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LIGHT TOUCH Build the right combination of predictive tools and technologies to proactively monitor your electrical systems

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The Reliability Excellence® Journey


Performance Management Audits & Assessments Equipment History Equipment & Process Design Work Measurement Management Reporting

PROCESSES Work Management Work Planning Work Scheduling Operator Care Asset Care Loss Elimination Workforce Development Materials Management


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Governing Principles Goals & Objectives Organizational Structure Budgeting & Cost Control Occupational Health & Safety Employee Involvement


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Overall Leadership Technology is just a tool to achieve greater reliability 09 / HUMAN CAPITAL

Why Can’t I Get My Project Approved? 25.0 24.0 23.0 22.0

Learn why you may have to challenge leadership if you want to get things done 11 / TECHNOLOGY TOOLBOX

Smart Environment Controls How the IoT can keep your buildings more comfortable, cost-efficent, and secure


13 / ASSET MANAGER 20.0 19.0


How to Manage Land with Your CMMS Keep track of who’s doing what where on the property occupied by your plant





Light Touch

The Future of Energy Management

What to Watch For in 2017

Build the right combination of predictive tools and technologies to proactively monitor your electrical systems

The technology to better manage production and energy systems is out there. Why is it taking so long for industrial plants to adopt it?

Interconnectivity, wireless, mobility, digital sensors, and smart MRO lead the way


Condensate Management 101


Best of Plant Services 2016 Our annual review of the maintenance issues and reliability trends that defined the past year

Bernard Norris, Director, GT Base Fleet Product Line at GE Power & Water “Everything is going to be digitized.”


Compressed air condensate is hazardous waste – here’s how to manage it safely 30 / PRODUCT ROUNDUP

PLANT SERVICES (ISSN 0199-8013) is published monthly by Putman Media, Inc., 1501 E. Woodfield Road, Suite 400N, Schaumburg, IL 60173. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals Postage Paid at Schaumburg, IL and additional mailing Offices. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor Information: Frontier/ BWI,PO Box 1051, Fort Erie, Ontario, Canada, L2A 5N8. Printed in U.S.A. POSTMASTER: Send address changes to PLANT SERVICES, Putman Media, Inc., PO Box 3435, Northbrook, IL 60065-3435. SUBSCRIPTIONS: Qualified reader subscriptions are accepted from PLANT SERVICES managers, supervisors and engineers in manufacturing plants in the U.S. and Canada. To apply for qualified-reader subscriptions, please go to To non-qualified subscribers in the U.S., subscriptions are $96 per year. Single copies are $15. Subscription to Canada and other international are accepted at $200 (Airmail only) © 2016 by Putman Media, Inc. All rights reserved. The contents of this publication may not be reproduced in whole or in part without consent of the copyright owner. In an effort to more closely align with our business partners in a manner that provides the most value to our readers, content published in PLANT SERVICES magazine appears on the public domain of PLANT SERVICES’ Website, and December also appear on Websites that apply to our growing marketplace. Putman Media, Inc. also publishes CHEMICAL PROCESSING, CONTROL, CONTROL DESIGN, FOOD PROCESSING, THE JOURNAL, PHARMACEUTICAL MANUFACTURING and SMART INDUSTRY. PLANT SERVICES assumes no responsibility for validity of claims in items published.

Asset Management Software Leverage mobility and the IIoT to maximize asset performance and control costs 32 / CLASSIFIEDS / AD INDEX


Powering Up! At Rabalais I & E Constructors, our focus is on bringing you the power and controls to manage your power generation, petroleum, petrochemical, manufacturing, compressor station or solar/wind energy projects quickly. We are the industry leader in providing electrical and instrumentation services to the nation’s most notable companies. Our team of dedicated professionals has decades of experience in managing your needs. From temporary power to permanent, state of the art, cost-efficient instrumentation solutions, there’s just no substitute for experience. • Design/Build Capability • Primary & Secondary Systems • Ground Testing/Certification • Cathodic Protection • Generator Systems • Teldata/Fiber Optics • Panel Fabrication & Upgrades • Lighting, Security, Access Controls • Distributive Control Systems • System Integration

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OVERALL LEADERSHIP Technology is just a tool to achieve greater reliability

EDITORIAL STAFF THOMAS WILK Editor in Chief CHRISTINE LaFAVE GRACE Managing Editor ALEXIS GAJEWSKI Associate Editor, Digital Media STEPHEN C. HERNER V.P., Creative & Production DEREK CHAMBERLAIN Senior Art Director DAVID BERGER, P.ENG. Contributing Editor PETER GARFORTH Contributing Editor SHEILA KENNEDY, CMRP Contributing Editor TOM MORIARTY, P.E., CMRP Contributing Editor

PUBLICATION SERVICES CARMELA KAPPEL Assistant to the Publisher JERRY CLARK V.P., Circulation JACK JONES Circulation Director RITA FITZGERALD Production Manager RHONDA BROWN Reprint Marketing Manager Foster Reprints (866) 879-9144 ext.194


One of the more interesting stories

to emerge from GE’s 2016 Minds + Machines conference is a new type of industry wearable. Just when you were kind of getting used to the idea of Google Glass and smartwatches, along comes something completely different: Internet-connected overalls. According to the story (http://plnt. sv/1612-OV), a demo at the M+M event showcased how sensors sewn into overalls can interact with proximity sensors can increase worker safety. In the demo, a utility worker wearing the overalls gets too close to an electrical panel, triggering a cutoff to the flow of electricity to the panel. Stephanie Sireau of GE Digital is quoted as saying that this new wearable technology is part of an overall mission “to integrate the worker into a digital industrial context,” adding that the same embedded sensors will also be able to deliver vital-signs data to help anticipate workers’ health problems. Did you see smart overalls coming? Did anyone in your organization, including the EH&S team and/or medical health professionals? Do you know if IT has a strategy in place on how to deploy wearables in the workplace? The ongoing digital industrial transformation is challenging the regular way of doing things, from operations and maintenance to supply chain and safety. As each new digital technology comes to market, it can feel like a race to keep up with the Joneses next door, who just invested in the latest wireless-enabled test tools or who might have just tied their CMMS into their MES system. The good news is that your facility already has the strongest asset in place to start (or continue) on your digital journey: your leadership team, the decision-

makers whose job it is to set strategy and approve projects and initiatives that drive positive results for your business. As Azima DLI CEO Burt Hurlock wrote in the Q3 issue of sister publication Smart Industry: “Like doctors to medicine or construction workers to building, industry needs leaders and managers and team builders to harness the new tools available to them. The technology will not deploy, implement,

DID YOU SEE SMART OVERALLS COMING? DID ANYONE IN YOUR ORGANIZATION? or perform on its own, and putting it to use correctly will demand specialized knowledge.” ( If there’s one recommendation I would make for 2017, it’s to embrace this challenge of cultivating best-in-class leadership. This kind of support is not always common; for example, as our columnist Tom Moriarty found in his 2015 leadership survey, supervisors in particular often don’t get quality leadership training before or after assuming leadership roles, yet they direct 80% to 90% of plant personnel, and have 70% influence over the attitudes and performance of their teams ( You can buy all the smart overalls you want, but unless you have leaders who help others understand why and how new tools will help drive success, those overalls are just another pair of pants.

Thomas Wilk, Editor in Chief, (630) 467-1300 x412 WWW.PLANTSERVICES.COM DECEMBER 2016 7

Going home safely at the end of the day requires proper training. That’s what we’ve been doing for over 50 years.


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WHY CAN’T I GET MY PROJECT APPROVED? Learn why you may have to challenge leadership if you want to get things done You had consultants come into your plant to do an as-

sessment. The consultants found a number of gaps between current performance and best practices. They provided a detailed report with prioritized recommendations and a solid business case. You provided the report to the plant manager, scheduled a meeting, and discussed the merits of going forward. Six months have passed, and no decision has been made to go forward. Meanwhile, several other projects were initiated. Why did this project not get the green light? In my 36 years of working in and around large, often bureaucratic organizations, there are some obvious answers and some that take a bit more contemplation. Competing priorities require senior decision-makers to make choices based on their judgment. Their judgment includes consideration of risk, which is based on the scale of the initiative, the benefits of it if successful, and the probability of being successful. Small projects, small risk. Big projects, big risk. Relationships play a substantial role as well; having a history of success and being someone who is easy to work with helps. The answer that requires more thought is how much latitude decision-makers have. How much autonomy the decision-maker has should be defined by the organization’s strategic guidance. If strategic guidance is weak, the decision-maker has more latitude. If strategic guidance is strong, the decision-maker will have less latitude. Strong strategic guidance provides more clarity for goals to be achieved, constraining the leader’s latitude. Defining and following strategic guidance for an organization is analogous to defining and following a good maintenance management process. Guidance creates the opportunity for order – control and stability. Defining strategic guidance requires understanding the external market environment, forecasting the future desired state, and stating the organization’s mission, vision and values. From strategic guidance, an organization can specify goals. There are two general categories of goals: organizational performance and organizational mission goals. Organizational performance goals are your day-to-day performance targets. These include achieving or maintaining productivity, quality, unit costs, employee satisfaction, safety, and regulatory compliance at defined levels. Organizational mission goals are the initiatives that will advance per-

formance and capabilities beyond current performance levels. These include renovations, implementation of new processes that drive down costs or increase productivity, and/or expanded product or service offerings. From mission goals, the organization can select the most worthwhile initiatives that will meet those goals. So if your organization has strategic guidance with performance and mission goals and your assessment report

WITHOUT DEFINED STRATEGIC GUIDANCE, YOU DEPEND ON A DECISION-MAKER’S WIDE LATITUDE AND JUDGMENT. YOU ARE FIGHTING THE WINDS AND TIDES. provides an implementation plan that’s aligned with mission goals, why has the project languished for six months? That’s a different problem. Good strategic guidance is necessary, but it’s not sufficient. Guidance needs to be consistently executed – that’s a leadership issue. Culture happens by default and operates as a lagging indicator of leadership actions (or inactions). Leaders define the values and norms that they want projected throughout their organization. When senior leaders don’t challenge behaviors that conflict with intended values, then those values and norms are viewed as optional. Whether you’re a shop supervisor who wants to start up a vibration analysis program or a maintenance manager who wants to implement a best-practice maintenance management process, the barriers are similar. Without defined strategic guidance, you depend on a decision-maker’s wide latitude and judgment. You are fighting the winds and tides. If you’re a senior leader, decide what you want your culture by default to look like. If you’re a maintenance manager or shop supervisor, see what strategic direction currently exists. Observe whether senior leaders walk the talk. If they don’t, tactfully challenge them by asking that they support the strategic guidance or change it to something they will support. Go forth and do great things. Tom Moriarty, P.E., CMRP, is president of Alidade MER. Contact him at and (321) 773-3356. WWW.PLANTSERVICES.COM DECEMBER 2016 9

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SMART ENVIRONMENT CONTROLS How the IoT can keep your buildings more comfortable, cost-efficent, and secure Intelligent building systems and smart environment controls are among the greatest representations of the internet of things (IoT). Integrating all of the automated technologies used to manage temperature and humidity, light, water, energy, air quality, and motion in buildings allows owners and operators to reduce their operating costs and improve performance while enhancing the comfort and security of all occupants and lowering buildings’ carbon footprint. Following is a sampling of the enabling technologies and software. INTEGRATION, AUTOMATION, AND CONTROL

Smart buildings allow for real-time monitoring of environmental conditions. The integrated building management platform Desigo CC from Siemens improves control of heating, ventilation, air conditioning, lighting, and shading. All disciplines can be accessed and managed remotely from any device, at any time from the single platform. The Metasys Building Automation System from Johnson Controls improves efficiency of industrial building energy management, including HVAC, lighting, security and protection systems in industrial spaces. Metasys provides a completely mobile-optimized interface that can be accessed from any phone, tablet or laptop. “Metasys controls a variety of equipment types that serve very different spaces with very different comfort needs, from small packaged units controlling the office spaces to larger applied systems conditioning the manufacturing floor space,” says Mark Ziolkowski, director of building auto-


mation system product management at Johnson Controls. “Because it’s a distributed system, Metasys also supports a variety of networking and wiring options ideal for industrial spaces including serial-based wiring, IP/Ethernet-based wiring, wireless, or a mixture of all three.” SmartStruxure from Schneider Electric supports centralized, automated control of power, lighting, electrical distribution, fire safety, and HVAC systems to create healthier, more-productive

NEW TECHNOLOGIES ALLOW OWNERS AND OPERATORS TO REDUCE THEIR OPERATING COSTS AND IMPROVE PERFORMANCE WHILE ENHANCING COMFORT. environments. SmartStruxure’s connected mobile technology, says Robert Hemmerdinger, director of business development for SmartStruxure at Schneider Electric, breaks down traditional information silos and delivers information and real-time data via web access, graphics, trend visualizations, rich reports, and mobile applications. This increases employee satisfaction, productivity, and real estate value, he says. Advantech’s factory environmental monitoring solutions address water, temperature, humidity and air quality, the latter of which includes dust, gas, and carbon dioxide. The company’s latest product technology supports more interconnected and intelligent environmental control systems. “Our WISE-4000 Ethernet-based wireless IoT devices are integrated with IoT data acquisition, processing, and publishing functions, and provide data pre-scaling, data logic, and data logger functions in just one device,” says Tom Wohlwender, product engineer at Advantech. “All of the data can be accessed via mobile devices and published to the cloud with security anytime, anywhere, in any type of environment.” CONDITION MONITORING SOFTWARE

Web-based energy and water monitoring software from Noveda Technologies is compatible with building automation systems, energy management systems, and utility meters. Noveda partners with a variety of platforms, including Siemens and Honeywell, to simplify building systems integration, enabling real-time oversight of electric, gas, steam, water, and oil sources as well as heating and cooling systems. WWW.PLANTSERVICES.COM DECEMBER 2016 11



innovative approach to energy management. Some of its own automated factories are capable of operating for extended periods of time without lights, HVAC, or even personnel. FANUC’s factories in Japan are among the world’s most highly automated “lights-out” manufacturing facilities, says Claude Dinsmoor, general manager of material handling at FANUC America. “The automated lines utilize a large number of FANUC intelligent robots to robotize the operations that were previously manual,” he says. Email Contributing Editor Sheila Kennedy, CMRP, managing director of Additive Communications, at


The proliferation of IoT-enabled devices amplifies the need for interoperability of systems and access to integrated intelligence, says Govi Rao, president and CEO of Noveda. EXTREME ENERGY EFFICIENCY

Robotic automation product manufacturer FANUC takes an

COMPRESSOR SERVICE TIP #10 The Weather Outside Is Frightful Check your air compressor’s weather stripping and replace areas that are worn out. Also check the insulation to make sure heat is staying inside. For more helpful tips: – 866-546-3588


HOW TO MANAGE LAND WITH YOUR CMMS Keep track of who’s doing what where on the property occupied by your plant Land is a physical asset that must be managed like any

other asset. So which technologies are your best options for land management? You have a few options. Specialized software applications that support land acquisition and management exist, but these applications are typically standalone. Alternatively, a geographical information system (GIS) can be used to provide a geospatial representation of land parcels and the assets on them. However, a GIS is not hierarchical and is not designed to manage transactions such as projects, work orders, and so on. An enterprise resource planning (ERP) system is helpful in managing some transactions, such as lease payments, land-related document control, and contacts made with landowners, but it may not be fully integrated with other functions. Given that land is essentially a linear asset, perhaps what works best is a fully integrated land management solution with a CMMS as the core application for managing land parcels, landowners, and other stakeholders, as well as work order control, project management, contact management, financial management, and integration with GIS. These functions are discussed below. The capability and level of sophistication of your CMMS will dictate how much integration is necessary with specialized land management, ERP, and other systems.


Central to a land management system (LMS) is a land asset registry to record key information about land parcels (identification number, land type, location information, appraisal value, document reference numbers, etc.). Depending on how sophisticated your CMMS is, this will be accommodated through the CMMS asset register and/or integration with specialty LMS and GIS software. The location information you’ll need to maintain will depend on the local jurisdiction but may include lot and plan numbers, a Crown description, a survey or map reference, roadway intersections, GPS coordinates, and latitude and longitude coordinates. Depending on the land parcel’s shape, multiple coordinates can reference the outer limits or corners of the property, or one set of coordinates can represent the centroid. There may be multiple assets on the land that require referencing, such as trees, bridges, signs, walkways, furniture, structures, and/or facilities. These assets may or may

not be registered as separate assets, depending on the level of granularity required for tracking work history. Another key feature of the land parcel asset registry is the ability to maintain active and inactive records. For example, if a parcel of land is split or two parcels are combined, both the old and new reference information and history should be maintained with appropriate cross-referencing. This requirement is similar to that of all linear assets, such as water

YOUR CMMS WORK MANAGEMENT FUNCTIONALITY MOST LIKELY CAN PLAN AND TRACK ALL PERMITTING AND MAINTENANCE WORK DONE ON THE LAND. mains that are split, abandoned, replaced, or combined. Thus, each land parcel should have a status and corresponding “from/to” dates (also known as “since/until” dates) to keep more accurate records of land parcel history. STAKEHOLDER MANAGEMENT

Every land parcel has one or more stakeholders – the landowner, property manager, tenants and/or contractors – who will be referenced As with the land parcel, each stakeholder status should have a “from” and “to” reference date to keep track of active and inactive stakeholders. Stakeholder name and contact information will be included, and it’s critical that the software accommodate multiple address, email, and phone number fields, as many stakeholders have multiple addresses or phone numbers. Each stakeholder must be cross-referenced to one or more land parcels. Contracts and other documents as well as notes about preferred method of payment or correspondence may be included for a given stakeholder in the records, too. Your CMMS may be able to record stakeholder information through use of the supplier master or through integration with a specialty LMS and/or ERP package. WORK & PROJECT MANAGEMENT

Your CMMS work management functionality most likely can plan and track all permitting and maintenance work done on the land parcel itself (e.g., grass-cutting) or work done on individual assets on the land (e.g., replacing a wind WWW.PLANTSERVICES.COM DECEMBER 2016 13


turbine blade). The work tracked will depend heavily on your industry but can reflect a combination of conditionbased maintenance, routine preventive maintenance, and maintenance resulting from asset failure (for example,

cleaning up a pipeline oil leak reported by a landowner). For more-sophisticated work, such as a major dig or construction project, some advanced CMMS packages offer strong project management functionality.



Keeping track of all contacts made with stakeholders and the general public likely is a top priority. Some CMMS packages have this functionality built in; others offer it through integration with their ERP or other specialty software. Examples of these records include a history of correspondence sent to landowners requesting land access or notes entered regarding an encounter with a tenant (or his or her dog) during an inspection. Complaints received from a stakeholder or the general public would be recorded, too, regardless of whether they lead to work-order initiation. FINANCIAL MANAGEMENT

Companies may have legal agreements with stakeholders to pay on a regular schedule, as with lease payments, or on an as-needed basis, as with access fees. Payment records should be cross-referenced to an agreement’s document ID number, land parcel, landowner, and payee. Companies can use the CMMS supplier management functionality or an interface with their ERP system to manage payments. INTEGRATION WITH GIS

Combining the two major condition monitoring technologies; Leonova Diamond and Emerald incorporate sophisticated vibration analysis capabilities with HD ENV® and Shock Pulse HD technology to maximize your predictive maintenance program’s potential. Available options for 2 and 3 channel simultaneous vibration measurements, orbit analysis, run up/coast down, bump tests, dynamic balancing, laser alignment plus much more, in carbon fiber re-enforced rugged casing. Used with the user friendly but powerful Condmaster ® software makes the Leonova Diamond or Emerald the perfect fit for any industry. Intrinsically safe versions available. For a customized monitoring package to fit your specific needs, contact SPM Instrument!

A key requirement of LMS functionality is seamless integration with GIS. The GIS interface provides a visual representation of land parcels, fi xed assets, points of interest, etc. The GIS interface lets users fi lter and sort data within the CMMS and display the results on the map. Furthermore, users should be able to draw a polygon on the map to generate a list of associated land parcels and stakeholders for the purposes of, say, setting up a mail merge for all landowners who need to be contacted within a given area. Email Contributing Editor David Berger, P.Eng, executive partner and president of StraNexus Inc., at

Tel. 1-800-505-5636



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WHAT TO WATCH FOR IN 2017 Interconnectivity, wireless, mobility, digital sensors, and smart MRO lead the way For this year-end edition of Automation Zone, the Plant Services editors asked several industry professionals a simple question: What automation trend should MRO teams keep their eye on in 2017, and why? Jose M. Rivera, CEO, CSIA (Control System Integrators Association, (www. Interconnectivity will continue to be the main automation trend impacting MRO. Here is why: 1. Interconnectivity is not only bridging diverse systems – it is also forcing a closer collaboration between departments. There is significant value in sharing predictive maintenance requests with the production teams, as it empowers them to schedule a shutdown with the minimum impact on productivity. 2. Interconnectivity also means that information is inputted once and leveraged. This includes information captured in the field by service technicians. New systems are making the data acquisition and data download process very easy. This translates into higher utilization and better data to drive decisions. 3. Interconnectivity will allow technology to bridge the loss of expertise and experience from the retiring baby boomer generation with the abilities of the “digitally native” younger generations. Scott Kortier, InduSoft web studio senior technical engineer at Wonderware by Schneider Electric ( Mobile access to machine interfaces will play a critical role for maintenance and reliability teams. Not only does a fully mobile remote HMI make it possible to troubleshoot, diagnose, and service machines from anywhere in the plant, it also allows OEMs and value-added resellers to offer more capabilities for maintenance as a service (MaaS) from remote locations. Better mobility allows maintenance operators to run updates outside of business hours and allows operators to request remote assistance from maintenance personnel at another plant. We also expect to see Andon applications going into wider use in manufacturing beyond the automobile industry. (Andon is a visual system designed to notify management, 16


maintenance or other workers of a quality or process problem.) These Andon solutions offer best practices for getting the right team to the right location quickly in order to solve maintenance and reliability issues. With plug-and-play Andon templates available, there’s no reason not to implement these types of solutions in manufacturing. Bob Karschnia, VP and general manager of wireless, Emerson Process Management ( Wireless monitoring of plant equipment and instrumentation will be a major trend in 2017. Wireless applications give the right information to the right person at the right time. For example, wireless monitoring of steam traps or pump health gives a maintenance technician insight into the problem before going into the plant. He or she will “know before they go.” Wireless monitoring is growing exponentially. Emerson has installed more than 27,000 WirelessHART networks. Batterypowered wireless devices can be installed anywhere to monitor anything—especially on equipment where the cost of installing wired devices is cost-prohibitive. And, because WirelessHART provides access to all the diagnostic and status conditions available in HART instrumentation, plant engineers and technicians are now able to detect pending problems before they become serious enough to shut down a process. Michael Risse, vice president at Seeq ( The locomotive pulling all other trends is commercial off the shelf technology, and the locomotive’s engine is Moore’s Law; this is not just about doubling the density of transistors on a chip every 18 months. Instead, it’s the basis of a new model for computing hardware, software, and networking. In this context, Moore’s Law results in smaller computing platforms and higher-capacity hard drives, faster chips and cheaper components, and more pervasive connectivity. What this means for 2017 is the tradition of expensive, proprietary, on-premise, and centralized systems in manufacturing facilities will continue to crumble. In its place will be less-expensive open systems, often cloud-based, giving new advantages to customers in terms of cost, user mobility and interoperability. Certainly Exxon is giving the open systems initiatives a push through its Lockheed partnership, but it’s the engine in the locomotive doing the real work by driving down costs and setting expectations of end users for a new type of plant computing ecosystem.

Ryan Williams, product manager, Rockwell Automation ( From an MRO perspective, asset intelligence from converged information technology (IT) and operations technology (OT) systems can help organizations streamline maintenance and storeroom activities, reduce reliability risks, and create proactive maintenance strategies. Implementing this “smart MRO” approach begins with a comprehensive understanding of a company’s installed asset base. Although this can be done through a manual audit of assets, a better alternative is a diagnostic reliability service that automates the data-collection process. This involves using a control-layer application that can scan and autodiscover all active networked devices. The application collects identity information for each asset, such as its location, series, catalog number, and firmware. It also collects health information, such as current, temperature, and voltage, which is crucial to understanding asset integrity. Once collected, the asset-intelligence data can be sent to a database where it is stored, analyzed and modeled, and then delivered to workers in the form of actionable information through reports, dashboards, alerts and notifications. The data also is continuously scanned and updated to support ongoing asset tracking and monitoring. These automated, device-identification and healthmonitoring capabilities are at the heart of a smart MRO approach, and in 2017 and beyond will provide the foundation for creating data-driven maintenance and storeroom strategies. Tracy Doane-Weideman, product manager for analytics, Endress+Hauser ( In 2017, digital sensors will reduce maintenance costs, improve reliability and minimize process shutdowns for sensor replacements. Analytical sensors, such as pH, conductivity, and dissolved oxygen instruments, all have to be cleaned, calibrated, and periodically replaced. Maintenance of sophisticated sensors is proving to be a problem for some companies. Digital sensor technology solves the problem. Endress+Hauser installed pH sensors in the company’s chlor-alkali process with digital Memosens technology. Memosens probes can be precalibrated in the laboratory. The smart sensors also provide information on their state, allowing technicians to replace the probes only when necessary and to clean and calibrate them in the lab. And the process only has to be shut down for the few minutes it takes to replace a sensor.

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CONDENSATE MANAGEMENT 101 Compressed air condensate is hazardous waste – here’s how to manage it safely by Mark Krisa, Ingersoll Rand

How a facility manages its compressed air condensate

influences operational reliability and, because of the hazardous waste that condensate contains, affects a plant’s impact on the environment. It’s important that compressed air systems have a condensate management network in place. Knowing the environmental factors that produce more or less condensate, understanding the drain and piping systems, and identifying what condensate is made of are integral to properly maintaining a compressed air system.



When atmospheric air is compressed, the amount of water that can exist in a vapor state is reduced, causing the surplus water to condense into a liquid. This water mixes with other airborne constituents consumed from the environment along with traces of lubricant/coolant from the compressor. The resulting emulsification is referred to as compressed air condensate. The volume of condensate that is extracted from a compressor is based on the difference between how much water was present in the atmospheric air ingested into the compressor and how much water can remain in a vapor state at the temperature and pressure of the compressed air. Thus, a compressed air system will generate more condensate on a steamy summer day than on a cold, dry, winter day. PICKING THE RIGHT CONDENSATE DRAIN

Choices abound when it comes to drain manufacturers, but there are only a few common types of drains for compressed air systems. Drains can be categorized as manual drains, timer-based drains, or capacity-sensing drains. • Manual drains are a simple valve and are best suited for particulate filters in areas where condensate is low or nonexistent. These drains require periodic draining by an operator, but quite often no liquid is found. • Timer-based drains are typically solenoid or actuated-ball 18


valve-type drains with a fixed or adjustable timer. Although these drains are typically lower in cost, some are reasonably robust and are less prone to failing. The drawback is that these drains cycle only based on time, so they either discharge too frequently, which wastes compressed air, or they cycle infrequently, allowing condensate to collect and carry over into the system. • Capacity-sensing drains are the most efficient and adaptive type of drain, discharging only after a fixed volume of liquid has collected in the drain. These drains can function using some form of electronic sensing or can be completely mechanical using a float-type mechanism. Some low-cost units can be sensitive to contamination and may fail easily due to obstruction. This needs to be considered during the purchase process, with purchase directors weighing both application conditions and the degree of maintenance required. One common issue to be aware of is the use of strainers installed ahead of a drain valve. In theory, the strainer will collect larger particulate and protect the drain from failing because of obstruction, but the strainers often are neglected and become clogged. It’s important that if a strainer is installed, a manual valve and piping arrangement also be installed ahead of the drain to facilitate easy isolation for servicing and testing. PROPER PIPING TO MOVE CONDENSATE

Condensate piping must be configured to facilitate easy removal of every drain for service or inspection. A bypass should be installed on the discharge side of every drain to support testing the drain operation. This should include a tethered hose for systems to periodically test the condensate discharge rate using a scaled collection device over a fixed period of time. The quantity of condensate removed from the compressed air system will change based on the volume of compressed air consumed and the ambient conditions. On a hot summer day, a 100-horsepower compressor with a refrigerated air dryer can generate more than 45 gallons of condensate in an eight-hour shift. The same system during a subfreezing winter day would generate less than 1 gallon of condensate during a shift. Some maintenance programs may periodically measure the rate of condensate removal relative to operating conditions to establish a performance baseline. This data could be used to identify a deviation from the desired performance

and facilitate a more prognostic approach to maintaining compressed air system performance. It is a good practice to periodically test condensate for concentration of major constituents and pH level. This data can be helpful in troubleshooting quality issues associated with contamination. It is not uncommon to assume that compressed air condensate is the source of contamination for a processrelated issue only to find that the actual source of the problem is a local airborne pollutant or lubricant. This is a common misdiagnosis in paint applications that can be very sensitive to silicone or hydrocarbons. KNOW YOUR CONDENSATE AND PRACTICE SAFE DISPOSAL

Compressed air condensate can be acidic or basic depending on the environment. This can affect the rate of material degradation or corrosion. Having a good grasp on your condensate properties is valuable when selecting compressed air system materials such as piping, plastic tubing, valves, and fittings. Condensate should be tested during both the summer and winter to account for changes in the concentration of water present in the atmosphere. When attempting to diagnose an issue associated with the presence of specific compounds in the condensate, sampling frequency may also need to take into account wind and the ingestion of airborne contaminants from processes outside of the compressor’s intake. Depending on the chemical compositions of neighboring exhaust, temperature inversions may also be influential, causing an increased density of contaminants during morning hours when the ground is cold and air temperatures start increasing. Compressed air condensate is an emulsification of water, hydrocarbons, and other potential airborne

NON-CRITICAL-LOCATION SOLENOID DRAIN INSTALLATION Settings: 1 second on 15 minute cycles From Single Drain Source

Strainer with Blowdown Valve Isolation Valve



½" Union

Drain Inspection Valve ¼"

Check Valve for Tie in to Other Valves

Isolation Valve


Alternate Drain Inspection Valve Location

contaminants; therefore, it’s considered a hazardous waste and must be processed accordingly. Condensate cannot be discharged directly to a municipal sewage system and must be treated to reduce the concentration of contaminants to an acceptable level. Some facilities have a central wastewater treatment process that can treat the waste, but it’s important to consider the cost associated with treating the condensate compared with use of other methods. One alternative option is to use a condensate separation product dedicated to the air compressors to reduce oil from condensate down to an environmentally acceptable level. It is important to investigate details regarding the type of oil introduced into the condensate and the requirements to separate it from the water. Some oils will separate based on dwell time, while others may require chemicals to separate the oil from the water. Some may choose a distillation-type product that uses an electric heater to boil the water off as steam, leaving only residual waste liquid to be processed as hazardous waste. For some installations, there is no access to a drain-

Bypass Valve

age system, so the water from the oil/ water separator is discharged through an exterior wall and allowed to pool in the soil. Unfortunately, the water is not pure and will typically still have low concentrations of oil. Over time, the water will evaporate, leaving behind the oil. Eventually, enough oil will accumulate for the soil to be classified as hazardous waste, requiring costly disposal. Having a condensate management process, key data about a manufacturing facility, and awareness of temperature conditions will give maintenance staff the opportunity to address a system’s performance and issues before big problems arise. Proactively correcting condensate issues can help prevent excess condensate from carrying over into the network, saturating the piping system and contaminating production equipment. These factors will help facilities abide by hazardous-waste regulations and optimize the reliability of their compressed air systems. Mark Krisa is global air system performance leader for Ingersoll Rand Compression Technologies and Services. WWW.PLANTSERVICES.COM DECEMBER 2016 19


by Sheila Kennedy, contributing editor

LIGHT TOUCH Build the right combination of predictive tools and technologies to proactively monitor your electrical systems

25.0 24.0 23.0 22.0 21.0 20.0 19.0

The potentially catastrophic consequences of electri-


cal system failures and hazards must be avoided at all costs. Regular predictive maintenance (PdM) on electrical systems lets maintenance teams detect and correct problems before they can shut down equipment or production lines or cause a safety incident. Whether conducted in-house or outsourced to reliability specialists, PdM inspections – followed up with timely, precise repairs – can help protect against electrical accidents and save companies millions of dollars by reducing unscheduled downtime, lowering equipment maintenance costs, and extending the useful life of machinery. Is your electrical PdM program up to snuff ? Here, check out some of the newest electrical PdM tools and applications as well as popular testing options and practical PdM recommendations from industry pros.

Wide-ranging options exist for online/energized and offline testing of electrical systems. Tom Bishop, senior technical support specialist at the Electrical Apparatus Service Association (EASA) (, notes that there’s a wide scope of available inspection types with these common motor tests: Offline tests for motors • Insulation resistance tests • Polarization index tests • Motor electrical circuit parameters evaluation (resistance, inductance, and capacitance) • Rotor influence tests to check for open rotor bars



Online tests for motors • Measuring line voltages and currents

Technology has come a long way in the past 30 years, remarks John Bernet, mechanical application and product specialist at Fluke Industrial Group ( “There are now easy-to-use tools available for operators to screen components of electrical systems for potential problems,” Bernet says. “Technicians can then troubleshoot the problem to find the specific fault and recommend a correction and then use the same screening tools to verify that the fault has been corrected and quickly get the machine back into service.” The emergence of the internet of things (IoT) is extending the value of PdM. “By collecting data through connected maintenance technologies, personnel can better evaluate the asset’s utilization, environment, lifecycle, and performance,” says Emanuel Kourounis, services business development manager at Schneider Electric ( “This data also enables a more condition-based maintenance approach to help companies allocate limited resources in managing their op-ex and cap-ex budgets along with maximizing their general maintenance activities.” Thermal imaging One of the most effective PdM technologies for operating electrical systems is infrared (IR) thermography, says R. James Seff rin, director of the Infraspection Institute (www. “A thermal imager converts the normally invisible infrared radiation emitted by an object into a monochrome or multicolor image that is representative of the thermal patterns across the surface of the imaged object.” Many thermal imagers also can provide temperatures of imaged objects, he notes. Infrared inspections are conducted while the electrical system is energized and under load. Typical defects that may be found include loose/deteriorated connections, overloaded circuits, unbalanced loads, and defective equipment, Seffrin says. Predictive IR technologies can be employed to mitigate the potential for human error in monitoring and maintaining assets, notes Schneider Electric’s Kourounis. “Asset-specific algorithms, thresholds, and rules can be used to detect thermal abnormalities in the performance of the monitored assets, which can then be further analyzed by industry experts to validate the findings and develop a list of recommended next steps,” he says. Infrared technology reduces troubleshooting time, saves money, and can be safer – especially when a user is put in a potential arc-flash situation, adds Jim Huekels, business

Source: Schneider Electric

• Motor current signature analysis • Vibration analysis for electrically induced frequencies • Thermography • Ultrasonic inspection

Monitoring the condition of electrical equipment will help plant teams anticipate and plan maintenance activities.

development manager at FLIR Systems (www.fl “With thermal imaging technology becoming more affordable, facilities are able to have multiple cameras or ‘eyes’ in the hands of their maintenance personnel,” he says. “If you go back five years, users had to spend thousands of dollars on a thermal camera.” Ultrasonic inspection Ultrasonic inspection, another nondestructive test (NDT) technique, detects and isolates high-frequency sounds that are otherwise inaudible to the human ear. It is used to differentiate electrical discharge noises from normal sound patterns. Electrical inspection with ultrasound is being driven by three main factors: safety, electrical maintenance standards, and insurance company interest, says Adrian Messer, manager of U.S. operations at UE Systems ( “Safety is improved because we are able to inspect the energized electrical equipment without having to open it up,” Messer says. “Electrical standards, such as NFPA 70B and CSA Z463, specifically mention the use of ultrasound to detect corona, tracking, and arcing from energized electrical equipment.” He adds: “And, insurance companies are writing into procedures that before opening anything up to do visual and infrared inspections, ultrasound should first be used to detect any fault that may be producing high-frequency sound.” It’s best practice to use both infrared and ultrasound technologies together, as they detect different failure modes and together provide significant safety benefits, suggests Doug Waetjen, vice president of global operations at UE Systems. “Infrared detects resistance-based problems, like overheating fuses and insulation breakdown, while ultrasound detects ionization-based problems like tracking on loose and faulty connections in switchgear, tracking on transformer windings as well as cracked insulators, and destructive corona in substations,” he notes.



Motor current signature analysis Motor current signature analysis records and analyzes motor current readings to diagnose faults. This test is able to identify rotor cage failures that result in reduced output torque, increased stator current, and increased motor temperature, says EASA’s Bishop. Insulation resistance testing Insulation degradation can be detected with insulation resistance testing. This test is temperature-sensitive, and the readings must be corrected to a common base temperature. Bishop has seen insulation resistance tests identify motors with ground insulation weakness caused by moisture contamination that could have resulted in winding failure to ground if the motor had been started.

Source: Schneider Electric

Partial discharge testing Partial discharge (PD) monitoring looks for pockets of electrical breakdown within the insulation of electrical equipment. “In the past, PD monitoring was primarily used on higher-voltage machines rated over five kilovolts, but with the prevalence of low-voltage motors powered by variable frequency drives (VFDs), the use of PD monitoring is increasing,” remarks Bishop. PD technology is applicable to voltages higher than 2400 volts AC and can be applied to a wide variety of assets within an electrical distribution system, such as switchgear, some cable types, some bus duct applications, large rotating

Continuous monitoring reveals abnormal temperature readings for an aging transformer.



Source: UE Systems

Another effective combination is ultrasonic inspection and vibration monitoring. EASA’s Bishop said he has seen these methods used together to detect failing bearings, a situation that could have escalated into a rubbing fault between stator and rotor that would have damaged the stator windings. Finally, infrared and ultrasound windows from companies like Exiscan let inspectors look at and listen to energized switchgear without being forced to open enclosed cabinets, says UE Systems’ Waetjen. “By listening to what’s going on internally and only opening the door when no evidence of tracking or arcing sounds are present, the chances of an arc flash incident are greatly reduced.”

Ultrasonic inspection of enclosed cabinets (above) Long-range ultrasonic inspection (right)

equipment, and power transformers, says Schneider Electric’s Kourounis. “Continuous online monitoring is the ideal methodology for capturing activity and facilitating trending based upon available data,” he says. Wireless temperature monitoring Wireless temperature monitoring can be applied to everything from dry-type transformers to cable connections. Thermal monitoring combined with load profiling has proved to be a reliable means of monitoring equipment performance, says Kourounis. Oil analysis Oil quality and gases-in-oil analyses are additional PdM testing options. “Transformer oil should be monitored for its physical characteristics compared to the ASTM standards, which might include color, specific gravity, dielectric strength, moisture content, surface tension, contents of acids, carbon or furans,” says Kourounis. Gases-in-oil analysis, as Kourounis explains it, measures the existing percentages of specific combustible gases, such as hydrogen, oxygen, methane, ethane, ethylene, and acetylene, and indicates combinations and ratios that indicate potential problems. Fresh approaches and new applications A host of new tools and tactics are being used to inspect electrical system components. For example, EASA’s Bishop has seen increasing use of semi-automated measuring equipment along with software to analyze and trend data. FLIR is integrating thermal imaging into standard test equipment, as with the company’s new Infrared Guided


Ultrasonic inspection of electrical insulator

standpoint. “Finding one electrical problem before it burns up or blows up can save a significant amount of time and money,” says FLIR’s Huekels. “One save/find can pay for the all the thermal cameras you deploy in your facility 100 times over. Especially in a product line environment, a facility has to factor in its loss in production revenue for every hour that production is offline. It can be hundreds of thousands of dollars.” Schneider Electric’s Kourounis describes a recent customer example in which abnormally elevated C-phase temperature readings obtained through connected temperature monitoring of a 30-year-old dry-type transformer helped a facility director convince key decision-makers that the transformer was unreliable and could be at risk

Source: Fluke

In addition to helping keep workers safe, electrical PdM can offer a compelling return on investment from a production

Source: UE Systems

Measurement (IGM) line, consisting of digital multimeters and clamp meters. “IGM allows users to thermally scan equipment and enclosures to see where the problems are before they start hooking up test leads or start other troubleshooting measures,” says Huekels. The ubiquity of wireless connectivity, greater computing power, and the lower cost of memory have made it possible for test tools to automatically save data to a smartphone or other connection point and then transmit it to the cloud for storage and analysis, says Weishung Liu, product planner at Fluke Industrial Group. For example, Fluke test tools now have embedded Bluetooth radios, allowing the user to instantly save measurements to the software-as-a-service (SaaS) platform via a smart device. “Wireless sensors from Fluke allow technicians and engineers to leave measurement tools in place over a period of time to monitor, data-log, live-stream, and analyze key data collected,” says Frederic Baudart, Fluke Connect product specialist. One of the newest thermal imaging applications involves installed photovoltaic (PV) panels. “Compared to properly operating solar cells, defective solar cells operate at higher temperatures and are readily seen with a thermal imager. Infrared imaging can also detect thermal anomalies caused by faulty wiring,” remarks Infraspection Institute’s Seffrin. “Imaging may be conducted on foot using a handheld thermal imager to inspect the top or underside of operating panels. Or, for large installations, it may be conducted using purpose-built unmanned aerial vehicles (drones) or from a helicopter using a high-resolution thermal imager.”

Easy-to-use tools allow operators and technicians to inspect components of electrical systems for potential problems.



of failure. A similar experience at a sister substation four years prior cost the company close to $1 million in losses. Efforts are underway to replace the aging transformer. For EASA’s Bishop, detection of unbalanced voltages and currents has led to corrective actions that reduced the power loss and heating of electric motors and other threephase loads. “Not only was electrical energy use reduced,” he says, “but motor and other equipment reliability was increased. Corrective actions as a result of these early findings reduced the direct cost of motor repair and the indirect cost of downtime for the driven equipment.” When documenting the savings from PdM, it’s important to include downtime avoidance as well as any dollars saved from scrap or product imperfections related to production downtime, adds UE Systems’ Messer.


What else can you do to optimize your electrical PdM? Consider the following recommendations from industry pros. • Always look at all of the sections of the plant’s electrical system – from power coming into the plant to the drives and invertors, switchgear and motor controllers, and the motor that turns the pump or fan doing the actual work, says Fluke’s Bernet. “Any link in this chain is a potential failure and can lead to machine downtime, lost production, and increased maintenance costs,” he states. • W hether you’re doing inspections internally or using an outside service provider, insist on a multitechnology approach, suggests UE Systems’ Waetjen. “One technology cannot address all of the potential failure modes,” he says, “so you will be putting your people and your equipment at risk if you limit yourself to one.”

It’s It’slike likean anearly earlywarning warning system systemfor foryour yourmotors. motors. Reliably Reliably detect detect early-stage early-stage winding winding insulation insulation weaknesses weaknesses with with Baker Baker DXDX TheThe SKFSKF Static Static Motor Motor Analyzer Analyzer – Baker – Baker DX Surge DX Surge PD PD identifies identifies earlyearly problems problems withwith coil coil andand winding winding insulation insulation withwith an innovative an innovative resistive resistive measurement measurement approach. approach. There There is noisquirky no quirky radio-frequency radio-frequency antenna antenna to adjust, to adjust, andand it produces it produces consistently consistently reliable reliable high-resolution high-resolution PD waveforms PD waveforms thatthat identify identify insulation insulation defects defects andand weaknesses. weaknesses. VisitVisit,, or email or email for more for more information. information. THETHE POWER POWER OF KNOWLEDGE OF KNOWLEDGE ENGINEERING ENGINEERING

• FLIR’s Huekels recommends having maintenance personnel carry some thermal imaging tools to use in regular checks throughout the workday and having IR windows installed in all electrical enclosures to minimize exposure to arc flash dangers. • Infraspection Institute’s Seffrin cautions that thermal imaging is not a “point and shoot” technology, despite claims to the contrary. “Proper application of the technology requires a trained and experienced operator who is familiar with the equipment being inspected,” he says. “Thermographers should be certified and follow recognized infrared inspection standards, such as those published by Infraspection Institute.” • As experienced personnel are nearing retirement, capturing critical data and accurately interpreting the data in a digital world becomes imperative, comments Schneider Electric’s Kourounis. At the same time, leveraging the IoT will help move a facility into next-generation asset performance management. “When replacing aging infrastructure, consider switching to IoT-ready equipment,” he suggests. • EASA’s Bishop suggests using digital equipment that can store and compare the measured data at each interval during testing and ensuring that equipment is calibrated so that readings are accurate and repeatable. Bishop also cautions that sometimes PdM activities are given low priority. “Focus on maintaining the schedules and make certain that PdM personnel are not reassigned to other functions,” he urges. “Alternatively, consider outsourcing some or all of the activities if the schedules are at risk. Finally, when issues are detected, corrective actions should be carried out expeditiously.”

® SKF® is aSKF registered is a registered trademark trademark of the SKF of the Group. SKF Group. | © SKF | © Group SKF 2016 Group 2016

Sheila Kennedy, CMRP, is managing director of Additive Communications. Contact her at




T N A L P F O BEST ICES 2O16 SERV tful quotes to able and insigh or em m t os m e me of th m-filled 2017. r roundup of so , and momentu us ou t ro en pe es os pr pr e , w fe rvices editors to a sa fashion, – the Plant Se in 2016. Here’s it out in grand e om os s.c cl ce To vi . er ts ar What a ye ices and at plan ges of Plant Serv appear on the pa


“ While IIoT may be revolutionary in concept, it will be evolutionary in adoption for most companies. In other words, the Industrial Internet of Things is more of a journey than a thing.”

Leap of Faith IIoT adoption varies widely, but leaders push to get out in front

Break the reactive maintenance cycle / P.22 IONS

AIN FOR M antserv



OLUT T Syour Right-size three-phase SMAR induction motors / P.24 / P.15 M&R wins IIC: ring help Setting the on monito ConditiIIoT / P.19 standards / P.26 via your HMI

Four quick

David White, senior analyst at ARC Advisory Group “Leap of Faith,” January


“Mobility is essentially turning (field services, operations, and logistics) on its head. The field is just a geographic location; mobility allows us to give them access to all systems, people, and processes that are in the enterprise.”

ty your reliabili Define How future / P.28 efficient is your desiccant to dryer? / P.39 The IIoT comesair / P.32 compressed

Rohit Robinson, business line leader at Honeywell “Going Mobile,” February


inside ubiquitous mobility is next? Now that e is it taking us MS / P.11 plants, wher your EAM/CM Plus: Mobile

add-ons for

“People want to be portable, they want to be enabled, and the specific device doesn’t matter. People are expecting to do different things on the phone that, traditionally, industrial systems couldn’t do.” Kyle Reissner, industrial mobility platform leader at Rockwell Automation “Going Mobile,” February

“First and foremost, teach yourself to always think like an accountant instead of a maintenance professional. This is difficult for most of us, but how many of your decisions actually generate a hard dollar payback?”



PdM FORECAST NEW SURVEY: Readers want more from PdM / P.30

RELIABILITY ROI: Prove program payback / P. 38

Improve supervisor motivation

/ P.9

Tech that attracts young talent

/ P.11

America's skilled trades dilemma Quiz: Is your plant at risk of failure?

/ P.15

/ P.26

Phil Beelendorf, maintenance technology senior manager at Roquette America “2016 PdM Forecast: Reliability ROI,” March

“Sometimes I get blank looks in the sense that it sounds like ‘Star Wars’ – it’s off in the future someplace. Yet at the same time, those same people are wearing Fitbits on their arms; they’re wearing Apple smartwatches; they’re carrying smartphones that give you access to virtually anything anywhere in the world at any time.”


Rick Veague, CTO at IFS North America “See the Future,” April

IIoT-Enabled Monitoring Equipment / P.11 Industry Leaders Sound Off on PdM Survey / P.19 Energy Monitoring Double Feature / P.32 & 34 How (and Why) to Calculate OEE / P.41

What context-aware technology means for your plant

“Many people want to say they are using (PdM) technologies, so they acquire them. It looks good on paper to say that they are using them, when in reality the knowledge, support, and discipline needed to bring it to fruition does not exist.” Joe Anderson, CRL, CMRP, senior reliability manager at The Schwan Food Company “Industry Responds to PdM Survey,” April




“I think that this (technology) democratization that’s happening is changing the landscape of the tools that people have available to them, especially young people, and giving them the freedom to really go where their minds are taking them.” Dorothy Jones-Davis, co-founder at “Maker Faires: Building the Future,” May antserv




Build compressed air systems for scalability, reliability, and flexibility while also meeting audit goals. Should you stay or should you go? / P.9 Picking up good vibrations / P.19 & 22 Get your motor running / P.38 Makers rising / P.50

“ We’ve got scary technology moving at a very fast pace in an industry that may or may not be ready for it but that desperately needs it.”


Kimberley Hagerty, lean transformation manager at Pratt & Whitney “You Are Going To Have To Move Fast,” June ds g OSHA standar What evolvin for logies mean and new techno in your plant. electrical safety

ce Tools for Workfor / P.11 Development y Build Your Reliabilit Strategy / P.32

“We are in the middle of the next industrial revolution. Known as Industry 4.0 and synonymous with the industrial internet of things (IIoT), this revolution will require us to learn and apply knowledge and skills faster than ever – driving us to “super-skill” our abilities. Together: Get Your Stuff a Better for A Road Map P.38 Storeroom /

Gets Robotics Safety / P.42 an Upgrade

Tom Furnival, director of training services, Marshall Institute Super-Skill Me blog “The Thriver’s Guide to the Next Industrial Revolution,” June

“We want to cultivate that younger population. If I’m going to expect them to stay doing an assembly job for 20 years or even five years, (that’s) probably not realistic.”


Colin Cosgrove, president at Laystrom Manufacturing “Pizza and Continuous Improvement,” July




tackling the problem How is industry of counterfeit parts?

Build your CMMS dream team / P.15 The secret to reliability liftoff / P.23 to train operators How (and why) / P.40 on maintenance The key to IIoT: / P.43 Interoperability


High tech gets productive & personal

Machine knowledge: Share the wealth / P.11 Metrics that matter / P.22 Interview: CMRP of the Year Nezar Alshammasi / P.26 Pizza and continuous improvement / P.42

“As we get older, we tend to be more reflective about our lives and careers. It turns out that my father, who was my hero, was preparing me to be a good reliability engineer long before I knew what I wanted to do in life.” Terry Hall, senior reliability subject matter expert at Life Cycle Engineering “Six Reliability Life Lessons from my Father,” June

“There’s great value in aiming to become multiskilled. The goal isn’t perfection; the goal is to be above average and to adapt as necessary.” Heinz P. Bloch, owner of Process Machinery Consulting “Real Talk About Finding, Keeping a Job,” September

“Our surveys indicated that 28% of the respondents have experienced (counterfeits) ... The known cost impact of CFSI per incident, according to the respondents, ranged from $100,000 to $28 million.”

“The next big leap in cost reduction requires embracing a new paradigm: Industrial compressors are just electric heaters that happen to make compressed air.”

Makarand Hastak, head of construction engineering and management and professor at Purdue U. “This Is A Fake,” August

Wayne Perry, senior technical director at Kaeser Compressors “Industrial Compressor or Electric Heater?” September


LINKS TO ARTICLES See the full list of the year’s best quotes and articles at A Winning Compressed Air Strategy: Turn It Off!

“There was this thought that by buying this device, we now have PdM, and life would be great. There wasn’t really any foresight into building a PdM program.”

Achieve PdM Success: Be Like Mike

Brendan Russ, reliability engineer at Southern Gardens Citrus “Shake Off the Rust: The Rocky Road to Reliability,” September

Design for Reliability: Long May Your Assets Run

Going Mobile: Jim Hilton interview

RELIABILITY OR MAINTENANCE & SMART SOLUTIONS F SMART SOLUTIONS F OR MAINTENANCE & RELIABILITY Your 3-point strategy for control system maintenance / P.17 Manage the balance between awareness and action / P.9

Heinz Bloch: Keep expanding your skills to survive / P.19

Attract more women to industrial careers / P.32

Take stock of your spares program & unlock profit / P.23

Going mobile: Kyle Reissner interview

Improve motor control center safety / P.37

Doc Palmer: How to make planning & scheduling work for you / P.32

Be like Mike / P.46

SUSTAIN PdM SUCCESS Find the right leaders to breathe life into your PdM program


Recognize the seven critical success factors that keep strong predictive maintenance programs on track

“The effort to start or restart successful PdM programs begins with identifying leaders with the managerial skills to build and institutionalize the program.” Burt Hurlock, CEO at Azima DLI “Sustain PdM Success,” October

“I recommend starting with the one discipline that will add the most value to your organization and making it right before adding others. Also, all PdM programs should be audited on an annual basis to ensure they are operating as effectively and efficiently as possible.”

How To Attract Women to Industrial Careers How to Prevent Motor and Drive Faults How Motivated Is Your Team? Industrial Compressor or Electric Heater? Industry Responds to PdM Survey Involve the Reliability Engineer in Your CMMS Implementation

Paul Dufresne, CRL, CMRP, reliability improvement specialist “Shake Off the Rust: Get Back on Track,” September

Leap of Faith Make Energy Monitoring Mission-Critical Maker Faires: Building the Future

“Many plants have already tried to utilize PdM, and most have failed due to a lack of organizational ownership, lack of followthrough, and lack of vision. Communicate your plan, document your wins, and stick with it.”

Pizza and Continuous Improvement Real Talk About Finding, Keeping a Job

Greg Padesky, SkillPoint account manager at Advanced Technology Services “Sustain PdM Success,” October

Reliability ROI: Show ‘Em the Money

“The new standard for gold stars is predicting failures and planning the needed repairs around production needs. We now control when we fix things rather than when we have a breakdown. We own the machines rather than the machines owning us.”

See the Future Shake Off The Rust: The Rocky Road to Reliability Shake Off The Rust: Getting Beck On Track

Michael Macsisak, predictive maintenance technician at Nestlé Purina “Achieve PdM Success: Be Like Mike,” October

Six Reliability Life Lessons from my Father

“You may not even know you are paying ‘stupidity tax’ on your energy bill until you have had a close look at your system during weekend operation, and even then it may not be obvious. Ron Marshall, Compressed Air Challenge, Compressed Air Efficiency blog “A Winning Compressed Air Strategy: Turn It Off!” November


Embrace the "Grand Energy Transition" P.15

Sustain PdM Success This Is A Fake

Simulation modeling and advanced manufacturing P.22

Monitor motor vibration or optimize bearing lubrication? P.32

Take your pick of apps and modules that integrate with your core asset management system to mitigate risk, extend asset performance, and manage the unexpected

The role of insurance in reliability decisions P.37

Welcome to Super-Skill Me: The Thriver’s Guide to the Next Industrial Revolution “You Are Going To Have To Move Fast”



Consumers, according to the Product Adoption Lifecycle, can be grouped into one of five categories:

1. Innovators – Interested in anything new, quick to

The technology to better manage production and energy systems is out there. Why is it taking so long for industrial plants to adopt it? BY BILL HOLMES, HOLMES AUTOPILOT

In the early 1970s, I was part of the development team for

the On-Condition Maintenance System for the F-15 fighter jet. It was the first computer-based advanced instrumentation system for a U.S. Air Force plane. It changed the whole concept of aircraft maintenance from one of scheduled maintenance to conditioned-based and predictive maintenance. In the early 1980s, when I was an assistant professor at Purdue University and consulting with building owners to help them reduce their energy costs, I used what I had learned about monitoring airplane systems to design, build, install, and operate a similar system for all types of facilities. Using real-time screens and historical reporting, the system showed when, where, and how efficiently every utility dollar was spent within a facility. That first system evolved over time into the AutoPilot Industrial Diagnostics & Optimization System (iDOS) as it exists today. The system was designed to monitor key parameters and continuously analyze the thermodynamic efficiency of not just production and energy systems but the facility as a whole as well. It also identified waste and diagnosed specific problems, allowing operations and maintenance to move from a reactive to a proactive approach. I understood that what I learned in the Air Force about planes also applied to buildings. To fly a plane, a pilot must have real-time data on all aircraft systems and have it presented in a clear and easy-to-understand format – via cockpit gauges. To run a building efficiently, operators must have the same information. Fast-forward to December 2016. Unfortunately, little real progress has been made in the past 35 years. Rather than energy professionals basing fees on creating, verifying, and maintaining actual savings, a billion-dollar industry has emerged based only on “preparing” to save energy. Practitioners make their money from energy auditing, benchmarking, training classes, certifications, energy modeling, writing reports, filling out forms, and selling equipment.



In spite of the fact that this is ostensibly the Information Age, not the Estimation Age, more cities and states are making oldfashioned energy audits mandatory. They seem to be following the advice of the late management consultant Peter Drucker: “When a subject becomes obsolete, we make it a required course.” BARRIERS TO PROGRESS

Why don’t industrial plants have the information they need to operate all of their production and energy systems as efficiently as possible on an ongoing basis? The technology obviously exists. Just look at airplanes, automobiles, medicine, smartphones, and nearly every other sophisticated device or system other than buildings. And yet those in the energy profession still don’t give clients the information they need. They still use temporary instrumentation, energy audits, and benchmarking to produce mountains of reports and justify capital projects. One answer to why this occurs can be found in the Product Adoption Lifecycle (as can be found online at

adopt, and willing to pay a high price to be among the first to have a new product. Our early iDOS systems incorporated the Apple II and Hayes modems shortly after they appeared on the market. We switched to the IBM PC when it was introduced. Starting with the Basic program language, we moved to Microsoft Windows and Excel in 1985. I was at the Microsoft conference in New Orleans in 1992 when Access was introduced. We immediately adopted it for data storage. In 2008, we switched from a PC-based to a cloud-based system utilizing the MySQL database.

2. Early adopters – Defined as young

and restless, early adopters are opinion leaders. They were our first clients. We always referred to them as our champions.

3. Early majority – Value shoppers. Members of the early majority carefully observe the early adopters but wait to adopt innovative products until they are sure they will get value from them. They became clients only after visiting sites where iDOS had been in operation, talking to the owners, and viewing the results. 4. Late majority – As skeptics,

members of the late majority wait until an innovation has been accepted by a majority of consumers before adopting it themselves. We had few of these. Most skeptics wanted us to guarantee savings ahead of time. Many took the offer of utility companies who claimed they could provide the same information and service for free. However, the utilities didn’t have the same expertise or information.

5. Laggards – Traditionalists, laggards are the very last to adopt a new product. In my experience, this group largely describes the entire energy establishment, which has built a huge bureaucracy that is the source of all of its income and is content to use 40-year-old methods in working with clients. Max Planck, the German theoretical physicist who originated quantum theory and won the Nobel Prize for physics in 1918, put it directly: “Any generation of established scientists has too much vested interest in terms of reputation, pull, influence, money (grants), and huge amounts of ego involved to allow the so-called outlier theory to take all the limelight, glory, and spoils.” In other words, widespread adoption of our approach would mean that most in the energy efficiency profession would lose their sources of income. Things are changing, though, as the first kids who grew up with computers have risen to positions of authority in industry. That’s why cloud-based information systems are progressing so rapidly. Not only do younger leaders understand the value of information, but also they demand information access. According to Planck, “New scientific ideas never spring from a communal body, however organized, but rather from the head of an individually inspired researcher who struggles with his problems in lonely thought and unites all his thought on one single point which is his whole world for the moment.” He adds, “Experiment is the only means of knowledge at our disposal.” Many in government, utility companies and other large organizations with deep pockets are convinced they know all of the answers and have built bureaucracies to support their theories. They don’t understand that those of us who have spent our entire careers actually working with and trying to improve energy systems in the field are the ones with the real understanding. THE FUTURE

Technology has advanced to the point that it is now possible to inexpensively monitor, analyze, and securely store a virtually unlimited amount of data on giant servers on the cloud. Anyone in the world with access to the Web can view that data with a variety of devices. We have been proving in every project for nearly 40 years that permanent instrumentation with sophisticated analytics can optimize the operation of all production and energy systems as well as total facilities on a continuous basis. Don’t be a laggard. Jump into the future today: Add sensors to monitor your critical equipment and systems. Send production and energy data to a server on the cloud. Add software and analytics to put the data in the most usable form. Make the resulting information easily available to your employees, and train them to use it. As the IIoT and other tools continue to be defined and improved, you will already be decades ahead. WWW.PLANTSERVICES.COM DECEMBER 2016 29


ASSET MANAGEMENT SOFTWARE Leverage mobility and the IIoT to maximize asset performance and control costs IFS IoT BUSINESS CONNECTOR


IFS’ IoT Business Connector provides the ability to harness data gathered from products, assets, and equipment to identify actionable observations that trigger user-defined workflows in IFS enterprise soft ware. The IoT Business Connector provides plug-and-play connectivity with the Microsoft Azure IoT Suite for device communications and data analytics alongside open APIs to connect other IoT platforms or specialized IoT discovery applications.

Emerson Process Management introduces the AMS ARES asset management platform, which gathers data from multiple sensing technologies and provides a holistic view of the current health status of plant assets. Persona-based access to information ensures that the right personnel have access to clear health overviews of assets.


Maximo Asset Health Insights is used to join condition assessment readings from assets to historic information from work and equipment records and other influencers, such as weather incidents and maintenance history. These data sources are analyzed by the Watson IoT Platform, which feeds results back to Maximo in the Asset Health Insights work center. IBM


Smartware Group Inc. launched its first native mobile application for Bigfoot CMMS. Developed for iOS and Android devices, users can quickly navigate parts, work orders, and assets through the app’s QR code or swipe-gesture functionality. The app also provides offline editing access. Bigfoot eMAINT CMMS INTERACTIVE PLANNING AND MAPPING

Infor EAM v11.2 builds on the latest cloud-enabled offering and enables faster, more-effective maintenance services, providing capabilities to track and record incidents with workflow tasks and follow-up work orders. Core enhancements include case management, key management, asset reservations, and a contractor service portal module.

eMaint, a Fluke company, has added an interactive plans and mapping feature to its CMMS software, allowing organizations to visualize their maintenance management data on a floor plan, schematic, site map, or any other image. Users upload an image and place pins on it that point to their asset, work order, work request, or inventory record.





FactoryTalk AssetCentre v7.0 soft ware from Rockwell Automation automates discovery and tracks the status of devices, network switches, and soft ware on workstation computers across an entire facility or production operation and includes a mobile-friendly dashboard.

Meridium Inc.’s Asset Answers v2.1.1 cloud-based asset performance diagnostics solution provides comparative analytics and delivers visibility into asset data. Benefits include a weighting capability in the bad-actor function as well as the ability to benchmark asset performance anonymously against global industry peers.


Rockwell Automation



Meridium Inc.


Tofino Soft ware has released its latest suite of enhanced asset utilization reports, which includes asset availability reporting in support of OEE, asset downtime, production downtime, mean downtime between failures, and mean time to repair. Tofino NATIONAL INSTRUMENTS InsightCM ENTERPRISE

National Instruments’ enhanced version of its InsightCM Enterprise soft ware can help companies gain insight into the health of capital equipment. Offering multiple measurement tools in one, the soft ware features a workforce multiplier and complete accessibility to data and third-party packages. National Instruments MAINBOSS ADVANCED MAINTENANCE MANAGEMENT

MainBoss advanced maintenance management soft ware lets users track problem reports, complete work orders, schedule inspections and preventive maintenance work, and control inventory. Role-based security is offered. Thinkage Ltd. MAPCON CMMS MOBILE APP

Mapcon Technologies’ mobile CMMS includes image and document attachment, instant notification of dispatched work orders and purchase order approvals, collection of meter/gauge readings, and vendor information storage. Mapcon Technologies

Delivering leading-edge content by showcasing smart technology, reliable asset management and promoting a culture of safe, sustainable plant operations.


IIoT-Enabled Monitoring Equipment / P.11


Energy Monitoring Double Feature / P.32 & 34


How (and Why) to Calculate OEE / P.41

Heinz Bloch: Keep expanding your skills to survive / P.19


Industry Leaders Sound Off on PdM Survey / P.19


Your 3-point strategy S M A R T S O L U T I O N S F O R M A I N T E N A N C E & R E L I A Bfor I L control ITY system maintenance / P.17


Take stock of your spares program & unlock profit / P.23 Doc Palmer: How to make planning & scheduling work for you / P.32

High tech gets productive & personal

What context-aware technology means for your plant


PdM FORECAST How is industry tackling the problem of counterfeit parts?

Build compressed air systems for scalability, reliability, and flexibility while also meeting audit goals.

Machine knowledge: Share the wealth / P.11 Metrics that matter / P.22 Interview: CMRP of the Year Nezar Alshammasi / P.26 Pizza and continuous improvement / P.42

NEW SURVEY: Readers want more from PdM / P.30

What evolving OSHA standards and new technologies mean for electrical safety in your plant.

Improve supervisor motivation / P.9

Build your CMMS dream team / P.15 The secret to reliability liftoff / P.23 How (and why) to train operators on maintenance / P.40 The key to IIoT: Interoperability / P.43

Picking up good vibrations / P.19 & 22 Get your motor running / P.38 Makers rising / P.50

Tools for Workforce Development / P.11 Build Your Reliability Strategy / P.32 Get Your Stuff Together: A Road Map for a Better Storeroom / P.38 Robotics Safety Gets an Upgrade / P.42

Find the right leaders to breathe new life into your PdM program


As a complete asset integrity management solution, Visions Enterprise manages fixed and rotating equipment from a single platform, delivering extended asset life, seamless regulatory compliance, reduced shutdowns, and maximized ROI. Metegrity Inc.

RELIABILITY ROI: Prove program payback / P. 38

Should you stay or should you go? / P.9

w w w. Pl a n t S e r v i c e s .c o m

Tech that attracts young talent / P.11 America's skilled trades dilemma / P.15 Quiz: Is your plant at risk of failure? / P.26



Ajustco . . . . . . . . . . . . . . . . . 31

Kaeser Compressors . . . . . . . .36

ARC . . . . . . . . . . . . . . . . . . .35

Life Cycle Engineering . . . . . . . .4

Atlas Copco Compressors . . . .12

Noria . . . . . . . . . . . . . . . . . . . 15 . . . . . . . .2

Rabalais Instrument & Electrical Constructors . . . . . . .6

AVO Training Institute . . . . . . . .8

SKF. . . . . . . . . . . . . . . . . . . .24

Baldor Electric Co. . . . . . . . . . .3

SPM . . . . . . . . . . . . . . . . . . . 14

Endress + Hauser . . . . . . . . . . 10

Sullair . . . . . . . . . . . . . . . . . . 17

Custom REPRINts RepRints aRe ideal foR: n New Product Announcements n Sales Aid For Your Field Force n PR Materials & Media Kits n Direct Mail Enclosures n Customer & Prospect Communications/Presentations n Trade Shows/Promotional Events n Conferences & Speaking Engagements n Recruitment & Training Packages

Have a problem? Ask a question. Get an answer.

For additional information, please contact Foster Printing Service, the official reprint provider for Plant Services. Call 866.879.9144 or





Fabric Structures Natural Light & Low Cost Per Sq Ft

Hybrid Buildings Benefits of Metal & Fabric Buildings

Foundation Solutions Build Anywhere & Quick Construction


restrictions may apply


Contact Polly Dickson at 630.467.1300 x.396 Tel: 1-800-645-4174

SALES OFFICES MIKE BRENNER, GROUP PUBLISHER AR, AZ, Northern CA, CO, ID, IL, MN, MT, NE, NV, NM, ND, OK, OR, SD, UT, WA, WI, WY Phone: (630) 467-1300, ext. 487 Fax: (630) 467-1120 e-mail: BETH ROLFE, REGIONAL SALES MANAGER AL, Southern CA, CT, DE, FL, GA, LA, ME, MD, MA, MS, NH, NJ, NY, NC, PA, RI, SC, TX, VT, VA, DC, WV Phone: (630) 467-1300, ext.440 Fax: (630) 467-1120 e-mail:

MICHAEL CONNAUGHTON, ACCOUNT EXECUTIVE IA, IN, KS, KY, MI, MO, OH, TN, Canada, Literature Reviews, Inside Print and Digital Sales Phone: (513) 543-6432 Fax: (630) 467-1120 e-mail: POLLY DICKSON, INSIDE SALES MANAGER Classifieds Phone: (630) 467-1300, ext.396 Fax: (630) 467-1120 e-mail:

SUBSCRIPTION INFORMATION (888) 644-1803 or (847) 559-7360 REPRINTS RHONDA BROWN Reprints Marketing Manager Foster Reprints (866) 879-9144 ext.194 PUTMAN MEDIA, INC. 1501 E. Woodfield Rd. Suite 400N Schaumburg, IL 60173 Phone: (630) 467-1300




‘EVERYTHING IS GOING TO BE DIGITIZED’ Maintenance expertise is moving outside plant walls, GE steam turbine pro says Bernard Norris is the steam turbine services product line leader for GE’s legacy fleet. Based in Atlanta, where GE houses its remote Monitoring & Diagnostics (M&D) Center, he is part of the team involved in the company’s first-ever ESP installations for GE D11 steam turbines at combined-cycle power plants in Johnson, RI, and Elk Hills, CA. He spoke with Plant Services about the value of remote monitoring as a cost-savings tool and an aid in making repair-or-replace decisions, as well as what the future of monitoring looks like.

PS What value do GE customers get from having someone in Atlanta keeping an eye on their equipment? BN Our team is looking at performance, output, heat rate. They’re able to calculate or identify vibration issues or different load swings or decrease in the output. The team is proactively looking at the data and seeing if there are any issues with any unit in particular. With the project in California, we saw some potential rotor-bow issues, and that rotor-bow issue could impact operability or availability of the unit. We get involved and we say, “This is how much your unit is vibrating or there’s a rotor bow that could lead to vibration issues.” And then we propose to do a repair. In some cases customers will take the repair option. But in other cases, the customer will make a different decision and say, “I don’t want you to repair my rotor, I want you to replace it.” The benefit of replacing it is to reset the clock of the high-pressure and the intermediatepressure section of the steam turbine, extending the life of the unit as well as mitigating future risk of forced outage. We have the ability, the analytics, and the algorithms to assess a unit to tell a customer, “Your unit is experiencing rotor bow; here’s a way that we can mitigate this risk.” PS Do the algorithms reliably indicate whether a repair or replacement is the best option? BN The M&D algorithm will identify the severity of the rotor bow, whether (a bow is) 10 mils (0.01 inches) or 2 or 3 mils. We have the ability to measure to that level of accuracy. I won’t say that the repair solution is a quick fix. It will address the rotor, but the cycle is outside of the normal outage. Essentially it straightens the rotor and removes the bow so when the rotor is installed, it helps drives the right level of eccentricities and clearances. We have a value economic model that we’ll run where we’ll say, “Here’s the option for repair; here’s what the price 34


is for two years with payback.” But it also will show the cost to replace the entire rotor. And when you replace the entire rotor, you also get the additional 1.5% of output, as well as you get up to a 1% increase on efficiency of the unit. PS Can you go into a little more detail about that process? BN We have around 200 units in our D11 fleet. About 70% of those are monitored through our facility here in Atlanta. An engineer is pretty much on call 24/7. There’s always someone in the center looking at data. The teams look and see, OK, there’s a particular unit that’s having some issues. We then dispatch our regional application engineering team. In the case of Elk Hills, there’s an engineer out in Utah who’s talking to them quite a bit, visits them, etc. The regional application engineer will take a look at the data, based on the M&D, and assess the unit configuration and unit history. They’ll then tie that back to our sales and commercial process. They’ll engage the sales manager and present a high-level summary of findings stating, “Here’s what we believe the issue to be; here’s the remedy.” The sales manager looks at it and says, “OK, I know what the value drivers are for my customer; in this case that’s availability, more around life extension. The salespersons have some discussions with the application engineering team. And then they have a discovery session with the customer. It’s not, “Hey, we want to sell you the latest whiz-bang technology, and you have to buy it.” We want to put all the options on the table. PS Is this the future of plant maintenance – a collaborative, remote-based team effort? BN That’s exactly where the industry is headed. GE is really committed to developing the plant of the future, the “digital power plant.” Everything is going to be digitized, with the ability to monitor, the ability to analyze.


Not Getting Enough Supervision?


ure. We make a better compressor. More reliable. More Air for less energy. Easier to maintain. And quieter. But when it comes to efficiency, system design is critical.

You can run several very efficient machines, but not run them efficiently. That’s why we are such sticklers for system controls. Our Sigma Air Manager 4.0 makes compressors “play well with others”. Under SAM’s supervision, compressors don’t fight each other. And when they aren’t playing, they are off. No wasting energy idling or cycling. Beyond saving energy, SAM 4.0 ensures reliable steady pressure for production. It also minimizes run time which extends service intervals. Reduced cycling and idling means less wear and tear on the motor, starter, valves, etc. SAM 4.0 also provides full time energy monitoring and easy integration into plant control/IIoT systems. Stop neglecting your compressor and give it the supervision it needs with SAM 4.0.

Kaeser’s Sigma Air Manager 4.0 (SAM) compressed air management system brings the IIoT to industrial plants with its adaptive control, data storage, analysis, and predictive maintenance capabilities, and it does it all while ensuring a reliable, consistent supply of compressed air. Learn more at

Kaeser Compressors, Inc. • 866-516-6888 • Built for a lifetime is a trademark of Kaeser Compressors, Inc.

©2016 Kaeser Compressors, Inc.

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