixel Array with 0.05C NETD provides High Contrast, Clear Images while Maintaining ±1C / 1% Accuracy Set Individual Emissivity Values for Multiple Points or R300 Automatically Sets Emissivity Values for Points of known Temperature Sales@NECAvioInfrared.com www.NECAvioInfrared.com Tel: (800) 423-2344 Ext. 411
For more info, enter 90 at www.MT-freeinfo.com
MT-ONLINE.COM | 51
CAPACITY ASSURANCE MARKETPLACE
High-Performance, Synthetic Industrial Gear-Oil Family
xxonMobilâ€™s new Mobil SHC Gear Series is a line of high-performance, fully-synthetic industrial gear oils formulated to help general manufacturing and processing industries increase productivity and reduce costs by lowering energy consumption and extending oil drain intervals. Approved by Siemens for use in Flender gearboxes, these lube products, according to ExxonMobil, meet or exceed nearly every other major industry and OEM specification for industrial gearbox applications. The company notes that in statistically validated laboratory tests and field trials, these fluids exhibited energy savings of up to 3.6% compared with conventional oils.* ExxonMobil Corp. Fairfax, VA
For more info about ExxonMobil, enter 47 at www.MT-freeinfo.com
*Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and application. For more info about Flender/Siemens, enter 48 at www.MT-freeinfo.com
Customized, Targeted Lists For Your Marketing Needs
ATP List Services Ellen Sandkam www.atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 847-382-8100 x110 / 800-223-3423 x110 firstname.lastname@example.org / email@example.com For more info, enter 91 at www.MT-freeinfo.com
52 | MAINTENANCE TECHNOLOGY
For more info, enter 92 at www.MT-freeinfo.com OCTOBER 2011
CAPACITY ASSURANCE MARKETPLACE
Flame-Resistant/High-Visibility Option For Work Clothing
Digital Gas Pressure Switch/Transmitters
niFirst is now offering a high-visibility option of its Armorex FR® flame-resistant workshirts, pants and coveralls. The new lineup features 3M Scotchlite™ reflective striping that completely encircles elbow and knee areas, with shirts and coveralls also incorporating striping across back and waist areas. These uniforms are available on a rental or purchase basis.
roSense digital pressure switch/transmitters for air, non-corrosive gas and non-flammable gas applications feature a two-meter cable and three-color LCD display and provide two digital outputs and one analog output. Equipped with lockable keypad, they have three operation modes and offer six pressure-unit conversions, two vacuum-to-pressure ranges (-14.5 to 14.5 and -14.5 psi to 14.5 psi), selectable response times to eliminate chattering and a fast zero reset.
AutomationDirect Cumming, GA
UniFirst Corp. Wilmington, MA
For more info, enter 49 at www.MT-freeinfo.com
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7-Step Best Practice Lubrication Program Professional Self-Directed Implementation ToolKit
Tap into your Liquid Gold for less than $20 per day!* Whether you’re looking to increase asset utilization and maintainability, reduce contamination, downtime, energy consumption and/or your carbon footprint, or simply cut your maintenance and operating costs, you’re ready for a 7-Step Best Practice lubrication program! For more information on this “expert in a box” approach to successful lubrication programs, contact ENGTECH Industries at 519.469.9173 or email firstname.lastname@example.org * Amortized over one year
For more info, enter 93 at www.MT-freeinfo.com
MT-ONLINE.COM | 53
INFORMATION HIGHWAY For rate information on advertising in the Information Highway Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 / E-mail: email@example.com Web Spotlight: EMERSON
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 95 at www.MT-freeinfo.com www.graceport.com/3mt_informationhighway
Emerson Process Management is the knowledge leader in control valves and instruments— Fisher® brand products have remained the process control industry leader for more than 130 years. Emerson delivers time-tested and innovative solutions designed to help customers increase process availability and reduce plant maintenance cost. This is enabled by world class products from generalservice offerings to specialized solutions. Emerson’s process experience and worldwide research, engineering, manufacturing, and service operations serve the process industries worldwide. For more info, enter 94 at www.MT-freeinfo.com www.EmersonProcess.com/Fisher
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 96 at www.MT-freeinfo.com www.kabelschlepp.com
ATP List Services Specializing In
Machinery Health Personnel PM & PdM Field Service • Mgt • Sales • Hrly Nationwide • Conﬁdential • All Fees Company Paid
TOLL FREE 877-386-1091
In order for us to send
MAINTENANCE TECHNOLOGY to you FREE,
we are required by the US Post Office to have a completed and signed renewal form once a year.
You may renew online at
www.mt-online.com 54 | MAINTENANCE TECHNOLOGY
Customized, Targeted Lists For Your Marketing Needs www.atplists.com Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110 firstname.lastname@example.org email@example.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010
For rate information on advertising in the Classified Section Contact your Sales Rep or JERRY PRESTON at: Phone: (480) 396-9585 e-mail: firstname.lastname@example.org
M A I NM TA EI NNT EA N NA NC C EE
TECHNOLOGY TECHNOLOGY ®
October 2011 Volume 24, No. 10 •
Agilent Technologies ..........................................www.transcat.com/agilent .................................260,280 ..........34,35 American Trainco...............................................www.americantrainco.com ...............................76,82...............29,45 ATP Lists...............................................................www.atplists.com.................................................91 ..........................52 Azima DLI ...........................................................www.azimadli.com/trio......................................67 ..........................10 Baker Instument Co...........................................www.bakerinst.com ............................................77 ..........................31 Baldor Electric Company..................................www.baldor.com..................................................66 ............................7 CyberMetrics Corp.............................................www.cybermetrics.com......................................61 .......................IFC Electro Static Technology ..................................www.est-aegis.com ..............................................80 ..........................43 Emerson Process Management-Fisher...........www.emersonprocess.com/fisher.....................94 ..........................54 Engtech Industries Inc. ......................................www.engtechindustries.com .............................93 ..........................53 Exair Corporation ..............................................www.exair.com/48/199.htm ..............................81 ..........................44 Fastenal .................................................................www.fastenal.com................................................62 ............................1 FLIR Commercial Systems, Inc........................www.flir.com/e-mt ..............................................75 ..........................27 Fluke......................................................................www.fluke.com/p3series ....................................74 ..........................23 FosteReprints.......................................................www.fosterprinting.com ....................................63 ............................2 Grace Engineered Products. Inc.......................info.graceport.com/pesd ....................................78 ..........................32 Grace Engineered Products. Inc.......................www.graceport.com/3mt_informationhighway..95 ..........................54 Grainger ...............................................................www.grainger.com ..............................................65 ............................5 i Quantum Solutions .........................................www.i-qs.com ......................................................79 ..........................40 Inpro/Seal.............................................................www.inpro-seal.com ...........................................98 ........................BC Marshall Institute, Inc ........................................www.marshallinstitute.com/qwik ....................89 ..........................50 Meggitt Sensing Systems ...................................www.wilcoxon.com.............................................85 ..........................45 Mincom, Inc. .......................................................www.mincom.com/freetrial ..............................84 ..........................44 Mobil Industrial Lubricants..............................www.mobilindustrial.com.................................72,73...............20,21 NEC Avio Infrared Technologies/SOLTEC ...www.necavioinfrared.com.................................86,88,90 ....47,49,51 NEC Avio Infrared Technologies/SOLTEC ...www.necavioinfrared.com/g100promo ..........83 ..........................45 NETA ....................................................................www.powertest.org..............................................97 .......................IBC Process Industry Practices.................................www.pip.org .........................................................87 ..........................48 Royal Purple, Inc.................................................www.royal-purple-industrial.com....................261,281 ..........36,37 Strategic Work Systems, Inc..............................www.swspitcrew.com..........................................92 ..........................52 U.S. Tsubaki Power Transmission, LLC ..........www.kabelschlepp.com ......................................96 ..........................54 Access MT-freeinfo.com and enter the reader service number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website.
Submissions Policy: M T 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. Statement of Ownership, Management, and Circulation (Requester Publications Only) 1. Publication Title
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09/27/11 05. Number 8 9of Issues 9 _Published 5 7Annually 2 9 6. Annual Subscription Price 12
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MT-ONLINE.COM | 55
VIEWPOINT Mike Rice, Senior Vice President, Projects and Services, Schneider Electric
Better Energy Management Starts With Awareness
hile safety and reliability remain a key management initiative, I see a shift taking place in our industry. The best industrial organizations are focusing not only on boosting productivity and reducing operating costs, but on improving their systems’ overall efficiency. These organizations are moving beyond basic maintenance strategies and incorporating preventive maintenance programs, power-system studies, electrical-distribution equipment upgrades and, of course, energy-management plans. This approach becomes a differentiator for their businesses—and can translate into substantial energy savings and dollars.
Our company recently sponsored a poll through Harris Interactive in which we asked Fortune 1000 CEOs a number of questions about energy efficiency. The results showed that 88% of these Fortune 1000 senior executives feel business has a moral responsibility—beyond regulatory requirements—to make their companies more energy efficient. However, the vast majority (61%) of respondents say that cost savings are required to initiate projects.
When it comes to energy management, companies are leaving a lot of cash on the table these days. That’s unfortunate, since every company has an opportunity to capture significant energy savings.
Understanding the business value In any organization, understanding the business value of energy management allows managers to work with their power bills as an asset, not just as a fixed cost they have to pay every month. In many cases, companies can cover the cost of facility upgrades or other business priorities through energy-bill savings that are achieved as a result of active energy-management initiatives. Many companies have the ability to fund energy-management projects out of their capital budgets, using the savings (as much as 30% or more) as the basis for the investment. We are seeing something very interesting today: Most company leaders know the exact cost of their IT or healthcare spending. However, most of them do not know the costs associated with their energy use. (And this energy spend is generally the single largest controllable operating expense a facility has.)
Cash is king—and companies are leaving a lot of it on the table when it comes to energy management. That’s unfortunate given the fact that every business has an opportunity for significant energy savings. Technologies exist to make energy visible and manageable. Facilities need to take an active role in cutting their energy consumption. Putting a program in place to measure, monitor and improve is crucial.
Being proactive about energy Active energy management—the process of measuring where you are today, fixing the basics, then automating and continuously monitoring and improving—can typically reduce consumption by 30% or more. It’s a fast way for companies to maximize short- and long-term cost savings with technologies that are readily available today.
Putting it simply I truly believe that most companies want to be good corporate citizens regarding their energy usage. They often just don’t know where to start. Awareness is a great first step. The next is taking action. It really is a simple task. Change the way you think about energy and realize it’s good for the environment and good for your bottom line. MT For more info, enter 06 at www.MT-freeinfo.com
The opinions expressed in this Viewpoint section are those of the author, and don’t necessarily reflect those of the staff and management of MAINTENANCE TECHNOLOGY magazine.
56 | MAINTENANCE TECHNOLOGY
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