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DECEMBER 2013 • VOL 26, NO 12 •


Link HSE Data To Enterprise Asset Management Health, safety and environmental data can be more accessible and useful when included in a plant’s EAM system. John Reeve


5 Questions Plant Managers Should Ask Themselves About Their Power Systems The answers to these critical questions can reveal the actual condition of a facility and its ability to stay up and running safely, efficiently and profitably.


Profiles Of Leading Suppliers To Industry


My Take



12 16 18 26 68




Compressed Air Challenge





Information Highway




Supplier Index




Steam Into The New Year With Informed Boiler Repair/Replace Decisions Resolving to upgrade a steam system can lead to welcome dividends. The level of upgrade depends on several factors.

Bearing In Mind: Combating Counterfeiting NSK updates us on what the bearing industry is doing to help protect your operations from the scourge of counterfeit products and what you can be doing as well. Jane Alexander, Deputy Editor

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Editorial Office: 1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 Subscriptions: FOR INQUIRIES OR CHANGES CONTACT JEFFREY HEINE, 630-739-0900 EXT. 204 / FAX 630-739-7967

Maintenance Technology® (ISSN 0899-5729) is published monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodicals postage paid at Barrington, Illinois and additional offices. Arthur L. Rice, III, President. Circulation records are maintained at Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Maintenance Technology® copyright 2013 by Applied Technology Publications, Inc. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Maintenance Technology®, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@ Submissions Policy: Maintenance Technology® gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc. permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. “Maintenance Technology®” is a registered trademark of Applied Technology Publications, Inc. Printed in U.S.A.


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Jane Alexander, Deputy Editor

Bringing Home A Bad Report Card


ecember rolled in with a big chill for many parents this year. I’m not referring to the weather, but to all-over-the-news reports of recently released standard test results showing (sigh) that American high-school students are continuing to lag behind their European and Asian counterparts in math, science and reading. According to an Associated Press (AP) article published in the Washington Post on Dec. 3*, roughly half a million students in 65 countries and educational systems took part in the 2012 Program for International Student Assessment (PISA) that’s coordinated by the Paris-based Organization for Economic Cooperation and Development (OECD). Given every three years to 15-year-olds, the test is designed to assess problem-solving skills based on a 1000-point scale. Note these findings. Read ’em and weep:

■ Math: U.S. average score was 481. (Average scores ranged from 368 in Peru to 613 in Shanghai, with an international average of 494.) ■ Science: U.S. average score was 497. (Average

scores ranged from 373 in Peru to 580 in Shanghai, with an international average of 501.) ■ Reading: U.S. average score was 498. (Average

scores ranged from 384 in Peru to 570 in Shanghai, with an international average of 496.) While the AP/Washington Post article went on to quote U.S. Education Secretary Arne Duncan

calling our kids’ failing to score in the top 20 on math, reading or science “a picture of educational stagnation,” that’s just part of the story. The fact is U.S. PISA scores haven’t changed much since this testing began in 2000, even as students in countries like Ireland and Poland have shown improvement and moved ahead of ours. As a keen observer—i.e., strong supporter— of North American educational and workforcedevelopment efforts (and as a doting mom and grandmother), I do have a dog in this fight. These U.S. PISA results disturb me (and should disturb you, too). Not everybody seems to feel that way, however. Another take appears in a recently re-posted Blog on the Website entitled “Why It’s Never Mattered That America’s Schools ‘Lag’ Behind Other Countries (2013 Edition).”** Gregory Ferenstein posted the original version last year in light of other dismal U.S. test results. In it, he raised several compelling points. I don’t buy into all of them, but I do agree that U.S. high-school students aren’t always graduating with the requisite critical-thinking skills needed in college; and that colleges aren’t always equipping students to hit the ground running when they do find jobs. (Imagine that!) I urge you to check out this piece and the pro and con comments it received for yourself. It’s good reading. In the meantime, for yet another contrarian view on critical-thinking skills, etc., turn to page 80. Respected industry veteran Heinz Bloch has some things to say. Happy Holidays! MT

* **


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NASA Partners With Virginia’s Commonwealth Center For Advanced Manufacturing To Boost Innovation NASA Langley Research Center in Hampton, VA, and the Commonwealth Center for Advanced Manufacturing (CCAM) have announced a partnership that makes the space agency the first government member of the applied research center. As a government member, NASA will bring access to unique government facilities and programs and provide liaisons to CCAM’s Industrial Operations Board and Technical Advisory Council. NASA scientists will conduct research and development at CCAM and NASA Langley as collaborative work between NASA, CCAM, industry partners, the University of Virginia, Virginia State University and Virginia Tech. “NASA’s expertise, along with the capabilities of the CCAM members, industry and academia, is a great combination, tailor-made for advancing innovative technologies,” says Stephen Jurczyk, NASA Langley’s Acting Center Director. “It’s an exciting partnership that will strengthen our nation’s engineering and manufacturing capabilities.” As Dr. Michael Beffel, CCAM Interim President and Executive Director notes, “NASA inventions and technologies have changed history and the products we use every day. CCAM research will benefit from the agency’s longstanding pursuit of innovation.” Based at a state-of-the-art facility in Prince George County, VA, CCAM provides production-ready advanced manufacturing solutions to member companies across the globe. Members guide the research, leveraging talent and resources within CCAM and Virginia’s top universities through a collaborative model that enables them to pool research and development efforts to increase efficiencies. CCAM industry members include Canon Virginia, Inc., Chromalloy, Newport News Shipbuilding, Rolls-Royce, Sandvik Coromant, Siemens, Sulzer Metco, Aerojet, Hermle Machine Co., Mitutoyo, TurboCombustor Technology Inc., Buehler, Cool Clean Technologies, GF AgieCharmilles, Blaser Swisslube and Mechdyne.



PEOPLE PEOPLE Nidec Corporation, headquartered in Kyoto, Japan, has named Kei Pang as Chief Executive Officer of Nidec Motor Corporation (NMC). Pang, who had served NMC as President and COO since April 2012, replaces Patrick Murphy, who resigned his position in October. Pang joined the organization in 1984, when it was known as Emerson Motor Company. In the years since, he has worked in multiple leadership positions across a variety of businesses, including serving as President of Commercial and Industrial Motors prior to the company’s 2010 acquisition by Nidec. Yokogawa Electric Corp. has named Rene Aldana as Managing Director of Yokogawa Canada Inc. Reporting to Yokogawa Corp. America President Chester J. Mroz, he will oversee all of the company’s business operations in Canada. Aldana’s background includes 20 years of experience in automation solutions for the oil and gas industry. He formerly worked with Valmet in Canada (which later became Metso), Telvent and Schneider Electric, where he held roles in Customer Service, Project Management and Regional Business Management. After completing an executive MBA in 2008, he was promoted to Vice President, Oil and Gas International for Schneider. Curtiss-Wright Corp. recently announced the promotion of Thomas P. Quinly to the position of Chief Operating Officer. He succeeds David C. Adams, who previously had been named as President and Chief Executive Officer of the Corporation. Quinly has more than 30 years of experience across the defense, aerospace and commercial industries. Prior to assuming his new position, he led Curtiss-Wright’s Controls segment.



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ACQUISITIONS MISTRAS Group, Inc., the well-known supplier of asset-protection technologies and services, has acquired Carmagen Engineering, Inc., a professional engineering consulting and training firm. Since 1986, Carmagen has provided a wide range of services focused on the oil & gas industry, including plant operations support; profit-improvement analysis; turnaround planning and execution programs; and technical training ranging from process safety to reliability and maintenance, to asset design and integrity instruction. Lincoln Electric Holdings, Inc., has acquired an ownership interest in Burlington Automation Corporation (Burlington), a leader in the design and manufacture of 3D robotic plasma-cutting systems. Based in Hamilton, Ontario, Canada, Burlington serves a wide base of customers in the structural steel, construction, oil & gas and general fabrication markets in North America. The company’s main products are sold under the brand PythonX®.

Emerson Process Management has opened its new $25M global headquarters in McKinney, TX, for the design, testing and manufacture of regulator technologies, including pressure-regulator and reliefvalve solutions to help oil and gas, chemical, refining, power and other industries run their processes and operations with optimal, safe and reliable performance. A corporate anchor tenant in The Gateway development at the interchange of U.S. 75 and the Sam Rayburn Tollway, the site is home to a world-class research facility with a flow lab capable of testing products in extreme conditions, as well as various materials and environmental laboratories. The Mckinney site is one of several Emerson investments in Texas, including a $34M Emerson Industry Center for Hydrocarbon and Energy and $30M Americas headquarters for valve-automation technologies, both in Houston, and a new $25M Austin complex for the process-systems and solutions business.


On a related note, Emerson Process Management and Mitsubishi Power Systems Americas, Inc. (MPSA), have extended their alliance for turbine retrofit projects in the Americas. The alliance brings together Emerson’s expertise designing and engineering automation and control systems for the power industry with MPSA’s extensive experience in gas and steam turbine technology and service, providing power generators with an alternative to their original controls, service and parts supplier for long-term turbine support. Established in 2008, the alliance supports retrofits of W501F, W501B, W501D5A, W501A, W501D5 and W251 gas turbines, as well


as all models of Mitsubishi and Westinghouse-technology steam turbines. MPSA has unique expertise on Westinghousetechnology turbines since Mitsubishi was involved in the design and development of this technology through licensing and alliance agreements with Westinghouse. Russellstoll® Interconnection Systems by Thomas & Betts (T&B) has combined its product line with the ABB Industrial Plugs and Sockets product line to enhance T&B’s industrial connector selection. Facilitated by ABB’s acquisition of T&B last year, the consolidation of the two lines creates one of the market’s most comprehensive selections of explosion-proof, heavy and light industrial, moisture- and corrosion-resistant plugs, sockets, connectors and receptacles that range from 20 to 600 Amps. According to T&B, its proprietary pin-and-sleeve products will be branded as Russellstoll® Interconnection Systems, which reflects more than 20 years of the line’s premium brand equity for innovative solutions in light- and heavyindustrial applications. ABB Industrial pin-and-sleeve products, also known as IEC Plugs and Sockets, in reference to their compliance with International Electrotechnical Commission 60309 standards, will continue to capitalize on the reputation of the catalog’s ABB brand in the global industrial market.

Zep, Inc.’s North American Sales & Service business has launched Zep Energy, a new division dedicated to meeting the needs of oilfield service companies that cater to the oil and gas industry. In addition to providing a wide assortment of high-performance maintenance, repair, and operations (MRO) products, the division provides Oil & Gas Specialists to work closely with customers in a range of support services.



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BRIGHT SPOT ASSOCIATIONS ISA (the Instrument Society of America) has announced that Beamex, a global supplier of calibration products, services and support, will be the Society’s Strategic Partner for Calibration. Under this arrangement, Beamex and ISA will work together to provide ISA members and customers access to Beamex’s world-class calibration resources, including publications, case studies, seminars, expert advice and more. The partners will also work to co-develop custom Web seminars for ISA members and customers, and Beamex will have the opportunity to host events for ISA training . students; to provide guidance and insight into calibration topics in conjunction with ISA’s training development team; and to donate equipment and resources for the Society’s educational offerings related to calibration.

Support for the Power Transmission Distributors Association (PTDA) Foundation signature project, Industrial Careers Pathway® (ICP), amounted to nearly $200,000 in 2013. NSK’s Brian Short, this year’s Fund Drive Chair, says the group continues to see an extraordinary outpouring from the power transmission sector for the Foundation and ICP. “PTDA members recognize the importance of building tomorrow’s workforce,” he explains. “They are willing to invest because they know ICP resources will help them spread the word about the rewarding careers in industrial distribution. We are also pleased that our Alliance Partners, the American Supply Association (ASA), the Industrial Supply Association (ISA) Educational Foundation and NAHAD, the Association for Hose and Accessories Distribution, continued their strong financial support for the ICP initiative.” Next year’s fund-raising efforts are already in gear, having kicked off in October at PTDA’s 2013 Industry Summit. The Vanguard Campaign, recognizing members who pledge to the 2014 Fund Drive before year-end 2013, is off to a record start. Even before the end of the Industry Summit, the campaign had received pledges in excess of $55,000, with the total currently at $67,700 and growing. The PTDA Foundation, a 501(c)(3) corporation whose work is funded solely by donations, was established in 1982 to enhance knowledge, education, professionalism and productivity within the power transmission/motion control industry. The Foundation’s ICP program is a multifaceted North American workforce initiative that focuses on building awareness among 18-34-yearolds about careers in industrial distribution, and links students and job seekers through partnerships with local educators and employers. For more information, visit

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UPTIME This column is the second in an evolving series focusing on the new Asset Management Standard slated for release in January 2014. (See MT October 2013 for Part I.)

Bob Williamson, Contributing Editor

ISO 55000 Management Systems: Part II — The People Side “In our company we often talk about the importance of leadership and teamwork in the functioning of maintenance organizations and even in the bigger picture, the success of the company. How will leadership and teamwork play out in ISO 55001 Asset Management – Management Systems – Requirements?” Great question. ISO 55001 will call for levels of LEADERSHIP and TEAMWORK that far surpass what most businesses have ever experienced. The Standard’s requirements are a significant departure from many of the old habits that have developed over decades of design, procurement, construction/ installation, startup, commissioning, operations, maintenance and the decommissioning of equipment and facilities. This degree of CULTURE CHANGE mandates that top-level management not only comprehend what asset-management systems are all about, but also what culture change is all about—and how to be effective leaders and managers of workplace change. As our facilities and manufacturing technologies and systems become increasingly inter-related, the people who operate and maintain them must depend on each other in a collaborative manner. Reliable electro-mechanical processes depend on teamwork among various roles and departments in the company. And this level of teamwork requires leadership that goes well beyond traditional supervision and management roles. Now, on top of fairly complex facilities and manufacturing processes, let’s put an “asset-management system” in place to establish an asset-management policy and objectives and all the processes (i.e., integrated plans, business processes and information systems) to assure proper and consistent management of assets. That’s the essence of ISO 55001. Leadership and teamwork across traditional organization boundaries and culture change WILL be required in most cases. Three key interdependent elements of success Leadership and teamwork are all about PEOPLE (i.e., human assets). People make things happen: good, bad, indifferent. When people are organized into a specific goaloriented business, they can accomplish much more than they could individually. Many minds and hands focused on common goals can achieve significant business results: desirable products, services, profits, wages, benefits. 12 |


When business results are based on equipment and facilities (PHYSICAL ASSETS), it takes much more than people to make a business succeed. The equipment and facilities must be reliable and perform as intended. These physical assets directly impact profit and loss, safety and environmental incidents, and on-time delivery of goods and/or services to paying customers. There is also a third element here: WORK PROCESSES. The procedures that people use to manage the physical assets must also be reliable. ISO 55001 specifies the requirements for an “asset-management system”—in essence, another layer of work processes that’s overlaid on the routine and day-to-day work processes. The new ISO 55000 Asset Management Standard focuses on PHYSICAL ASSETS (among other not-sophysical assets) and asset-management-system WORK PROCESSES. While there are requirements pertaining to the PEOPLE side of asset management, there is NO prescription for engaging people in the standard: It’s left up to the business’ top management to define and deploy. Thus, the “people side” is liable to be the weakest link in conforming to ISO 55001 requirements (as it was with the ISO 9000 Quality Management Standards). Leadership expectations for top management The suite of ISO 55000 Asset Management Standards addresses the principles of asset management along with the many associated terms and definitions. The “meat” of the Standard is contained in ISO 55001. These are the specific “requirements“ for an asset-management system—the “shall” statements that leave little doubt as to the required conditions. What is most interesting is that each section in ISO 55001 starts with one of two phrases: n “The organization shall” (52 times) n “Top management shall” (5 times)

The term “Top Management” in the Standard represents the LEADERSHIP element, which requires the addition of TEAMWORK to achieve anything. “Top Management,” as used in ISO 55001, means that the ultimate responsibility for making the asset-management system function rests squarely at the top of the organization. “Top Management” is defined as: DECEMBER 2013


“(A) person or group of people who directs and controls an organization at the highest level” (ISO 55000, 3.1.24) The overarching role of “Top Management,” as discussed in ISO 55000 (Overview, Principles & Terminology), is described this way:

management system, at planned intervals, to ensure its continuing suitability, adequacy and effectiveness.” Section 5 of ISO 55002 (Guidelines) contains three separate “Leadership” guidelines for “Top Management,” including: n 5.1 Leadership and commitment

“Top management should create the vision and values that guide policy, practice and actively promote these values inside and outside the organization.” (Elements of an asset-management system: – Leadership) And, “Top management and leaders at all levels are responsible for ensuring that appropriate resources are in place to support the asset-management system.” ( There are a number of sections that speak to “Top Management’s” role and responsibilities within the ISO 55001 Standard: Section 5 of ISO 55001 (Requirements) speaks to “Leadership.” In this section, there are three separate “Leadership” requirements for “Top Management,” including:

“…however, it is important that ownership and accountability for asset management remains at the top management level.” n 5.2 Policy

“The asset-management policy should be authorized by top management and thereby demonstrate commitment to asset management.” n 5.3 Organizational roles, responsibilities and

authorities “The responsibilities and authorities of key functions should be defined. This should include both internal and outsourced roles and responsibilities. The interfaces between organizational functions should be clearly established.” Section 9 of ISO 55002 (Guidelines) also speaks to “Performance Evaluation,” with another specific reference to “Top Management:” n 9.3 Management review

n 5.1 Leadership and commitment

“Top management shall demonstrate leadership and commitment with respect to the asset-management system…” n 5.2 Policy

“Top management shall establish an asset-management policy…” n 5.3 Organizational roles, responsibilities

and authorities “Top management shall ensure that the responsibilities and authorities for relevant roles are assigned and communicated within the organization.” Section 9 of ISO 55001 (Requirements) speaks to “Performance Evaluation” and includes another specific reference to “Top Management:” n 9.3 Management review

“Top management shall review the organization’s assetDECEMBER 2013

9.3.1: “Top management should review the organization’s assets, asset-management system and assetmanagement activity, as well as the operation of its policy, objectives and plans, at planned intervals, to ensure their suitability, adequacy and effectiveness.” Leadership, teamwork & culture change ISO 55001 will demand a substantial culture change in most organizations. Old habits—“But that’s the way we’ve always done things”—will probably have to change. This is especially true for organizations that have numerous “silos” of responsibility, each with differing roles, responsibilities, accountabilities and financial implications, not to mention the personalities and egos linked to them. True “asset management” cuts through many of these traditional organizational silos because asset management, by design, spans the entire life cycle of physical assets: from concept, design, procurement, construction/installation and startup through commissioning, operations, maintenance and decommissioning. MAINTENANCETECHNOLOGY.COM | 13


In the life cycle of physical assets, there are many departments, work groups and individuals within an organization that make decisions and take actions regarding the asset. If contractors are used, they too play an integral role. When we insert all

of these different players at appropriate points across the entire life cycle, you can imagine the gaps that show up: different ideas, interpretations, priorities, expectations, budgets, documentation and communications. (Imagine! Most of us

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have lived through the problems that these types of disconnects generate.) The “people side of asset management” cannot be taken lightly. Furthermore, we can’t look to the ISO 55000 suite of standards as a tool to make people (Top Management and everybody else) get on board. It’s not there. Sure, there are references to “roles and responsibilities” and “communications,” but there’s nothing regarding how to gain “buy-in” or “ownership” or “participation” or “engagement” from individuals or entities that are defined as “Stakeholders” by the Standard.

• Plant Surveys • Tech Support • Software • Machine Tags • Training • Oil Analysis

‘It takes a village to raise an asset’ Sorry: My choice of a subhead isn’t meant as a reference to Hillary’s 1996 book. Rather, it’s a nod to some rural (and not so rural) cultures that believe in “community” when it comes to raising a child. The same principle applies to assets—especially physical assets. In the real world, it takes an “organizational village” to care for assets throughout their entire life cycle. That, I believe, is the central premise driving the adoption of ISO 55001 Asset Management — Management System Requirements. In some companies and businesses, that priceless sense of community—a “we’re in this together” type of thinking and feeling—may need to be re-instilled by Top Management at the onset of the new asset-management journey. MT Robert Williamson, CMRP, CPMM and member of the Institute of Asset Management, is in his fourth decade of focusing on the “people side” of world-class maintenance and reliability in plants and facilities across North America. Email: DECEMBER 2013



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

Spare Advice Things have come a long way from the days when spare-parts hoarding and stashing was not only common practice, but often the only guarantee that items would be on hand when needed. This still happens, of course, but with less frequency and is frowned upon. Advances in electronic parts tracking and ordering have taken spare-parts management out of the dusty corners into the light. Now, most technicians appreciate that a well-managed spare-parts management “system” (whether handled in-house or by vendors) can keep costs low and inventory available for virtually all situations. How do your spare-parts management practices stack up? If you’re like most MT Reader Panelists, they’ve improved significantly in recent years, though tweaking may still be needed. Here’s our group’s perspective on this key sector of maintenance support: Q: How does your operation manage its spareparts inventory? How efficient is it? “We have a central location where the parts are stored. In that location, we have the purchaser and an attendant. The attendant helps everyone who enters the parts area to find and check out all parts. This ensures that part counts are correct. The Maintenance Manager manages the system [aided by] a Parts Review Committee that will look at parts in the system and make decisions on each part as needed. It works quite well.” …Production Support Manager, Midwest “We use an integrator to manage our storeroom. It is relatively efficient. We have been using this integrator for nearly eight years.” …Reliability Maintenance Engineer, South “Our system is a computerized inventory-control system managed by two people. We’ve used it for

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about eight years with very good success. It is attached to the equipment we are using and can inform us on what parts we buy most. This then relates back to the maintenance group for equipment-reliability evaluations. Parts are handed out as needed and logged in by the user. About 90% of the time we know what part was removed and where it was used.” …Senior Maintenance Engineer, West Q: How critical is good spare-parts management to your operation’s success? “Very critical, because we need to maintain high uptime. Parts people work very closely with the maintenance people so there is no downtime due to lack of a part.” …Senior Maintenance Engineer, West “With some of the turnarounds we have, it is quite important to have the emergency parts when we need them.” …Senior Maintenance Mechanic, South “Because we have mostly foreign-made equipment, spare parts inventory is hugely important.” …Reliability Maintenance Engineer, South Q: What, if anything, could be done to improve how your operation manages spare parts? “We need a more efficient way to return unused parts as well as an improved method for streamlining our inventory of must-have parts.” …Maintenance Coordinator, Mid-Atlantic “At times there will not be 24/7 coverage. This can open up the possibility of having empty bins when you need a part. There are also times when people will not check out parts if there is no storeroom attendant. It’s unfortunate, but a fact of life.” …Production Support Manager, Midwest



Most of today’s technicians realize that a well-managed spare-parts management ‘system,’ handled either in-house or by outside vendors, can help keep costs low and inventory available in all situations. “We do a good job managing our spare parts. The maintenance engineers are responsible for deciding which spares should be stocked.” … Reliability Maintenance Engineer, South “Our process needs to be moved back in-house. We used to have in-plant cribs, which worked great. The system we have now is controlled by a commodity company that couldn’t manage its way out of a paper bag. It is so flawed that when we actually have a part at the warehouse we tear up paper like confetti and throw it in the air. It is very frustrating. We are constantly trying to buy parts online because a lot of the parts houses don’t keep inventory on hand, and we have long lead times that are unacceptable.” …PM Leader, Midwest Q: What lessons have you learned about effective spare-parts management? “I’ve learned that the most critical spare part in your facility is the one you need, but don’t have.” …Reliability Maintenance Engineer, South “Control is the key: how much; how fast can I get it; how many do I need to keep in stock; who has access to these parts; and keeping good relationships with suppliers. Also, do not allow maintenance staff to keep parts in their toolboxes. This can be OK only if you can control it without too much pressure. And keep the lowest inventory on hand as possible; do not over-stock and do not always buy the cheapest.” …Senior Maintenance Engineer, West “Do not put repaired electronics boards back in the storeroom without first verifying that they work. Multiple times, we were burned by a repaired board that didn’t work when it was installed during a breakdown. So, we created a process to verify and track all repaired parts in our system. Also, centralize all of your parts. This


will help you to reduce inventory and ensure you have the part when you need it.” …Production Support Manager, Midwest “Limit physical access to spare parts. Unlimited access leads to loss of inventory control and stock-outs. Do not separate the spare-parts management function from the maintenance function. They should both be under the same manager to ensure common direction and goals.  Also, make the effort to create and maintain bills of material for all critical equipment.” …Maintenance Engineer, West “The best spares system I’ve seen is at a soft-drink plant with a top-class CMMS program. They use bar codes to identify and track every major item on the plant floor and in their efficiently organized stores. Each mechanic uses a PDA to scan and upload/download data while performing service tasks. In-house stock is catalogued with crossreferences to alternate options and all other items required, including exploded views of assemblies. This is all done on their PDAs. The worst systems are those with racks of many different parts lacking labels, no evidence of tracking and with too many items of unknown parentage.” …Consultant, Tester and Trainer, Canada

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 Click on “Reader Panel” under the “Info” tab, and follow the instructions. If accepted, you will automatically be entered into a drawing for a cash prize after one year of active participation.



Achieving Operational Excellence Gary Mintchell, Executive Director


ince joining Applied Technology Publications and the Maintenance Technology team the first of September, I’ve been studying, talking with people and trying to anticipate where the industry is going so we can best serve all of our clients. You will see many improvements in the coming months as we work to update the style and content to make us even more relevant today. The magazine itself will undergo a makeover, but the Website will, too. Website development takes some time, but in a few months, you’ll see a noticeable upgrade. First, we will be eliminating the URL in favor of We will also improve user experience and update content daily with even more information to help you do your jobs better. MARTS is back, but with a totally new format and focus— “achieving operational excellence through asset performance.” MARTS has always attracted decision-makers. Over 80 percent of 2013 attendees were managers, professionals and engineers with decision-making authority. The 2014 edition will build on the tradition of attracting the brightest minds in predictive maintenance by adding specific tracks for operational excellence and technology. One track is designed to appeal specifically to maintenance and reliability professionals with discussions of predictive maintenance tools and management topics. Another is designed for plant managers and engineers with a focus on operationsmanagement tips and strategies. We’ll also emphasize more of the latest automation, control and information technologies that directly impact reliability and operational excellence. Register today to be part of the conversation about achieving operational excellence in your organization. Team registrations are welcome. Some of the topics already committed include: ■ Total Productive Maintenance Made Easy and Affordable ■ Asset Management: Understanding ISO 55000 ■ Gain Value from Planning ■ Driving Overall Equipment Effectiveness (OEE) For

Business Results

■ The Process Instrumentation Crisis ■ What Key Performance Indicator to Use and When ■ The Failure Effect ■ Forensics of Electric Machines ■ How We Won the North American Maintenance

Excellence (NAME) Award ■ Do Corporate Reliability Awards Help? ■ Foreign Material Management ■ Driving Contractor Performance ■ Optimize Results Through a Culture of Excellence ■ Next-Generation Asset Reliability Solutions

Two days of in-depth workshops (Tuesday and Friday) are also available. Choose from one or two of six offered. These eight-hour intensive sessions taught by industry leaders include the following topics: ■ Results-Oriented Reliability and Maintenance ■ Understanding ISO 55000 For Improved Asset

Management ■ How to Develop a Culture of Excellence ■ How to Base-line Your Maintenance System for

Improved Productivity Presenters include professionals from companies such as Eli Lilly, Jacobs Engineering, Syngenta Crop Protection, Haynes International, Mississippi Lime, Pennsylvania Power and Light, and Emergent BioSolutions. I love conversations. Send a note any time. You can also find me on LinkedIn and follow me on Twitter at @garymintchell. Check out the Maintenance Technology group on LinkedIn—ask questions and participate. As our Website undergoes improvements, there will be increased opportunities for you to voice your opinions. MT Gary Mintchell,, is Executive Director of Applied Technology Publications. He also writes at For more info, enter 01 at

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Mining value...

Link HSE Data To Enterprise Asset Management Health, safety and environmental data can be more accessible and useful when included in a plant’s EAM system. John Reeve


hy an EAM (enterprise asset management system) would be implemented without addressing personnel safety in terms of a safety culture, hazard analysis, risk management, change management and compliance reporting is perplexing. This health, safety and environmental (HSE) information can be tracked outside the EAM, but it makes more sense to include it there: EAM software already tracks asset performance/history and provides an integrated format where work originates, asset registries are stored, maintenance plans are documented and worker records are kept.

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Accident, Incident or Near-miss

Investigative Analysis

Improvement Activity

Impact Analysis "MOC"

Action Tracking

Fig. 1. The five main steps in an HSE scenario

Job safety and hazard analysis are equally important parts of work management. In the course of operating and maintaining equipment, personnel can encounter safety hazards that result in injury. Just as most operation and maintenance (O&M) organizations try to predict and prevent functional failures, they should emphasize job safety and hazard mitigation by trending past incidents to lower or prevent their occurrence. It makes sense to closely integrate or consolidate asset maintenance with HSE tracking (refer to Fig. 1). Not every operation and maintenance activity will have a related job-safety event. But when such activities do, the data should be captured and tracked. An investigative analysis may follow, especially in the case of personnel injury or equipment loss. When an improvement plan is identified, it should be preceded by an impact analysis (or management of change) before implementation. Additionally, the leadership team may establish specific actions that will need to be tracked. The work-order process A typical work-order process includes: (1) work planning and hazard analysis, (2) work execution and (3) work-order feedback/closeout. The relationship of HSE data to this process is substantial. A maintenance backlog, for example, may contain safety-related work that is required to correct an existing safety issue. Work orders may also come with

attached safety plans because most O&M organizations are very safety-conscious. Once the job starts, however, anything can happen. The worker might get interrupted, or other hazards might be discovered. The job could turn out to be bigger than originally planned, or a supervisor might ask the worker to move faster. And when staff is hurried, unexpected events—such as accidents—occur. These incidents must be reported, but the culture will dictate what gets reported: Will it be everything, including near-miss incidents, or only accidents that result in injury or lost work time? Moreover, management might have performance metrics tied to injuries that are, in turn, tied to bonuses. These issues must be considered if management is serious about creating and maintaining a strong safety culture. The cost of a reactive environment Unplanned events incur added costs, and can include a high level of emergency/urgent maintenance work. This type of work may have no planning and few safety instructions, which directly affects worker safety and job quality. Environments where a reactive approach is dominant can, therefore, induce worker frustration, which can be followed by a lack of trust. Reactive maintenance isn’t just bad for the asset: It’s also bad for the worker.

Reactive environments can fuel worker frustration and a lack of trust. Taking a reactive approach to maintenance, therefore, isn't just bad for your equipment, it's also bad for your human assets. DECEMBER 2013



Tail-Board Meeting

Control Room JSA Review

Visit Job Site

Fill Out Pre Job Brief Card

Maintenance Shift Reviews All Work for the Day

Ops Shift Supervisor Discusses Work with Your Crew

Assess Site Work Conditions

Use Card as Checklist of Things to Look For

Verify LOTO/ Start Job

Maintain Contact with Operations

Fig. 2. Typical steps in a Job Safety Analysis (JSA) or a Job Hazard Analysis

One solution to this scenario is the Job Safety Analysis (JSA)—also called a Job Hazard Analysis (Fig. 2). This is a detailed document stored in the control room by most industries. Every maintenance worker should review the applicable JSA for each work package tied to the asset/system. This ensures that, from the start of each work-day to the end, an emphasis on job safety is part of every work package—and both human and equipment assets are protected. The data-relationship benefit There is a natural relationship between asset management and HSE. For example, they share the same data-management components and resource codes. If an accident occurs on a job site, the equipment/location/area should already exist in the EAM system. If the workers involved were operations or maintenance, these resource codes would also reside in the EAM system, along with qualifications, certifications and requalification dates.

If a failure investigation is performed, the analysis might look at operational policy/procedure, training records, asset history, planning/scheduling, hazard identification, risk assessment and management-of-change (MOC) documents. With all this data inside a single EAM system, the HSE management team can more quickly link all pieces of the puzzle. Also, EAM/HSE system end-users have increased visibility to health and safety issues that could affect job safety. By having one integrated system, the ability of maintenance, operations and engineering to safely work together is greatly improved. Getting past the existing system It’s likely that any given organization will already have a system in place for managing HSE. Such a system might be paper-based, spreadsheet-based or built upon singlefunction software. There are drawbacks to each, as noted in Fig. 3.



Primarily Paper-Based

HSE department prefers to manage paper, and stores documents in file cabinets.

Despite paper supporters’ belief that documents are easier to manage in a file cabinet, electronic documents in EAM systems are far easier to manage and share.

Excel and Access

HSE department tracks and trends data using isolated spreadsheets.

Although flexible and familiar, these are not true relational databases with integration capabilities. Also, front-end screen entry capabilities may be missing, and reporting features may be limited to a single spreadsheet.

Spot Solutions

HSE department purchased a standalone software product intended to perform a specific function, such as environmental tracking or safety management.

Stand-alone products are singularly focused with little ability to expand or integrate. Plus, they have an additional longterm cost due to licensing, upgrades and possible integration requirements. The benefit of an EAM product is a single point of entry and natural data relationships.

Fig. 3. Drawbacks associated with typical stand-alone, non-EAM-linked HSE-data management systems

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Besides relying on EAM systems to track large volumes of information, best-in-class organizations use theirs to help predict and prevent. There can be pain when changing any system and process, especially with old ones that have been in place for a long time. Still, there is usually a cost benefit in consolidating smaller systems into one standard product. Apply ‘EAM thinking’ to HSE data O&M managers often depend on the EAM system to track large volumes of information. Best-in-class organizations also use this system to predict and prevent. Here are several tips that can add efficiency to an integrated EAM/HSE system: 1. Set up automatically recurring PM activities to schedule annual safety/environmental training venues. 2. Set up automatically recurring audits and surveys; include a list of pre-built questions, and record attendee names. 3. Initiate the MOC review process inside the EAM. Create a Yes/No field on the main work-order screen titled, “MOC Review Required.” This would then electronically route to the HSE officer for assessment and tracking within the MOC application. 4. Track compliance and regulatory requirements inside the EAM system. Activate automatic notifications by setting up bulletins via email or EAM-system workflows pertaining to compliance reporting or other trends. 5. Create a library of definitions pertaining to HSE, such as “What is an incident versus an accident?” 6. Create a high-level list of HSE policy statements, such as “All incidents, accidents and near-misses shall be reported.” 7. Record operations’ shift-turnover logs in the EAM system so vital information is immediately available to all. Record all work-package turnover notes (for work not done at end of shift) in the work-order long description field. With rotating shifts, there is a risk that vital information pertaining to job status might not be turned over. DECEMBER 2013

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Capture work-order feedback as log entries, especially those involving safety- and hazard-mitigation suggestions. This creates a permanent record of suggestions, which can then be electronically routed for management review. Track accident/incident events with text recommendations and provide code categorization of these events so the data can be grouped and trended to identify worst offenders. By managing by exception, the HSE officer might request additional safety training to address falls and trips. Add a “Risk Assessment” field to the main work-order tracking field. This indicates the level of risk a maintenance activity involves. The choices could be (a) No Significant Risk, (b) Maintenance Observer Required, (c) HSE Dept. Representative Required On-Site. For example, if a heavy object is being lifted, the HSE Dept. Representative would ensure all safety instructions are followed and no one is in the path of a moving object. Most EAM systems have powerful reporting engines, including the capability to download to Excel, ad-hoc reporting and KPI tracking. These features, along with the ability to easily search, select, sort, bookmark and save queries, provide an advantage when filtering data to be used by analytical reports. The risk of data isolation When HSE data is purposely isolated from other core systems, cost and risk are added to the organization. Furthermore, if members of the HSE group infrequently logs onto the EAM system, they may depend solely on someone telling them—via email, phone or paper form—that a safety issue or hazard exists. Users may see this as two separate management systems and wonder why they are not integrated. Keep in mind, when managing heaps of paper, that there will always be risks. These can include missed deadlines, missed reports, missed HSE training and missed audits, as well as unclear references to job location or assets. Bet on the EAM/HSE link to add value The EAM/HSE single-database design is your best bet for the future. Software brand is not the issue. It comes down to a willingness to combine HSE and EAM data. Sometimes management may choose to isolate certain data for legal reasons—but this can still be stored in the EAM system with the added benefits of analytics, trending and referential integrity. O&M personnel want to access HSE data to help them do a better job (and do it safely). The workforce will see both functions as equal partners. MT John Reeve has spent 25+ years supporting CMMS/EAM users across a range of industries. He currently is a Manager and Senior Consultant with Cohesive Information Solutions. Email: For more info, enter 02 at DECEMBER 2013

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Lubrication Checkup Gearbox Overheating By Dr. Lube, aka Ken Bannister

Symptom: “We’ve recently noticed that one of our critical gearboxes has started to run so hot that it can be barely touched by hand. It’s normally just warm to the touch. How detrimental is this situation, and what can we do about it?”


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Judging by your description of the gearbox to the touch of a hand, I estimate its temperature to be around 150 F (or 65 C)—the approximate temperature when the hand has to be lifted within three seconds of touch. That’s too hot, especially since the normal “warm to the touch” temperature would be approximately 104 F (or 40 C). An oil-temperature rise reacts according to the Arrhenius rule—a temperaturechange-dependent failure-rate rule—that states for every 18 degrees F (10 degrees C) increase in temperature of the oil, the lubricant life cycle is halved. Your higher gearbox temperature means the unit is in danger of a premature failure.

Prescription: 1. Check the current oil level and for evidence of leakage. Is the drain plug tight? Low oil levels in both splash and pressured systems can cause overheating. 2. When did you last change the oil? Old, oxidized oil can cause sludge build-up in the bottom of the reservoir and increased viscosity. If the oil was recently changed, was it replaced with incompatible gear oil or incorrect viscosity? Both scenarios can cause internal friction, leading to overheating. 3. If you have a pressurized system, check for a plugged suction. 4. Is the gearbox full of debris or dirt? Are the oil-fill cap and reservoir breather in place? Internal and external debris can create a thermal blanket that raises the temperature of the gearbox and oil. 5. Is a new external heat source causing the temperature to change? Did the operating parameters change and surpass the equipment’s design criteria? Use an infrared thermometer or camera to check for heat diffusion on the gearbox and local “hot spots.” Often, one or more of the above situations can be responsible for a hot-running gearbox—pinpointing the culprit(s) is difficult without seeing the equipment. If my recommendations don’t resolve your issue, considering contacting a professional lubrication-management consultant for assistance. Good Luck! MT Ken Bannister of Engtech Industries, Inc., is a Lubrication-Management Specialist and author of Lubrication for Industry (Industrial Press) and the 28th Edition Machinery’s Handbook Lubrication section (Industrial Press). For in-house ICML lubrication certification training, Ken can be reached at 519-469 9173 or by email at

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5 Questions Plant Managers Should Ask Themselves About Their Power Systems

The answers to these critical questions can reveal the actual condition of a facility and its ability to stay up and running safely, efficiently and profitably.


hether in an industrial facility or a power plant, many of today’s challenges regarding power-system protection are the same. Organizations are trying to mitigate rising costs and adapt to shrinking budgets in the face of changing regulatory requirements and aging infrastructures. This can result in less emphasis on maintenance and preventive services—which can compromise the reliability and performance of critical electrical assets.

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Plant managers should ask the following questions to prevent problems with the health and performance of these assets, which directly affect productivity and profitability. #1. Have testing and commissioning services been conducted? Commissioning is important to power systems and processes because of the increasing complexity of the systems themselves—creating more opportunities for problems. Due to the staggering cost of unplanned outages or failures, today’s facilities must perform reliably from the start and every day after. Appropriate commissioning activities help ensure reliability by identifying the culprits behind power-system failures and outages. Nearly 70% of early equipment failures can be traced to installation, startup or design deficiencies. Unnecessary outages are often due to improper coordination and calibration of protective devices, wiring errors, design errors and human error. Commissioning can help detect and correct these problems before failures or outages occur. Commissioning is also the answer to a wide variety of other concerns. Ensuring the operations and maintenance (O&M) staff has adequate resources and training, improving safety, and boosting efficiency can all be addressed by specifying the right commissioning activities. A comprehensive approach, encompassing a wide range of building systems and spanning the entire design/build process, results in the greatest value to project owners—i.e., a variety of benefits that help meet the need to maintain power availability. When best practices are followed and the appropriate activities are specified, the facility owner will be rewarded with systems and assemblies that meet specific, well-documented project requirements and perform in accordance with the design intent. Commissioning helps to ensure that projects are successful and are delivered on time and on budget. Benefits of commissioning include:

Single-source accountability… The Commissioning Authority (CxA) streamlines all commissioning and quality assurance, advises the contractor on project schedules and provides single-source accountability for the entire process. Cost-effective problem resolution… The commissioning process helps identify system-related problems early in the project, when correcting them is most economical. An informed workforce… One outcome of the commissioning process is a robust knowledge base about the new system or process that can be used for quality training activities, training materials and O&M resources. Involving the CxA in the training process and Systems Manual preparation ensures that the O&M staff is prepared and equipped to operate and maintain the newly commissioned system. Data-supported decision-making… Commissioning creates extensive documentation for benchmarking system changes and trends. The data can be used to identify future problems with the system or process, maintain optimal operations and evaluate future maintenance decisions. Improved efficiency… If efficiency features have been built into the new system, commissioning activities can verify that they function as intended. Commissioning can also ensure that the O&M staff has training and operating resources to fully leverage the design efficiencies. These activities ensure the intended energy efficiencies and maximize energycost savings.

Less unplanned downtime and fewer repairs… Preventing or greatly reducing the possibility of an outage is perhaps the greatest value commissioning provides. Commissioning activities ensure that mission-critical equipment is properly installed and that systems are fully integrated.

Enhanced safety and compliance… The commissioning process produces a safer workplace and reduces owner liability by uncovering safety problems throughout the project. The CxA may also ensure that owners and O&M staff receive proper education on safe operating and maintenance procedures pertaining to electrical and mechanical equipment.

Reduced life-cycle costs… Done properly, commissioning improves power-system performance throughout the facility life cycle. Better system performance reduces operation and maintenance costs as well as energy consumption.

LEED certification… Commissioning is a requirement for LEED certification. Projects attempting the certification must complete basic commissioning activities and can complete enhanced commissioning activities for optional credit.




Return on investment… The benefits of commissioning often create a return on investment that far exceeds the cost of commissioning itself. Emerson’s Electrical Reliability Services—through cost/benefit analyses of key issues corrected during several completed commissioning projects—revealed value for the owner well beyond the cost of commissioning. These analyses took into account only material and labor costs and did not factor in the cost of downtime that likely would have occurred had the issues not been resolved. #2. Does your site routinely perform predictive maintenance? Identifying defective power-system components and other conditions that could result in fire or electrical breakdown can often be accomplished with predictive maintenance, such as infrared testing and partial discharge testing of cables or switchgear. In fact, partial discharges are often the first indication of insulation deterioration, which is the leading cause of electrical failures, according to NFPA 70B. Only qualified and experienced personnel should perform this testing and analysis. Seek a service provider that has experience with all makes and models of powersystem components including generation, transmission and distribution-protection systems. #3. What type of preventive maintenance is being conducted? It’s natural for electrical equipment to degrade over time, but it doesn’t have to fail. Preventive maintenance services evaluate equipment condition and determine the most costeffective and manageable solution to improve its overall performance, safety and reliability. Typical equipment to be inspected and tested includes switchgear, circuit breakers, transformers, switches, relays, generators, batteries, cable and other devices. Elements of a good preventive maintenance program should include: ■ Identification of equipment or systems that may malfunction ■ Establishment of schedules and procedures for routine

inspections that are in accordance with NFPA 70B recommendations and InterNational Electrical Testing Association (NETA) standards ■ Periodic testing of plant equipment for structural soundness ■ Prompt repair or replacement of defective equipment

that is identified

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■ Easy access to spare parts for equipment that requires

frequent repairs ■ Use of an organized record-keeping system to schedule

tests, document inspections and trend results ■ Evaluation of trends and subsequent adjustments to

procedures and programs ■ Commitment to ensure that records are complete and

detailed, and that they record test results and follow-up actions ■ Preventive maintenance inspection records kept with

other visual inspection records Additionally, NFPA 70E requirements mandate accurate, up-to-date and legible single-line diagrams. Documentation is essential for troubleshooting and communicating information about your power systems. A comprehensive site survey is essential to develop or update existing singleline diagrams or complete electrical-system drawings. #4. Do you have a plan in place to address aging or obsolete infrastructure? The components comprising your electrical distribution system will eventually become worn or obsolete, especially when considering today’s rapid rate of technological advancement. Depending on where you are in the plant’s life cycle, the cost to keep these assets in operation can continue to rise despite best efforts to maintain the equipment, and the cost of complete system replacement can be prohibitive. Life-extension services can lengthen the useful life of your assets and return them to optimum operating levels. From preventive maintenance and trip unit upgrades to complete retrofits, rebuilds and replacement breakers, life-extension services can likely be designed to fit any budget and customized to your specific operating requirements and application. Representing one of the best values in equipment upgrades for power systems is the replacement of electromechanical relays. Relay retrofits and upgrades provide a fast, cost-effective way to leverage the advantages of microprocessor relays without the expense of installing new switchgear. Seamlessly retrofitting your existing switchgear with new microprocessor relays adds the benefits of self-testing, event reporting, fault identification and arc-flash detection. These advantages make troubleshooting and maintenance easier and safer. Plus, microprocessor relays provide the system information needed to improve protection, reliability, efficiency and compliance with International Electrotechnical Commission (IEC) 61850. DECEMBER 2013

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#5. Is your site in compliance with applicable safety requirements? Electrical power is the pulse of your facility. While it is vital to your operations, it also is dangerous, and accidents can be catastrophic and costly. Organizations such as Occupational Safety and Health Administration (OSHA) and NFPA have become more proactive in establishing worker safety standards and regulations. Staying on top of complex regulatory requirements can be difficult using only internal resources. By partnering with a qualified service provider, facility managers can rely on people familiar with industry standards and recommended best practices to ensure compliance. An effective safety program should provide training and awareness of potential electrical hazards. It should also identify hazard/risk evaluation procedures, electrically safe work procedures, proper tools and Personal Protective Equipment (PPE), as well as risk-mitigation strategies. The electrical-safety program must be documented and audited at least every three years to verify the principles and procedures are in compliance

with NFPA 70E. Arc-flash labels must also be affixed to your electrical equipment in accordance with 70E provisions. OSHA can and does enforce the NFPA 70E guidelines. The best way to meet necessary requirements is to conduct a comprehensive facility assessment to identify areas of risk and non-compliance, then formulate a plan to bring your facility into compliance in the most efficient way possible. Conclusion Power systems are among the most valuable assets in your plant and can have the biggest impact on the bottom line. The cost to build and maintain them is high, and failures within the systems almost always lead to substantial losses. Addressing the five questions outlined in this article will help you ensure maximum power-system performance, efficiency and reliability, as well as keep your workplace safe. This information was provided by Emerson Network Power’s Electrical Reliability Services Group. For more info, enter 04 at

Go Online and See Our Entire 2014 Training Schedule! Arc Flash Electrical Safety NFPA 70E®

Air Conditioning & Refrigeration

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What Will You Learn: • How to identify electrical hazards • Safe approach distances • Improvements in Personal Protective Equipment (PPE) • “Hot Work” rules • Lockout/Tagout procedures • Safety requirements for electrical installations

What Will You Learn: • Fundamentals of HVAC/R • Regulations, codes, and standards • Different types of refrigerants • Types of auxiliary system components • System diagnostics, servicing and troubleshooting • FREE EPA Section 608 testing is included

What Will You Learn: • How PLCs work • Parts and System congurations • Hardware considerations • Organization and Function of Ladder Logic • Troubleshooting PLC systems and components • Identifying input/output faults

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What Will You Learn: • Electrical fundamentals • Equipment for everyday use • Understanding your building’s electrical system • Working safely with electricity • National Electrical Code® basics • Wire selection & installation • Basic troubleshooting

What Will You Learn: • Boiler fundamentals • Combustion and heat transfer • Operation & testing of boilers • Boiler room safety • Controls and safety devices for automatically red boilers • Inspection and maintenance of commercial/industrial boilers

What Will You Learn: • Basic skills and OSHA requirements for electrical troubleshooting • Learn to troubleshoot control circuits, motors, power distribution, lighting circuits, PLCs and VFDs • Read and interpret ladder diagrams • Identify a successful electrical preventive maintenance program

What Will You Learn: • Introduction to the NEC® • Wiring and protection • Wiring methods and materials • Cords, receptacles, switches, switchboards, panel boards and other equipment for general use • Using and understanding tables • Understand the 2014 NEC® changes


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Calling All Innovators! Don’t just leave it to ‘the other guy’ to show off his/her innovation. You Could Be Our Next Grand-Prize Winner! Enter Now.

Categories: Innovative Devices, Gizmos & Gadgets Innovative Processes & Procedures Innovative Use of Third-Party Resources Honoring the essence of innovation in maintenance and reliability, entries will be judged on the following elements:

Practicality. . . Can it be adopted across industry? Can it be easily replicated, manufactured or sold?

Simplicity. . . Is the ROI less than 3 months? Is the idea intuitive and easily understood?

Presented By

Applied Technology Publications

Deadline for Entries is Midnight, December 31, 2013. Our Grand-Prize Winner & Runners-Up Will Be Announced Early 2014.

Details & Entry Forms Available At

Impact. . . Reliability Ergonomics (operator, maintainer) Safety Energy reduction Environmental Maintainability (reduces maintenance)

Sponsored By The Innovators At




ALL-TEST Pro, LLC Allied Reliability Group American Trainco Baldor Des-Case Corporation Fluke Corporation FS-Curtis Grace Engineered Products Grainger IRISS, Inc. Kluber Lubrication Ludeca Inc. Meggitt Sensing Systems Milwaukee Electric Tool

61 59 64 36 38 39 58 40 41 42 59 43 44 45


Nidec Motor Corporation NSK Corporation OILSAFE by Fluid Defense PdMA® Corporation PIP—Process Industry Practices Royal Purple LLC Scalewatcher SKF USA Condition Monitoring SPM Instrument Inc. TEAM Industrial Services Tri Tool, Inc. U.S. Tsubaki Power Transmission Update International WEG Electric Corp.

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46 48 49 60 61 50 51 62 64 52 63 54 55 56


Easy Call. Big Payoff.

Save Energy. Save Money. Motor-driven equipment accounts for 63% of your plant’s electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow or call in Baldor’s Installed Base Evaluation Team to identify improvements you can start making today.

targeting inefficient motors and mechanical drives as well as identifying systems where adjustable speed drives could be added to save even more energy. This report will provide recommendations for immediate action along with long term strategies… all positively affecting your bottom line.

The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors, drives and mechanical power transmission products, both in operation and from spares inventory. The IBE Team will produce a comprehensive report and plan,

If you’re ready to do something about your growing electricity consumption, email the Baldor IBE specialists at or call (864) 281-2100 to receive case studies with realworld savings. It’s an easy call with a big payoff.


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Reduce Your Plant’s Energy Consumption CORPORATE REPORT 2013

Call in the Baldor IBE Team In today’s business climate, virtually every manufacturing plant is searching for ways to reduce energy consumption and lower operating costs. By identifying older, inefficient motors and mechanical power transmission components and replacing them with BaldorÝReliance Super-E Premium Efficient motors and BaldorÝDodge gearing and bearing products, you can potentially realize huge energy savings. ®



Plus, an Installed Base Evaluation (IBE) provides the end user the framework for a motor management system and can identify where adjustable speed drives (ASD) might be added for substantial energy savings and better process control. An IBE can assist with Operational Equipment Effectiveness (OEE) Initiatives.

You can expect immediate and long term benefits from your IBE survey:

Each IBE report includes: ÝÛYour potential energy savings

ÝÛEnergy savings

ÝÛA detailed list of your current products in service

ÝÛImproved uptime through better system and process reliability

ÝÛYour expected payback/timing ÝÛRepair/replace comparisons ÝÛInventory/spares analysis ÝÛLocal rebate and incentive program details

$ 2500


ÝÛSimplified purchasing and inventory management ÝÛProduct availability


Continuous Use


If you’re struggling with rising energy costs and consumption, schedule an IBE survey today.


80 Hrs Per Wk


(864) 281-2100


40 Hrs Per Wk

0 $.06

ÝÛIdentify ASD opportunities for energy savings and improved process control

$.09 $.10 $.07 $.08 POWER COST PER KWH



©2013 Baldor Electric Company



$.15 For more info, enter 262 at


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Des-Case Corporation


es-Case understands the importance of fluid cleanliness and the role it plays in helping to ensure that equipment investments last longer. For more than 25 years, we’ve pioneered solutions to help maintain lubricant quality specific to customer applications. Featuring designs unparalleled in the marketplace, Des-Case products are used wherever lubricant life and performance are essential to daily operations. Count on Des-Case Why do many of the world’s leading companies, distributors and OEMs trust Des-Case to help keep their equipment and plants running smoothly? 1. Detection: Our Lubrication Transformation Services (consulting and training) help companies detect reliability problems and identify steps to address them, including implementation of practical machinery lubrication-management practices and cost-benefit analysis that support comprehensive programs. 2. Prevention: Getting clean, dry oil into machines (and keeping it that way) is one of the most fundamental elements of precision lubrication. Upgrading vent caps to high-quality Des-Case desiccant breathers and using lubricant storage systems and oil transfer/ filtration systems helps machines achieve optimum reliability and production uptime. 3. Removal: High-quality Des-Case fluid-handling devices remove dirt and water, helping equipment run at peak capacity. From small, portable machines to full-featured vacuum dehydration systems, customizable filtration devices are an integral component of proactive maintenance in unique environments. 38 |

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

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

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

Des-Case Corporation 675 N. Main St. Goodlettsville, TN 37072 Ph: 615.672.8800

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Fluke Corporation


ounded in 1948, Fluke Corporation is the world leader in compact, professional electronic test tools. Fluke customers are technicians, engineers, electricians and metrologists who install, troubleshoot and manage industrial, electrical and electronic equipment and calibration processes. In September 2013, Fluke Corporation introduced the new 1730 ThreePhase Energy Logger (shown here), an intuitive, easy-to-use tool with professional-level energy data gathering capabilities. The Fluke 1730 breaks new ground by enabling a broader category of maintenance professionals to confidently gather energy data, while the accompanying Fluke Energy Analyze software scales from the analysis and reporting needs of the facility manager to the advanced analytical requirements of electrical engineers. Even well-run facilities can experience energy waste, most commonly through equipment and system inefficiencies or by operating at expensive times of day on the utility rate schedule. Detecting those wastes requires logging energy consumption over time, using expensive power quality analyzers operated by engineers with advanced training. Unfortunately, those cost and skill barriers have made energy audits impractical for many facilities. The Fluke 1730 Energy Logger changes that. A streamlined energylogging tool with a straightforward, DECEMBER 2013 / CORPORATE REPORT

tions, and an on-screen wizard for interval setup. It has the highest safety rating in the industry (600 V CAT IV/1000 V CAT III), can be powered directly from the measured circuit, eliminating the need to find a power outlet, and has two USB ports for fast data downloads to PCs or standard thumb drives. Data logged by the 1730 can be imported into the Fluke Energy Analyze software for further processing and archiving. The software allows users to analyze energy or load profiles, including zoom-in and zoom-out on details; add comments, pictures, and other information to data; overlay different logging sessions; create reports; and export measurement results. For more information on the Fluke 1730 ThreePhase Electrical Energy Logger, visit: www.fluke. com/1730, or to view the Fluke 1730 video series (featuring introduction to energy logging, quantifying energy usage, saving money, and more), visit:

intuitive design, the Fluke 1730 allows technicians to perform load studies and energy logging right out of the box. The results provide facility managers with the information necessary to identify and prioritize energy saving projects. The compact energy logger conducts key measurements of voltage, current, Fluke Corporation power, and power factor to identify PO Box 9090 areas of energy waste. All measured Everett, WA 98206 values are logged automatically and Ph: 800.44.FLUKE can be reviewed during logging. or 800.443.5853 Common setup errors are rectified, through re-engineered cables, digital For more info, enter 263 at check and auto-correct of all connecFor more info, enter 264 at

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Grace Engineered Products


n 1993, while working on a friction welder retrofit project at John Deere, Phil Allen was on the cusp of discovering the first of two new niches in the electrical safety business. The machine I/O was located in the front while the electrical panel—with a 250 hp drive and a 400 amp main feed—was inconveniently located at the rear of the machine. The only way to access the equipment for maintenance was to open the doors, but the maintenance supervisor understood this caused a potential hazard. The supervisor insisted that they “keep those doors closed!” He wanted to put a PLC programming convenience interface or panel interface connector on the operator console where “all the I/O were located.” The engineers at Grace decided to accept the challenge and responded with a panel interface connector that contained a printed circuit board and cable solution. They housed it in a NEMA 12/4 rated, rectangular connector enclosure and the customer loved it! The local distributor loved it. It became obvious that Grace should offer this solution to all of its customers. Putting convenience interface inserts into standard rectangular enclosures (supplied by Harting USA) was a spectacular idea. Over the next few years, other variations of the original panel-mounted interface emerged, but were met with lackluster success. It became clear that even if Grace designed and stocked a thousand different varieties, customers would require something different. Customers needed the exact connector, the exact cable and the exact outlet configuration for their application—no more, no less. Understanding this second piece of information gave Phil Allen the winning recipe. He put his resources in place to build convenience interfaces and panel interface connectors according the customers’ precise specifications. Our 40 |

motto quickly emerged: “Any Cable, Any Connector, Any Combination!” Sales boomed as increasing numbers of maintenance electricians called in to ask for “one of those Grace ports.” Soon the product was officially named GracePort®. To date, Grace Engineered Products has designed and sold tens of thousands of GracePorts®. The number of uniquely designed components grows daily—there are an infinite number of possibilities. Remarkably, nearly all orders ship within 3-4 business days from receipt of the order, and Grace will put the customer’s own logo on the interface for only $20 more. But There’s More to This Story While GracePort was the first of Grace’s successful technologies to enter the marketplace, under the leadership of company president Phil Allen, it’s been joined by a number of others. Today, our lineup includes a range of permanent electrical safety devices (PESDs) and thrudoor voltage detection solutions that can help ensure electrical safety in a facility— including mitigating arc flash risk—while increasing employee productivity.

Keeping personnel away from live voltage is foundational to electrical safety. More important, electrical safety demands a precise answer to this crucial question: “Is voltage present?” PESDs go a long way in providing the very first answer to this all-important concern, while a voltmeter provides personnel with a second, redundant answer. PESDs also provide visibility of voltage from outside the enclosure without exposing personnel to the hazard. Surprisingly, operations that use PESDs on their equipment have found this concept to be overwhelmingly embraced by all levels of maintenance people.

Grace Engineered Products, Inc. 5001 Tremont Ave. Davenport, IA 52807 Ph: 800.280.9517

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elping industries ensure worker and work-place safety is a continuous pursuit for Grainger. One area of concern is helping to prevent suspension trauma after a fall. Safety managers often believe their job is complete if they can keep their employees from an impact injury during a fall event at work. Unfortunately, postfall suspension trauma and timely rescue are often ignored when employers are building a fall protection plan. While waiting for rescue after a fall-related event, suspension trauma is a real threat. What is Suspension Trauma? Suspension trauma can be caused by any situation where a worker is forced to stay upright without the ability to use his legs or move. The use of a personal fall arrest system during a fall event can be the cause of this situation. Even under the most ideal circumstances when a rescue plan is in place, suspension trauma should always be treated as an emergency situation because it can become fatal in less than 30 minutes. During a fall event, several things occur that can lead to suspension trauma. Because the worker is suspended in an upright posture with legs hanging, blood begins to pool in the legs. The safety harness straps can exert pressure on leg veins, compressing them and reducing blood flow back to the heart. If circulation is impeded enough, the heart rate will likely abruptly slow, reducing oxygen to the brain. DECEMBER 2013 / CORPORATE REPORT

helps blood get to the heart and reduces the amount of blood pooling in the legs. How Do You Stand While Hanging in a Harness? A worker can stand in a harness by employing suspension trauma relief straps. These typically come packaged in two pouches that attach to each side of a harness. During a fall event, the worker can deploy the trauma relief straps, creating a loop that the worker can put his feet into and press against to simulate standing up. This allows the leg muscles to contract and can relieve pressure from the leg straps to help improve circulation. For more information on fall protection equipment and the associated standards, check out these Grainger Quick Tips Technical Resources online at®: Under normal circumstances, faint-ing and collapsing to the ground would occur, positioning the head, heart and legs at the same level, thus returning blood flow and oxygen to vital organs. Unfortunately, during a fall event, the harness keeps the worker upright. The worker faints but cannot collapse and circulation isn’t restored.

• #130 Fall Protection Equipment • #131 Construction Fall Protection, Subpart M • #347 ANSI Z359: A New Lift to Fall Protection Standards

Steps to Reduce the Potential for Suspension Trauma One of the ways to slow the progression of suspension trauma is to stand up. Under normal circumstances, when a worker is standing, the leg muscles must contract to provide support and maintain balance, which puts pressure on the veins. This pressure, along with a series of one-way valves in the veins,

W.W. Grainger, Inc. 100 Grainger Parkway Lake Forest, IL 60045 Ph: 800.Grainger or 800.472.4643

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rotecting people, profits and equipment is at the heart of everything IRISS does. For over 15 years, IRISS has developed technology, tools and training to modernize energized electrical maintenance programs. 9 Ways IRISS IR Windows Have Taken Customers’ Electrical Maintenance Programs to the Next Level… 1. Protect from arc flash and electrocution Stay Safe: IR windows eliminate the exposure to inherent risks related to panel cover removal by providing a safe barrier between staff and energized equipment. 2. Leverage a multi-technology approach All-in-One-Solution: Ultrasound ports provide a systematic inspection point. An infrared image and visual inspection of energized electrical components provides the maintenance expert with vital information about the condition of electrical assets. 3. Primary & back-up power ready to perform 24 x 7 x 365 Reliability: Prepared existing and back-up power reliability by utilizing infrared window technology to efficiently eliminate electrical vulnerabilities safely. 4. Proactive reputation Anticipation vs. Reaction: Developing a reputation for mitigating risks by having the tools and technology in place to safely and efficiently inspect electrical systems provides the ultimate peace of mind for all stakeholders and is worthy of promoting.

5. Minimize shutdowns to perform maintenance Eliminate Need for Shutdowns: IR windows enable maintenance staff to assess and test the health of electrical assets anytime without having to schedule a shutdown of power. Inspections can be completed during full, normal operation. 6. Robust electrical infrastructures to support the growing energy needs Powerful System Design: IR windows can be installed in existing as well as OEM equipment allowing safe access to continuously inspect the health of the growing system. 7. Electrical assets performing at maximum efficiency Energy Conservation with Efficient Electrical Systems: The use of IR windows optimizes the power production itself because it allows maintenance staff to identify and eliminate any faults that are draining energy consumption. IR windows are an energy-efficient solution that can save tens of thousands of dollars in electrical bills, labor, and productivity.

8. Realized Return on Investment (ROI) Mitigate Costs thru Prevention: Maintaining OSHA & NFPA 70E compliance for safe and effective electrical inspections is made easiest with the use of IR windows. 9. Safety and Maintenance Academy of Reliability Technologies™ Work SMART, Not Hard: Continual learning is essential to ensure staff is prepared to mitigate and problem-solve solutions. SMART offers several unique classes that provide graduates the knowledge and practical experience necessary to complete electrical maintenance inspections safely and efficiently. For more info visit:

IRISS, Inc. 10306 Technology Terrace Bradenton, FL 34211 Ph: 941.907.9128

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Ludeca, Inc.


ts founding partners established LUDECA in 1953. In 1982, LUDECA became the exclusive representative of Prüftechnik AG for the United States, the Caribbean and Venezuela. Today, this representation includes marketing and support responsibilities for the entire Alignment and Condition Monitoring Divisions. LUDECA pioneered laser shaft alignment technology in the U.S. market with the introduction of its legendary OPTALIGN® system, manufactured by Prüftechnik in Germany in 1984. OPTALIGN’s then newly patented reflected laser technology was years ahead of its time, revolu- Ludeca’s ROTALIGN® ULTRA is just one example of the tionizing the field of shaft company’s state-of-the-art technologies. alignment and saving plants untold thousands of dollars in our state-of-the-art Miami Training downtime and repairs. Today, with a Center), as well as repair, NIST calibraproduct lineup headed by its globally tion and high-end engineering consulrespected ROTALIGN® ULTRA IS tation services. and OPTALIGN® SMART and SHAFTALIGN® tools, LUDECA remains No Excuses for High Vibration, America’s leading vendor of laser Misalignment and Unbalance in shaft alignment technology, We also Your Plant offer geometric measurement systems, LUDECA proudly announces the bearing heaters, shims and laser pulley recent launch of its microsite www. alignment tools. Inspired by the LUDECA services the vibration company’s “Keep It Running” slogan, analysis field with state-of-the-art this site has been designed to support portable and online condition moniLUDECA’s new message of “No toring systems, featuring the awardExcuses for High Vibration, Misalignwinning VIBXPERT® II vibration ment and Unbalance.” Visitors to analyzer and balancer with the powerful will find a OMNITREND® software as well as wealth of solution-related resources, VIBNODE® and VIBCONNECT® RF including Blog posts, video tutorials, online condition monitoring systems. white papers and other information We also provide alignment, vibration on state-of-the-art maintenance techand balancing training (onsite and at nologies. DECEMBER 2013 / CORPORATE REPORT

According to Ana Maria Delgado, Marketing Manager, LUDECA, Inc., “There’s no excuse to let high vibration levels, misalignment or unbalance cost you money. You can increase machine reliability and minimize costly downtime through precision laser shaft alignment and proactive condition monitoring solutions. When you have the best systems and support in the industry on your side, you don’t need excuses. Our mission at LUDECA, for over 30, years has been keeping America’s industry running.”

LUDECA, INC. 1425 NW 88th Ave. Doral, FL 33172 Ph: 305.591.8935

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Meggitt Sensing Systems


own power generating systems and cooling towers that all need to be monitored. Monitoring the motor fan at the top of a cooling tower is vital, for example, because if the cooling

toring. When properly positioned and monitored, vibration sensors effectively identify the changes in the mechanical performance of wind turbines that are the telltale signs of a developing fault.

Real-World Applications Modern oil and gas refineries, nuclear reactors, manufacturing plants and smaller turbines can have thousands of essential, but non-critical, pieces of rotating equipment. Although the failure of such fans, pumps, motors, blowers and compressors is unlikely to cause a major catastrophe, it can be costly and endanger people, equipment or the environment. Employing industrial vibration monitoring helps ensure that industrial processes are not interrupted, safety is maintained, environmental laws are adhered to and maintenance can be planned well ahead of any potential failure. Oil and gas refineries use rotating machines that variously pump fuel, water and air. These plants have their

tower shuts down, the water won’t be available to cool other processes and so those parts will also cease operating. As companies seek to be more competitive and employ fewer maintenance staff, industrial vibration monitoring is the only effective way to keep track of the health of a vast array of equipment around the clock. In the wind industry, industrial vibration monitoring has proven to be so effective that many insurance providers won’t provide coverage without it. When the first wind turbines were installed in Europe, their planetary-style gearboxes were prone to failure due to gear-oil overheating and mechanical wear caused by gusts of wind and misalignment. Turbines often caught fire, resulting in lengthy and costly downtime. Operators needed a way to monitor the health of their turbines and turned to vibration moni-

Correcting malfunctions at an early stage can save thousands of dollars in repair fees, as well as reduce costs from lost output. Today, Meggitt’s sensors and systems help monitor vibration on as many as 10,000 wind turbines.

eggitt Sensing Systems specializes in highly reliable industrial vibration sensors and conditionbased monitoring and predictive maintenance applications. The facility produces a wide range of Wilcoxon Research® vibrationmonitoring products for industrial, process control, military and test measurement. The company offers a variety of sensors, including hazardousarea certified, 4-20 mA output, high/low frequency, high-temperature, underwater, seismic and helicopter. Hermetically sealed and manufactured under ISO 14001 and AS9100 quality standards, our sensors are built to last and offer the longest product lifetime in the industry.

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Meggitt Sensing Systems 20511 Seneca Meadows Parkway Germantown, MD 20876 Ph: 301.330.8811 or 800.WILCOXON

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Milwaukee Electric Tool


hen it comes to power tools, there isn’t an expert out there who knows what works better than the professional tradesman. At Milwaukee, we take the time to walk in their shoes…we get out on the jobsite to work side by side with real craftsman to understand the demands of a constantly changing workplace and how we can best deliver solutions that help them work both faster and smarter. This has been our commitment from the beginning. Since we began in 1924, Milwaukee Tool has led the industry in both durability and performance by providing the best in professional, heavy duty power tools and accessories. With an unwavering commitment to the trades, Milwaukee continues to revolutionize the power tool industry with a focus on providing innovative, trade-specific solutions. We know pros sweat the small stuff, and so do we. We pay attention to the small details that make a big difference. This user focus not only leads to solutions for real jobsite challenges, but fuels the disruptive innovation seen across all product lines. This fall, Milwaukee expanded their award winning M18 FUEL™ line with GAME-CHANGING new products. Each boasting performance that rivals their corded counterparts, the new products include an M18 FUEL™ SAWZALL® Reciprocating Saw, M18 FUEL™ 6-1/2” Circular Saw, (4) M18 FUEL™ High Torque Impact Wrenches and (2) M18 FUEL™ 4-1/2” - 5” Grinders. “With unmatched advancements in the motor, battery and electronic technologies, each of the new M18 FUEL™ products represent breakthrough innovation within our cordless ecosystem. These tools will provide unprecedented levels of productivity and flexibility for the user,” says Christian Coulis, Director of Marketing for Milwaukee Tool Corporation. “The performance and durability DECEMBER 2013 / CORPORATE REPORT

that these tools bring can only be reached by combining the absolute best technologies with worldclass engineering and jobsite testing.” In addition, as more buildings implement complex process and control automation equipment to manage new systems, measuring tools that identify problems before they occur, and in a time-efficient manner, have never been more important and needed. At Milwaukee Tool, this provides a window of opportunity. “Our focus is on providing users with innovative and high-performance solutions that will increase productivity on the jobsite,” says Ernie Racenet, Director of The M12™ 160x120 Marketing for Milwaukee Thermal Imager is just Tool Corporation. one of many innovative In 2012, Milwaukee products that Milwaukee launched the ultimate Tool launched this year. predictive maintenance tool, the M12™ 160x120 Thermal Imager. A display features do things differently than we have done high-resolution thermal images for in the past to provide the best solutions simplified diagnostics, while a visual in the industry. camera captures photos right on the device. This provides users with the best information available, every time, no matter where they are, allowing them to schedule maintenance during downtimes. Whether it is through game-changing Milwaukee Electric Tool Corp. technology like you see in our M12 & 13135 W. Lisbon Road M18 FUEL cordless lines, or strategic Brookfield, WI 53005 partnerships that drive a dramatic shift Ph: 800.729.3878 in predictive maintenance like you or 800.SAWDUST will see from Milwaukee in coming months on our Thermal Imaging line, we are constantly looking for ways to For more info, enter 270 at | 45


Nidec Motor Corporation


idec Motor Corporation (NMC) is a leading manufacturer of commercial, industrial and appliance motors and controls. NMC’s product portfolio features a full line of highefficiency motors, large and small, that serve industrial, residential and commercial markets in applications ranging from water treatment, mining, oil & gas and power generation to pool and spa motors, air conditioning condensers, rooftop cooling towers and commercial refrigeration. The Nidec flagship brand, U.S. MOTORS®, has a 100-year history and a strong reputation in industrial motors. The U.S. MOTORS brand is a bridge from a rich, solid past to a bright and expanded future. Today, Nidec Motor Corporation is committed to developing new technologies and products that help our customers solve problems, improve efficiencies and protect the environment. Leading with a New Line of Inverter Duty Motors A perfect example of how Nidec is leading the vertical motor industry is the recent introduction of a new line of stock Vertical HOLLOSHAFT® inverter duty motors with a bearing protection system to help mitigate bearing problems caused by shaft voltage. The use of inverters in pumping applications has increased dramatically over the past few years. The combination of an inverter and induction motor with a pump produces an economical variable speed drive system that has the potential to provide energy savings and process optimization. It may also lead to improved system reliability. Unfortunately, inverters can be tough on electric motors. Those used to supply adjustable frequency power to induction motors do not produce sinusoidal output voltage waveforms. 46 |

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

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

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

Nidec Motor Corporation 8050 West Florissant Ave. St. Louis, MO 63136 Ph: 888.637.7333 For more info, enter 271 at CORPORATE REPORT / DECEMBER 2013


DECEMBER 2013enter / CORPORATE REPORT For more info, 272 at

| 47


NSK Corporation


SK’s Asset Improvement Program (AIP) provides real answers to real problems. Our AIP program is not a disguised attempt to sell you so-called “solutions.” It is, in fact, a well-proven platform that combines your own knowledge of the working environment, culture, processes and problems in your business, with the engineering expertise and innovation of NSK. Our solutions are quantifiable and measureable in terms of lowered costs, increased efficiencies and reduced downtime, resulting in increased profitability. What makes NSK’s AIP program different and more successful is the close working dialogue we have with our clients to identify and understand the problems that affect them, as well as the impact of these problems on their business financially. We are committed to helping solve problems that are costing you valuable time and money, by offering you a real opportunity to unlock additional profitability through improved machine reliability and increased working knowledge. The AIP Value Cycle Our AIP program works with you through a structured, pre-planned approach called the AIP Value Cycle. The Value Cycle consists of five stages: Situational Analysis, Value Proposition, Value Implementation, Value Measurement and Shared Best Practice. Stage One, Situational Analysis, consists of NSK completing an assessment to understand the problem and its frequency, as well as what the implications are to your business. NSK engineers then consider different methods to implement in order to solve the problem at hand. NSK then presents a recommendation, including the costs, lead times, and 48 |

other associated factors at Stage Two, Value Proposition, where we are able to field your questions and concerns. At Stage Three, Value Implementation, NSK works together with you to create a mutually agreed upon implementation plan. While working on your implementation plan, we take into account any deadlines, key milestones, etc. in order for you to achieve the forecasted savings. Stage Four, Measuring Value, is where we work with your own personnel to ensure that the forecasted savings are actually realized. In the final stage, Shared Best Practice, we discuss with you, and any other departments that may be having similar problems to those we had just resolved, how they could also potentially benefit from hearing about how we did with the AIP program! By progressively working with you at every stage of the AIP Value Cycle, NSK helps you see the potential savings available and ensures that you achieve the stated benefits. We have a “Your success is our success” mentality and by utilizing the combined experience and

expertise of NSK and our distributors, we have the capability to deliver the ultimate—peace of mind knowing that we are proactively working to make you more profitable. Increase knowledge, improve reliability and unlock profitability with AIP by NSK. . . See how NSK’s AIP Program can bene-fit your company. Read our AIP Service Spectrum information and industry case studies at: http://www.

NSK Corporation 4200 Goss Road Ann Arbor, MI 48105 Ph: 800.675.9930

For more info, enter 273 at CORPORATE REPORT / DECEMBER 2013


OILSAFE by Fluid Defense


he OilSafe® Visual Lubrication Management System from Fluid Defense Systems is the company’s easy-to-implement, flagship innovation that helps users keep their storage areas clean and safe and prove their commitment to best practices.

Providing a Range of Benefits Customizable, visually intuitive labels ensure consistent fluid identification throughout the manufacturing environment. The OilSafe Work Center provides safe, compact bulk storage and contamination control to promote best practices for lean manufacturing, 5Rs, 5S and OSHA right-toknow compliance. In-line filtration and precise-pour transfer containers simplify maintenance and safeguard workflow. As a result, plants benefit from a complete system that covers the entire process loop and works with any existing maintenance process. “Our OilSafe transfer containers and labels have long been the industry standard to reduce contamination and spills. We recognized a need in the market to add bulk storage and dispensing to create a fully integrated system for managing lubrication from delivery to point of application,” explains John Gillian, Chief Executive Officer for Fluid Defense. “That’s why we’re proud to introduce the OilSafe Work Center.” The OilSafe Work Center is the only modular, scalable bulk system of its kind. Each tank has its own pump and built-in filtration to prevent fluid crosscontamination and keep fluid storage areas organized, clean and free of the 55-gallon drums that are commonly used. According to Gillian, “It’s a safe and reliable solution that helps companies across the world instantly establish bulk-storage best practices on the plant floor and prevent the inefficiencies, downtime and lost production that can cost hundreds of thousands of dollars.” DECEMBER 2013 / CORPORATE REPORT

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

Serving a Range of Applications The OilSafe Work Center has been successfully implemented in applications such as manufacturing, mining, food and beverage, defense and more. Available in multiple configurations, each system is customizable to suit the application and budget. The scalable, plug-andplay design extends the life of the Work Center, minimizing downtime and increasing efficiency. In addition, the palletized, fully assembled pods allow for quick set-up and efficient transport. After years of delivering strong results, OilSafe has become the recognized standard in several key industries. Fluid Defense’s dealer network has a distribution reach into more than 45 countries and is partnered with worldclass suppliers.

To learn more about the OilSafe Work Center and the OilSafe Visual Lubrication Management System, visit

OILSAFE by Fluid Defense 2001 Greenfield Road Montgomery IL 60538 Ph: 630.280.8930

For more info, enter 274 at | 49


Royal Purple LLC


◆ Long Oil Life: Synfilm GT has outstanding oxidation stability that greatly extends oil change intervals while keeping equipment clean.

oyal Purple was founded as an industrial lubricants company by John Williams, a pioneer in developing synthetic lubricants. In the early 1980s, Williams was asked by an oil production company to solve chronic bearing failures in their large compressors. He set out to produce a lubricant with the ability to handle the extreme demands of equipment. New Lubricant Technology Williams’ work resulted in a new additive technology that fortified lubricants with an unusually high film strength capable of protecting rotating-equipment components under extreme operating conditions. In addition, the technology had exceptional oxidation stability for long oil life and provided outstanding protection against rust and corrosion in both wet and high temperature applications. This new additive technology—called Synerlec®—became the cornerstone of the Royal Purple product line. Synfilm® GT is one of the innovative products that uses Synerlec technology.

◆ Saves Energy: Synfilm GT has an extremely low coefficient of friction that is proven to save energy over conventional oils. In rotating equipment these savings frequently exceed the total cost of the oil within several months making what was once an oil expense a profit.

Royal Purple’s blending and storage tanks

◆ Synthetic Solvency: Synfilm GT’s natural solvency cleans up dirty equipment and keeps it clean. Though the Synfilm GT formulation has the ability to reliably lubricate many different types of equipment, Royal Purple produces a complete range of high performance lubricants for nearly every industrial application.

Versatility ◆ Synfilm® GT is Royal Purple’s most versatile lubricant. In the appropriate viscosity grade, it is recommended for use in gas and steam turbines, centrifugal compressors, pumps, vacuum pumps, blowers, bearings, gears, worm gears and more. It is a long-life, high-film-strength, energyefficient, synthetic lubricant that significantly increases bearing life and equipment reliability. ◆ Synfilm GT gains its performance advantages over competing mineral and synthetic oils through its superior blend of synthetic base oils plus Royal Purple’s proprietary Synerlec additive technology. This unique 50 |

◆ Excellent Corrosion Protection: Synfilm GT’s tough oil film forms an ionic bond on metal surfaces, which acts as a preservative oil during shutdown and provides instant lubrication at startup.

Royal Purple LLC 1 Royal Purple Lane Porter, TX 77365 Ph. 888.382.6300

additive technology is proven to make equipment run smoother, cooler and quieter, as well as more reliably and efficiently. Performance Advantages ◆ High Film Strength: Synfilm GT protects bearings far beyond the ability of other turbine oils, carrying significantly greater loads.

For more info, enter 275 at CORPORATE REPORT / DECEMBER 2013


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

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

For more info, enter 276 at


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Founded in 1973, Team Industrial Services is the worldwide leader in minimizing equipment and asset downtime, providing on-line maintenance, inspection and repair. We provide critical services to our customers that enable them to maintain and operate their facilities and equipment in a safe and productive manner. Our line of specialized industrial services includes bolting/torquing, concrete repair, emissions control, L_JOHUNLYZLY]PJLZÄLSKTHJOPUPUN Ä[ULZZMVYZLY]PJLOLH[[YLH[PUNOV[ tap/line stop, isolation test plugs, leak repair, manufacturing/engineering, mechanical integrity, NDE/NDT inspection, specialty welding, turnkey tank program, valve insertion, and valve repair. We employ only the best, most X\HSPÄLK[LJOUPJPHUZ[VLUZ\YLLHJO and every job is completed to the highest standards every time. Our quality management system requires ongoing technical training for all personnel. Additional training and documentation are required based on ZWLJPÄJ[LJOUPJHSQVIYLX\PYLTLU[Z In addition to our services, Team’s 0:6JLY[PÄLKLUNPULLYPUNKLZPNU and manufacturing facilities provide

the highest quality pipe repair, leak sealing and hot tapping hardware, sealants and related products. A company-wide commitment to quality control, safety and quick response drives the manufacturing of all Team products 24/7/365. In our 40 years of experience in inspection, maintenance, repair, and compliance, we’ve come across a variety of unique business and industry challenges. We provided solutions for each of these challenges, which we then utilized to better our team, better our services and better our processes. Whether our customers are working on a capital expansion project in a nuclear power plant, planned maintenance in a paper mill, emergency repair to a mining massive loader assembly, or HZJOLK\SLK[\YUHYV\UKPUHYLÄULY` more than likely one of our technicians has performed similar work in a similar situation. Our customers have grown to count on Team when the going gets tough. However, we approach any project, big or small, with the same intensity to ensure each job is completed safely and to the highest standards every time. That is why HSE&S and quality are the core driving forces

behind everything we do at Team. We maintain management systems and documented work procedures designed to assure compliance with all applicable laws, regulations and internal requirements, as well as to facilitate the continuous improvement of our processes, products, and personnel. Our highest priority at Team is the safety of our employees, clients, and other contractors. We are committed to safety excellence and strive daily for Zero injuries and incidents. Today, we are rapidly growing our global footprint across a wide range of industries - with service locations PUÄ]LJVU[PULU[Z>LYLJVNUPaL that our global success is ultimately measured by our customers’ [Y\Z[HUKJVUÄKLUJL^OPJOJHU only be earned through continuing outstanding service. Team’s trained HUKJLY[PÄLK[LJOUPJPHUZHYL available worldwide 24/7/365. From single part repair to turnarounds and shutdowns – planned or unplanned – Team has the training, experience, technology and knowhow to deliver high-quality maintenance, inspection, and testing services anytime, anywhere. For more info, enter 277 at

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Can you spot the difference?


Bolting/Torquing Concrete Repair Emissions Control Exchanger Services Field Machining Fitness for Service Heat Treating Hot Tap/Line Stop Isolation Test Plugs Leak Repair

Manufacturing/ Engineering Mechanical Integrity NDE/NDT Inspection Specialty Welding Turnkey Tank Program Valve Insertion Valve Repair


| 53


U.S. Tsubaki Power Transmission


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

54 |

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

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

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

U.S. Tsubaki Power Transmission, LLC. 301 E. Marquardt Drive Wheeling, IL 60090 Ph: 800.323.7790

For more info, enter 279 at CORPORATE REPORT / DECEMBER 2013


Update International A long-established, proven leader in practical, in-depth machinery vibration knowledge and training now provides cutting-edge, innovative tools to help make it all really happen!


or the past 47 years, Update in the first place. The DT6 changes all Simple-to-use hardware makes the International has been a leader that. One simple touch provides 6 DT6 useful even for mechanics and and key innovator in the channels of acquisition, automated trades people to quickly and easily field of machinery vibration phase synchronization/adjustment and check their own work upon startanalysis and prevention. Founded by relationship rule processing/display. up—the foundation of true, proactive Ralph T. Buscarello, Update brought The DT6 is a cost-effective way to precision-based prevention that is at the vibration analysis out of limited “Black easily add the power of phase to the heart of the largest possible savings from Box” thinking into the hands of any understanding and decision making vibration control. mechanically minded person through non-technical, practical and in-depth training. Working with almost every major oil, chemical, pulp & paper, power etc. company in North America and throughout the industrial world has provided Update with the unique real-world insights into what it takes to get the highest returns from vibration-control programs. Update pioneered and advanced key innovations including the use of phase, understanding resonance and the importance of prevention of vibration through precision practices. In keeping with this tradition, we have recently developed innovative hard- Time, Frequency and Phase, all with no prior setup or advance knowledge necessary, make the DT6 ware and software designed to easy, powerful and versatile. make it even easier to quickly and effectively get the information process of analysts. Further, the DT6 is Practical, In-depth, necessary to understand and prevent also a valuable tool for various departHands-on Vibration Training vibration problems in the first place. ments, consultants and small plants— & innovative Tools For anyone who needs to see the condition of Analysts, Managers DT6 — Nothing else like it their rotating machines. Our new DT6 creates a breakthrough And Trades in the extremely important (yet often not understood) area of phase analysis. While Time and Frequency plots say a lot about machine condition, phase is necessary to complete the whole picture. Yet until now, just collecting and docuPh: 800.530.4215 Fax: 303.985.3950 menting phase data proved too much of a hassle—even if it could be obtained For more info, enter 280 at DECEMBER 2013 / CORPORATE REPORT

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WEG Electric Corp.


ounded in 1961, WEG has grown into a global solutions provider of industrial electrical technologies. WEG is the largest industrial electric motor manufacturer in the Americas and one of the largest manufacturers of electric motors in the world—producing more than 10 million units annually. Committed to growth on a global scale, WEG continually invests in stateof-the-art manufacturing facilities and processes, and the development of new and improved industrial electrical solutions. WEG offers a diverse and integrated product line that includes motors, drives, controls, transformers and generators. WEG has committed to an R&D investment of 3% of annual global sales. Severe Duty is Standard with WEG With WEG, you do not need a special motor for severe duty. Note these features, capabilities, ratings and certifications:

■ Exclusive W-Seal 364T and larger

provides superior bearing protection ■ Taconite labyrinth seal 586 Frame

and larger ■ Exclusive WEG painting system

exceeds 200hrs ASTM 117 corrosion test (exceeds IEEE841 standard)

■ All NEMA Premium ratings have a

1.25 service factor (up to 100 HP) resulting in cooler operation and extended life of the motor ■ All Cast Iron Construction,

including Terminal Box and Fan Cover

■ Balanced to 0.08 inches per second

vibration limits (meets IEEE841 standard)

process control software is designed to reduce system operation and maintenance costs, while increasing process accuracy and protection. The software provides multiple-pump control and protection, as well as system monitoring and protection. Pump Genius can be applied to any system that requires constant flow or pressure. Pump Genius software works with the CFW11 drive to control system processes. The software monitors system pressure or flow and manages pumping requirements.

■ Four-bolt conduit cover with glued

Neoprene gasket ■ Impregnation resin and magnet

■ Solid feet for reduced vibration

wire are insulation class H

levels and impact absorption ■ Stainless steel nameplate, laser■ Optimized ventilation system for

cooler operation and extended life ■ High Grade FC200 cast iron

provides superior mechanical strength and heat dissipation

edged with high contrast background ■ Corrosion-proof drains ■ Inverter Duty per NEMA MG1,

Part 31 ■ All WEG W22 motors are totally

enclosed, fan-cooled units with a true IP55 rating against dust and moisture 56 |

Pump Genius Control up to 6 pumps dynamically alternated and controlled. Pump Genius

WEG Electric Corp. 6655 Sugarloaf Parkway Duluth, GA 30097 Ph: 800.ASK.4WEG or 800.275.4934 For more info, enter 281 at CORPORATE REPORT / DECEMBER 2013

Motors | Automation | Energy | Transmission & Distribution | Coatings Motors | Automation | Energy | Transmission & Distribution | Coatings


Severe Duty is Standard with WEG W22 motors.

You do not need a special motor for severe duty. Severe Duty is standard with WEG W22 motors. High performance with maximum energy efficiency is the goal of the WEG W22 electric motor. High efficiency and low cost of ownership throughout the entire motor lifetime have been the basis for the W22 development. A design created to maximize performance and energy savings. Optimized cooling system, large and accessible terminal box, exclusive bearing seal system, low vibration levels, and a 1.25 service factor are just a few of many STANDARD features of our W22 motors. Available in NEMA Premium or Super Premium Efficiency levels.

To learn more about the W22 features and benefits or to locate a WEG Distributor near you, please contact

1-800-ASK-4WEG or visit Transforming Energy into Solutions


For more info, enter 282 at

Š 2013 WEG Electric Corp.

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t FS-Curtis we strive to be the most trusted and dependable compressed air solutions provider in North America. All of the products outlined below are sold and serviced through a nationwide network of full-service distributors.

Reciprocating For applications where air demand fluctuates significantly, reciprocating compressors are the most economical and reliable choice. FS-Curtis CT, CA, and ML Series meet this need at three distinct price points. We also offer products for climate control, vacuum, and oil-less applications, as well as large reciprocating machines (30-125hp).


Fixed Speed, Variable Speed and Oil-Free Rotary For applications requiring continuous

air, FS-Curtis offers a variety of rotary screw compressors. For smaller applications, our SEG and SE product lines (5-50 hp) feature whisper-quiet operation and optional UltraPack, which provides continuous-duty, dry, filtered air in one space-and-service-andmoney-saving package. Our RS machines (15-300 hp) are a robust and time-tested solution that comes either enclosed or unenclosed, saving money and increasing serviceability if low-noise levels aren’t a requirement. Our GSV and AF machines (20-200 hp) are variable speed options that match air flow to demand, saving money on energy. Finally our ZW (20-50 hp) machines are an ideal choice for applications requiring oil-free continuous-duty air. Air Treatment To complement our compressors, we

offer a complete line of air treatment products: refrigerated (10-3000 cfm), dessicant (10-5400 cfm), and membrane dryers (1.39-138.1 cfm); and filtration and separation products to match our dryer offering. Please contact us via one of the following channels to schedule an on-site consultation or simply to learn more.

FS-Curtis St. Louis, MO 63133 Ph: 800.925.5431 For more info, enter 283 at





   777&3#524)3#/!-%2)#!.#2!&43-!.3()0 34,/5)3 -/53!

For more info, enter 284 at

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Allied Reliability Group

llied Reliability Group helps companies build wealth and competitive advantage through world-class Predictive Maintenance (PdM) integrating the full array of technologies. Since 1997, Allied Reliability Group has been the industry leader in designing and implementing customized, integrated approaches for identifying defects in assets utilizing Condition Based Monitoring (CBM) services and measuring Return on Capital Investment in Asset Management. Through the integration of a full array of technologies, Allied Reliability Group can fully identify defects in mechanical, electrical and stationary assets. This integrated approach to an equipmentmaintenance program builds lasting ROI and measurable impact on asset health by way of the following techniques:

■ Vibration Analysis ■ Oil Analysis ■ Infrared ■ Ultrasound ■ Motor Circuit Analysis ■ Reliability-Centered Lubrication ■ Energy Management ■ Power Quality Analysis ■ Sensory Inspections

Allied Reliability Group’s versatility offers our clients flexibility through these four basic Delivery Models: 1. Internal Training 2. Outsourced Services 3. Hybrid Training and Outsourcing 4. Remote Diagnostics and Analysis Our employees hold over 195 certifications in vibration, ultrasonics, infrared thermography, motor circuit analysis, oil analysis and lubrication. We also

boast the most Certified Maintenance and Reliability Professionals (CMRP) of any service organization—more than 50 CMRPs. Contact us today to get your Condition Monitoring program on track and saving you money.

Allied Reliability Group 4200 Faber Place Drive Charleston, SC 29405 Ph: 843.414.5760 For more info, enter 285 at


Kluber Lubrication


lüber Lubrication is one of the world’s leading manufacturers of specialty lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Klüber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which have earned it an excellent reputation in the market. The company holds all common industrial certifications and houses a test facility hardly rivaled in the lubricants industry. At Klüber, we continue to pioneer advances in order to translate previously inconceivable concepts into fully functional reality. We make these crucial contributions with over 2000 DECEMBER 2013 / CORPORATE REPORT

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

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

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

For more info, enter 286 at | 59



hen you think of predictive maintenance, electric motor testing, condition monitoring, energy cost analysis, or motor circuit analysis training, if you don’t think of PdMA® Corporation, you should! An industry leader and innovator, PdMA® has over 30 years experience in the predictive maintenance and condition monitoring field. Our MCE® (offline), Emax (online) and MCEmax® (offline/online) testers are utilized by a variety of industries around the world. All testers are designed to monitor and trend the condition of AC induction, synchronous, wound rotor, and DC motors and their circuits. Among the testing capabilities are: power quality, power circuit, stator, rotor, insulation and air gap. The new M-series tester also has the ability to perform a Six Channel In-Rush test and to auto-

PdMA® Corporation and in their state-of-the-art-training facility in Tampa, Florida. In addition to the training courses, Regional User Group Meetings and free workshops are conducted throughout the year in locations around the world. Free video tutorials on the Six Fault Zones and other predictive-maintenance-related topics are available on the PdMA® website (

matically verify the MTAP and asset are correctly linked for testing. Designed to increase safety (PPE not required) and reduce connection time for online motor testing the MTAP2® and MTAP3 motor test ports allow you to capture data quickly to determine motor health. PdMA® also offers a variety of training courses both at the user’s site


A Leader In Electric Motor Testing

PdMA® Corporation 5909-C Hampton Oaks Parkway Tampa, FL 33610 Ph: 800.476.6463 For more info, enter 287 at

For more info, enter 288 at

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LL-TEST Pro, LLC (ATP) manufactures handheld, battery-operated, portable instruments for the testing of motors, generators, transformers and other coil-based devices. Worldwide sales, service and training is available for our line of instruments that perform De-Energized testing (Motor Circuit Analysis), Energized testing (Electrical Signature Analysis) and Power Quality Analysis (including an easyto-use, energy-saving calculation report) for Predictive Maintenance Testing, Quality Control, and Troubleshooting.

Versatility By being able to choose the ideal ATP instrument for a customer’s need—be it just troubleshooting or more demanding predictive maintenance—the initial investment is very low and will produce a rapid ROI for the contractor.

12,000+ Instruments Sold Worldwide ATP’s motor-testing instruments are used daily for improving rotating-equipment reliability, reducing energy consumption and lowering overall plant operating costs. Several models have received “Best Product” awards worldwide. Network of Contractors While Electrical-Motor System testing has become an important part of successful rotating- equipment reliability programs, many potential customers cannot support an internal testing program. We know that contractors are perfectly positioned to offer these services, which will bring a new revenue stream to their businesses. Electrical Machinery Diagnostics Workshops ATP offers IACET-accredited Electrical Reliability Training courses worldwide.

Taught by Bill Kruger, world-renowned for his Theory and Application of Motor Diagnostics courses, attendees earn CEU credits in these Energized and De-Energized Testing Courses that focus on electric-motor theory and operation to provide a comprehensive view of the principles and solutions needed to diagnose electric-motor-system issues. The knowledge gained arms attendees with the expertise needed to implement reliable predictive maintenance programs in their facilities. ALL-TEST Pro, LLC PO Box 1139 Old Saybrook, CT 06475 Ph: 860.399.4222 or 800.952.8776 For more info, enter 289 at


PIP—Process Industries Practices


013, the year after we celebrated our 20th anniversary, has been a tremendous one for PIP – Process Industry Practices. We have added 11 new Members to our consortium since November 2012, bringing our Membership to 74 participating owner and contractor companies. Our Subscribers and Licensees have grown to 59 companies and educational institutions in 2013, from 46 in 2012. PIP Members continue to share the goal of reducing total installed costs of process plants by up to six percent through the implementation of common industry practices. Our Members also share the goal of spreading the use of PIP Practices across the industry, within the industry and to all other process industries to create a true “industry standard.” Get to Know Us PIP is a Member consortium of process DECEMBER 2013 / CORPORATE REPORT

plant owners and engineering construction contractors harmonizing their internal standards for design, procurement, construction, and maintenance into a set of industry wide practices for voluntary use. Organized in 1993, PIP is a separately funded non-profit initiative operating under the umbrella of the Construction Industry Institute at The University of Texas at Austin. PIP publishes and maintains recommended Practices for the process industry in the following disciplines: ■ Civil/Structural/Architectural ■ Coatings/Insulation/Refractory ■ Electrical ■ Hygienic Process Piping ■ Machinery ■ Piping & Instrument Diagrams ■ Piping ■ Pipeline Systems

■ Process Control & Analyzers ■ Vessels/Exchangers/Tanks

Practices include design, selection, specification, and installation information. PIP has published over 460 Practices. A current listing of published Practices is available at

Process Industry Practices 3925 West Braker Lane Austin, TX 78759 Ph: 512.232.3041 For more info, enter 290 at | 61



SKF USA Condition Monitoring - Fort Collins

otors drive industry and, ultimately, the success of corporations and organizations all over the world. Maintenance professionals need visibility into the health and condition of rotating equipment to help them make good decisions about maintenance or repair of that equipment. SKF Condition Monitoring designs, manufactures and markets electric motor test equipment that helps maintenance professionals, repair shops and motor-manufacturing operations efficiently maintain and repair equipment. For example, the Baker AWA-IV and Baker DX series of static motor analyzers perform a comprehensive array of insulation and circuit tests on off-line (powered-down, or static) motors to detect problems that would lead to motor failure and unplanned

downtime. The SKF Dynamic Motor Analyzer – EXP4000 helps troubleshoot problems with motor/machine systems by monitoring the quality of power fed to a motor, the motor’s performance and the condition of the load placed upon it. The SKF Online Motor Analysis System – NetEP provides continuous visibility into motor/machine health twenty-four hours a day, 365 days a year from the safety of an office or any remote location with a computer and access to the Internet. For rock-solid quality assurance and accurate condition monitoring of the electric motors and generators—and the systems they drive—that your business depends on, there’s an electric motor test or monitoring instrument from SKF that can acquire and analyze the vital information you need. SKF has the solutions you need to efficiently main-

tain your operation’s motorized equipment, keep it up and running properly and minimize the costs of motor failures and unplanned downtime.

SKF USA Condition Monitoring 4812 McMurry Ave. Fort Collins, CO 80525 Ph: 800.752.8272

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Tri Tool, Inc.


rom the beginning, Tri Tool, Inc. has built a reputation for manufacturing excellence with equipment designed to be rugged, reliable, easy to set up and operate, while delivering maximum performance and versatility. This commitment has resulted in Tri Tool’s continued growth to become a world-leading producer of precision portable machine tools for pipe and tube severing and beveling, and specialty in-place machining for plant maintenance and piping system construction. Tri Tool’s advanced line of AdaptARC® mechanized multi-process welding equipment features the dynamic OrbitMaster® Programmable Weld Controller and patented DualARC® weld head for GTAW, FCAW, GMAW-P (Pulsed Spray) and GMAW-S (Short Arc). AdaptARC® welding technology produces maximum performance,

dependable precision, ease-of-use and rapid changeover between modes. ■ Tri Tool’s Services Division provides

that you get the finest custom tools possible, and exactly the right equipment solutions to satisfy your specific requirements.

a nationwide network of support facilities and a dedicated staff of highly trained field machining and code welding technicians who stand ready to respond to your on-site machining and welding requirements.

Tri Tool looks to the future with an unwavering dedication to the design of innovative, quality products, supported by the highest level of customer support in the industry.

■ Tri Tool’s equipment rental offers a

cost-effective project management option that is ideal for scheduled or emergency outages, new construction, decommissioning or short-term machining projects. ■ Tri Tool’s Special Engineering offers

state-of-the-art custom equipment design, backed by quality OEM manufacturing experience, ensuring

TRI TOOL INC. 3041 Sunrise Blvd. Rancho Cordova, CA 95742 Ph: 916.288.6100 For more info, enter 293 at

OUR ERROR-FREE COMMITMENT For on-site service, you can count on Tri Tool for reliable and outstanding project execution. Our Service technicians are highly skilled and trained to be experts in field services. With our culture of safety, integrity and hard work we consistently deliver error-free project results. Fossil and Boiler Maintenance Specialty Machining and Welding Services Consultative Services for Outage Planning Custom Engineering Projects Equipment Rental

“Tri Tool’s performance, with their commitments to Safety, Human Performance, and Quality was exceptional. Their personnel and equipment reflected the Standards of Excellence expected by the Site.”

Call today to consult with a on-site service expert.


888-345-5015 • 916-288-6100 •


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PM is committed to maintaining your critical machinery, anywhere, anytime. Making maintenance a profitable part of your company is what drives ours. We offer a wide product range from high-tech portable instruments and online systems to comprehensive software. Our intelligent solutions are cost-effective, constructive and complete. They make an excellent foundation for a proactive approach to maintenance—integrated in your normal maintenance activities to provide you with an overall picture. SMP’s Leonova Diamond and Leonova Emerald products, for example, combine high-definition vibration-analysis technology and Shock Pulse capabilities in lightweight, durable, carbon-fiber-reinforced, intrinsically safe packages. The most advanced IECEx certified instruments on the market, Leonova Diamond

SPM Instrument Inc. and Emerald both comply with the strictest IECEx standards and, thus, can be used in zones 0 - 2. Both products utilize the latest Shock Pulse HD® method for rolling-element early-damage detection and lubrication analysis. The Leonova Diamond is an easy-to-use, yet sophisticated, 3-channel vibration analyzer, where as the little brother Leonova Emerald is a single channel unit. Both instruments have attachments for Laser Tachometer/IR Temperature and can utilize a noise-cancelling headset for Stethoscope readings and even voice recording of comments in noisy environments. Attachments and modules for Balancing, Orbit Analysis, Laser Shaft Alignment and more can be added to optimize your analytical power and maximize your rotating-machinery assets. Programmable function keys,

ergonomic right- or left-handed design and powerful/versatile Condmaster PRO software make the Leonova Diamond or Emerald a perfect fit for any industry. Upon request, we will put together the monitoring-equipment package best suited to your economic and technical requirements.

SPM Instrument, Inc. 780 Bailey Hill Road, Suite #3 Eugene, OR 97402 Ph: 800.505.5636 or 541.687.6869 For more info, enter 295 at



or over 10 years, American Trainco has worked tirelessly to help companies all over the U.S. and Canada limit downtime at their facilities and create safe work environments for their employees. We provide live, instructor-led training seminars in public settings or privately at your facility for maintenance personnel in large buildings, plants and industrial facilities. Among our most popular training topics are “Basic Electricity for the Non-Electrician,” “Arc Flash Electrical Safety NFPA 70E®,” “Electrical Troubleshooting,” “Air Conditioning & Refrigeration,” “Boiler Operation, Maintenance & Safety,” “Programmable Logic Controllers,” “Variable Frequency Drives,” “Pumps and Pump Systems,” “National Electrical Code®,” “HVAC,” “Hydraulics,” “Emergency Power,” “High Voltage Electrical Safety” 64 |

American Trainco and many more. Plus, we can provide testing and certification for the EPA Section 608 exam. At American Trainco, we instruct and guide our students in gaining hands-on knowledge they can immediately apply in the workplace. We make sure they can keep their plant or facility up and running—and we make sure they can do it safely. We encourage our students to discuss the issues and problems they face in their own jobs every day, ensuring that they will gain the practical information they need that is specific to their facility, enabling them to fix problems, create and maintain a safe workplace, and keep their equipment up and running now! Visit us at www.AmericanTrainco. com to see our entire 2014 training schedule and list of seminar topics or call 877-97-TRAIN for more information.

American Trainco, Inc. 9785 Maroon Circle, Suite 300 Englewood, CO 80112 Ph: 877.97.TRAIN or 877.978.7246

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The PPE You Don’t Wear

Instead of suiting up in PPE, suit down while increasing safety and productivity by doing lock-out/tag-out through the panel door with Permanent Electrical Safety Devices (PESDs) by Grace Engineered Products. t

Most PESDs install in 30mm holes on the panel door or flange


Voltage indicators allow for the visual indication of both AC and DC voltage


Voltage portals utilize a NCVD pen as a redundant check for the voltage indicator

Increase compliance to NFPA 70E / CSA Z462 with PESDs! For more information visit

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Steam Into The New Year With Informed Boiler Repair/Replace Decisions Resolving to upgrade a steam system can lead to welcome dividends. The level of upgrade depends on several factors.


ith 2014 right around the corner, many people are making New Year’s resolutions. Unfortunately, most resolutions don’t seem to last beyond six weeks. On the other hand, if your resolution list includes ways to help your site save money, optimize equipment and processes, become more sustainable or all of the above, with a properly specified and/ or maintained steam boiler, you don’t have to worry about making it past the six-week mark. The right boilers (backed by the right boiler decisions) have the potential to improve your operations for years to come. Boilers are the workhorses of a facility. Providing the steam required for a plant’s processes, their applications are varied. Although these units are often ignored, plants can find themselves in total shutdown mode when they fail—as if a utility had turned off the electricity.




Out with the old and in with new, or otherwise For sites that depend on steam systems, it’s important for boilers to operate reliably, efficiently and safely. Newer designs can do all that and more: Among other things, they’re more compact, reliable, efficient and environmentally friendly than older, conventional models. Determining the feasibility and cost-effectiveness of simply repairing aging or ailing units or totally replacing them is easy if you follow this straightforward checklist: ■ Determine Your Need: Not all in-service boilers are

repairable. Repairing one that’s too small or inefficient for the application may not be the best use of your capital budget. It makes sense to do your homework and compare your existing boiler(s) with those that are currently on the market. You may find it more practical to purchase a new unit. Consider what you have, what you think you need and all of the options that are available to you. Many modern boilers incorporate control systems and allow economizers to improve efficiency. Such a purchase can quickly pay for itself. Should your operation prefer not to replace its existing boiler(s), if at all possible, you’ll need to thoroughly evaluate the equipment to make sure it can support retrofits or repairs. ■

Consider Purchase and Operating Costs: If you decide to purchase a new boiler—either to improve efficiency or save money—you should first look at the operating cost of the new unit. While a cheap boiler may seem attractive at first glance, make sure you factor in fuel cost, which can quickly outweigh the initial capital cost. Look at a 10-year operating cycle and examine your total expenses. If that enticingly cheap unit you’re considering buying were to use more fuel or require more maintenance and repair over the long haul, it would cost more to own it.

■ Match Your Purchase To Your Needs (Exactly): With

a full understanding of how steam is used to produce energy, pick either single or multiple units that match the criteria you need. For example, if you need a boiler to run only for a short time and not continuously, consider a quick-starting unit to save on operating labor and fuel. Conversely, if you need a boiler to run continuously or at high power, opt for a more efficient model and add a stack economizer—which will quickly pay for itself through the life of the unit and allow you to reuse and recycle process heat.

■ Thinking Newer/Younger May be Better: While retrofit-

ting may help your boiler in the short term, in the long run the sizing of feed-water treatment systems must also be considered. Consider using a newer unit as your primary equipment, and an older one as backup. ■ Get Steamed Up: Steam usage is also a critical consid-

eration. Odds are that your boiler usage has increased since you purchased the equipment. Adding newer, more efficient models and having one undersized unit as a backup will help you get the job done with a strong reliability margin. If your steam usage has decreased, consider replacing an existing unit boiler with several smaller-sized ones to help with fuel savings. ■ Cheaper by the Dozen (or by Two): While multiple units

will cost more during the initial installation, they will quickly pay for themselves in improved efficiency. If a burner should go out, production downtime can be a very expensive liability. Multiple backup boilers translate into less of a production risk. ■ Stay Abreast of Applicable Regulations: Check appro-

priate agencies for current and possible regulatory changes. Repairs and retrofitting to adhere to changing regulatory requirements can become expensive. If such a scenario is a possibility, a boiler replacement might be the cheaper course of action. ■ Customer Service is Key to Long-term Success: Always

remember that a boiler’s vendor and repair provider can be just as important an investment as the equipment itself. Make sure that you review a company’s ability to provide continued support and how timely it is in responding to service needs. Verify, as well, that any service agreements are within your budget. Don’t forget the intangibles Intangibles are items that are usually difficult to put a price on during an estimate or comparison. Still, they can end up costing copious amounts of cash. Factory-skid-mounting of equipment is an example of an item that can be included in a boiler-purchase contract: This type of mounting will not only save in installation costs, it also can save engineering hours and allow the new unit to be up and running faster. Availability of spare parts and performance guarantees should also be considered. MT The information in this article has been supplied by Clayton Industries, Inc. For more info, enter 05 at




PdM Tools & Services Versatile And Precise Temperature Scanner


luke Calibration’s 1586A Super-DAQ Precision Temperature Scanner features up to 40 analog input channels and scan rates as fast as 10 channels per second. With the flexibility of both internal and external input modules, the 1586A is designed for use both on the factory floor where channel count and scan speeds are important, and in the calibration laboratory where accuracy and quick input connections are required. The 1586A can measure thermocouples, platinum resistance thermometers (PRTs), thermistors, dc current, dc voltage, and resistance. It also offers temperature measurement accuracy of plus-or-minus 0.005 degrees Celsius for PRTs, 0.5 degrees Celsius for thermocouples and 0.002 degrees Celsius for thermistors. It features four modes of operation (scan, monitor, measure and digital multimeter) and alarms that indicate when a channel measurement exceeds an assigned high or low limit. The scanner is suited for applications such as thermal mapping, process sensor calibration, quality control testing, life-cycle testing, process monitoring and more.

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Fluke Corp. Everett, WA

Handheld TTR Tester


egger now offers a handheld, battery-operated transformer-turns-ratio (TTR) tester, the TTR20. The instrument measures turns ratio, polarity and excitation current in single-phase and three-phase transformers, current and potential transformers, as well as voltage regulators. TTR20 uses replaceable AA batteries and can measure high turns ratio of 10,000:1 with the lowest excitation voltage and excitation current up to 100 mA. The TTR20 tests at 55 Hz to provide consistent results, features multiple voltages to keep current low, and will not saturate cores. The unit has leads available in four lengths and features a large backlit LCD screen. Megger claims repeatability to be better than 0.5%. The design of the TTR20 allows the user to operate the test set while holding it in one hand; the unit needs no additional software and comes ready to use complete out of the box. Megger Norristown, PA For more info, enter 07 at

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Belt/Sheave Laser Alignment


he Mr. Shims Belt/Sheave Laser Alignment System shows both parallel and angular misalignment, making aligning equipment faster and more accurate than other methods. It’s also possible for the alignment to be done by one technician. Mr. Shims comes in a carrying case with a battery-operated, laser line emitter and three adjustable targets that all connect magnetically to the sheaves. The laser and targets set up in minutes, showing you exactly what to do. According to the company, the system can help reduce vibration, extend the life of belts and sheaves, aid in proper belt tensioning, and help eliminate downtime and production delays. Mr. Shims Villa Park, IL For more info, enter 08 at


Leonova Diamond and Emerald are the latest proof of our commitment to developing first class condition monitoring products for more profitable maintenance. Use SPM HD for accurate rolling element bearing analysis. Reduce data collection time with tri-axial vibration measurements. Add balancing, laser alignment, orbit analysis and much more, all in a rugged and lightweight instrument. For a total Condition Monitoring package, contact us today!

Tel. 1-800-505-5636 l

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TECHNOLOGY SHOWCASE Belt/Sheave Laser Alignment Tool

Automated Oil-Analysis Reports

T Mr. Shims Belt/Sheave Laser Alignment Tool delivers these important benefits... Reduces vibration Extends the life of belts and sheaves Aids in proper belt tensioning Eliminates downtime and production delays

3-D Sales Corporation, d/b/a Mr. Shims

P.O. Box 6744 Villa Park, IL 60181 1-800-72-SHIMS (1-800-727-4467) Fax: 630-832-5744 For more info, enter 87 at

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ribologik’s expert system generates oil-analysis reports automatically without human intervention, which can help prevent errors and interpretation differences among experts. Tribologik® ISO 17025 : 2005 laboratories monitor the condition of lubricants and equipment, including oil and equipment diagnostic, maintenance recommendations and the logic behind these recommendations. They also provide raw test results, testing history of equipment and trends. Tribologik contains over 2,000 maintenance rules and algorithms applied to industrial and transport oils, greases, coolants and equipment, including engines, hydraulics, bearings, gearboxes, differentials, transmissions, compressors, etc. It is the result of more than 20 years of continuous research and development on oil analysis, tested in real maintenance by major corporations. Thousands of performance rules have been assembled and new information is continually being added from maintenance manuals, manufacturers, technical data, oil tests and human experience, improving the accuracy of Tribologik’s oil-analysis reports and recommendations. Tribologik is available under licensing or SaaS agreement.

Tribologik Corp. Montreal, QC, Canada For more info, enter 09 at

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Overcoming Your Challenges

Efficient Compressed Air Piping By Ron Marshall, for the Compressed Air Challenge (CAC)


etting your compressed air to flow where it needs to go requires a transmission system—a network of piping that connects your compressors to the end-uses. This piping system can have a big effect on the overall efficiency of your equipment. Around the 100 psi range, for every increase of two psi in compressor-discharge pressure caused by piping pressure differential, compressor power increases by 1%. Piping is required in the compressor room to connect the compressors, dryers and filters together in a logical arrangement using wet and dry headers. In addition, a distribution header transmits the output of the compressed air room to general areas of the plant. Down-drop piping at the end-use connects the distribution header to the compressed air uses. Generally, the desired maximum pressure differential measured between the discharge of the compressors and the furthest point in the distribution system should not exceed 10%. Since this calculation includes the air dryers and filters, where most of the system pressure differential normally occurs, that leaves only 2 to 5% for the piping distribution system. Based on years of experience, the Compressed Air Challenge has developed some recommended guidelines to achieve these levels: Compressor-room headers… Header sizing should be large enough so the air velocity in the pipes does not exceed 20 fps (feet per second) in velocity at expected peak flows. Entry points into the header should be at a 45-degree angle to prevent back-pressure. Use of T-connections and two flows in opposite directions should be avoided.

Distribution-header pressure differential can be greatly reduced by installing a loop system rather than radial feeds. Use of smooth-bore pipe—such as aluminum or copper—can reduce losses. Take care not to downsize because of this effect or benefits could be lost. Down-drops… The connections between the distribution header and various end-uses should be sized based on end-use flow characteristics and length of the drop. Installing standard-sized piping drops is not a good practice, as some end-uses requiring high flows for short durations may be starved for air pressure during such events. At first glance these recommended pipe sizes may seem excessive compared to typical sizes. For example at 100 psi, using 2” pipe, the flow should not exceed 220 scfm to keep piping velocity under 20 fps, and no higher than 330 scfm to stay under 30 fps. The energy savings gained, however, can quickly pay for the larger piping size. More information about compressed air piping issues can be found at the CAC Website ( or in our Best Practices for Compressed Air Systems Manual. While visiting the Website, check out CAC’s upcoming training schedule in our online calendar. MT For more info, enter 10 at

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, or email:

Distribution headers… Piping from the outlet of the compressor room to end-use down-drops should be sized so the air velocity does not exceed 30 fps or, in cases of very long runs, sized large enough so the total pressure differential does not exceed the 2 to 5 % percent pressure differential mentioned above.




Bearing In Mind:

Combating Counterfeiting Special to MT

NSK updates us on what the bearing industry is doing to help protect your operations from the scourge of counterfeit products and what you can be doing as well. Jane Alexander Deputy Editor


ounterfeit bearings are an ever-increasing problem for end-users around the world. These counterfeits don’t simply reflect an illegal, unethical practice, they also pose a danger to industrial operations, finances and lives. The biggest problem with counterfeits is that, to the untrained eye, they can be difficult to identify. Moreover, not only do they not perform like authentic parts, they have no warranty— which leaves buyers with no recourse when problems occur. According to bearing manufacturer NSK, counterfeits fall into two categories: black- and grey-market bearings:

■ Black-market counterfeit bearings are fake bearings that

may or may not appear to look identical to an authentic bearing, depending on the quality of the counterfeiting. They range from very poor replications to ones that can be extremely convincing. Whether or not a counterfeit bearing looks like an authentic product, it is still a fake that can fail unpredictably, cause machine damage and pose many safety issues. 72 |


■ Grey-market counterfeit bearings are genuine bear-

ings that are sold through unauthorized channels, either online or in-store. While a grey-market product might be “authentic,” its unauthorized distribution makes it exempt from the standard product warranties that come with genuine products. Bearings that are 6” or less in diameter tend to be the most commonly counterfeited, as they are easiest to ship. Using these bearings can have devastating repercussions: Losses to your business can include equipment damage, downtime, excessive repair and replacement costs and, possibly, injuries or worse. Bearing industry initiatives The bearing industry takes counterfeiting very seriously— so much that the World Bearing Association launched a global, online anti-counterfeiting campaign ( in 2010 to increase awareness and educate industry about the DECEMBER 2013


When purchasing bearings from online sources, remember that what you see is not necessarily what you get. Furthermore, an offer that looks too good to be true probably is. dangers posed by counterfeit product. Working in cooperation with global law enforcement and leading manufacturers and suppliers, the association has made progress in reducing the prevalence of counterfeit product, but there remains much to do. As a World Bearing Association (WBA) board member and anti-counterfeit committee member of the American Bearing Manufacturers Association (ABMA), NSK has implemented a robust internal program to combat counterfeit bearings. Since its inception five years ago, the company’s anti-counterfeiting team has been working hard to monitor counterfeit and unauthorized product entry to the North American market. “Our team has developed a highly effective working relationship with U.S. Border Control,” says Theresa Orr, Assistant General Counsel at NSK. “We provide the information they need to easily identify illegal shipments, such as who our authorized importers are, the ports they typically use, how our products are packaged, our trademarks and copyright registrations, and our authorized U.S. distributors.” Working in partnership with the WBA/ABMA, NSK’s anti-counterfeiting team has successfully executed a number of raids in foreign countries, seizing thousands of unsafe, counterfeit bearings headed for the North American market. Once the counterfeits are seized, the company disassembles and thoroughly examines samples of the bearings, recording key details in a reference database. This allows trends to be identified so that U.S. Customs and Border Control can be alerted, thus making the importing of counterfeit bearings that much more difficult. While the efforts of the WBA/ABMA, key industry players and U.S. Customs and Border Control personnel are help-ing make the North American bearing market more secure against counterfeiting, the Internet presents another significant challenge: As international goods are increasingly accessible online, so is an abundance of counterfeit goods— including bearings. How you can join the fight When purchasing bearings from an online distributor, what you see isn’t necessarily what you get. “In some cases,” DECEMBER 2013

explains Theresa Orr, “the bearing shown on a Website isn’t the type or model that is delivered. In others, the product may be damaged due to inadequate protection through improper packaging, often the case when legitimate bearings are purchased through unauthorized distributors.” As Orr describes the situation, since these bearings are not covered by the manufacturer’s warranty, your business is left exposed. “The bottom line,” she says, “is that if you are considering purchasing a bearing online, it is critical to verify with the manufacturer that the source is an authorized distributor.” NSK’s anti-counterfeiting team, working with the ABMA and U.S. Customs and Border Control, is intercepting more counterfeits than ever. The continual fight requires vigilance, though. That means being proactive on multiple levels so that sales people, distributors and affiliates are wellinformed about the counterfeiting issue and how to identify counterfeit products. To avoid purchasing counterfeit products and safeguard your equipment and processes: ■ Always buy from a trusted source. By purchasing your

bearings only from authorized distributors, you can be confident about the product’s performance. Authorized distributors can be found on manufacturers’ Websites. ■ Educate yourself and your personnel about the growing

counterfeit bearing problem and reiterate the importance of approved purchasing processes and channels. ■ Recognize that an offer which looks too good to be true

probably is. Saving money is tempting, but risks to your business far outweigh cost savings you hope to realize. ■ If you suspect that you may have purchased counterfeit

bearings, be sure to contact the brand manufacturer immediately. For more details, visit, the American Bearing Manufacturers Association (www.americanbear or NSK ( MT For more info, enter 11 at



Energy-Saving Motor Soft-Starter


ranklin Control Systems, formerly Cerus Industrial, has released the IMS-RV (Industrial Motor Starter – Reduced Voltage) energy-saving soft-starter. It features proprietary Starter Control Module (SCM) technology, which provides protection and utility-grade power monitoring, while saving as much as 50-75% of installation and component costs compared to traditional motor starters. Start-up current limit is adjustable, as is the initial voltage and start time, and additional features include multiple starting modes such as voltage ramp, current limited start and torque boost. Franklin Control Systems Hillsboro, OR For more info, enter 30 at

Enhanced Security For Vision Systems


ognex Directory Server (CDS) software version 1.0, for the company’s line of In-Sight® vision systems, centralizes authorization and authentication control for all users networkwide. CDS leverages industry-standard IT infrastructure and protocols such as LDAP, SSL and HTTPS for network security. Credentials are passed to CDS for authentication when someone initiates a log-in to an In-Sight Camera. User-specific permissions are then transferred back to the camera. Permissions can be set for each user and access can be customized by job parameters, camera settings, In-Sight Explorer maintenance functions and more. Cognex Corp. Natick, MA For more info, enter 31 at

Large Industrial-Robot Family


BB Robotics has introduced the IRB 6700 robot family, its seventh generation of large industrial robots. The IRB 6700 is available in payloads from 331 to 661 lb. (150 to 300 kg), reaches from 8.5 to 10.5 ft. (2.6 to 3.2 m), and is designed for spot welding, material handling and machine tending. According to the company, power consumption has been lowered by 15 percent, total cost of ownership has been reduced by up to 20 percent compared to previous models, and maintenance has been optimized, doubling the time between service intervals. Access to motors has also been improved and technical documentation for maintenance has become easier to read and understand through the use of improved graphics and 3D simulations called “Simstructions.” The new model is available with LeanID, an Integrated Dressing (ID) designed for easier programming and a smaller footprint. It has also been built to withstand harsh working environments and is available with ABB’s ultimate Foundry Plus 2 protection system. ABB Robotics Auburn Hills, MI 74 | MAINTENANCE TECHNOLOGY

For more info, enter 32 at DECEMBER 2013


Custom Seals For Hydropower Service


Shaft Grounding System


KF has introduced a comprehensive range of custom-machined sealing solutions exclusively engineered for applications in the hydropower industry. The company can supply virtually any kind of seal for any application and in any quantity, dimension and profile. All can be manufactured from a proprietary self-lubricated cast polyurethane material blend that, according to the company, offers up to four times the service life of conventional seal materials. Additional material options are also available to meet specific application demands.

elwig Carbon’s new line of shaft grounding systems can help protect motors from bearing failure, a major cause of motor downtime. The stock kits fit most motors and various shaft sizes, and are easy to install, maintain and work effectively in contaminated environments. The grounding assemblies divert static and induced electrical currents in the motor shafts away from the bearings, protecting them from pitting and potential damage.

SKF Lansdale, PA

Helwig Carbon, Inc. Milwauke, WI

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Busway For IT And Data Centers


chneider Electric’s Powerbus™ Busway is rated to 400A at 600V and designed for IT and data-center infrastructures. The product replaces traditional centralized cable distribution runs with a more flexible method of power distribution above the equipment, easing energy monitoring and reducing energy losses without adding to the unit’s footprint. It also offers high plug-in unit density, with up to 20 openings every 10 feet. New 240V and 480V tap-off boxes can accommodate up to three circuit drops per plug-in unit and rack-mounting kits ease installation by directly mounting the busway to APC™ brand racks.

EL’s SEL-2245-4 AC Metering Module, available on the SEL-2240 Axion® Distributed Control and Integration Platform, integrates accurate voltage and current measurement with high-speed sampling for event recording. The AC Metering Module includes four ac voltage inputs and four ac current inputs, with event reports sampled at rates ranging from 1–24 kHz with an rms accuracy of 0.1 percent. The Axion’s rugged design and operational environmental ratings are well suited for demanding control and monitoring applications.

Schneider Electric Palatine, IL

Schweitzer Engineering Laboratories, Inc. Pullman, WA

For more info, enter 35 at DECEMBER 2013

Control-System Power Management


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Advanced-Process Welding Module


incoln Electric’s Power Wave® advanced welding power module performs several welding processes: shielded metal arc, metal inert gas (MIG), pulsed MIG, tungsten-electrode inert gas (TIG) and Surface Tension Transfer® (STT®). The advanced module reduces burn-through and increases wire feed speed and cleaning compared to earlier products. STT is a controlled MIG short-circuit transfer process that uses current controls to adjust the heat independently of wire feed speed for good penetration, low heat input control and reduced spatter and fumes. With STT welding capability, the module can also help the welding of open root gaps with highfrequency inverter technology. Also, SST welding incorporates a high-frequency starting mode that can be controlled at the wire feeder or power source user interface. The careful use of high-frequency starting can improve the appearance of TIG welding arc starts and helps to reduce contamination caused by scratch start. Lincoln Electric Co. Cleveland, OH For more info, enter 37 at

Expanded Industrial Network Product Line


ockwell Automation is expanding its AllenBradley Stratix family of industrial switches and routers, as well as new wireless and security products designed to meet industrial networking requirements. Expansions include the Stratix 5700 managed industrial Ethernet switch with embedded Network Address Translation (NAT) for simplified integration of IP-address mapping; Stratix 5900 services router to provide routing and security for Layer 2 or Layer 3 networks; and new fiber and power over Ethernet (PoE) options for the Stratix 5700, Stratix 8000 and Stratix 8300 switches. New products coming in early 2014 include the Allen-Bradley ArmorStratix 5700 switch with IP67 protection, and Stratix 5100 wireless (802.11N), dual-band 2.4 GHz and 5 GHz access point. The Stratix line uses the Cisco IOS to help ensure secure integration of business-critical services and support from operations to the enterprise. Rockwell Automation, Inc. Milwaukee, WI For more info, enter 80 at


For Formore moreinfo, info,enter enter38 DECEMBER 2013


Smart Pressure Transmitter For Hazardous Environs


Metric Plummer Block Bearing Assemblies

he 815PT Smart Pressure Transmitter from SOR is a stick form-factor smart pressure transmitter. Rated explosion-proof, the transmitter is suitable for hazardous locations and hostile environments. The 815PT s circuiting is protected by a 316SS housing with 316SST and 17-4SST wetted-parts, and has hermetically sealed flying leads. In addition to such popular continuous outputs as 4-20 mA and 1-5 VDC, it also offers HART and Modbus RTU communications. As with most SOR products, the 815PT is custom-configured, built, calibrated and tested to customer specifications. The transmitter joins SOR s 800 series of pressure devices, including the 805PT and 805QS.

SOR, Inc. Lenexa, KS For more info, enter 39 at


he new line of Timken® SNT plummer block housed bearing assemblies includes metric-sized plummer block designs with high-performance spherical roller bearings. Shaft sizes range from 20 mm to 400 mm, for straight or tapered shafts. The Timken SNT plummer block housed unit features cast-iron housings and four sealing options to meet application and environmental demands. Assembly design and finish are designed to lower operating temperatures and increase load-carrying capabilities compared to traditional spherical roller bearings. Housings can also be ordered in cast steel or ductile iron for extremely demanding applications. The Timken Co. Canton, OH For more info, enter 40 at

“Industrial Lubrication Fundamentals” 3-Day, On Site, Certification Preparation Training Program

With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certified lubrication personnel working on your reliability efforts!

Unlock the Secrets that let you Tap your True Maintenance Potential and Maximize Asset Reliability! World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprint all commence with a best practice lubrication program! Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certification exams. Exams can be arranged to take place at your site immediately following the training. For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certification Domain of Knowledge Content. Contact ENGTECH Industries Inc at 519.469.9173 or email For more info, enter 89 at



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: Web Spotlight: U.S. Tsubaki

Need an air compressor with proven performance? Whether you’re a large manufacturer or a shade tree mechanic, we have the right oil-lubricated or oil-free, fixed or variable speed compressor for you. Right away. Learn more about FS-Curtis products and distributors, and see the compressors in stock at our St. Louis headquarters, where we’ve been located since 1854, by visiting For more info, enter 93 at

U.S. Tsubaki is a leading manufacturer and supplier of Roller Chains, Engineering Class Chains, Power Transmission Products and KabelSchlepp Cable & Hose Carrier Systems. The Tsubaki name is synonymous with excellence in quality, dependability and customer service and support. An intense focus on research and development, along with continuously modernized production facilities and highly trained engineers allows Tsubaki to provide you with the right solutions for all of your application needs. For more info, enter 90 at

Emerson Process Management announces the new CSI 2140 portable vibration analyzer. This analyzer simultaneously captures four channels of data plus phase for fast collection and easy implementation of machinery health testing onsite. With four channel monitoring, the CSI 2140 can be used for dual orbit sleeve bearing monitoring, 4-plane balancing, and advanced troubleshooting in the field. For more info, enter 91 at



Air Sentry® is a leading developer of contamination control products that keep particulate matter and excess moisture from the headspace inside gearboxes, drums, reservoirs, oil tanks, etc. that hold oils, greases, hydraulic fluids, and fuels. Air Sentry breathers and adapters ensure longer fluid life, better lubrication and lower maintenance costs. For more info, enter 95 at

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

ATP List Services

In order for us to send

Customized, Targeted Lists For Your Marketing Needs

to you FREE,

we are required by the US Post Office to have a completed and signed renewal form once a year.

Contact: Ellen Sandkam 847-382-8100 x110 800-223-3423 x110


You may renew online at 78 |

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 92 at

PIP is a consortium of process plant owners and engineering construction contractors harmonizing member’s internal standards for design, procurement, construction and maintenance into industry-wide Practices. PIP has published over 450 Practices. A current listing of published Practices is available on the PIP website at: For more info, enter 94 at

MAINTENANCE TECHNOLOGY 1300 S. Grove Ave., Suite 105, Barrington, IL 60010



DECEMBER 2013 Volume 26, No. 12



RS #


Air Sentry .......................................................... ALL-TEST Pro,,289 ....................24,61 Allied Reliability ..................................74,285 ....................23,59 American,296 ....................32,64 Baldor Electric,262..................36,37 Des-Case ..........................................................67,263 ......................5,38 Emerson Process IFC Emerson Process Engtech Industries Inc. .......................................89.................................77 ..............................................................264...............................39 39 FS-Curtis Air,93 ....................58,78 58,78 FS-Curtis Air ..........................................................284...............................58 58 General Electric Company ......................................................63...................................11 Grace Engineered Products, 40 Grace Engineered Products, Grace Engineered Products, .....92.................................78 Grainger Grainger ..........................................97................................BC Innovator Of The Year Award IRISS, IRISS, ................................................................267...............................42 42 Kluber Lubrication North America 26 Kluber Lubrication North America ...........................................286...............................59 59 Lubriplate Lubricants Co. 14 Ludeca,268 ....................31,43 .........................................65...................................4 Meggitt Sensing Systems,269 ....................33,44 Meltric Corporation ..........................................................84,88 ......................69,70 Milwaukee Electric Tool Corporation ............72.................................15 Milwaukee Electric Tool Corporation ............................................270...............................45 Monroe Infrared ..........................................86.................................70 70 MR ......................................................87.................................70 70 Nidec Motors ......................................................271,272..................46,47 NSK,273 ......................2,48 OILSAFE by Fluid ...........................................77.................................27 OILSAFE by Fluid ............................................................274...............................49 PdMA Corporation,288.......................60 Process Industry ...................................................................69,290,94.........10,61,78 Royal Purple, .................................75,275 ....................25,50 Scalewatcher,276 ....................11,51 11,51 SKF USA Condition Monitoring - Fort,292.......................62 62 SPM Instrument, Inc. ...............................................295,83 ....................64,69 Strategic Work Systems, TEAM Industrial ...............................277,278..................52,53 Test Products International (TPI) ...........................................82,85 ......................69,70 Tri Tool, ............................................................293,294.......................63 U.S. Tsubaki Power Transmission, LLC ......................................................279,90 ....................54,78 U.S. Tsubaki Power Transmission, LLC .........................................................96..............................IBC IBC Update International ...................................280...............................55 55 WEG Electric Corp.,282..................56,57

Access and enter the reader service number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s Website. Submissions Policy: Maintenance Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Reproduction of Materials: Materials produced by Maintenance Technology may not be reproduced in any form for any purpose without permission. For Reprints: Contact the publisher, Glen Gudino (847) 382-8100 ext. 119. DECEMBER 2013


DECEMBER 2013 • Volume 26, No. 12 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603

SALES STAFF CT, KY, ME, MA, NH, NY, OH, RI, TN, VT, ON, QC 18 Oxford Lane Middletown, NJ 07748 Office 732-275-1167; Cell 908-415-3719 RUSSELL BRODY AL, DC, DE, FL, GA, MD, MS, NC, PA, SC, VA, WV 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY IA, IL, IN, MI, MN, NE, ND, SD, WI 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 Direct 708-557-1021 PHIL SARAN AR, KS, LA, MO, NM, OK, TX 5930 Royal Lane, Suite E #201 Dallas, TX 75230 972-816-3534; Fax 972-767-4442 GERRY MAYER AZ, CA, CO, ID, MT, NV, OR, UT, WA, WY, AB, BC, MB, SK 6746 E. Tyndall Circle Mesa, AZ 85215 480-396-9585 JERRY PRESTON CLASSIFIED ADVERTISING 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x112; Fax 847-304-8603 TIM STEINGRABER


viewpoint Heinz Bloch, Process Machinery Consulting

A Contrarian View: Tradition Will Fail You


he recent Texas A&M University (TAMU) Turbomachinery and Pump Users Symposia (Sept. 30-Oct. 3, 2013, Houston, TX) were again structured to convey a technology status overview to attendees from industry. But there’s more to these symposia: Sitting in on discussiongroup sessions allowed us to observe the level of understanding—and the knowledge gaps—that exist in operations today. Close to 400 companies were exhibiting at the Symposia, and dozens of relevant technical sessions were arranged for the estimated 5000 attendee/participants. TAMU has, for a number of decades, spearheaded highly effective discussion groups at its events. In these sessions, experienced leaders facilitate interaction between individuals who have questions and others who are willing to offer experience-based answers. As expected, questions came from audience members who varied greatly in age and experience. Not surprisingly, those questions and their answers also differed in relevance and complexity. Some questions could be answered in less than one minute; others, such as “when do I use a reciprocating compressor and when would it be best to use a centrifugal machine” would have required reams of data and several days to answer. The response to 98% of all questions, however, can be found in the literature to which we have access. And that observation brings me to the point: There aren’t many readers among the audiences we typically see at industry gatherings like the referenced TAMU Symposia. People seek to invest 60 seconds to get answers to 24-hour problems. Many still want to spend no more than $100 to get rid of a $1,000,000 issue. More than ever, budgets for entire grass-roots projects are now based on cost estimates reflecting the cheapest machines, unserviceable configurations and unrealistically low anticipated maintenance costs. Sadly, some reliability engineers insist on looking at old specifications and making them tighter. These tradition-bound individuals often do so in a misguided,

ill-advised effort to just do something—anything— to improve equipment reliability. That kind of thinking leads to guesswork or blindly following stale anecdotes a doughnut-provider conveyed years ago. (Consider the Symposia attendee who related his determination to use shaft packing where his competitors had switched to mechanical seals four decades ago.)

We desperately need to infuse realism into the rungs of management and their non-reading staffers. Again, the fallacy of simply tightening a specification came to the fore more than once in Houston. Yet, it can be shown that tighter specifications do not automatically translate into smarter, more reliable and extended-life machinery. Instead, well-researched specifications increase safety, equipment reliability and bottom-line profits. We desperately need to infuse realism into the rungs of both management and their non-reading staffers. There is an obvious unbalance—a lack of thinking—in plants and facilities that tolerate repeat failures and refuse to acknowledge the link between failure events and safety incidents. Industry has not achieved a reasonable balance in allocating training time and inculcating resourcefulness without allowing safety step-outs. Industry leaders should start by holding themselves accountable before pushing blame down to their employees. There are many books that show details, not consultant-conceived generalities, on how improvement was achieved by Best-of-Class performers. Such performers learned from others and learned from prior art. That learning started with reading and not by sticking to every old tradition. MT

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




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Maintenance Technology December 2013