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5 | How will you get ahead at your job?
Studies point to manufacturing jobs as highly technical and secure.
8 | How does your salary match up?
Salaries remain virtually flat, and unemployment levels are very low
SOLUTIONS
12 | Enhancing oil, gas platform operations with the right components
Recognizing the best materials to use for fluid system components is critical to realizing successful outcomes for oil and gas professionals
19 | Important considerations when sizing linear and direct-drive technologies
Linear motors and direct-drives can be overlooked due to a rotary servo motors
24 | Select the right PPE to take control of electrical risks
To keep workers safe and lower risk, proper PPE must be in use
30 | Why you should consider using steel conduit and tubing
Steel conduit is a versatile and safe wiring method to choose when building commercial and industrial buildings
32 | ESG and how to be a good corporate citizen
Before defining ESG goals, understand the full scope of ESG and its importance 36 | Digital twin technologies enable facility efficiency
Get a better handle on real-time information
38 | Addressing electrical safety hazards
Considering newer products and technologies can improve personnel safety
42 | Vertical turbine pump tips and tricks
Vertical turbine pumps are vulnerable to damage because of constant use in applications
2023
Preventing fluid system component corrosion begins with choosing the best materials of construction for the end-use application. Courtesy: Swagelok
CHRISTINA MILLER, Assistant Content Editor CMiller@CFEMedia.com
CHRIS VAVRA, Web Content Manager CVavra@CFEMedia.com
MICHAEL SMITH, Creative Director MSmith@CFEmedia.com
AMANDA PELLICCIONE, Director of Research APelliccione@CFEMedia.com
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow JOHN GLENSKI, President, Automation Plus
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to author an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Efficient motor management
• Electrical safety
• Expert Q&A: Asset management
• Expert Q&A: Hazard protection and hazardous environments
• Lubrication
• Material handling
• Pneumatic and hydraulic controls
• Predictive maintenance
• Process piping
CFE Media Contributor Guidelines Overview
Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about — engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
* https://tinyurl.com/PlantEngineeringSubmissions gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.)
* If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online.
* Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.
LEARN MORE AT:
https://tinyurl.com/PlantEngineeringSubmissions
How will you get ahead at your job?
According to the recent Plant Engineering salary survey, 50% of respondents have worked for their current employer fewer than 15 years, with 19% reporting they’d worked for their employer less than 5 years. When compared to a similar question asked 10 years ago about the time a respondent has worked in his current position, only onethird indicated they’d been in it fewer than 19 years.
$99,000 before bonuses. That number tracks with the 50% of respondents who have been with their employer fewer than 15 years; these survey respondents earned $100,779 before bonuses.
Amara Rozgus,
The workforce has become more apt to change jobs in the past decade, which points to several things:
• Changing jobs is the primary way to earn more money. A Pew Research Center study looked at this during the COVID-19 pandemic, and continues to study the trend.
• The management culture is more employee-focused, and it’s up to the employer to keep the employees happy.
• Work-life balance is a requirement for Generation Z (born between 1997 and 2012).
• A lack of challenges on the job causes people to leave. Employees also want to have the opportunity for a promotion in their position.
• Company loyalty, common across all industries, has dissipated. What makes people stick around? Most respondents (83%) viewed manufacturing jobs as secure. Overall, the unemployment level is low and compensation is pretty high. For example, the average base annual salary for those who work 40 to 44 hours per week is approximately
The industry continues to surge ahead, and surpass labor expectations. But, like many industries, manufacturing jobs are going unfilled. Not seen as “sexy,” people are going to school to learn skills unrelated to manufacturing — business ranks No. 1, according to the National Center for Education Statistics. A 2021 study by Deloitte and The Manufacturing Institute pointed to the 2.1 million manufacturing jobs that will go unfilled by 2030.
The salary survey respondents flagged many of the skills that various studies also highlight. To enhance their jobs, 71% of Plant Engineering respondents indicated they needed engineering skills to get ahead in their profession. Close behind were business skills, including project management (70%), communication/presentation (54%) and computer (53%)
Where do manufacturing jobs go from here? Both the Deloitte and Plant Engineering studies called out the need for additional training, much of which leads to digital transformation within a business. Because 41% of salary survey respondents said there were fewer than 100 employees at their location, that implies there is a lot of opportunity for growth, training and changes at these smaller facilities. PE
Editor-in-Chief
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How does your salary match up?
Salaries remain virtually flat, and unemployment levels are very low
TInsightsu
Salary survey insights
uCompany profitability played a big role in the bonus compensation of 2022 Plant Engineering salary survey respondents.
uEngineering skills remain the No. 1 skill needed by salary survey participants.
he 2022 Plant Engineering salary survey results were a mixed bag. While the average compensation with bonus was up slightly above a five-year average, it dropped compared to the previous year.
When reviewing the high-level results of the 2022 study, the average base salary was $102,294 and the average nonsalary compensation was $13,079. For full details, see the compensation tables.
When reviewing the average of the past five years of data, there is a very slight decrease of base salary (average of $102,571) and an increase of nonsalary compensation (average of $11,608). In comparison, information collected in 2021, which was a reflection of 2020 salaries, was the most impressive, with the average compensation with bonus reaching $123,313.
FIGURE 1: The average age of respondents was 54 years old, which equals the five-year average. Courtesy: Plant Engineering How old are you?
Bonus compensation was up year over year, due to a host of reasons (respondents could select several options):
• Company profitability: 50%
• Personal performance: 44%
• New business, sales increase: 23%
• Product profitability: 20%
For this salary survey, the response group was diverse. When asked about the main focus of their job, responses were:
• Maintenance: 17%
• Controls: 14%
• Electrical and power: 10%
• Industrial: 10%
This is echoed by the wide variety of business areas and job responsibilities of respondents:
• System integration, consulting, business or technical services: 7%
• Food, beverage, tobacco manufacturing: 7%
• Miscellaneous or other manufacturing: 7%
• Government or military: 6%
• Oil, gas and petroleum, including refining: 6%
• Instrumentation, control systems, test, measurement or medical equipment manufacturing: 6%
And most respondents are at smaller facilities, with 71% at companies that have fewer than 500 employees, and 32% at companies with fewer than 50 employees. These respondents also have another positive attribute: Four in 10 (43%) of respondents have a bachelor’s degree, and 20% have a master’s degree. This trends along with the fact that 75% of survey respondents have a job title of engineering, maintenance or supervisor; 21% are in management, with the title of president, VP, general manager or something similar.
For how many years have you worked in your current industry?
FIGURE 2: According to the 2022 Plant Engineering salary survey, the typical employee has been in the industry an average of 28 years, and about one-fifth (19%) have been at their current job 5 years or less. Courtesy: Plant Engineering
The salary survey outlook
According to the Bureau of Labor Statistics, the unemployment rate in the manufacturing sector remains historically low at 3.1% in 2022. In comparison, unemployment was 4.4% and 7% in 2021 and 2020, respectively.
The average workweek for those in the entire manufacturing sector (all job titles) is 40.3 hours, according to the Bureau of Labor Statistics. For the 2022 Plant Engineering salary survey study, the average was 46 hours. Again, this may directly relate to those with management titles, or the fact that respondents are from a varied background with a wide variety of responsibilities.
And most survey participants like their jobs, which 83% believe to be a secure career. Nearly three in four (39%) indicated “I love going to work every day.” About half (52%) said, “It's OK, glad to have a job, I can deal with it.”
To improve in their profession, respondents shared details about skills they or others in similar positions could use to get ahead:
• Engineering: 71%
• Project management: 70%
• Communication/presentation: 54% PE
Amara Rozgus and Amanda McLeman, CFE Media and Technology
A survey was emailed to Plant Engineering audience members and information was collected in November 2022. A total of 162 qualified responses were returned, with a margin of error of +/-7.7% at a 95% confidence level. Participants frequently had the option to select more than one response, thus totals do not always equal 100%.
Table 1: Salary breakdown by age
1: The prime years for survey respondents appears to be in their 50s, and the average age of respondents was 54 years old. Courtesy: Plant Engineering
Table 2: Average compensation by primary
discipline involvement
TABLE 2: The top pay goes to those involved in computers or electronics, which includes cybersecurity, computerize maintenance management systems, software and similar. Courtesy: Plant Engineering
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ENGINEERING SOLUTIONS
OIL AND GAS
Brian Van Valkenburg, Swagelok Co., Solon, Ohio
Enhancing oil, gas platform operations with the right components
Recognizing the best materials to use for fluid system components is critical to realizing successful
outcomes for oil and gas professionals
The oil and gas market has evolved over the past decade to become more focused on safety than ever before. As a result, it is increasingly important for the fluid systems that transport caustic materials at elevated temperatures and pressures to be reliable and leak free. With this renewed safety focus, oil and gas operators who are trying to keep their environment and workers free from harm must build systems with the highest quality components possible.
The question of how to find reliable components is a challenge for all platform operators. They are seeking to control operational costs and account for labor shortages while still using the best components. In short, they want to find components that do not need to be changed as often and have the potential to last for the lifetime of their platforms.
The desire for long component service lives relates to the increasing complexity of the vari-
FIGURE 2: Pitting corrosion can easily form on 316/316L stainless steel tubing contaminated by acids, salt water and other deposits. Courtesy: Swagelok Co.
FIGURE 1: Preventing fluid system component corrosion begins with choosing the best materials of construction for the end-use application. Courtesy: Swagelok
ous fluid systems that support platform operations. Between instrumentation lines, hydraulic power, chemical injection, deluge systems and other components, a single platform might have 50,000 feet of tubing, more than 20,000 fluid system components, no fewer than 10,000 fittings and potentially 8,000 mechanical connections.
Keeping each of these contact points operating at peak performance is no small feat and it starts with choosing the right components for the job. That means selecting fittings and fixtures that resist pitting (see Figure 2) and crevice corrosion (see Figure 3), both of which are common in offshore oil and gas applications.
To avoid these problems, platform operators must maintain an in-depth understanding of metallurgy and materials science. It is vital to have proper training programs to allow oil and gas professionals to keep corrosion from compromising their systems and putting the environment and team at risk.
But how do companies find the appropriate training to ensure their teams have the necessary knowledge? Working with a reliable supplier who offers training programs on how to select and specify the proper components can certainly help.
Which component is needed?
Harsh oceanic conditions can lead to various types of corrosion (see Figure 4), causing components to fail long before the platform. Under difficult operating conditions at sea, replacing these components may be expensive and can be risky. Hence, the desire for long-lasting components.
Yet, deciding what materials make the most sense for enabling long-term component use in specific applications is often more complex than it may first appear. In addition, the various factors involved are not always easy to understand.
Historically, 316 stainless steel tubing, which
has a passive, chromium-rich oxide layer on its surface in ambient temperatures that protects it from corrosion (see Figure 5), has been the most common material used in oil and gas applications. It usually performs adequately and has a proven track record of affording the proper corrosion resistance for many applications. However, as performance requirements have ratcheted up, 316 stainless steel has become less ideal. Fortunately, it is no longer necessary to rely solely on 316 stainless steel because new alloys are available that also resist corrosion well, includ-
Continued on page 16
FIGURE 3: Localized crevice corrosion (left) is likely to form between tubing and tubing supports (right). Accelerated reactions take place within the confines of the crevice, allowing corrosion to proliferate. Courtesy: Swagelok Co.
FIGURE 4: Corrosion occurs when a metal atom is oxidized by a fluid, which leads to a loss of material in the metal surface. It may appear in the form of general (rust), pitting or crevice corrosion or a variety of other types. Courtesy: Swagelok Co.
Learningu
Objectives
• Discover how proper materials science training programs can help oil and gas professionals prevent corrosion from compromising their systems.
• Learn how training can help operators choose the right component materials to resist pitting and crevice corrosion in offshore oil and gas applications.
• Understand why materials science training should focus on local and regional regulations or other geographic-specific factors.
ENGINEERING SOLUTIONS
right choice for many applications, particularly if the system in question is not subject to harsh environmental conditions like sun and salt spray exposures. It is important to understand, however, that not all 316 stainless steels are created equal. Those with higher concentrations of nickel and chromium and that exceed the ASTM International minimums can improve corrosion resistance and reliability.
Insights
Oil and gas components
uComponent reliability is an ongoing issue for oil and gas project managers.
uSelecting training programs for oil and gas professionals is difficult, and selecting a trainer with real-world experience benefits the student.
Continued from page 13
ing duplex stainless steel, 6 moly stainless steel and others. But should oil and gas professionals always specify higher-performing alloys for every situation? Not necessarily.
Choosing the proper materials for individual applications should be informed by a multitude of factors, including environmental conditions, required performance and cost. But choosing a particular material just because it is simple to use may unnecessarily increase expenses in the long run.
For example, 316 stainless steel offers good ductility, which means it is easy to form and weld. At an attractive price point, it may still be the
At the same time, if the system is transporting sour gas, even the highest quality 316 stainless steel may not be sufficient to resist sour gas cracking or sulfide stress cracking (see Figure 6). Sulfide stress cracking is a common, severely corrosive combination of hydrogen sulfide and moisture, which weakens the metal in question and makes it more brittle.
This phenomenon often happens on offshore platforms, particularly now that more sour reservoirs are being developed throughout the world. The brittle metal is more prone to cracking when it is subjected to the combination of tensile stress and corrosion. In these situations, it makes more sense to specify advanced alloys like Alloy 825, Alloy 625 and others. The requirements may be found in the NACE MR0175/ISO 15156 standard.
In between these two extremes are other opportunities to use other alloys that can perform optimally depending on the application. For some oil and gas applications, it may only be the tubing that needs to be an advanced alloy, while the
FIGURE 5: Stainless steels automatically form a passive, chromium-rich oxide layer on the surface in ambient air (top), protecting the material from corrosion. If this outer layer is damaged (middle), it will reform automatically (bottom). Courtesy: Swagelok Co.
FIGURE 6: Sulfide stress cracking is common in fluid systems containing sour gas, as the metal deteriorates due to contact with hydrogen sulfide and moisture. Courtesy: Swagelok Co.
‘ Choosing the proper materials for individual applications should be informed by a multitude of factors, including environmental conditions, required performance and cost.’
tube fittings can be made of 316 stainless steel. Understanding these subtle differences can be the difference between the success or failure of a system, which is why a thorough understanding of materials science is so crucial. Training oil and gas professionals to have a robust understanding of materials will allow them to optimize their choices and provide the most value to their operations.
How to build a materials science training program
Training oil and gas professionals in the intricacies of materials science is a complex task. Being able to differentiate between effective and ineffective training courses is key. One should start by evaluating whether the instructors have real-world experience and are thoroughly trained themselves so they can provide effective training for your team.
To be effective and successful, training programs cannot be generalized. Instead, they should be specific to the needs and challenges of the facility where the training is taking place. The trainer should have a full understanding of local circumstances, regulations and other geographic-specific factors that can affect particular facilities (see Figure 7). After all, the regulations governing a facility in the Gulf of Mexico will vary significantly from those for a plant operating in the northern United Kingdom. Trainers should be able to adapt their presentations to meet specific operational needs.
For example, there is a thriving but still emerging oil and gas market in Malaysia, Indonesia, Singapore, Thailand and Vietnam. Suppliers with sufficient local knowledge may recognize that materials science and corrosion training are what these markets need most at this point in their development. Training teams from those suppliers can offer specific metallurgy and materials sci-
ence training that can improve the knowledge of all industry stakeholders, leading to more effective education and promoting long-term success.
In a different market or different facility, the training needs may be significantly different. Working with reliable suppliers who can adjust their training to meet specific needs is key. The trainers should be able to delve into specific questions about alloys to ensure the right components are specified.
Because no two oil and gas platforms are alike, it is critical to work with trainers who understand how each platform operates. Decisions about how tubing and fittings are installed, how they are cleaned or what kinds of elements they are exposed to will ultimately affect what materials will be best for particular applications. Proper understanding of these subtle differences can make the training even more effective and build trust in the supplierplatform relationship.
Reliable suppliers should always have ongoing conversations with their customers about material science training as well as materials selection and specification. After all, localized service and specific expertise can be the difference between the successful operation of a system and a catastrophic failure. PE
Brian Van Valkenburg is training and services marketing manager for Swagelok Co.
FIGURE 7: Materials science training should focus on local and regional regulations or other geographic-specific factors to ensure it relates to your facility’s operations.
Courtesy: Swagelok Co.
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Important considerations when sizing linear and directdrive technologies
Linear motors and direct-drives can be overlooked due to a rotary servo motor, but manufacturers could miss out on the benefits a linear or direct-drive could provide
When considering both linear and direct-drives, it is important to factor in immediate costs compared to long-term costs.
Whether users are cross-referencing, integrating or retrofitting a linear or direct-drive application, feeling comfortable with sizing will not only speed up the automation process, but also greatly impact performance.
Oftentimes, both linear motors and directdrives are overlooked by their just as capable counterpart, the rotary servo motor. In doing so, manufacturers could be missing out on the benefits a linear or direct-drive could provide.
Understanding mechanical data
When sizing for any application, it is best practice to start with the basics: involving the critical moving payload, external payloads, orientation, length and the motion profile. Further analyzing these topics provides solutions for determining importance in position settling time, desired accuracy and repeatability, rigidity and identifying space and environmental constraints.
By considering these performance metrics and gathering the mechanical data, users can compare linear and direct-drives with that of using a rotary servo motor.
Linear motor technologies are separated into two categories. One is a linear motor stage that creates direct-to-linear motion; its electrical com-
ponents produce the motion and the other linear technologies involve rotary motors, which convert the rotary torque into linear motion by using a ballscrew, belt and/or rack and pinion transmission.
In comparing the two categories by some performance metrics, machine builders would consider that the linear motor stage overall outperformed the rotary-to-linear motion technologies, even after applying a fully closed loop encoder to enhance settling time, accuracy and repeatability.
For a further study in linear technologies and their application uses readers should read the Control Engineering article “Choosing linear servo motors for the right application” by Matt Pelletier from 2021.
Objectives Learningu
• Understand that mechanical data supports machine performance.
• Validate motor and drive sizing with the support of software.
• Consider design longterm versus initial costs in direct-drive systems.
uDirect-drive motors are more suitable for rotary applications, which require more torque at lower speeds than linear motors.
uWhile sizing an application, using the latest sizing software can reduce the chances of oversizing or undersizing a motor for an application. It also allows people to compare and contrast between motor capabilities.
While linear motors and direct-drives share many advanced precision similarities, the use of a direct-drive is more suitable for rotary applications, which require more torque at low speeds. In a similar comparison between a direct-drive and rotary motors that have a gearbox and or belt and pulley system, the direct-drive outperformed each in several performance metrics.
When applying a rotary servo motor gearbox and/or a belt and pulley mechanism, applications experience long-term effects like increased backlash, loss in rigidity and wear on precision capabilities. A direct-drive system simply bypasses all these long-term effects associated to transmission components, as a direct-drive can support the weight of the entire load.
For a further study on direct-drive technologies and their application, read the article “Directdrive servo tutorial, application update” by Matt Pelletier from 2022.
When sizing any application, having the mechanical data at hand alongside the performance metrics that are considered important will help users feel more comfortable when considering a different approach to what they would have normally. For even further assistance in sizing, running the mechanical data in a sizing soft-
ware will not only help produce the motors best for the application, but also provide application results for when considering a linear motor and/or direct-drive alongside the rotary counterpart.
Validate sizing with the support of software
In the course of sizing an application, there are many advantages of using the latest sizing software. Not only can machine builders reduce the chances of oversizing or under-sizing an application, they can also compare and contrast between motor capabilities to garner bill of materials, or BOM, information for next step decision matrices.
Sizing software offers a step-by-step platform that guides users through a wide range of application possibilities, complete with an intuitive editor to enter load data, mechanical transmissions and move profiles. Lastly, the software generates a finalized report that contains servo system capabilities versus application requirements with a complete BOM for processing.
In the initial “User Info” tab in the Yaskawa SigmaSelect software, users should enter application information and or sizing analyst information for future cross-referencing, machine design changes, etc.
FIGURE 2: “Load Editor” tab: mechanical data implementation.
The next tab, “Load Editor,” involves entering the application mechanical data. The following example consists of a “Pick and Place” — ballscrew application with the following mechanical data:
• Slide mass: 20 kg.
• Payload: 60 kg.
• Screw length: 1,200 mm.
• Screw lead: 20 mm.
• Screw shaft diameter: 20 mm.
• Stainless steel.
• Linear guides with nylon bushing.
• Coupler aluminum height: 60 mm.
• Coupler inner diameter: 20 mm.
• Coupler outer diameter: 38 mm.
The motion profile involves (see Figure 1):
• Intermediate dwells of 0.5 seconds.
• Placing speed: 4.5 inches/second with a slot of 3 inches.
• Transfer speed: 20 inches/second.
• Ending dwell for part remove/reload.
In the “Load Editor” tab, data was entered for: critical load mass (kg), the selected ballscrew lead (mm) and the slide’s mass (kg) (see Figure 2). The mechanical data is then used to determine important characteristics involving friction coefficient (N), ballscrew inertia (kg*m2) and coupling transmission inertia (kg*m2) (see Figure 3).
In the preceding tab, “Profile Editor,” the expected motion path was entered. The motion profile generates graph options for position, velocity, acceleration, jerk and estimated torque. Performance metrics for accuracy, repeatability and time cycle are crucial assets in this stage. It is recommended to review not only mechanical data, but the expected motion profile for optimization possibilities.
Once the motion profile is optimized, the SigmaSelect software generates a list of potential motors and amplifiers capable of meeting the motion demand. Considering the four key sizing notes alongside categorizing for “Cost Factor” and/or filtering for speed, inertia, torque, etc. will help select and or compare motors for:
• Inertia ratio.
• Speed.
• Max torque at speed.
• Rms torque at speed.
From the list of sizing factors, it is generally recommended to keep the application inertia ratio mismatch value lower than the allowable ratio value, as this will assure the motor can control the load at the desired speeds. Keeping the application required torque within a general 80% of the rated or peak torque values allows for buffering for the application.
For this example, the motors were categorized by their cost factor starting from least to most. For this application the SGM7J-08A*A, was the suitable candidate, as it met all the requirements with the application gaining an additional 80% factor of safety, a wider scope creep for future machine changes. On the other hand, the SGM7G-03A*A is 11% more in initial costs and only provides a 60% factor of safety, lower values in rated/peak torques and peak speed of 3,000 revolutions per minute.
When a motor is selected for final revision, the “Motor Details” tab provides users an in-depth graphical and motor analysis, while displaying the root mean square (shown as RMS) and peak values in intermitted or continuous periods.
In this example, the motor values fall within the continuous cycle, while it satisfies both inertia mismatch and speed demands (see Figure 4). The next tab, “Regeneration,” would detail whether the application needs an external resistor for negative torque produced. It did not. Finalizing the assessment will generate a PDF with all of the application specifications.
To compare the ballscrew application to a linear motor, SigmaSelect allows for intuitive edits to adjust applications without having to start over. Keeping previous information stored, allows for on-the-fly changes. The only edit other than changing mechanism type was in the application’s friction coefficient for a linear motor’s ball bearings.
‘ When sizing for any application, it is best practice to start with the basics.’
FIGURE 3: Coupler inertia, length, inner and external diameter and material. Courtesy: Yaskawa
ENGINEERING SOLUTIONS
‘ Machine builders could find themselves sacrificing speed and repeatability, as they allocate replacements.’
The motor results were filtered specifically for the Sigma Trac II linear stage to demonstrate a complete solution comparable to the ballscrew approach. A linear stage system is specifically built to order, fully tested and ready to use out of the box.
Filtering for cost and the list of key sizing factors, the ST2F-A1A* meets the motion speed demands, while keeping RMS values continuous, with peak values allowing room for higher force and potentially increased application speed. The motor results also specify for an additional 5% more in initial costs, but the motor ST2F-A2A* has double the factor of safety and force values than the ST2F-A1A*. The ST2F-A1A* updated application did not require an external resistor.
SigmaSelect software has progressively developed to allow more possibilities that involve transmission components like belt actuator, belt conveyors, ball/lead screw and rack and pinion. It caters to a variety of other applications that can be optimized, while keeping machine builders as much a part of the process and detailing motor recommendations. Having the possibilities to asses and compare without extra work supports end users to consider sizing alongside software.
Consider design long-term versus initial costs
Using the ballscrew versus linear motor stage application, the design costs between the two systems are vastly different for the same application and will remain different for the entirety of the
system’s life span. The SigmaSelect software solely offered a cost factor for the ballscrew’s motor and its associated servo amplifier. Machine builders would have to source for their own milled to length ballscrew, coupler, linear guide with nylon bearings and if performance metric accuracy is desired, a fully enclosed encoder. The system would also then require either outsourcing or in-house engineering installation support to initially mount, align, wire and tune the system.
As the system is in operation, machine builders will have to continue to supplement component replacements. For example, the ballscrew will incur increased backlash and decreased repeatability, rigidity, etc. over time. Machine builders could find themselves sacrificing speed and repeatability, as they allocate replacements.
In comparison, the SigmaSelect software provides the cost factor for the Sigma Trac II as a fully complete solution that is built to order and tested. Machine builders simply provide a flat mounting surface and bolt for their payload. The solution results in a repeatability of a 10 million double-stroke design life before the need for inspection. In comparison to the ballscrew, the Sigma Trac II is the more expensive of the two, but in the long run, it out lasts the ballscrew application, maintaining its speed, repeatability and rigidity longer.
In a further analysis when considering design costs, keep in mind the following: When the forces are high and the speeds are lower, ballscrews become a good option. Linear motors offer moderate force at high speed, while a ballscrew is capable of higher forces at lower speeds. The load-side feedback of the linear motor offers better accuracy and repeatability with fewer moving parts. Ballscrews are also limited in their length, as deflection occurs at high speeds. Increasing the diameter helps, but increases the amount of load inertia. Sigma Trac II stages can be up to 1920 mm long.
Overall upfront cost of linear motors is higher than actuators, but production factors, such as settling time and repeatability create payback scenarios that can be very short. PE
Dulce Maria Varela is a Regional Motion Engineer for Yaskawa America Inc. Her experience comes from time spent supporting various types of applications at different stages in their automation process.
FIGURE 4: Motor details are shown in the program here. Courtesy: Yaskawa
ENGINEERING SOLUTIONS
PERSONAL PROTECTIVE EQUIPMENT
Tom Pitts, Schneider Electric, Boston
Select the right PPE to take control of electrical risks
Employers and employees must ensure proper personal protective equipment is in use to keep workers safe and lower risk
Maintenance employees are exposed to more electrical hazards than in the past. Technology advances have caused an increased risk to maintenance employees due to the number of devices using electricity as an energy source. Most of the electrical incidents employers investigate are caused by an employee’s lack of understanding on how to protect themselves from a hazard that they cannot readily see.
According to the most recent United States Bureau of Labor Statistics data from the Census of Fatal Occupational Injuries, 126 workers died due to exposure to electricity in 2020. This was the lowest level since the survey started in 1992. But that is not to say the risk is going away anytime soon.
Another factor that increases employee electrical safety risk is the current labor market conditions. Employers rely on our people to work more
hours and do more with less. The lack of electrical preventive maintenance programs, fatigue and subsequent human error are factors employers cannot ignore. Employers cannot forgo an equipment PM, qualified employee training, a hazard analysis for the task or situational awareness to recognize when a condition is unsafe just to keep our facilities running.
The problem is that electrical energy creates an unseen opportunity for exposure that increases the risk of injury. For example, exposure to electrical shock can range from internal organ and muscle damage to burns and possible death. Arc flash events can cause death due to an explosive projection of molten material, concussive blast, toxic gas exposure, fire or falls.
Consensus standards such as NFPA 70E: Standard for Electrical Safety in the Workplace have been in existence for more than 40 years and have been incorporated by reference into regulations for more than 30 years.
Therefore, it is not enough for a maintenance employee or their supervisor to plead ignorance for not providing or wearing personal protective equipment after an electrical incident. Employees working with electrical systems must understand the proper shock and arc flash PPE to wear when working around exposed energized conductors operating at or greater than 50 volts alternating current or direct current.
Whether an employee is working on a 120 Vac light switch, a 480 Vac heating, ventilation and air conditioning unit, power distribution panels or any other type of equipment with exposed energized conductors, it is imperative that they protect themselves and their co-workers from the hazards of electricity.
Understanding electrical hazards
First, let’s look at the electrical hazards hierarchy to understand when maintenance employees are at a
FIGURE 1: Electrical hazards hierarchy. Courtesy: Schneider Electric
Table 1: Class of rubber insulating equipment per 29 CFR 1910.137
FIGURE 3: Rubber insulating gloves and leather protectors. Courtesy: Schneider Electric
higher risk (see Figure 1). Each step of the electrical hazards hierarchy has equal importance to overall safety, with risk reduction varying between the steps.
For example, levels 1 to 3 are designed to control the risk before it gets in close proximity to the employee. Levels 4 to 6 assume that the employee is already exposed to the electrical energy and needs to be kept safe while he or she is close to the hazard by using the appropriate PPE.
PPE is the least effective risk control method and should only be used as a last resort. Employers should first eliminate the hazard by creating a zero-energy state using lockout tagout (level 3). But even the act of de-energizing to create an electrically safe work condition and reenergizing to return to normal operation (level 4) requires employees to wear the appropriate shock and/ or arc flash PPE before performing maintenance work.
Shock protection PPE
Employers know that high voltages are dangerous, and low voltages can be extremely dangerous as well. Shock injuries are dependent on the magnitude, frequency, path and time duration of electrical current through the body. All other factors being equal, the degree of injury increases the longer the body is in contact with the circuit.
As long as there is voltage present, it will try to push any available current (as low as 5 to 10 mil-
* The top of the cuff of the protector glove shall be shorter than the rolled top of the cuff of the insulating glove by at least the distance specified in this table.
liamps) through the body. When making contact with a source, electricity will travel throughout the body — looking for a ground source (see Figure 2). The path it takes is critical. When it travels through the chest area, including the lungs and heart ventricular fibrillation (stopping of rhythmic pumping action) may cause a very serious injury.
For shock protection PPE, NFPA 70E section 130.7 requires:
• Rubber insulating gloves (tested up to the voltage the technician is working with) and leather protector gloves (gauntlets) over the top of the insulating gloves.
• Electrical hazard rated footwear (as needed).
• Class F or E rated hard hat (as needed).
• Safety glasses or goggles (as needed).
• Rubber insulating sleeves (as needed).
• Understand that there are ways to lower electrical risks and improve safety conditions for employees.
• Know that using proper personal protective equipment, such as equipment that includes shock protection and arcrated protection, the risk to employees is greatly diminished.
• Review the proper shock and arc flash personal protective equipment to wear when working around exposed energized conductors operating at or greater than 50 volts alternating current or direct current.
FIGURE 2: Electrical current path through the human body. Courtesy: Schneider Electric
ENGINEERING SOLUTIONS
Arc-rated clothing, minimum arc rating of 4 cal/cm2 (see note 3)
Arc-rated long-sleeve shirt and pants or arc-rated coverall
• Arc-rated face shield or arc flash suit hood (see note 2)
Arc-rated jacket, parka, rain wear or hard hat liner (AN) protective equipment:
• Hard hat
• Safety glasses or safety goggles (SR)
• Hearing protection (ear canal inserts)
• Heavy duty leather gloves (AN) (see note 1)
• Leather work shoes (AN)
Arc-rated clothing, minimum arc rating of 8 cal/ cm2 (see note 3):
Arc-rated long-sleeve shirt and pants or arc-rated coverall
• Arc-rated arc flash suit hood; or arc-rated faceshield (see note 2) and arc-rated balaclava
Arc-rated jacket, parka, rainwear or hard hat liner (AN) protective equipment:
• Hard hat
• Safety glasses or safety goggles (SR)
• Hearing protection (ear canal inserts)
• Heavy duty leather gloves (AN) (see note 1)
In addition, to protect against electric shock, it is important to not wear any conductive items (jewelry, belt buckles, etc.) that could come into contact with exposed energized electrical conductors.
Arc-rated PPE
• Leather work shoes 3
Arc-rated clothing, selected so that the system arc rating meets the required minimum arc rating of 25 cal/cm2 (see note 3):
Arc-rated long-sleeve shirt (AR)
• Arc-rated pants (AR)
• Arc-rated coverall (AR)
• Arc-rated arc flash suit jacket (AR)
• Arc-rated arc flash suit pants (AR)
• Arc-rated arc flash suit hood
• Arc-rated gloves (see note 1)
Arc-rated jacket, parka, rainwear or hard hat liner (AN) protective equipment:
• Hard hat
• Safety glasses or safety goggles (SR)
• Hearing protection (ear canal inserts)
• Leather work shoes
Arc-rated clothing, selected so that the system arc rating meets the required minimum arc rating of 40 cal/ cm2 (see note 3):
Arc-rated long-sleeve shirt (AR)
• Arc-rated pants (AR)
• Arc-rated coverall (AR)
• Arc-rated arc flash suit jacket (AR)
• Arc-rated arc flash suit pants (AR)
4
• Arc-rated arc flash suit hood
• Arc-rated gloves (see note 1)
Arc-rated jacket, parka, rainwear or hard hat liner (AN) protective equipment:
• Hard hat
• Safety glasses or safety goggles (SR)
• Hearing protection (ear canal inserts)
• Leather work shoes
Table legend:
AN = as needed (optional)
AR = as required
SR = selection required
Notes:
(1) If rubber insulating gloves with leather protectors are required additional leather or arc-rated gloves shall not be required. The combination of rubber insulating gloves with leather protectors satisfies the arc flash protection requirement.
(2) Face shields shall meet the requirements of NFPA 70E. An arc flash suit hood may be worn in lieu of a face shield.
(3) Arc-rating is defined in NFPA 70E.
In addition to the shock protection PPE noted above, if the hazard analysis indicates an incident energy of 1.2 cal/cm2 or more, the use of arc-rated PPE is required. NFPA 70E Table 130.7(C)(15)(a and b) specifies arc flash PPE category 1, 2, 3 or 4.
The higher the category number, the more protective the PPE is to prevent a burn injury. In addition, any underlayers that are worn beneath the arc-rated PPE must also be arc-rated or nonmelting untreated natural fiber. If the risk assessment determines the level of hazard is greater than the available PPE, even if the work is allowed, it should not be carried out.
Why do workers need PPE?
The electrical hazards that exist can cause serious injury or death to maintenance workers. Employers should have very strict expectations and requirements for anyone that is working around electricity. Despite years of experience and training, maintenance workers still suffer injuries related to electricity on the job.
Many employees who work with electricity don’t believe that an accident will happen to them, but records prove otherwise. Employers and employees must work together to make improvements to electrical safe work practices. Automobiles did not always have, but because we do, traffic-related fatalities have declined significantly since these inventions have been implemented. PE
Tom Pitts is director of safety and environment for Schneider Electric Global Supply Chain.
FIGURE 4: Example of arc-rated personal protective equipment category 2, up to 8 cal/cm2. Courtesy: Schneider Electric
In 2023, Atlas Copco Celebrates 150 Years...
From the compressed air and gas team, we want to say a heartfelt ‘thank you’ to all our employees, customers, and suppliers who have been part of our journey. We could not have achieved it without you! As we pass this milestone, our unwavering commitment is to continue to provide innovation which empowers our customers to grow and drive society forward. empowers which innovation
ENGINEERING SOLUTIONS
Dale Crawford, Steel Tube Institute
Why you should consider using steel conduit and tubing
Steel conduit is a versatile and safe wiring method to choose when building commercial and industrial buildings
FIGURE 1: Steel Conduit protects against fire and explosion and ideal in highrisk areas like gas stations, grain elevators and refineries. Courtesy: Steel Tube Institute
There are many options contractors have while selecting wiring methods; however, steel conduit and electrical metallic tubing, are versatile wiring methods often used as electrical raceways for power, data and communication throughout commercial and industrial buildings. These are the safest materials to use when choosing building wiring methods. Steel conduit and EMT are non-combustible, have long lifespans, are extremely resilient, in addition to being completely recyclable.
Steel conduit and EMT are viable options in fire safety design, yet they sometimes don't make the list because they do not have a fire rating. When request for proposals or project bids require fire resistance scores, while conduit and EMT have none, contractors or specifying engineers may not include these valuable choices in their specifications.
To better understand why steel conduit and EMT are excellent choices when prioritizing fire safety, there are many factors to consider like fire resistance ratings, building codes and thermal protection.
miss out on the chance to evaluate steel conduit and EMT.
Because fire resistance ratings only apply to assemblies in their entirety, using steel conduit or EMT as part of a fire-rated assembly can improve the fire resistance rating because the conduit and EMT have a zero score and zero combustibility, supporting the fire resistance of the overall assembly. Even with a zero score, it remains important to be sure to review all local codes for penetrations, emergency circuits and fire pump circuits before installation.
Penetration of fire-resistance rate assemblies
Steel Conduit
uContractors have many options when selecting wiring methods, but steel conduit is noncombustible, has long life-spans and is extremely resilient.
uElectricians must consider the benefits of using steel conduit and tubing before choosing a lower end wiring method.
Learn the facts
Before working with steel conduit and EMT, it’s important to consider building codes and fire ratings. Steel conduit and EMT are both considered non-combustible by building codes. Because of this, they do not have fire ratings. This can possibly confuse contractors and installers who do not have experience with steel conduit and EMT. If builders require a fire rating or if project bids evaluate or score based on this, they may
The National Electric Code and building codes require that openings around raceways which penetrate a fire-resistance rated assembly be sealed so that the possible spread of fire or products of combustion will not be substantially increased from one area to another. This can be accomplished by the use of a listed penetration firestop system or by use of annular space filler in accordance with building code exceptions. As steel conduit and EMT are noncombustible, it is not required that they have a fire-resistance rating but the area around the conduit or EMT must be properly filled with materials, such as cement, mortar or grout so that the fire-resistance rating of the building is maintained. Always refer to local codes prior to installation.
Thermal protection of steel raceways
Using steel conduit or EMT creates a fire-safe system with many other benefits. Using conduit or EMT in fire-rated enclosures provides a safe
solution. Steel conduit and EMT can also be embedded in concrete, adding flexibility of design and safety, as concrete resists combustion. Buildings can also use a listed wrap system which further protects the integrity and safety of a steel raceway. Wrap systems can be easy to install and cost effective.
Using steel conduit or EMT in a listed circuit integrity system is another way to have an effective fire resistive installation. Circuit integrity systems are listed to UL 2196 and use circuit integrity cables within systems such as those with steel conduit or EMT to achieve fire ratings of 1 or 2 hours. The system must be installed as listed to achieve the fire rating meaning the size and type of cable, conduit and fittings must match what is included in the listing. Refer to the listing requirements of the system, the NEC and local codes to be sure of installation requirements on circuit integrity systems
Although routinely installed in fire-rated assemblies, steel conduit and EMT do not have a fire rating and are considered non-combustible by most building codes. Before using steel conduit or EMT, however, be sure to check all NEC and local codes
to be sure the commercial or industrial assembly is admissible by local standards.
Fire safety is an essential part of any specifying process and engineers can amplify building effectiveness by recognizing all their choices and tools as they select and recommend their installations. PE
Dale Crawford is the Executive Director and Director of conduit of the Steel Tube Institute where he is responsible for the organization’s activities to promote the growth and competitiveness of steel pipe and tubular products throughout North America.
Objectives Learningu
‘ Steel conduit and EMT are non-combustible, have long lifespans, are extremely resilient, in addition to being completely recyclable. ’
• Discover how steel conduit is a versatile wiring method often used as electrical raceways for power, data and communication throughout commercial and industrial buildings.
• Learn how steel conduit and EMT are non-combustible, but the area around the conduit or EMT must be properly filled with the right materials to maintain the fire-resistance rating of the building.
• Understand how steel conduit or EMT as part of a fire-rated assembly can improve the fire resistance rating because the conduit and EMT have a zero score and zero combustibility.
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY
Paul Lachance, Brightly Software, North Carolina
ESG and how to be a good corporate citizen
Before manufacturers can define their ESG goals in the new year and beyond, it’s important to understand the full scope of ESG and why it’s important
Over the past several years, manufacturing leaders have increasingly invested in environmental, social and governance practices to reach their goals. There are a multitude of reasons to support ESG principles, but the term itself can feel nebulous to many. Before manufacturers can define their ESG goals in the new year and beyond, it’s important to understand the full scope of ESG and why it’s important.
What is ESG?
When people hear the term ESG, they often think about environmental impact. However, it’s important to understand that this is an oversimplification and ESG encompasses much more than the physical environment. It also includes an organization’s impact on people and community, as well as its responsibility to be a good corporate citizen. ESG can be broken down into the following:
• Environmental refers to how an organization is treating the planet. Decarbonization, reducing waste, fuel switching and greenhouse gas emissions can all fall under this category.
• Social refers to how an organization treats its people, including its employees, customers, surrounding communities, stakeholders and more. Issues like diversity, equity and community partnerships would fall under this category.
1: Brightly Stream helps organizations meet ambitious energy, water and carbon targets with scalable environmental, social and governance (ESG) data software and expert services. Courtesy: Brightly Software
FIGURE
• Governance refers to whether the organization is acting as a responsible corporate citizen. This category can span from hard-hitting issues like corruption and bribery to whether an organization’s leadership team is representative of the diverse populations it serves. One example of this is the existence of campaigns like the 30% club, which works to boost female representation on all boards and C-Suites globally.
A common analogy that companies should think about is “corporations are citizens and they should act accordingly.” Just as citizens shouldn’t litter while driving or should look to add solar power to their homes organizations should do everything in their power to protect the planet where they can. And, just as citizens should practice kindness around neighbors, teammates and friends organizations should treat their people and surrounding communities with respect.
Why ESG?
For starters, fulfilling ESG goals can help an organization’s topline growth. In recent years, there has been increasing demand among consumers for ESG-focused products and services, as well as increased interest among investors. This value prop also extends to the ways ESG can help an organization with cost reduction. By reducing costs along the value chain, such as reduc-
FIGURE 2: Brightly Asset Essentials helps organizations reduce maintenance costs, improve productivity and make smarter operations decisions. Courtesy: Brightly Software
‘ ...ESG encompasses much more than the physical environment. ’
ing water and energy use, saving on packaging materials or downsizing contribution, achieving ESG and financial goals often go hand in hand. While shifting to a low-carbon operating environment can seem like a massive investment in the moment, the major long-term financial benefits are well worth it. Doing so will set an organization up for success, ensuring that the next generation of plants will be more efficient, more profitable and attract the next generation of workers.
ESG also helps to reduce the risk of making decisions that can negatively affect both internal and external regulatory compliance. The truth is that ESG initiatives create better relationships with regulatory organizations and the community where a manufacturer operates. According to McKinsey, a poor regulatory strategy can put 30% of corporate profits at risk. Actively communicating and delivering on ESG goals will go a long way in ensuring the sustainability of a business.
Internally, ESG also helps to attract and retain top talent. Studies show that Gen Z employees prefer to work for purpose-driven organizations and nearly 71% would even take a pay cut to do so. Overall, there is a substantial upward trend in the
• Understand the full scope of ESG and why it’s important for manufacturers.
• Know the benefits of ESG in practice.
• Learn how to overcome challenges to reaching ESG goals within the manufacturing industry.
ENGINEERING SOLUTIONS
‘ Studies show that Gen Z employees prefer to work for purpose-driven organizations and nearly 71% would even take a pay cut to do so.’
value consumers place on sustainable companies that are striving beyond the bare minimum.
The many benefits of ESG in practice
There are numerous examples of the positive benefits of ESG in practice, such as when Samsung produced medical diagnosis cameras by repurposing old smartphones or when Shell developed a renewable gasoline with 20% lower CO 2 emissions. Across industries, a decarbonization or energy management plan will lead to long-term sustainability savings. Efficiency-focused Industry 4.0 technologies will create longer-lasting assets, less waste and more efficient operations. This will lead to increased trust from consumers.
At the same time, ESG principles make for a stronger and ultimately more profitable company. With access to more data than ever before, manufacturers can now make more informed decisions about their operations and adhere to ESG principles, helping them become better organizations, reduce costs and become more attractive investments.
Industry 4.0 tech like “internet of things” — many still have a long way to go in effectively leveraging it. Without data as the foundation of any modernization initiative, future upgrades are not set up to succeed in our current climate. Without increased education and communication around the many benefits provided by ESG efforts — from decreased costs to healthier communities — companies will continue to run into the same, avoidable challenges.
ESG reporting requires diligence and investing in the right software partner can automate this process, creating a single source of truth for all data related to ESG and initiating decision making.
Further, ESG investing requires analysts to review ESG metrics and reporting data from an organization. This is often a subjective process, as the range of factors and metrics across ESG can be large and difficult to summarize, especially without the right software in place.
Finally, we still have a long way to go in standardizing the environmental aspect of ESG.
“Greenwashing” continues to be an issue across industries, so it’s important for manufacturers to get really clear on their goals before embarking on a sustainability plan. Seeing a consistent, long-term impact on how an organization uses its resources will require the appropriate planning, team members, resources and KPI tracking.
A good corporate citizen
u
Insights
ESG insights
uEnvironmental, social and governance, known as ESG, encompasses the physical environment, as well as an organization’s impact on people and community and its responsibility to be a good corporate citizen.
u By adhering to ESG principles, manufacturers can become better organizations, reduce costs andbecomemoreattractive investments.
From a social perspective, there are obvious benefits to supporting diversity, equity and inclusion initiatives. As the workforce continues to age and retire at an alarming rate, having DEI initiatives in place will prove invaluable for ensuring top talent remains in the workforce. Further, employing technology to aid in operations can help reduce stress and burnout among employees, improving retention.
Overcoming challenges with ESG in manufacturing
While most facility managers have access to data that can illuminate the benefits of ESG initiatives — data, which can be wide ranging, from
Again, I’d like to highlight the phrase “corporations are citizens and they should act accordingly.” While it’s true that manufacturers must be profitable, they should not be profitable “at all costs.” Alternatively, being a good corporate citizen — one that helps the planet, its employees and its surrounding neighborhoods — will lead to greater financial gains, increased trust and long-term success. PE
Paul Lachance is a manufacturing technology consultant on behalf of Brightly Software. He is a lifelong entrepreneur and company-builder with a focus on industrial software.
As a plant manager, you have enough to worry about, the efficiency and reliability of your equipment shouldn’t be one of them. With a full range of processing equipment designed for efficiency, safety and reliability, Spiroflow can provide the right solution to fit your process needs. Backed by over 50 years of industry expertise, our team of engineers is here to help solve your complex processing challenges so that you can focus on what you do best - running your plant.
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY
By Bassem Ammouri, Schneider Electric
Digital twin technologies enable facility efficiency
Get a better handle on real-time information
Insightsu
Digital twin technology
uDigital twin technology is an ideal solution that can be leverage to address issues, as it enhances operational efficiency and reduces the potential of exposure to hazards.
uThis technology fosters innovation and efficiency by enabling seamless collaboration and providing access to realtime data, which helps streamline diagnosis and troubleshooting.
Electrical power operation within data centers and manufacturing facilities is a complicated process that requires thoughtful management and large amounts of available power. Electrical power quality is a crucial piece of the puzzle that keeps facilities running efficiently, yet businesses can be vulnerable to certain threats that disrupt electrical power systems, varying from weather to cybersecurity and physical security to inadequate equipment.
When these possibilities become the reality, unplanned power outages occur. The consequences of unplanned outages not only increase safety risks for personnel but have serious financial consequences as they can result in damaged equipment, corrupt files, and lost data that are very expensive to fix. For example, in the data center industry, 30% of all reported outages cost more
than $250,000 to correct, with many exceeding $1 million, according to the Uptime Institute. In the oil and gas industry, one outage can cost anywhere from $800,000 to $3 million per outage event. And in the semiconductor industry a single electrical event often exceeds $3.8 million.
Although power outages are often triggered by uncontrollable weather events, there are other factors that come into play as well, such as uncontrolled operation and neglected maintenance. The good news is modern power management technology is very effective in preventing unplanned outages and other harmful instances from occurring. Digital twin technology in particular is an ideal solution that electrical engineers and facility managers can leverage to address these issues, as it enhances operational efficiency and reduces the potential of exposure to hazards.
Risk reduction for operators
There are various risks involved in electrical system operations, especially when considering the scarcity of resources that operators and power system engineers have access to. Engineers are often limited to working with static-paper or pdfbased electrical single-line diagrams, which makes it difficult for engineers to maintain and update the electrical systems documentation.
The deployment of digital twin technology fosters innovation and efficiency by enabling seamless collaboration and providing access to real-time data. This helps streamline diagnosis and troubleshooting which, consequently, improves production and process optimization. ETAP’s digital twin platform, for instance, provides intelligent single-line diagrams (iSLD) that utilize digital twin technology in active blue-
FIGURE 1: Digital twin platforms can provide single line diagrams in active blueprints of single phase and three phase power systems. Courtesy: Schneider Electric
prints of single-phase and three-phase power systems.
Real-time power system training
An Operator Training Simulator (OTS) is a training tool which harnesses the real-time data from a digital twin, in a safe offline environment for personnel training on the operation of power systems. It helps to develop and improve operator competency through real-world simulated learning, laying out various pre-defined scenarios and contingency plans that give operators a more complex understanding of the electrical system’s operation and predict system response before action implementation.
Not only is this method cost-effective, but it reduces risk of potential safety hazards as well. With the ability to review predefined scenarios using real-time system data, operators can predict system response before taking action. The precise “what if” scenarios enable operators to sharpen decision-making and avoid the risk of subjecting themselves to dangerous situations. Additionally, practical post-mortem analysis and event playback
capabilities speed up incident response times for
Bassem Ammouri is director, energy management software, Schneider Electric.
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FIGURE 2: With the ability to review predefined scenarios using real-time system data, operators can predict system response before taking action. Courtesy: Schneider Electric
engineers. PE
ENGINEERING SOLUTIONS
Marty Kronz, AutomationDirect
Addressing electrical safety hazards
Considering newer products and technologies can improve personnel safety, especially when combined with a “design for safety” approach and appropriate automation
In many industrial plants and facilities and some commercial facilities, the mitigation of electrical shock and arc flash hazards are topof-mind issues for protecting people and property as well as regulatory compliance. These types of safety issues impact all types of operations and not just the largest industrial sites. Small manufacturers and commercial operations such as data centers all need to address potential electrical hazards.
There is a lot of relevant information available regarding application and governance of safety provisions, ranging from laws, to standards, to best practices. The expectation is each workplace establishes evolving policies, procedures and program
controls to mitigate worker risk to an acceptable level. This practice is often referred to as an electrical safety program.
Most companies invest in and specify technologies for mitigating risks and controlling hazard exposures. These are guided by well understood methodologies, such as the National Institute for Occupational Safety and Health Hierarchy of Controls. In support of these best practices, this article identifies how some newer products and/or the addition of automation, can increase the effectiveness of safety controls.
Performance and prescription for electrical safety
The Electrical Safety Foundation International collects data from the U.S. Bureau of Labor Statistics to publish the Workplace Electrical Injury & Fatality Statistics. From 1992 to 2010, there has been a significant reduction in electrical injuries — more than 50% — which can be attributed in part to the application of new technologies and best practices, which have reduced risk and exposure to electrical hazards. However, this positive trend is tempered because the number of nonfatal electrical injuries flattened to an average of about 5 per day from 2010 to 2020 (around 2,000 per year).
FIGURE 1: Lockout/tagout devices are one of the best understood methods of placing equipment into a safe state, but there are many opportunities for applying intelligent devices and newer methods to improve worker safety. Courtesy: AutomationDirect
It seems electrical safety advances have reached a point of equilibrium with respect to results. However, there is still room for new technologies, along with an emphasis on improved designs and practices, to further reduce the frequency of electrical injuries (Figure 1).
Electrical safety and lockout/tagout are governed by two main requirements determining the “what” and the “how” of these systems. The Occupational Safety and Health Administration provides performance-based workplace requirements (the “what”), such as 1910.147 The Control of Hazardous Energy (Lockout/Tagout). NFPA 70E:
Standard for Electrical Safety in the Workplace explains the prescriptive-based requirements (the “how”). Quoting from the NFPA 70E fact sheet document:
“NFPA 70E fleshes out how the performancebased requirements in the OSHA standards can be met by providing and defining minimum standard industry practices necessary for electrical safety. OSHA is the law and NFPA 70E outlines ways to comply with OSHA’s electrical safety requirements. This symbiotic relationship between NFPA 70E and OSHA electrical safety standards helps to increase safety in the workplace.”
A theory called the Rogers Adoption Curve models and categorizes how new innovations and technology move from introduction to widespread use. Observing companies and organizations that are innovators and early adopters provides a roadmap of where one would expect new technologies to be introduced and propagated for widespread future deployment. The strength of an electrical safety culture varies throughout commercial and industrial sectors and how proactive an organization is in general is often an indicator of how willing they are to adopt newer safety technology.
Two electrical safety technology trends
With this in mind, there are many evolving trends and technologies proactive companies should consider and apply to improve electrical safety by mitigating worker exposure to electrical hazards.
Access control
One growing safety trend is to limit worker access to potentially hazardous locations by means of intelligently-designed manufacturing cells, power distribution enclosures and equipment and control enclosures. Permission to access these and other types of protected locations can be controlled by one or more factors:
• Worker credentials based on training and skills.
• Confirmation of a worker wearing specific personal protective equipment.
• Condition of the equipment and whether it is in a safe/de-energized state.
2: Carefully applied automation, in conjunction with various safety-rated sensors, devices and emerging advanced technologies, serve to protect personnel and can also improve efficiency. Courtesy: AutomationDirect
The most basic access control programs are procedural. Users adhere to company requirements for equipment access or perhaps are issued a physical access control key when they are trained to perform the work properly and safely.
However, innovators and early adopters within several industrial and commercial vertical markets are deploying more advanced access control based on technology, networking and automation (Figure 2). The driving factors for these approaches are to improve risk mitigation, efficiency and speed.
A typical use case would be the design of a manufacturing cell with enclosed electrical equipment. The cell is normally locked from operator use while energy (electrical, pneumatic and/or other) is present. However, the interior of the cell can be accessed by electricians with the proper training, PPE and tools. A system of sensors and controls is deployed to accomplish the cell locking/unlocking task. One way to do this is by providing a pushbutton so the qualified operator can request entry to the cell. Upon detecting a button push, an automatic safety system will move the equipment to a safe position and de-energize electrical, pneumatic and other power sources. Once the equipment is verified as safe using appropriate sensors, the entry gate is unlocked. Existing standards provide guidance for these types of applications.
IEC 61508 is a standard defining safety integrity levels, along with methods of applying, design-
Insightsu
Electrical safety
uElectrical safety has improved thanks to more awareness and adherence to standards, but more improvements can be made thanks to new technologies and increased emphasis on design.
uAccess control and absence of voltage testing (AVT) are two growing trends in electrical safety and can keep workers safe from arc flash or other electrical safety hazards.
FIGURE
ENGINEERING SOLUTIONS
ing, deploying and maintaining automatic safety-related systems. ISO 13849 is a safety standard providing requirements and guidance for control systems design. There are many sensing devices and controllers to help ensure operators are only allowed to approach equipment when it is safe and the equipment is driven to a safe state if any condition is breached (Figure 3). The most common are:
FIGURE 3: There are many common types of safety-rated devices, such as interlocking safety switches and safety light curtains, which are essential for designing safe systems. Newer technologies will continue to enter the market for this purpose, so designers should remain open to innovations supporting a “design for safety” approach. Courtesy: AutomationDirect
• Safety switches, edges and bumpers, which detect if hardware is moved to open the cell or if an operator is approaching the protected area
• Interlock safety switches and trapped key interlock switches holds hardware closed if the cell is not safe and releases hardware if the cell is safe
• Emergency stop buttons and cablepull safety switches, which allow operators to trigger the emergency stop circuit
• Safety light curtains and safety laser scanners allow safety automation systems to detect if people are moving into a cell through an open space
• Two-hand controls and safety enabling switches helps ensure operators are in a safe location before a cell is energized
• Safety relays and safety controllers are used in conjunction with sensors and other devices to disable power to a cell or equipment, putting it into a safe state when necessary.
Absence of voltage tester
An example of recent innovation in the electrical safety arena is recognition in the 2018 edition of NFPA 70E of a new technology option for verifying the absence of voltage within electrical equipment. Electrical equipment is often provided
with a disconnecting means. To verify the equipment is de-energized, the user must wear proper PPE while performing a live-dead-live test. This means using a voltmeter to first test a known live circuit (verifying the meter is functioning correctly), then using it to check the circuit to be worked on is dead and retesting once more on the known live circuit (verifying the meter is still functioning).
Absence of voltage testers is a new category that has been developed and incorporated into the NFPA 70E. Some versions of this device are available with SIL3 safety-rated contacts, much like a safety controller or relay, so they can be integrated with other controllers and devices. This approach provides an automated method to enable an enclosure to be unlocked when an absence of voltage is confirmed. Devices and technologies like AVTs are making it easier to automate safety, while improving the efficiency and performance of safety systems.
Design for safety
Many daily experiences have been changed over the last few years through the application of technology to mitigate risk and automate repetitive tasks. For example, backup automobile cameras used to be an expensive and rare technology, but now they are common and are an additional tool along with rear-view mirrors to improve rearward visibility. Intelligent robotics — some able to work collaboratively side-by-side with humans — are able to perform repetitive or hazardous manufacturing or assembly tasks where in the past human workers may have experienced monotony leading to carelessness and injury.
Similarly, designers and end users should also be open and innovative with respect to opportunities for automating lockout/tagout and other tasks that have been manual- or procedural-based for decades.
Adding safety features and leveraging technology up front — following a “design for safety” approach — not only mitigates the exposure of workers to hazards, but in many cases increases efficiency and throughput. PE
Marty Kronz is a product engineer for AutomationDirect.
The Importance of a Proper Lubrication Program
David Reh | Director of field engineering and training services, Lubriplate Lubricants Company
Proper lubrication is essential to maintaining the bottom line, but starting a lubrication plan can seem to be an overwhelming proposition. Not having an effective program can result in hundreds of hours of downtime and lost production. Where does one begin faced with such a daunting task? This article will discuss methods to implement a comprehensive lubrication program, or how to possibly improve one already in place.
The first thing that should be done is to define the program’s goals and objectives. Many plants want to consolidate inventory, reduce costs, and to ensure that the correct products are being used in the right places, especially in regard to any applicable legislation or food grade lubrication requirements. A qualified lubrication expert can assist with each of these goals, and advise you on what may or may not be a practical plan based on their experience.
Even a seemingly small accomplishment can be crucial. Some examples might include consolidating multiple gear oils into a single one, inventory reduction, or identifying an opportunity to save money through the advantages of using a superior lubricant. A few successes like these along the way help to keep the ball rolling.
Implementing a color coding plan, tagging equipment, and employee training are also smaller sized goals that can be accomplished fairly quickly with a moderate effort and reap much larger benefits in the long term. Another example of this is oil analysis. Oil analysis can be a good place to start, because it can be started on critical equipment without a lot of effort, and carries with it a potentially large return on the initial investment.
With each small part of the project that is completed, employees become more invested in the continuance of the program as it builds towards the conclusion a comprehensive lubrication program that saves money in the long run.
Lubriplate provides it’s customers with a complete extra services package. These services include a technical support hotline and e-mail, complete plant surveys, customized, color coded lubricant tags, lubrication maintenance software, plant user training and no charge oil, fluid and grease analysis. For more on this subject and customer assistance call 1-800-733-4755 or e-mail LubeXpert@lubriplate.com
ENGINEERING SOLUTIONS
MECHANICAL PUMPS
Eugene Vogel, EASA
Vertical turbine pump tips and tricks
Vertical turbine pumps (VTPs) are ubiquitous and used in many different applications constantly, which makes them more vulnerable to damage because of constant wear
Vertical turbine pumps (VTPs) are ubiquitous and are often used as sump pumps for lifting water or other pumpage out of reservoir. When fitted into an enclosing “can,” they become an inline pump with a suction nozzle, benefitting from a long vertical shaft that can accommodate multiple impellers. Given their simple design, VTPs are not technically demanding to repair, but a few tips and tricks can always make the task a little easier.
VTP applications and features
VTPs cover many applications including service water intake for power plants or manufacturing facilities, flood control, irrigation, sewage lift stations, building sumps and general manufacturing.
They also may employ various application-specific features.
• The simplest configuration is an open line shaft exposed to the pumpage in the column. The line shaft also can be enclosed in a tube to provide better lubrication (either oil or clean water) for line shaft bearings.
• The pump and associated driver mount on an elbow that turns the discharge flow from vertical (up the column) to horizontal.
The horizontal discharge from the elbow can be above or below grade.
• Many VTPs use a packing gland while some have mechanical seals.
• VTPs often have mixed-flow impellers; single axial-flow impellers are not uncommon.
• As mentioned above, VTPs may have an open sump suction, or they may be enclosed in a can, providing a suction nozzle.
Most VTP applications can also be handled by submersible pumps, which are somewhat more reliable and much easier to install and remove. But VTPs cost less than submersibles, offer more flexibility in hydraulic design with multi-stage configurations, and use a standard vertical motor that is not submerged, accommodating medium-voltage implementations.
FIGURE 1: Measure the shaft position before disassembling the pump. Courtesy: EASA
FIGURE 2: An annular key mounted impeller. Courtesy: EASA
Types of damage
VTPs are rugged machines that tolerate harsh environments. Because the bowl assembly is hidden “down-hole,” they often run to failure and arrive for repair in very bad condition. Seized bearings, broken shafts, and severe corrosion damage are not unusual. However, VTPs are not mechanically sophisticated so even severely damaged units can often be repaired.
Typical VTP repair issues include damaged line shafts, pump shafts and associated bearings due to lubrication by pumpage containing abrasive, wearaccelerating contaminates. Suction bells, column sections and shaft-enclosing tubes are also subject to corrosion damage from pumpage, which may even penetrate the rabbet joints between bowl sections. Impeller damage may result from corrosion, erosion, cavitation, and encounters with large debris sucked into the pump.
As with all industrial pumps, VTPs may be pumping hazardous, toxic, or flammable liquids. Service technicians should wear appropriate
personal protective equipment (PPE) until they disassemble and decontaminate all pump components
Disassembly and repair tips and tricks
Shaft position. Measure the shaft position bottom and top before disassembling the pump (Figure 1) and then replicate those dimensions during reassembly. If the pump is laying horizontal, be sure to push the shaft to the full bottom position with the impeller bottom setting on the bowl. Many impellers mount with tapered collets that must be in the correct location on the shaft. Otherwise, the shaft extension dimension will not fit the coupling and driver.
Top-down or bottom-up? Some VTPs secure impellers to the shaft with annular keys that fit into annular keyways in the shaft. The keys will be bolted to the top of the impellers, so disassembly must be from the top-down to access the annular key bolts (Figure 2).
But most VTPs secure impellers to the shaft by driving tapered collets into them from the top with a collet driver. To disassemble these pumps, drive the collets up out of the impeller from the bottom with the same collet driver. Therefore, disassembly will be from the bottom-up. While it is possible to disassemble these pumps from the top-down by driving the impeller down off the collets, many service centers find this more difficult.
Tip: When assembling impellers with tapered collets, drive the collets on very tight. Some service centers warm impellers to expand them for mounting, ensuring an extra tight fit once they cool off and contract.
Threaded couplings. Line shafts are often connected with simple threaded couplings, shafts butted against each other, and these can be difficult to
‘ A trick for loosening these couplings is to hold a large sledge or anvil against one side while striking the other with a hammer.’
FIGURE 4: Loosening a frozen threaded coupling. Courtesy: EASA
FIGURE 3: A tapered collet mounted impeller with collet driver. Courtesy: EASA
FIGURE 6: This shaft-enclosing tube had to be cut in pieces due to severely corroded threads. Courtesy: EASA
FIGURE 5: Examples of special couplings. Courtesy: EASA
ENGINEERING SOLUTIONS
8: Statistical analysis of VTP manufacturer bearing clearances. Courtesy: EASA
Courtesy: EASA
unthread. A trick for loosening these couplings is to hold a large sledge or anvil against one side while striking the other with a hammer (Figure 4). Check the impeller to determine if the threads are righthanded or left-handed. Applying heat may also help loosen a frozen coupling but cutting it off with a torch may be more economical. Most replacement threaded couplings are commodity items from vendors.
Caution: A few coupling designs are more sophisticated than simple threaded couplings (Figure 5). These are expensive, so don’t cut them with a torch.
Frozen/corroded bolts. There can be a lot of bolts securing column sections and bowl sections together. Sometimes these bolts come out with reasonable force; sometimes they don’t. When these bolts are corroded or frozen in place, many service centers find it easiest to cut the heads off with a torch. The heat from cutting will loosen the remaining stud for removal with a stud tool.
Threaded shaft-enclosing tube and column sections. When these sections are threaded together, they can be hard to loosen if corroded or frozen. These sections of pipe are not difficult to replace, so cutting them with a torch may be an easier “disassembly” method (Figure 6). Vendors have common pipe sizes that require cutting threads on each end.
Line shafts and pump shafts. Line shafts and pump shafts are often smooth and only threaded on each end, so replacement is often more economical than repair. When replacing shafts, specify pump shaft quality (PSQ) of the correct alloy for the application. PSQ shafting is normalized to remove all stresses, and ground and polished to precision dimensions.
9: Linear regression analysis model “guestimates” for VTP bearing clearances. Courtesy: EASA
Static components. Many static VTP components with corrosion damage can be repaired by welding, coating or a combination of the two. For example, metal repair epoxy compounds can be troweled in place to cover and repair corrosion damage. Corroded or damaged rabbet fits between bowl sections and column sections must be machined true to ensure proper bearing alignment. When the radii are corroded or damaged, it may be necessary to machine off the male fit and install a ring to repair the damage (Figure 7). The perpendicularity can be corrected by facing off rabbets.
Caution: If impellers mount with annular keys, the keyways on the new shaft must be adjusted to fit refaced bowl sections.
Tip: Replacement couplings, bearings, column sections and various other VTP components may be available from vendors specializing in VTP parts. Search “Vertical turbine pump parts” for possible listings.
FIGURE 7: A ring was machined to replace this damaged male rabbet.
FIGURE
FIGURE
Shaft-to-bearing clearance: A common question about replacing line shaft and bowl bearings is, “What is the proper clearance between the shaft and bearing bore?” For horizontal machines, there are various “rules of thumb” for calculating bearing clearance, typically using a set amount plus an adder for each inch of shaft diameter (e.g., 0.003” + 0.002”/in of shaft diameter).
However, vertical bearings have no steady radial load against which to develop a hydraulic lifting force. In fact, review of some VTP manufacturers’ data indicates a wide range of values that don’t track directly by shaft size. The best available guidance is statistical analysis of data providing clearance “guestimates” based on linear regression analysis models (Figures 8 and 9).
Factors that affect whether a particular pump should have closer or looser bearing clearances include how straight the line shaft is, how true on center the bearings are bored (considering variation from column joint runouts), the rotating speed, and the type of pumpage. Higher speeds,
‘ Factors that affect whether a particular pump should have closer or looser bearing clearances include how straight the line shaft is, how true on center the bearings are bored, the rotating speed, and the type of pumpage. ’
truer bearing bores and straighter shafts argue for closer clearances, and conversely for looser clearances. When considering these factors, the statistical analysis results can still be helpful.
VTPs are often more economical to repair than replace. These tips and tricks provide only a glimpse at the typical repair process. Quality repair requires service centers have the necessary machine tools, technical resources, and training to address the severe damage often found on failed VTPs. PE
The Electrical Apparatus Service Association (EASA) is a CFE Media and Technology content partner.
The voice of the engineering community speaks loud and clear in the following pages featuring the corporate profiles for companies participating in the 2023 Executive Voice program.
We offer our sincere thanks to these advertisers:
ABB Motors and Mechanical Case iZ
Digi-Key Electronics Flexicon Flowserve Corporation RS SEW Eurodrive, Inc. Spiroflow
As we enter 2023, the world’s industries stand at an energy crossroads. The climate change urgency demands action from all parties, and energy shortages have led to inflationary pressures and new energy security challenges.
Improving energy efficiency is an under-exploited opportunity to reduce both costs and emissions. While there has been a lot of discussion about how individuals can contribute to saving energy, the significant potential for energy efficiency and cost improvements in industry has received less attention.
Industry accounts for 42% of global electricity demand, and iron, steel, chemical and petrochemical industries are the largest consumers of energy among the world’s top-five energyconsuming countries (China, United States, India, Russia, and Japan). This energy consumption carries even higher costs in the current inflationary environment, so the importance of energy efficiency in this context cannot be overstated.
As a result, ABB and other members of the Energy Efficiency Movement created a playbook for industrial leaders to help them find ways to address energy efficiency and reduce energy costs and carbon emissions. It details 10 actions they can take right now beyond basic measures like switching equipment off when not in use, converting fluorescent or halogen lighting to LED, or insulating walls and piping.
The 10 actions in The Industrial Energy Efficiency Playbook have three traits in common:
1. They rely on mature, secure, and widely available technologies 2. They are material enough to have a meaningful impact on both energy costs and emissions
3. They can be deployed quickly, without complex or expensive integrations or capital investments
This list is by no means exhaustive. It should be viewed as a collection of short and medium-term opportunities for industry, as well as an invitation to discuss and document solutions and best practices.
I invite you to visit join.energyefficiencymovement.com today to download your own copy of The Industrial Energy Efficiency Playbook , and join the Energy Efficiency Movement to demonstrate your commitment to a more sustainable world. I also invite you to engage with #energyefficiencymovement on social media to share your energy challenges and discuss ideas and lessons learned.
Tel: 479-646-4711 New.abb.com
Scan the QR code to download the Playbook.
Jesse Henson President of ABB NEMA Motors division
Case Controls and iZ Systems are world leaders in industrial compressed air, vacuum, and cooling water automation and controls technology. They also provide plant demand and supply side auditing, system design, and energy management solutions. They have recently announced the merger of the two companies. The new company, Case iZ, combines the individual strengths of each company’s more than 30 years of experience in reducing energy consumption and improving production efficiencies and product quality, by stabilizing and controlling pressure and flow in plant utility systems. The extensive experience has enabled the Case iZ Team to develop solutions that provide maximum benefit for their industrial clients.
Case iZ combines the individual strengths of each company’s more than 30 years of experience in reducing energy consumption and improving production efficiencies and product quality.
Case iZ engineers design, build, and program state of the art automation and control solutions on the Rockwell Automation Allen-Bradley platforms. Our methods and capabilities of managing and controlling all sizes, makes, and types of compressors, air treatment, vacuum pumps, and cooling water systems, allows Case iZ to provide our clients comprehensive, turn-key, guaranteed return on investment projects. This enables the team to provide a complete solution for the plant, starting with system design through a competent operating plant.
The Case iZ solution utilizes IIOT technology for data collection and analysis, monitoring and displaying real time system parameters and energy status. An on-line dashboard, along with data and trending screens, provide plant operators live information to better manage their overall plant systems. System alerts can be set up to provide notification when parameters are outside of target values.
We stand ready to help solve your problems related to the compressed air and water utilities. That can be a local controller built on Allen Bradley hardware and plant wide automation system or complete analysis of supply side and demand side applications.
Please contact Case iZ for a free initial assessment of your plant’s potential for energy reduction and production improvement opportunities.
Case iZ headquarters in Evansville, IN
Global electronics distributor
Digi-Key Electronics offers more than 13.4 million electronic components and automation products from over 2,300 quality name-brand manufacturers. The company’s reputation extends worldwide as the provider of the widest selection of electronic components in the industry, ready for immediate shipment. With products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike.
use of digital tools, industry leading supplier partnerships, and a breadth of product that is unrivalled by any other, Digi-Key paves the way as a one-stop shop to serve customers in a unique automation landscape.
Digi-Key is the preferred supplier for industrial automation, control and safety products, carrying a broad portfolio including advanced controls like PLCs, HMIs, motion, safety and robotics.
Digi-Key is a $5 billion company and employs more than 5,200 people, delivering over 27,000 packages per day to customers in 180 countries around the world.
The key differentiators of service that made Digi-Key who they are today, have laid the foundation for what Digi-Key brings to the world of automation tomorrow. Through the
Digi-Key provides detailed technical resources and robust search functionality to help you find the exact parts you need, including a range of EDA and design tools, reference design library and free online schematics tools, on-demand multimedia library, comprehensive article library and community forums, and much more.
Digi-Key’s Marketplace gives customers access to even more products and services, benefiting applications such as industrial automation, test and measurement, IoT solutions, and virtually all things related to technology innovation.
In 2022, Digi-Key opened its new, 2.2 million square foot Product Distribution Center expansion to meet and exceed customers’ expectations more efficiently.
Dave Doherty President, Digi-Key Electronics
Digi-Key provides numerous Supply Chain solutions, including eProcurement options, bonded inventory and just-in-time shipping. The website is updated regularly with new features in response to customer feedback and industry needs.
Digi-Key has also invested in innovations including cut tape printing, providing more products and services within the ecosystem and expanding the Digi-Key Marketplace.
Digi-Key provides the best possible service to customers, 24/7/365 by phone, email or chat. From prototype to production, Digi-Key has the resources and products to enable the world’s ideas!
1-800-344-4539
sales@digikey.com
www.digikey.com/automation
“ With products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike. ”
Digi-Key’s Product Distribution Center Expansion (PDCe) opened in 2022
Fl lexicon Corporation engineers and manufactures bulk handling equipment from stand-alone units to automated systems that are integrated with new or existing process equipment and storage vessels throughout the plant.
Virtually any bulk solid material or blend
Flexicon equipment can handle virtually any bulk material, from large pellets to sub-micron powders including friable materials, free- and non-free-flowing products, and materials that pack, cake, plug, smear, fluidize or separate. After more than 25,000 installations, Flexicon is knowledgeable about virtually all bulk materials and blends that customers are likely to encounter.
Lifetime Performance Guarantee
The Flexicon Lifetime Performance Guarantee assures customers of a successful result, regardless of whether they purchase one piece of equipment or an automated plant-wide system, providing added assurance that customers can trust their process, and their reputation, to Flexicon.
Designed and constructed to industry standards worldwide
All Flexicon equipment is available in carbon steel with a variety of durable industrial finishes, and stainless steel in industrial and food, dairy and pharmaceutical finishes, including designed and constructed for 3-A certification and USDA acceptance.
Stand-alone
equipment
The Flexicon line of stand-alone equipment includes: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers and Weigh Batching and Blending Systems. Numerous model configurations are offered within each equipment category, as basic, low cost units up to engineered, automated, highcapacity machines.
Large-scale bulk handling projects
Customers can alleviate the burden and risk of designing large-scale bulk handling systems, coordinating multiple suppliers, integrating components and trouble-shooting start-up, by relying on Flexicon’s Project Engineering Division for it all.
Flexicon can evaluate customer material(s), plant layout, throughput rates, cost, cycle times and other parameters, and engineer the optimum solution to individual bulk handling problems in the form of CAD drawings that integrate Flexicon and other equipment with new or existing equipment in the customer’s plant.
In addition, Flexicon can test customer materials on full-size test equipment, build the equipment, supervise installation, validate the project, and train customer personnel to operate it— anywhere in the world.
Manufacturing on four continents
David Gill President
Flexicon manufactures equipment in the US, UK, Australia and South Africa, maintains dedicated factory representation in Spain, France, Germany, Singapore, Indonesia, and Malaysia, and also markets equipment and systems through an extensive network of Applications Engineers worldwide.
The company holds 36 patents in 13 countries.
Imagine a global, end-to-end partner for industry, dedicated to solving problems with innovation and expertise so customers can drive their business forward. Imagine that. RS can.
As an omnichannel solutions provider for designers, builders, and maintainers of industrial equipment and operations, RS (formerly Allied Electronics & Automation) aims to make amazing happen for a better world with an unrivaled choice of ground-breaking product and business solutions that keep core industrial companies up, running, and growing in the industrial automation, electronic, and electromechanical spaces.
company, RS Group, and make doing business with customers even more rewarding. They are on a journey to provide access to even more solutions, support, and expertise, with one goal: working together as an end-to-end partner for engineers, OEMs, and MROs in the Americas.
RS supports customers across the entire product life cycle, whether through innovation, engineering expertise, and technical support in the design phase, improving time to market and productivity in the build phase, or reducing purchasing costs in the maintenance phase. With tailored solutions that are essential for the successful operation of their businesses, customers rely on RS to deliver knowledge and help them save time and money along the way.
On February 6, 2023, Allied Electronics & Automation — a 95-year-old company with a rich history as a radio parts business turned industrial distribution giant — transitioned its brand to RS to increase partnerships with other companies under their parent
With more than 3.5 million products from more than 650 trusted suppliers in the Americas, RS carries more automation and control brand names than any other distributor in North America. It also offers a comprehensive suite of services and tools including the industry’s largest collection of 360° product images, an extensive range of 3D CAD models, more than 1.1 million up-to-date datasheets, and a highly experienced technical support team. In addition, RS publishes a series
“ [RS is] on a journey to provide access to even more solutions, support, and expertise, with one goal: working together as an end-to-end partner for engineers, OEMs, and MROs.”
of Expert Advice articles, interviews, and podcasts crafted to place critical industry knowledge and expertise at its customers’ fingertips and help them identify product and technology solutions as unique as their businesses.
As an employer, RS is committed to ensuring its organization is authentically and sustainably diverse to seek and embrace the very best talent. RS believes people are the center of its business and are vital to keeping the global organization moving forward. When it comes to company culture, the organization continuously strives to improve diversity, inclusivity, accessibility, and representation so that employees are empowered to bring their true self to work every day.
Tel: +1 (866) 433-5722 us.rs-online.com
Douglas Moody
RS President, Americas and Chief Services Officer, RS Group
As a world leader in drive technology and a pioneer in drive-based automation, SEW-EURODRIVE has established a reputation for quickly solving the most difficult power transmission and motion control challenges. Since introducing the combined gearmotor in 1931, we have been bringing the best in drive technology to our customers worldwide.
SEW-EURODRIVE brings the best in drive and automation technology to our customers worldwide.
More than just gearmotors
SEW-EURODRIVE offers much more than just components. We offer the expertise and expanded line of control components and software to drive them. Our team of automation experts understand the latest technology and can solve even the most complex motion control challenges.
Being a single-source automation partner radically sets us apart from others. Our team of automation engineers provides the expertise, project planning, software, commissioning, and worldwide support for your most challenging motion control projects. They can serve as a valuable extension of your engineering team, reducing the stress and demanding workload. Our experts provide a solution of perfectly matched SEW components that have been designed to work together seamlessly.
PRODUCT INNOVATION
MOVI-C Automation Platform
In addition to engineering excellence, SEW-EURODRIVE is also known for innovative new products. Our MOVI-C® modular automation system is a flexible one-software, one-hardware automation platform that combines fully integrated drive components, control electronics and automation software – all from a single source. The key to the MOVI-C platform is that each of those components is designed to work together perfectly.
The MOVI-C platform utilizes the latest automation technologies –from AC motors and gear units to ultra-efficient permanent magnet servomotors, control electronics, and software. Machine builders will appreciate the seamless integration and prebuilt software modules tailored to the customer’s application.
MOVIGEAR® for decentralized drive installations
MOVIGEAR is the all-in-one mechatronic drive system that combines the gear unit, IE4 motor, and electronics in one compact unit. Recent updates include fully integrated Ethernet/IP communications and digital motor integration. Advanced single-cable technology carries power, feedback information, and control signals along a single hybrid cable between decentralized devices.
FLEXIBILITY
Our products are based on a unique system of modular components that can be assembled in literally millions of different configurations. So, every drive solution is custom built to our customer’s exact specifications. Our five regional assembly centers in the U.S. stock millions of dollars of our modular inventory for quick delivery of drive solutions and spare parts.
864-439-7537 www.seweurodrive.com
Spiroflow is a global leader in mechanical dry solids conveying, bulk bag loading and unloading equipment, and control systems engineering. We lead the industry in safety, dust containment, sanitation, ergonomics, design and speed and are excited to now be part of the Automated Handling Solutions group along with our partner Cablevey Conveyors.
As an engineered solutions provider, and equipment manufacturer, we offer the industry’s most expansive line of mechanical process conveying solutions and bulk bag-handling equipment to convey bulk materials, both powder and granular, within your production process.
Spiroflow is very excited to now include the full range of Cablevey tubular drag conveyors in its product portfolio. The totally-enclosed Cablevey tubular cable drag conveyors offer a variety of clean-in-place options. This collaboration allows Spiroflow to offer best in class wet and dry hygienic cleaning features for fast and effective cleaning without having to disassemble the conveyors.
Because we offer such a wide range of conveying methods, our engineers will evaluate your needs objectively, so you receive the ideal conveyor for your application.
We are also known for our expansive line of Spirofil® bulk bag fillers, bulk bag dischargers, bulk bag conditioners, custom designed hoppers, bin activators, and bin, bag, box and drum dischargers, as well as best in class control systems including end-of- line robotic palletizing solutions.
We offer the widest range of mechanical conveyors for dry bulk solids and ingredients with our Flexible Screw Conveyor, Aeroflow® aero mechanical conveyor and complete portfolio of Tubular Drag Conveyors, now including the industry leading Cablevey® cable drag conveyor.
Spiroflow Automation Solutions Inc. excels as an end-to-end Control Systems Integrator with expertise in food processing, paint and coatings, ammonia detection, motion control and themed entertainment.
As a full-service industrial control, networking, and automation provider, our people help make your
manufacturing process work smarter and more efficiently to get the most out of the control systems we provide.
Keeping customer service at the forefront of our brand, Spiroflow is committed to providing our customers the right solution, not just any solution, for your bulk material handling and automation needs.
What you run through our equipment is your business — how you keep it running is ours!
Learn more about our fully equipped material test lab by scanning the QR code.
sales@spiroflow.com • 704-215-4624 spiroflow.com
Spiroflow’s corporate headquarters in Monroe, NC
Andy Forrester
Vice President of Sales, Americas
GET ON THE BEAT
BOILER TECH SUPPORT
Topog-E® Gasket Company, formulates and mixes its own rubber manufactures superior moldedrubber handhole and manhole gaskets for steam, hot water boilers, water heaters, softeners, deaerators, make-up tanks, and other selected pressure vessels.
Topog-E® Gaskets have become an industry standard since 1956. Topog-E® Gaskets seal quickly, completely, preventing seepage, corrosion and pitting. They peel off easily leaving clean surfaces for inspection.
Topog-E® Gasket Company offers a FREE Technical Specification and Usage Guide containing useful information about boiler maintenance safety.
For more information contact:
Topog-E Gasket Company 1224 North Utica Fax: 918-587-6961 Tulsa, OK 74110 www.topog-e.com Tel: 800-587-7123 info@topog-e.com
Also, FREE a pocket slide rule that charts steam temperature versus pressure.
Advertisers' Index
ABB Motors US .C-4 .https://baldor .abb .com/ec-titanium
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Publisher/Midwest
Matt Waddell MWaddell@CFEMedia.com
3010 Highland Parkway, Suite #325 312-961-6840
Downers Grove, IL 60515
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West, TX, OK
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Northeast
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Publication Services
Jim Langhenry, Co-Founder and Publisher, CFE Media JLanghenry@CFEMedia.com
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Reduce your power consumption with industry leading rotor technology
Tomorrow’s efficiency
Upgrade to ABB’s Baldor-Reliance® ultra-premium EC Titanium™ integrated motor drive, and lower your overall energy cost. These motors are specifically designed for VFD operation that help optimize overall performance at reduced speeds and loads, ideal for fans, pumps, and compressors.
•More than 10% efficiency gains compared to NEMA premium
