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Level Switches
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Endress+Hauser Soliphant® FTM20 vibration rod point level switches detect fine- or coarse-grained, non-fluidized bulk solids in silos, hoppers, and bins. They can even detect solids underwater, such as sediment buildup in a tank.
• 8.86in. insertion length
• PNP N.O./N.C. selectable or DPDT relay outputs
• 1-1/4in. or 1-1/2in. male NPT process connections
• Select models offer CSA general purpose or FM hazardous location ratings
• IP66/67, NEMA 4X protection rating
Temperature Sensors
Starting at $23.00 (THMJ-B02L06-01)
Temperature sensors provide accurate and reliable feedback for temperature control and monitoring applications.
• Optris infrared pyrometers
• Temperature switches and transmitters
• Thermocouples, RTDs, and thermowells
• ProSense 10K3 series thermistors
• Digital temperature switches/transmitters
NEW! Tru o®TKM Series Paddle Wheel Flow Meters
Starting at $944.00 (TKM-15-P)
• 4 to 20 mA and pulse outputs
ICON Process Controls Truflo® TKM series paddle wheel liquid flow meters provide reliable, full-pipe liquid flow measurement with exceptional long-term performance. They deliver outstanding value and are constructed with a chemically resistant PVC body, ideal for corrosive liquid applications.
• Sensing ranges up to 357 GPM
• ShearPro® paddle wheel design features 78% less drag than older paddle designs
• ShearPro® through-pin design eliminates finger spread and lost paddles
• 1/2 to 2in. schedule 80 socket process connections
• NEMA 4X and IP66 protection rating
Pressure Sensors
Starting at $79.00 (LPPT25-20-0015H)
Rugged pressure switches and transmitters provide accurate and reliable feedback for pressure control and monitoring applications. Switches provide simple setpointtripped signals, while transmitters can provide gauge, absolute, or differential pressure analog readings. Hygienic models and models for potable water applications are also available.
Newest Addition:
AttaBox Heartland/Heartland
SL Hinged Screw Cover Enclosures
Attabox Heartland enclosures starting at $83.00
The hinged screw cover con guration of the AttaBox Heartland series enclosures provides the highest level of protection against water intrusion with a NEMA 6P rating. These enclosures feature opaque covers and can be padlocked for added security.
• Constructed of polycarbonate with UV inhibitors
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• Variable-depth side-mount capability
AutomationDirect is continually expanding our offering of quality enclosures from the best
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• Fully non-metallic hinge, does not penetrate inside enclosure
SECURE STRAW
DUAL SPRAY NOZZLE WITH PERMANENTLY ATTACHED STRAW
SPRAY LUBRICANTS WITH... THE POWER TO PROTECT!
This tough, tacky, extreme pressure lubricant was developed for the lubrication of open gears, slides, pins and other applications where an adhesive lubricant is needed. It is also excellent for fifth wheel applications.
11 OZ. Spray Can Part No. L0152-063
A super multi-purpose, white lithium-based grease of medium density. Sprays like a fluid, congeals to a grease. Excellent for latches, locks, hinges, tools, battery terminals and other hardware.
11 OZ. Spray Can Part No. L0034-063 FMO-350-AW H1 Food
Grade Spray Oil
A multi-purpose, NSF H1 registered, anti-wear fortified, USP mineral oil-based, food grade machinery lubricant. For use in food and beverage plants where a NSF H1 registered oil is required. ISO viscosity grade 68.
12 OZ. Spray Can Part No. L0882-063
A multi-purpose, NSF H1 registered food machinery grade silicone lubricant for use on bottling, dairy and food processing machinery. For slides, chains, O-rings, rubber seals and general lubrication.
9.5 OZ. Spray Can Part No. L0723-063
ERGONOMIC DESIGN
COMFORT TRIGGER RECESSED TO HELP PREVENT ACCIDENTAL DISCHARGE
DUAL POSITION SPRAY STRAW IN UP POSITION FOR PRECISION PIN-POINT APPLICATIONS
GHS COMPLIANT LABELING ON BACK PANEL INSURES COMPLIANCE WITH OSHA REQUIREMENTS
SCANABLE QR CODE ON SIDE PANEL FOR QUICK ACCESS TO PRODUCT INFORMATION AND SDS SAFETY DATA SHEETS
Chain & Cable Fluid - Penetrating Oil
A superior, cleansing, non-gumming penetrating oil. For wire rope, chains, cables and general lubrication. Prevents rust and corrosion.
11 OZ. Spray Can / Part No. L0135-063
A specially developed product designed for metalworking operations. Excellent for drilling, tapping, cutting and grinding.
11 OZ. Spray Can Part No. L0185-063
A NSF H1 registered, food grade lubricant in handy, easy to use spray can. Contains LUBRI-ARMOUR Anti-Microbial Additive. Fortified with anti-wear, anti-rust and anti-corrosion additives. NLGI #1
11 OZ. Spray Can Part No. L0231-063
Penetrating Oil
An eco-friendly, bio-based, biodegradable (Pw1), lubricating oil for general lubrication. Provides a long lasting protective film that prevents friction, wear, rust and corrosion.
11 OZ. Spray Can Part No. L0721-063
Ultra 22 Food Grade Penetrating Oil
11 OZ. Spray Can Part No. L0931-063 Biodegradable
A NSF H1 registered, multi-purpose, synthetic, chain and penetrating fluid. For use on food processing and bottling machinery. For chains, slides, tools and general lubrication. ISO viscosity grade 22.
Gear Shield Extra Heavy
FGL-1 H1 Food Grade Spray Grease
Metal Working Fluid
Spray Lube ‘A’ - White Lithium Grease
EVs
and power systems for industrial plants | 14
VIEWPOINT
5 | Want to play the whack-a-mole tariff challenge?
The results of this study show manufacturing plants are directly affected by tariffs.
INSIGHTS SOLUTIONS
8 | These experts reveal all you need to know about asset management
This panel of experts delves into how to develop a successful asset management strategy.
14 | Here are five EV fleet charging priorities for industrial plants
Emphasize power system flexibility to safely meet the incremental energy demands of electrified industrial fleets.
18 | How choosing the best grease can reduce mechanical failures
Choosing the right grease and proper application are essential for implementing a sound lubrication strategy and preventing costly mechanical failures.
22 | How air can adversely affect lubricants, and how to avoid it
Taking seriously the potential performance, fluid life and machine longevity-related issues caused by air is an essential step in a modern plant maintenance plan.
26 | Six ways to boost compressor performance with oil sampling
Users of oil-flooded rotary screw air compressors can unlock significant benefits by implementing the recommendations in their manufacturerrequired oil sampling.
30 | How to integrate NFPA 70B with OSHA requirements
The transition of NFPA 70B from a recommended practice to a standard is changing how organizations approach electrical safety.
36 | Use VFDs with integrated PLCs for safe and reliable pumping systems
VFDs with built-in PLCs offer an efficient and effective method to create processes for pumping systems.
O N T HE COVER:
Integrating onsite
energy sources provides
Experience Centers in
(pictured) and Houston provide hands-on training environments where electrical and power experts can interact with real-world fleet EV charging applications and industrial power systems. Image credit: Eaton.
The Power to Perform with the Reliability to Trust
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CONTENT
CONTENT SPECIALISTS/EDITORIAL
AMARA ROZGUS, Editor-in-Chief ARozgus@WTWHMedia.com
SHERI KASPRZAK , Managing Editor SKasprzak@WTWHMedia.com
MICHAEL SMITH, Art Director MSmith@WTWHMedia.com
AMANDA PELLICCIONE, Marketing Research Manager A Pelliccione@WTWHMedia.com
SUSIE BAK, Staff Accountant SBak@WTWHMedia .com
EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS , PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: www.plantengineering.com/contribute-to-plant-engineering
• Asset management for energy efficiency
• Compressed air systems
• Expert Q&A: VFDs and VSDs
• Lubrication
• Maintenance and energy management tools
• Managing mechanical and electrical systems
• Preventive maintenance
• Robots to improve efficiency
• Rotating machine lubrication
WTWH Media Contributor Guidelines Overview
Content For Engineers. WTWH Media focuses on 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.
The link below 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: www.plantengineering.com/contribute-toplant-engineering
Want to play the whack-a-mole tariff challenge?
The results of this study show manufacturing plants are directly affected by tariffs.
Manufacturing professionals are constantly reacting to the unpredictable challenges presented by tariffs and trade policy shifts. Carnivals and amusement parks include a game that is a lot like the current administration’s tariffs — a game called whacka-mole. Like tariffs, one mole or problem is addressed (or whacked) and another one or two arise in its place. Fun to play but not easy to win.
(55%) and the necessary step of seeking alternative suppliers (38%). While some have diversified globally outside of countries like China (13%), a large portion (46%) report no major change in their sourcing strategy.
Amara Rozgus, Editor-in-Chief
The recent Plant Engineering Impact of Tariffs on U.S. Manufacturing study on the impact of tariffs offers valuable insights for U.S. manufacturing professionals grappling with today's complex global economy. While tariffs are intended to shape trade, the reality on the ground for plant managers is often increased costs and supply chain uncertainty, highlighting the deeply interconnected nature of modern manufacturing.
The report indicates that a significant majority, two-thirds of U.S. plant engineering professionals, have been impacted by tariffs or import duties in the past year. This has translated directly into the bottom line, with 60% reporting moderate to significant increases in overall costs. Products like electrical components, semiconductors and raw metals are cited as most affected.
Manufacturers have responded in various ways, including the difficult decision to pass costs to customers
Despite the stated desire for domestic reliability, actual reshoring or onshoring has been limited, reported by only 6% in this study. The challenges to bringing production back home are substantial and practical: higher labor or production costs (54%) and limited availability of domestic suppliers (53%) are primary obstacles. This underscores that while the idea of domestic production is appealing, overcoming global cost differentials and rebuilding extensive domestic supply ecosystems is a complex, long-term undertaking.
The survey reflects a nuanced view of current U.S. tariff policies, with 54% of manufacturing professionals viewing them negatively compared to just 19% positively. This sentiment likely stems from the whack-a-mole similarity to the tariff landscape, which many feel makes business decisions difficult.
Ultimately, successfully managing the impact of tariffs requires adaptability, clear communication across the supply chain and a pragmatic approach to sourcing that considers both domestic potential and global realities. Avoiding playing whacka-mole is high on everyone’s list. PE
Are
you ready
SECURE YOUR DOMESTIC NOW!
These experts reveal all you need to know about asset management
This panel of experts delves into how to develop a successful asset management strategy.
Question: What’s the current trend in asset management for industrial and manufacturing facilities?
Christine Nishimoto: Facilities are moving away from reactive asset management and toward predictive asset management. In practice, this entails combining artificial intelligence (AI)-powered tools with an asset life cycle management (ALM) approach. It’s a trend with major benefits. Smarter ALM translates
into time-saving automation, lower maintenance costs, increased sustainability and more.
Heath Stephens: The current trend has been to better optimize our limited maintenance resources and budgets. This means doing maintenance only when needed and ensuring maintenance is effective when performed. Over-maintaining assets means production lines are down unnecessarily; labor and expenses are wasted on nonproductive tasks and other assets go neglected. It also introduces the possibility of breaking a previously healthy asset in the process of servicing it. AI/ machine learning (ML) solutions provide another tool to improve reliability and reduce maintenance costs.
Objectives Learningu
• Discover the current trends in asset management for industrial and manufacturing facilities.
• Learn how artificial intelligence and machine learning (AI/ML) are changing the ways in which organizations approach asset management.
•Understand how enterprise resource planning (ERP) systems enhance data to better execute asset management strategies.
FIGURE 1 : AspenTech's Aspen Mtell Builder provides in-depth reliability and performance indicators so operators can determine asset health and make maintenance decisions. Courtesy: AspenTech
Doug Cooper Director, Product Management
Aspen
Technology Houston
Stacey
Jones Global Portfolio Leader, Asset Performance Management ABB, Houston
Question: What future trends should engineers, plant managers and designers expect for asset management in the next year or two?
Stacey Jones: Embracing industrial digital transformation is critical. This includes integrating AI/ ML and internet of things (IoT) technologies to enhance predictive and preventive maintenance. Real-time data analytics will play a significant role in optimizing asset performance and reducing downtime.
There’s also a growing emphasis on sustainability and environmental, social and governance (ESG) strategies. Companies are increasingly aligning their asset-management practices with ESG goals to improve efficiency and reduce environmental impact
Doug Cooper: Over the next one to two years, engineers, plant managers and designers should expect the integration of asset management systems with operational systems to increase efficiency. This will be accomplished using AI/ML technologies that will provide greater insight into the health of plant equipment so reliability, maintenance and operations teams can enhance decision making. This increased interaction will improve equipment reliability and availability while meeting production needs that will maximize revenue and decrease costs.
Stephens: AI/ML tools for advanced predictive reliability and asset management are already here and have been for some time, but their cost and complexity barriers continue to fall. Over the next couple of years, I expect more integration of AI on the user interface/configuration side of the applications to make them even easier to deploy and maintain.
Nishimoto: Agentic AI has huge potential for asset life cycle management. I foresee AI agents that can continuously monitor sensor data from physical
Participants
Drew Mackley
Reliability Solutions Director Emerson Knoxville, Tennessee
Heath Stephens
Digitalization Leader
Hargrove Controls & Automation
Mobile, Alabama
assets, detect anomalies and orchestrate the entire maintenance workflow. For example, these agents could predict failures before they occur, automatically schedule maintenance during optimal time windows, coordinate with inventory systems to ensure parts availability, dispatch technicians with the right skills and generate detailed repair instructions. The agent would learn from each maintenance cycle to improve future predictions and optimize the asset's total cost of maintenance. IBM is planning to launch agentic AI for asset management later this year and we expect this technology to become an integral part of asset life cycle management.
Question: How has the integration of artificial intelligence (AI) and machine learning (ML) impacted traditional asset management strategies?
Drew Mackley: AI can mean a lot of different things to a lot of different people. At Emerson, we have many different AI-driven solutions in our portfolio covering a wide array of use cases. For example, AI is built into wireless monitoring solutions to help identify and assess bearing and lubrication health — two common asset fault conditions. Some technologies even have first principles rules built in to guide the AI for a deeper dive into asset and process health. In both cases, the AI can help not only identify the problems but also provide severity, so personnel know how quickly they need to act.
This is where AI shines. There’s a lot of data and it can point to a lot of problems in rotating equipment, but they don’t all have the same severity or the same capacity to impact operations. Balance, misalignment, looseness and more are all common, but in many cases, an asset can run for years with
‘ Over the next one to two years, engineers, plant managers and designers should expect the integration of asset management systems with operational systems to increase efficiency.’
— Doug Cooper
Christine Nishimoto Director of Asset Management Products
Asset Lifecycle Management at IBM Los Angeles
INSIGHTS
‘ AI and ML algorithms analyze vast amounts of data to predict when assets are likely to fail, allowing for timely maintenance and reducing unexpected downtime.’
— Stacey Jones
those conditions. The most challenging solutions require some intelligence to sort out. People can do that, but it takes time to go through all that data and often, those expert personnel need to be doing other things. AI can help lighten that burden, doing much of the data analysis to free personnel up to fix and prevent the problems.
Jones: AI and ML automate many routine tasks, such as data entry and analysis, freeing up human resources to focus on higher-value activities.
AI-powered systems offer real-time monitoring of asset performance, enabling immediate responses to potential issues and optimizing asset utilization
AI and ML algorithms analyze vast amounts of data to predict when assets are likely to fail, allowing for timely maintenance and reducing unexpected downtime.
These technologies provide data-driven insights, helping asset managers make more informed decisions. AI can identify patterns and trends that might be missed by human analysis.
Cooper: The integration of AI/ML has increased and enhanced the insights available to engineers on equipment health. AI/ML allows customers to uti-
lize increased data to move toward a more predictive maintenance culture and get out of a reactive mode of performing maintenance when equipment breaks down. It also provides prescriptive guidance to maintenance personnel on how to remediate the predicted failures on their equipment. This predictive and prescriptive guidance allows maintenance personnel to plan their work in a much more cost-effective manner, saving maintenance dollars and reducing downtime from unexpected equipment failures.
Stephens: Traditional asset management strategies are based on either scheduled maintenance routines or triggered by one or two key indicators. It is often unclear how effective the maintenance activities were. AI/ML analyzes multiple equipment health and process signals to develop a much more sophisticated profile of a properly operating asset. These multivariate asset profiles provide much earlier predictions of asset failures and better verification that maintenance activities were effective. This allows assets owners to better schedule nonroutine maintenance activities and better target which assets to perform routine maintenance.
FIGURE 2: Maintenance should only be conducted when needed to avoid unnecessary downtime and wasted resources. Courtesy: Hargrove Controls & Automation
Nishimoto: AI — from the more traditional machine learning to emerging generative AI capabilities — has been a boon for asset management strategies. AI tools and technologies can at once operate in detail and at scale, providing oversight that no human alone can match.
Question: Describe the successes from using programs and systems that incorporate asset management. This may include IoT-based systems, industry 4.0, etc.
Stephens: It's easy to forget sometimes that the latest technological advances depend on a foundation of other, sometimes older technologies. New AI/ML tools for asset management depend on a well-instrumented system. This may be from traditional wired instrumentation or from newer industrial (IIoT) sensors. Cloud services also bring the power of off-premises computing and external data analysis to better diagnose and predict asset issues.
Question: What types of computer applications are in use to support your asset management functions?
Jones: Applications such as enterprise asset management (EAM) and computerized maintenance management systems (CMMS), historians and distributed control systems all play a crucial role in supporting asset management. When these systems are properly integrated and leverage advanced technologies like AI, ML and generative AI’s large language model, the combined workflow can provide realtime alerts, identify likely root causes and recommend actions. When you couple this with planning and scheduling tools, you can create a comprehensive response to upset events. In the next few years, I think these types of systems will be used to augment human decision making but will become more automated overtime.
Question: When considering your most effective asset management strategies, what are the advantages?
Cooper: The most effective asset management strategies provide a greater understanding of equipment health that will allow decisions to be made on when the equipment needs to have intrusive maintenance performed to prolong the life of the equipment. Understanding equipment health will allow standard preventive maintenance strategies and routines to be optimized. This way, only necessary maintenance is performed and extraneous maintenance activities can be eliminated. This optimization will free up maintenance resources to concentrate on planning for the necessary maintenance activities at the right time to optimize production requirements. This will ultimately result in huge cost savings on maintenance and increased revenue from decreased downtime.
Question: Describe how you use enterprise resource planning (ERP) and other systems to provide better data and information flow throughout the company.
Cooper: ERP can be combined with
asset management software to offer a comprehensive view for managing equipment. By combining the information in ERP systems, operators and maintenance personnel can effectively plan any work that needs to be done on the equipment by understanding spare part levels and upcoming maintenance on equipment. ERP data can also be utilized to identify the bad actors in the equipment by helping to calculate mean time between failure or overall equipment effectiveness. This helps maintenance and reliability personnel focus on the equipment that is causing the most issues at the facility.
Question: What are some of the key challenges for improving asset management at your facility?
Nishimoto: I work with manufacturers around the world to improve their asset management strategies. While no two manufacturers are exactly alike, there are a handful of common challenges manufacturers face in this department. Many manufacturers have a patchwork of asset management systems and tools rather than a unified solution. Many still have a mindset focused on reactive maintenance rather than predictive or financially optimized maintenance. And many believe harnessing AI on their factory floor requires a small army of computer scientists. Today’s AI tools are accessible and require little or no coding experience to train and operate.
Jones: One of the biggest challenges is effectively tracking and managing assets. This includes keeping accurate records of asset location, condition and maintenance history.
Scheduling and planning maintenance tasks can be complex. Identifying the right time and resources for maintenance activities is crucial to prevent equipment failure and ensure optimal performance. Managing and securing vast amounts of data generated by asset management
u
FIGURE 1 : Using AMS Optics, asset health is delivered to relevant users in a clear and meaningful way. Teams can act before a problem affects the process — resulting in poor product quality or worse, a costly shutdown. Courtesy: Emerson
systems is a significant challenge. Ensuring data integrity and protection against cyberattacks is essential.
Balancing the costs associated with asset management, including maintenance, upgrades and replacements while optimizing asset utilization is a continuous challenge.
Insights
Asset management insights
uArtificial intelligence (AI)-powered tools can enhance asset management, saving time and unnecessary effort.
uData is critical for effective asset management, and humans are critical for providing quality data used in asset management tools.
uIntegrating tools like historians, enterprise asset management and computerized maintenance management systems are critical for success.
Question: What tips would you offer to someone newly tasked with asset management duties?
Jones: Use data analytics to monitor asset performance and identify areas for improvement. Data-driven insights can lead to more efficient and effective asset management.
Use EAM systems and other relevant software to streamline processes. These tools can help with tracking, scheduling and data analysis.
Stay updated with the latest trends and technologies in asset management. Attend workshops, webinars and training sessions to enhance your skills.
Nishimoto: One word of advice: data. Every workstation, assembly robot, conveyor belt and motor produce real-time data. When harnessed correctly, asset managers can unlock enormous benefits. Setting AI models to work on this data can generate new insights, like predictive maintenance recommendations and heightened productivity, like automated inspections.
Cooper: There are several recommendations for someone newly tasked with asset management duties. First, examine existing data and determine what pieces of equipment are causing the most issues in terms of downtime and repair costs. This will allow asset management professional to concentrate on those areas that will show the most benefit quickly. Secondly, ensure there is sufficient data being fed into systems that allow decisions to be made about how much and when maintenance should be performed. Third is to establish lines of communication between various disciplines such as reliability, maintenance, subject matter expertise and operations.
Question: What challenges and risks do you see in implementing AI-driven asset management solutions and how can these be mitigated?
Nishimoto: Asset managers must ensure they are collecting and managing quality data — if the inputs are flawed, the outputs will be flawed, too. Asset managers must also ensure the artificial intelligence (AI) systems they deploy are trustworthy. For example, are the insights and decisions AI models produce transparent and explainable? Are they safe and secure? These challenges and risks can be addressed by integrating comprehensive AI governance and AI security frameworks. PE
When an opportunity for being better or the best at what we do is available, why wouldn’t we take it?
As Engineers, Technicians etc., we should and, need to know what we are doing. Having a better understanding of our role is something that we can accumulate as we perform our jobs, but sometimes things come along that are ‘out of the norm’, just different or more complex than we can educate ourselves on, or perhaps related to a subject you may have only briefly covered during your formal education.
On the job training is only as good as those we are learning from, sometimes we need to seek additional help especially with much of the newer technologies we see today. While we could read books, manuals and these days even watch videos on the subject they often lack the ‘hurdle’ component, that’s the bit where we need additional guidance when something just didn’t make sense.
Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist.
While finding time to take advantage of these opportunities may be a challenge, we should take them when we can. Companies such as DEWESoft offer opportunities both in-house and a variety of locations around the country to provide that training from beginner to expert in a variety of different subjects, consider the advantage and ultimate time saving as well as possibly creating local experts so the future on-the-job trainings you give will truly cover the needs of the role.
“ Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist. ”
+1-855-339-3669 • sales.us@dewesoft.com • www.dewesoft.com
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Training session with Dave Gallop, Business Development Training Manager — Dewesoft
ENGINEERING SOLUTIONS
COMMERCIAL AND ELECTRIC VEHICLES
Joe Cappeta, Eaton, Pittsburgh
Here are five EV fleet charging priorities for industrial plants
Emphasize power system flexibility to safely meet the incremental energy demands of electrified industrial fleets.
Electric vehicles (EVs) are increasingly being adopted across industrial environments like warehouses and distribution centers to reduce emissions, fuel costs and maintenance requirements. Whether it’s fleet vehicles or electric forklifts, establishing safe and flexible charging infrastructure is essential to support an always-on, sustainable working environments. However, implementing effective EV charging infrastructure (EVCI) involves much more than simply adding charging devices. It requires reimagining existing electrical systems to enhance flexibil-
ity and scalability — allowing industrial facilities to safely, cost-effectively and efficiently accommodate the growing energy demands of EV charging. This means optimizing power system design and selecting the right strategies to support increased energy loads while maintaining reliability and affordability.
The electrical infrastructure supporting industrial facilities must be able to adapt to change. To achieve this, electrical engineers designing EVCI systems must understand how the customer plans to use the charging stations and be well-versed in EV charging hardware options and software platforms. Here are the five critical considerations:
1. Understand how the EV charging system will be used
It’s essential to develop an EV charging strategy that takes into consideration all of an industrial facility’s needs. Conducting a feasibility analysis before planning EVCI deployment can provide insights into the capabilities of existing power systems to determine what’s needed to meet charging needs into the future.
The type of charger required depends on the typical distance driven per day and the size of the battery on fleet vehicles. For example, if fleet vehicles include sedans, pickup trucks and vans that are driven less than 200 miles per day and are plugged in at the end of each day, alternating current chargers should be adequate to provide a full charge overnight.
On the other hand, direct current fast chargers, which can charge most passenger EVs up to 80% within 15 to 45 minutes, are well-suited for aroundthe-clock or on-the-go operations but require higher electrical capacity due to increased power demand.
FIGURE 1: Direct current fast chargers are well-suited for around-the-clock or on-the-go operations but require higher electrical capacity due to increased power demand. Courtesy: Eaton
Fleet and plant managers must also determine how chargers will be accessed to meet the requirements of different vehicle types at different times of the day. Several configurations are available:
• EV charging can be connected directly from the breaker panel through a junction box with a charging cable at the parking location.
• A pivoting retractable cable reel mounted to the ceiling or wall keeps cables out of walking paths and parking stalls, enabling more spaces to be equipped for charging with the same number of chargers.
• Oversizing the panel allows for easy expansion of charging infrastructure later, making it simple to install additional chargers or add conduit and breakers for future needs.
• Busway, a common electrical distribution solution in industrial environments, can be used to integrate chargers directly into the bus plug, providing a scalable and future-proof footprint.
2. Use software to optimize EVCI functionality
A well-planned EV charging infrastructure should provide the flexibility to charge fleet vehicles as well as other vehicles that visit the site. Creating multiuse EV charging systems is complex, but software solutions can help streamline the process.
Fleet and plant managers can implement software that enables multiuse EV charging by differentiating between fleet and visitor usage. These platforms allow for different pricing structures based on user type. For instance, a driver can scan a QR Code or radio-frequency identification fob and the system will determine the appropriate pricing structure.
Additionally, software platforms help fleet managers:
• Organize, navigate and troubleshoot charging infrastructure easily.
• Add or modify charging stations as needed.
• Establish pricing policies based on flat rates, time, energy consumption or other criteria.
3. Stretch the capabilities of existing energy infrastructure
Many industrial facilities may lack the electrical capacity to safely accommodate new charging systems. Careful planning and system design are essential to maximize return on investment while minimizing costly site upgrades associated with pulling more power from the electric grid.
Load management technology plays a key role in optimizing EVCI. By implementing intelligent load management, more chargers can be installed while ensuring they deliver only the optimal amount of power required. When available capacity is reached, the software limits energy consumption to prevent overloads. This approach enables load shedding, avoiding the risk of exceeding incoming service capacity. If existing electrical capacity simply cannot meet expected demand, upgrading utility service will be necessary.
An alternative to utility service upgrades is investing in a microgrid EV charging ecosystem that incorporates an energy storage system and onsite renewable energy sources. This infrastructure investment can improve energy self-sufficiency and accelerate decarbonization goals. Battery energy storage systems make it possible to store off-peak energy from the grid or energy generated from onsite renewables, allowing the facility to switch to stored energy during peak utility rate periods — and even monetize excess energy when possible.
A complete load analysis should be performed
vehicle (EV) charging busway enables the ability to expand and reconfigure infrastructure with no concrete work required. This overhead power distribution technology makes it easier to deploy, scale and manage EV charging. Courtesy: Eaton
Learningu
Objectives
• Understand the power system design challenges of industrial electric vehicle charging infrastructure (EVCI) with a focus on creating safe, scalable charging systems for all needs.
• Familiarize yourself with technological advancements, tools and approaches helping industrials sustainably and cost-effectively accommodate the electrical capacity demands of EVCI.
• Grasp the safety implications of component and software specification.
• Gain an awareness of EVCI cybersecurity considerations and best practices.
FIGURE 2: Electric
ENGINEERING SOLUTIONS
FIGURE 3: Integrating onsite renewable energy sources provides added electrical capacity for electric vehicle charging without utility service upgrades. Eaton Experience Centers in Pittsburgh (pictured) and Houston provide hands-on training environments where visitors can see electric vehicle charging infrastructure and industrial power systems at work. Courtesy: Eaton
before installing EV chargers of any voltage and thoroughly testing load shedding capabilities to ensure critical loads are not sacrificed when EV charging demand exceeds available panel capacity. The needs of the application should come first, keeping in mind that exceeding bare minimum NFPA 70: National Electrical Code requirements is often advisable.
Insights
EV insights
uElectric vehicle (EV) adoption in industrial settings is growing, requiring welldesigned EV charging infrastructure (EVCI) to support fleet operations while ensuring safety, scalability and cost efficiency.
uEffective EVCI planning involves assessing energy demand, optimizing power distribution, integrating smart load management andprioritizingcybersecurity to create a flexible and future-proof charging ecosystem.
4. Implement scalability for the future
When upgrading or designing building systems, conducting an EV charging feasibility analysis is crucial to planning for future EVCI capacity needs and avoiding significant costs later. Future-proofing electrical architecture ensures that new EV chargers can be easily added as required.
Scaling EV charging infrastructure over time can spread investment costs and allow businesses to transition to EVs at their own pace. Properly sizing electrical service and power distribution feeders to accommodate future growth is critical to avoid hidden costs. Load calculations must be performed to determine whether an existing panelboard can handle the additional load. If this step is skipped or done incorrectly, there is a high risk of charging station failures, damage to the electrical system and even injury.
To size EVCI for future growth, start by assessing current and projected EV demand, such as a 20% annual increase over five years. For example, if a building currently has 10 EVs, in five years, it may need to accommodate 25 EVs. If each charger has a calculated load of 7.2 kilovolt amperes (kVA) per space (or 3.3 kVA per space with energy management), the future total load for 25 chargers would be:
Without an energy management system and intelligent load management:
25 chargers x 7.2 kVA = 180 kVA
With an energy management system and intelligent load management:
25 chargers x 3.3 kVA = 82.5 kVA
To ensure scalability, the electrical panel should be sized accordingly, likely with a panel capacity of 200 kVA or more. Installing a dedicated subpanel, smart charging systems and conduits for future expansion will help manage growth.
Energy management systems enable dynamic load control, further enhancing scalability. If demand continues to rise, the system can easily support up to 50 chargers (360 kVA without energy management or 165 kVA with energy management). Integrating onsite renewable energy sources such as solar can further enhance capacity down the road.
5. Prioritize cybersecurity
Connectivity is essential for managing charging networks effectively. Charging stations must communicate securely with owners, operators and the grid to authorize charging, manage payments and regulate electrical loads.
Fleet managers, plant management teams and facility operators must ensure seamless integration between charging hardware and software while prioritizing cybersecurity. Charging solutions should comply with open charge point protocol and be developed using a secure development life cycle methodology. Cybersecurity must be incorporated at every level, including ports, communication modules and third-party controllers. Monitoring vulnerabilities and allowing only trusted firmware updates are critical measures to ensure security.
Establishing a robust cybersecurity program with periodic network assessments can help organizations stay ahead of potential threats, safeguarding both physical assets and operational data.
Flexibility is a priority for EVCI
The electric revolution is here. While many fleets are still in the early stages of EV adoption, building safe, secure and scalable infrastructure is crucial to supporting and accelerating the transition to electric transportation.
‘Future-proofing electrical architecture ensures that new EV chargers can be easily added as required. ’
By implementing EVCI with safety and flexibility in mind, industrial organizations can avoid unnecessary costs and complications if systems need to scale in the future.
However, as EV adoption grows, best practices and technology for EVCI design will continue to evolve. Industrial facilities must remain adaptable and you can help ensure that their energy infrastructure is always optimized for what’s next. PE
Joe Cappeta is sales director, energy transition at Eaton.
LUBRICATION
Brandon Thompson, CITGO Petroleum, Houston
How choosing the best grease can reduce mechanical failures
Choosing the right grease and proper grease application are essential for implementing a sound lubrication strategy and preventing costly mechanical failures.
One of the most important components in any manufacturing plant is the lubrication of its machinery and equipment. Lubricants play a vital role in the performance and longevity of any machinery.
Unfortunately, a significant percentage of mechanical failures are caused by lubrication issues, often due to improper grease selection, contamination or breakdown under stress. Bearings seize, robotic joints fail and construction equipment
grinds to a halt, not because of mechanical defects, but because the wrong grease was applied or the right grease couldn’t withstand extreme conditions.
The good news is that these failures are entirely preventable with the proper grease selection and application.
Understanding the science behind grease and how its key components impact load performance and shear stability in varying applications can help optimize equipment performance and liability. Choosing the right grease helps avoid common lubrication pitfalls, reducing failures and improving machinery longevity.
The science behind grease: a precision-engineered solution
Whenever a new machine or component is installed, one of the first things to be addressed is the type of lubricant or grease to use. Lubricating grease is a semi-solid structure that consists of three main components: oil, additives and thickener and it is used primarily to reduce friction in several critical components and applications.
Understanding the key properties of grease can help operators in the selection of the right lubricant for their operational needs. There are three main properties:
Base oil type: The base oil type is crucial in selecting the right grease for machinery as it determines the grease’s performance under different operating conditions, such as temperature, load and speed. Base oils make up 80% to 90% of grease, so their properties impact the grease’s ability to lubricate effectively. The American Petroleum Institute has five base oil designations and characteristics:
• Group I, II and III are base oils derived from crude oil, suitable for general applications but can break down at extreme temperatures or loads.
FIGURE 1: A ball wear test shows the wear scar measurement on a lubricated surface. A smaller wear scar indicates better protection against metal-to-metal contact. High-performance extreme pressure greases with molybdenum disulfide or other anti-wear additives help extend component life by reducing friction and wear. Courtesy: CITGO Petroleum
Objectives Learningu
• Understand the science behind grease and how essential components like base oil, thickener and additives can affect the load performance, temperature and water resistance and shear stability in varying applications.
• Identify common lubrication pitfalls — such as hightemperature breakdowns and contamination and water washouts — and learn how to prevent these fails.
• Learn best practices on selecting and applying the right high-performance grease for specific equipment needs to reduce lubrication-related failures and improve equipment longevity.
• Group IV and V are synthetic base oils that are ideal for a wide range of temperatures and extreme conditions, providing greater resistance to oxidation, temperature changes and wear.
Base oil viscosity: Grease is made up of 80% to 90% oil, which makes the viscosity of the base oil crucial. Viscosity affects the oil's resistance to flow and plays an important role in maintaining proper lubrication, preventing wear and reducing excessive heat.
Additive package: Additives enhance grease with antioxidants and corrosion inhibitors, modify base oils properties with pour-point depressants and viscosity index improvers and provide grease with extreme pressure characteristics and metal deactivation.
Consider extreme pressure greases
An extreme pressure (EP) grease is specifically formulated to handle heavy shock loads and high-pressure environments, providing protection against wear, contamination and environmental factors while prolonging the life of bearings and other components.
EP greases are enhanced with additives like graphite and molybdenum disulfide (known as “moly”), creating an extra barrier between machine surfaces. These greases can withstand extreme temperatures and pressures and offer water resistance to wash-out and corrosion in moist environments.
EP greases are rigorously tested for water resistance and pressure handling ability, with grading based on performance.
Why greases fail: common lubrication pitfalls
When implementing an ineffective lubrication strategy, plant operators often make mistakes that can negatively impact equipment wear, lifespan
2: The grease on the right maintains its protective layer, resisting removal under high-pressure water exposure, while the grease on the left shows significant breakdown. Choosing grease with strong water spray-off resistance ensures continued protection in wet conditions and prevents premature lubrication loss.
Courtesy: CITGO Petroleum
and overall efficiency. These errors can also lead to costly repairs and unplanned downtime.
• Failure mode 1: Lack of EP protection: Highload applications such as robotic automation, construction equipment and hydraulic systems require EP additives to prevent excessive wear. Non-EP greases without moly or calcium sulfonate shear under pressure, leading to metal-on-metal contact and overheating.
• Failure mode 2: High-temperature breakdown: An important indicator of quality in grease is its dropping point — the temperature at which it passes from a semisolid state to a liquid under defined test conditions. A grease should have a dropping point that is safely above the highest operating temperature to avoid run-out during application. Using a grease that exceeds its dropping point leads to the grease losing its ability to lubricate and creating wear and potential machinery failure.
is often determined by dye additives and does not indicate performance characteristics. The choice of thickener, base oil and additives is what determines grease suitability for different applications. Courtesy: CITGO Petroleum
FIGURE 3: Grease color
FIGURE
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FIGURE 4: Routine maintenance and proper grease application techniques are essential for ensuring equipment longevity. Selecting the right grease and applying it at the correct intervals prevents premature wear and unplanned downtime. Courtesy: CITGO Petroleum
• Failure mode 3: Contamination and water washout: Using greases with low water resistance can create washout and increase risk of contamination. Water can weaken the structure of grease, washing away lubrication and leading to higher friction and wear.
How high-performance greases improve equipment longevity
Implementing a sound lubrication approach featuring the right high-performance greases can help operators enhance equipment longevity, as these formulations offer specialized protection against common wear factors. Key benefits include:
GET MANUFACTURER
& OIL USE WITH LE PROGRAM
Seeking to improve its sustainability practices, a manufacturer did a pilot lubrication reliability program with LE. For the rst 2 compressors, results included lower energy use, extended oil drains, and reduced waste oil. Total savings were $20K per year.
• EP greases with moly additives reduce wear under extreme pressure, making them ideal for heavy equipment, manufacturing machinery and industrial robotics.
• Calcium sulfonate thickeners provide builtin EP protection, ideal for industrial bearings and hydraulic systems.
• Synthetic base oils prevent oxidation and breakdown in extreme heat, while lithiumand aluminum-complex greases have higher dropping points to ensure continuous lubrication.
• Polymer-enhanced greases improve water resistance, preventing contamination-related failures.
Best practices for grease selection and application
To maximize machinery performance, efficien-
cy and lifespan, operators should follow these best practices when selecting and applying grease:
• Follow original equipment manufacturer recommendations: It is recommended to follow manufacturer guidelines or consider load, temperature and environmental conditions when choosing a grease.
• Choose the right formulation: It’s important to choose the right grease for the application, such as EP greases for high load conditions and synthetic-based greases for extreme temperatures.
• Implement a preventive lubrication strategy: Regularly monitoring and addressing potential contamination risks will help maintain ideal grease performance.
Lubrication as an engineering strategy
Lubrication is not just a maintenance task;
it is a critical engineering strategy that directly impacts equipment lifespan, operational efficiency and cost savings. Proper grease selection is crucial in reducing premature equipment failures, as it ensures optimal performance and longevity of machinery components.
With the right grease, equipment runs longer, breakdowns are reduced and businesses save money. Instead of treating lubrication as an afterthought, companies should integrate lubrication into their performance and reliability strategies.
To take lubrication strategy to the next level, assess a production facility’s current grease selection and determine if it is optimized for load, temperature and contamination risks. Upgrade to an EP, high-temperature or polymer-enhanced formulation where needed. PE
Insightsu
Grease insights
uUsing high-performance greases and following best lubrication practices can significantly improve equipment longevity, reduce downtime and enhance overall operational efficiency.
uThis article will explore best practices for selecting and applying the right highperformance grease to help enhance equipment’s durability and efficiency.
Brandon Thompson is a Product Manager at CITGO Petroleum.
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LUBRICATION
Peter and Cameron Surette, JAX Inc., Menomonee Falls, Wisconsin
How air can adversely affect lubricants, and how to avoid it
Taking seriously the potential performance, fluid life and machine longevity-related issues caused by air is an essential step in a modern plant maintenance plan.
While air is typically seen as a beneficial resource, air in the wrong places can present significant problems in a manufacturing plant. From the efficient functioning of equipment to the performance and life of fluids to the longevity of plant equipment, the presence of air can have negative consequences.
There are three key issues that air can cause in lubrication systems and machinery.
Air entrainment and foaming within lubricants
There are important and distinct differences between air entrainment and foam. Air entrain-
ment is the physical phenomenon of air pockets being trapped in a fluid, while foam is the accumulation and stabilization of that entrained air to the top layer. Entrained air stays in the mass of the fluid. Due to its relatively small size, entrained air has difficulty escaping, whereas foam is present above the fluid at the fluid/air interface.
Any fluid will intrinsically contain some degree of dissolved air, but certain lubrication applications and transfer methods can increase the contact between fluid and air. This, in turn, increases dissolved air. Splash lubrication methods, pumping oil from one container to another, recirculation systems and other open fluid movement mechanisms are interactions which can propagate air.
In contrast, some lubrication and transfer methods entrain almost no additional air, such as drip lubrication, single-pass systems and some high-temperature applications where air easily escapes due to low fluid viscosity.
u
Objectives
• Learn about the three major problems caused by air in lubrications.
• Review ways to identify lubrication problems caused by air entrainment.
• Understand how to mitigate or eliminate lubrication issues caused by air.
The viscosity of fluids plays a significant role. Air can escape lower viscosity fluids like those in hydraulic systems more easily. Thicker fluids found in gear boxes make it more difficult for air to escape. Higher viscosity products may require additional considerations to fight foam and air.
Release of entrained air is critical in applications like hydraulics. Hydraulics rely on an immediate fluid response with a given input for predictable and smooth operation. Air compresses; fluids do not. If too much air is entrained, the response time for a given input is dramatically reduced, leading to inconsistent operation.
Reducing or eliminating foam is also critical for several reasons. Foam and the air it contains will interrupt fluid film formation and inconsistent fluid film will lead to several operating issues,
FIGURE 1: Entrained air in a sample of oil, creating a cloudy appearance. Courtesy: JAX Inc.
‘If too much air is entrained, the response time for a given input is dramatically reduced, leading to inconsistent operation. ’
including increased metal-on-metal contact and corrosion. Foaming is typically a symptom of rogue air ingested into the system through line leaks, low fluid levels or breather or filler cap deficiencies.
Foam can also be generated when incompatible fluids are mixed resulting in a chemical reaction. This is often one of the earliest tip-offs that incompatible fluids have been inadvertently mixed in service.
Many machines have some sort of sight glass window where one can evaluate if air is trapped in the fluid. They should be regularly monitored.
If persistent foam is an issue, you may even see it begin to rise out over the piece of equipment. This is unsightly and could cause a slipping safety hazard or even the possibility of contaminating products in production.
Foam resistance and strong air release characteristics become more critical as oil reservoirs in modern machinery become smaller to save space. For example, smaller hydraulic reservoirs allow less dwell time and head space for the fluid to release entrained air or dissipate foam before it is reintroduced into the circulation system.
First, find and repair leaks. Any part of a closed system that is not closed has a potential to entrain air into the machinery. Leaks are not always easy to detect so using dye — either visual or fluorescent — can help locate the sources of leaks.
If the component is not a closed system, ensure fluid levels are proper and filling methods and operating environments are not contributing to air introduction. The proper, recommended amount of oil in the unit will help ensure that excess air is not being mixed into the oil via churning or turbulence.
Synthetic base stocks, especially polyalkylene glycols (PAG) and esters, are inherently less prone
to aeration issues, making them a good option to enhance air release if that is a major troubling concern. Unfortunately, air release is a physical phenomenon that additives are unable to improve with great success, so switching to a synthetic fluid is an option to improve air release if a mineral oil-based lubricant is experiencing issues.
Choose lubricant formulations that contain appropriate antifoam components. Antifoam agents work by destabilizing air bubbles so they pop, and by enabling smaller bubbles to join to form big bubbles, making it easier for them to escape the fluid. This allows bubbles to burst before they conglomerate and form a persistent colony. Popular defoaming chemistries are silicones or polymethacrylates. These additives need to be present at the proper amount as undertreating or overtreating can aggravate entrainment and foaming issues.
without air.
FIGURE 3: Trend graph of a hydraulic system’s reaction time, with and
Courtesy: JAX Inc.
FIGURE 2: Foam at the top of an oil sample. Courtesy: JAX Inc
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Foaming will also be caused by particulate matter in fluids that attract air. Ensure that filters are fresh or being cleaned and maintained regularly.
A good example where particulate contamination can cause foaming is metalworking fluid reservoirs. Foaming here can be so troublesome that tank-side antifoam mitigation may be used to facilitate foam dissipation and to refresh antifoam agents.
How air affects fluid oxidation
All commonly used lubricating and circulation fluids will oxidize in the presence of air due to oxygen. If air is not efficiently escaping the fluid, this will lead to early fluid condemnation due to excessive oxidation.
When entrained air oxidizes oil, acidic byproducts are created. If excessive air is being entrained and not removed effectively these acidic byproducts will not only shorten fluid life but can also corrode machinery, leading to the eventual failure of the equipment.
When no air is present, even mineral based fluids can function in applications for extended intervals. A good example is heat transfer fluids in closed systems with no air exposure. These fluids can last for extended periods in high-temperature operations simply because they are not subject to any exposure to air.
The first and easiest identifier of excessive fluid oxidation are our eyes and noses. Oxidized fluids will darken and often exhibit a burnt or “off” smell compared to new fluid. Used oil testing to deter-
mine acid numbers and oxidation levels through titration and Fourier transform infrared analysis will quantifiably determine the level of degradation to the fluid. When approaching condemnation limits, there will be additional issues such as increasing viscosity and a tendency to form deposits and varnish on components.
Temperature has a catalytic effect on fluid oxidation. There are general principles that vary by fluid type. For temperatures above 160°F, every additional 20°F can halve the service life of the fluid. Keeping lubricants and processes as cool as possible in service will increase both component life and the life of the lubricants protecting them.
If reducing temperatures and exposure to air are not feasible, monitor for signs of oxidation via routine laboratory testing and expect to change fluids based upon predetermined condemnation limits of trigger points like oxidation levels, acid numbers or viscosity increases.
If fluid oxidation is deemed to be excessive examine your choice of chemistry. Make sure the lubricants contain sufficient levels of antioxidant additives. These additives scavenge and neutralize the products of oxidation. In more extreme instances, synthetic lubricants will help alleviate issues regarding fluid oxidation because those based on polyalphaolefin, PAG, synthetic esters, alkylated napthalenes and others are significantly more resistant to oxidation providing cleaner and longer service life in the presence of air and oxidation prone environments. There are some more inert fluids such as perfluoropolyethers or silicones that may withstand oxidation stress even better but are generally poor lubricants.
Selecting lubricants to reduce rust and corrosion
In addition to having machines operate properly and the fluids last longer, the components of machinery should last longer. Protecting assets from air-related damage and degradation is part of a solid overall maintenance strategy.
Rust and corrosion are obvious examples of air-related damage. Modern lubricants typically are formulated with enough rust and corrosion inhibiting chemistry to adequately protect parts. Not all lubricants use the same types of chemistry for corrosion protection, however. LUBRICATION
FIGURE 4: Progression of in-service oxidation (test tubes). Courtesy: JAX Inc.
Selecting products designed for the application is critical. Engine oils, gear oils, hydraulic oils, chain oils, metalworking fluids and greases use significantly different additive chemistries to achieve rust and corrosion protection.
Parts exposed to air are certainly the most susceptible to rust and corrosion issues particularly, in areas where salt or chemical concentrations are high. A coating of proper lubricant will offer protection as long as the lubricant film adheres to the metal surfaces.
However, environmental factors or extended shutdowns can expose parts to air often with alarmingly adverse consequences. Components stored for extended periods require some type of long-term rust protection to be applied and adhered to their surface.
Cavitation and pitting wear are also serious problems. When small, entrained air bubbles collapse, a hot jet stream is created where air rapidly passes through the center. If this occurs in areas close to component surfaces, the localized shock waves and microjet streams will generate noise and cause micro pitting, which is surface damage on the interior of a machine.
Pitting can affect gear teeth, centrifugal pumps, hydraulic components and other parts that eventually leads to degradation of the asset. Individual pits can often be observed in softer materials after even a single bubble collapse.
Over time, the pitting caused by the collapse of these micro bubbles produces severe wear on components. This will manifest visually as a dull looking surface like fatigue failure. Light bounces off the metal randomly without reflecting directly back anymore; it is scattered. High volume flow rates will increase the intensity of pitting damage. If not remediated, this cavitation fatigue damage can become significant enough to crack metal deep through the surface until the part or surface no longer functions.
The first and easiest identifier of cavitation are hearing and touch. The collapsing air bubble cavities generate noise from shockwaves and the severity of the cavitation can often be readily gauged by the level of noise. The noise is also likely to be accompanied by vibrations. This is a great area for vibration analysis to determine norms and abnormal vibration levels. If there has been a detectable
FIGURE 5: Surface appearance: new versus pitted.
Courtesy: JAX Inc.
‘The easiest way to prevent cavitation is the elimination of air and micro bubbles from circulating systems. ’
loss of circulating pump efficiency, cavitation is also likely to be happening.
The easiest way to prevent cavitation is the elimination of air and micro bubbles from circulating systems. In most cases, this is not completely possible. Harder surfaces may resist cavitation pitting damage more effectively than softer ones, but eventually will suffer damage. Decreasing vibration by stiffening components has been shown to help along with taking steps to make sure internal surfaces are smooth. Eliminate areas where air may be trapped or the fluid may see excessive churning. Reducing fluid velocity, where that is feasible, will help lessen cavitation forces and alleviate damage.
Minimizing the presence of air in lubrication systems and machinery is essential for maintaining equipment efficiency, fluid longevity and overall plant reliability. By selecting the right lubricants, addressing leaks and implementing best practices for air management, manufacturers can mitigate the risks of air entrainment, oxidation and cavitation-related damage. A proactive approach to monitoring and maintenance will ensure optimal performance, reduce costly downtime and extend the life of both fluids and equipment. PE
Eric J. Peter is an industrial lubrication technologist and the former president of JAX Inc. Cameron Surette is the lead fluids chemist at JAX Inc.
Insightsu
Lubricant insights
u Air trapped in lubricants can lead to foam, oxidation and mechanical wear, causing inefficiencies and potential equipment failures in manufacturing plants.
uSelecting the right lubricant formulation with antifoam additives, proper viscosity and oxidation-resistant properties — along with proactive maintenance strategies — helps minimize air-related issues and extend the life of both fluids and machinery.
LUBRICATION
Shawn Wood, Kaishan USA, Mobile, Alabama
Six ways to boost compressor performance with oil sampling
Users of oil-flooded rotary screw air compressors can unlock significant benefits by implementing the recommendations in their manufacturer-required oil sampling.
Oil sampling is a crucial part of owning and operating an air compressor, alerting users to key maintenance and performance issues that could damage key components and shorten its lifespan.
Original equipment manufacturers (OEMs) consider oil sampling the most essential maintenance procedure, especially critical if the compressors are exposed to excessive heat or contaminants or do not run often enough.
Analyzing an oil sample can identify key performance issues, allowing compressor users to take preventive action before they become problems. These concerns include:
• Component wear
• Damage to key components
• Oil contamination
• Reduced lubricant life
• Acid formation
Objectives
• Understand the importance of regular oil sampling for oilflooded rotary screw air compressors.
• Learn how to analyze an oil sampling report.
• Discover how the findings of an oil sampling report can improve compressor operation, efficiency and longevity.
• Varnishing
• Loss of efficiency
• Oxidation
• Corrosion
They are severe enough that most, if not all, compressor OEMs require customers to draw an oil sample and have it analyzed by an accredited, third-party lab.
For example, Kaishan requires customers to collect and analyze an oil sample every 2,000 hours of
operation with 1,000 hours recommended for foodgrade applications to maintain extended warranty protection (see Figure 1). Failing to collect an oil sample is one of the most frequent causes of warranty denials.
How to read an oil sampling analysis
An oil sampling report (see Figure 2) may look intimidating, but it makes more sense to understand what’s being measured and why. There are six key points to focus on:
1. Wear metals
2. Additive element levels
3. Other contaminants
4. Viscosity
5. Acid number
6. Water
1. Wear metals
As oil ages, key components begin to wear and form tiny particles, indicated by any wear metals detected in the analysis. If the analysis shows those particles are metal fragments, that’s an indication those components are experiencing mechanical wear:
• Iron particles point to steel parts, such as bearings, gears or rotors.
• Copper or aluminum might mean the problem is in seals or bushings.
2. Additives
Compressor oil contains antioxidant additives that improve thermal and oxidative stability and give the oil longer life. As a compressor is used, those additives are gradually depleted. The additives portion of the sampling analysis establishes how many of the elements, such as calcium and
magnesium, from the additives are still in solution, helping to neutralize the acid and prevent oxidation.
Compressor manufacturers work closely with their lubricant suppliers to select the right combination of additives for their specific designs and optimize compressor performance. As a result, it is recommended that owners follow their manufacturer’s recommendations when choosing oil for their units.
There’s a common misconception that this number shows the concentration of the additives remaining in the oil. But because these elements remain in the oil even after the additives break down, it only shows that the correct lubricant was used.
3. Other contaminants
Dust and sand contamination in the report’s contaminants section indicates that there are impurities in the oil, most likely originating in its intake air. If the contamination is silicon only, that indicates dust is the contaminant. Dirt shows up in a 3-to-1 or 4-to-1 ratio of silicon to aluminum. Check the inlet air filter and replace it if necessary.
4. Viscosity
Viscosity is one of the primary properties of compressor oil, mainly its thickness and ability to resist flow. Thus, the report’s viscosity section measures the oil’s ability to lubricate the compressor’s key components and absorb harmful contaminants.
FIGURE 1: It is recommended that engineers analyze an oil sample at a minimum of 2,000 hours based on the environment with more frequency recommended for challenging locations. Food-grade lubricants require even more frequent samples. Courtesy: Kaishan USA
Insightsu
Oil sampling insights
u Oil is the lifeblood of an oil-flooded rotary screw compressor.
u As oil ages, additives are consumed and additive levels drop below design parameters, allowing oxidation and acid formation.
uViscosity levels also increase with aging, potentially allowing contaminants and varnish to drop out of the oil.
uThe primary purpose of oil sampling is to extend the life of the lubricant and the compressor.
Viscosity will increase with age as the oil starts to break down.
5. Acid number
The report’s section on acid number, tracks the amount of oxidation and identifies the amount of acid in a sample. A high number indicates an elevated oxidation level and that the additives have been depleted, leading to acid buildup. One possible cause is running the compressor at a higher temperature than it should be.
Those oxidative byproducts can precipitate out of the oil solution when the concentration becomes higher than the fluid can keep soluble. The varnish
FIGURE 2: Varnish can drop out of the oil solution and adhere to components, reducing efficiency. Courtesy: Kaishan USA
ENGINEERING SOLUTIONS
that drops out can adhere to components, reducing efficiency. Solids will also drop out and form sludge.
As a result, a high acid level will damage a compressor if left uncorrected. At the very least, the oil should be changed, but maintenance personnel should also look for root causes, especially when a sample is drawn at less than the expected service interval.
6. Water
Water increases oxidation, reducing the oil’s effectiveness. This leads to increased rust and corrosion, even damaging rubber or polymers, such as seals and gaskets. Ultimately, it will lead to premature machine failure.
Water in compressor oil may also affect its viscosity and acidity. If the report shows water is detected in the sample, it may indicate the system is experiencing rapid cycling. It may not have time to exceed the pressure dewpoint temperature and remove moisture.
1. Wear metals, elevated
Wear metals, trace or minimal
2. Additive levels
• Metal components are experiencing abrasive wear
• Change oil
• Check contaminant levels
• Check bearings, seals, rotors, gears and bushings for wear
Using data from oil sampling analysis
An oil sampling analysis provides hard data on how long the oil will remain effective in an application and how often it should be changed.
3. Other contaminants (silicon, boron, etc.)
4. Viscosity levels
• Metal components are experiencing adhesive wear
• A fluid other than the recommended lubricant is present in the oil, potentially invalidating the warranty
• Problems with filtration or incoming air
• Oil is aging and absorbing more oxidative byproducts
5. Acid number
6. Water
• Acid buildup resulting from depleted additives and oxidation
• High running temperatures
• Check key components for imbalance, misalignment, low fluid level or corrosion
• Change oil
• Shorten service intervals if low levels recur
• Change oil
• Check filters, especially inlet air filter and replace if necessary
• Change oil
• Shorten service intervals if high levels recur
• High running temperatures
• Change oil
• Make sure you are following your manufacturer’s oil recommendations
• Service cooling system
• Shorten service intervals if high levels recur
• Rapid cycling, water entry through internal leaks
• Change oil
• Check for corrosion, high viscosity, high acid levels
• Address rapid cycling
• Check for and fix leaks
TABLE 1: Various problems can occur in an oil-flooded rotary screw air compressor. Here are ways to mitigate problems. Courtesy: Kaishan USA
In addition to the conditions of the rotary compressor oil, the analysis gives critical insight into the operational conditions of the compressor, indicating high levels of wear or corrosion.
It's an all-encompassing review of the lubricant and its integrity and it can provide critical insight into a compressor’s operation and environment.
We summarize the key measures, their causes and the recommended actions below.
Making the most of an oil sampling report
Owners of oil-flooded rotary screw air compressors can optimize the operation of their compressed air systems significantly by carefully reviewing the oil sampling analysis from their lab.
Regularly sampling oil will indicate whether it is being exposed to excessive heat or taking in contaminants. It can also detect excessive bearing wear, allowing for proactive maintenance, even avoiding an unplanned shutdown. It can help extend the life of the lubricant and equipment and measure the level of contamination, lubricant oxidation and additive depletion.
It’s beneficial for compressors exposed to excessive heat or contaminants or units that don’t run often enough. Most compressor OEMs require oil sampling to maintain their warranties. PE
Shawn Wood is a project manager at Kaishan USA.
When the pressure’s on to get the job done, our lubricants help keep your operation running strong. Mystik® Greases contain shear-stable thickeners and a proprietary combination of high-performance additives that provide superior protection in severe duty steel mill applications.
WE TAKE THE HEAT SO YOU DON’T HAVE TO. MADE TO MAKE IT LAST.
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ARC FLASH AND ELECTRICAL SAFETY
Herbert Post, Tradesafe, Las Vegas
How to integrate NFPA 70B with OSHA requirements
The transition of NFPA 70B from a recommended practice to a standard is changing how organizations approach electrical safety. This shift supports a proactive safety culture, reducing workplace accidents and enhancing worker confidence through standardized maintenance protocols.
EObjectives Learningu
• Learn how organizations integrate NFPA 70B: Standard for Electrical Equipment Maintenance requirements with the Occupational Safety and Health Administration’s (OSHA) 29 CFR 1910.147 to enhance safety compliance.
• Explore training methodologies that effectively blend electrical maintenance practices with hazardous energy control procedures.
• Examine common implementation challenges that maintenance personnel face when adhering to both NFPA 70B and OSHA regulations.
lectrical exposure is a serious risk. Over the past decade, 1,500 workers have lost their lives to preventable electrical incidents, many linked to equipment failure or uncontrolled energy.
In 2022, 147 people died from electrical exposure, according to the Bureau of Labor Statistics (BLS). These figures show the importance of both NFPA 70B: Standard for Electrical Equipment Maintenance and the Occupational Safety and Health Administration’s (OSHA) 29 CFR 1910.147, its federal regulation for the control of hazardous energy, which together tackle maintenance and energy isolation to safeguard workers.
NFPA 70B is a comprehensive standard for maintaining electrical equipment, outlining practices to prevent failures and mitigate hazards like fires or shocks. OSHA 29 CFR 1910.147 mandates specific procedures to control hazardous energy during maintenance, ensuring equipment is safely de-energized before work begins. Together, these standards create synergy. NFPA 70B’s focus on proactive maintenance complements OSHA’s energy isolation requirements, reducing risks such as electrical shocks and arc flashes that threaten workers daily.
Consider this sample scenario to illustrate the point. In a manufacturing plant, a large electric motor powering the assembly line overheats due to years of neglected maintenance, with dustclogged insulation degrading unnoticed. Without NFPA 70B’s proactive maintenance program, no inspections catch the fault, leaving the motor prone to an arc flash.
When it fails, two technicians are sent to repair it during a tight production window. Lacking OSHA 29 CFR 1910.147’s lockout/tagout (LOTO) procedures, they flip the main switch but miss a hidden secondary power feed from an emergency backup circuit, assuming the motor is de-energized. One technician probes the wiring, and the live feed triggers a violent arc flash, blasting the worker. The technician suffers third-degree burns, the second narrowly escapes and the motor shorts out completely, halting production for weeks. The plant faces hefty OSHA fines, medical costs and lost output — all consequences of failing to integrate NFPA 70B with OSHA LOTO, exposing a deadly gap in safety protocols.
Integrating NFPA 70B with OSHA 29 CFR 1910.147
But how can organizations integrate NFPA 70B with OSHA 29 CFR 1910.147 requirements? Here are four ways to achieve this effectively.
1. Develop a unified workplace electrical safety and maintenance policy
Creating a single, comprehensive policy document that merges NFPA 70B’s electrical maintenance program requirements with OSHA LOTO standards is the foundation of this strategy. The unified policy explicitly references both standards, outlining maintenance tasks such as inspections per NFPA 70B and LOTO procedures such as energy isolation and try out procedures per OSHA to ensure they’re addressed together.
‘NFPA 70B is a comprehensive standard for maintaining electrical equipment, outlining practices to prevent failures and mitigate hazards like fires or shocks.’
For example, at a bottling plant, management, maintenance and the safety department strategize together and draft a 10-page policy titled “Electrical Safety and Maintenance Protocol.” It mandates NFPA 70B quarterly motor inspections and requires OSHA LOTO for any repair. When a conveyor motor jams, technicians should first lock out both its main and backup power feeds and tag them, try the start/stop switches and inspect the motor’s wiring for wear, ensuring both steps are followed before work begins. Conducting frequent, documented reviews and audits of the program ensures effectiveness.
2. Use technology to align NFPA 70B with OSHA standards
Coordinating NFPA 70B’s maintenance intervals with OSHA’s 29 CFR 1910.147(d) LOTO execution can use asset management software like a computerized maintenance management system to synchronize these tasks seamlessly. The system schedules maintenance, like switchgear inspections every 12 months and triggers corresponding LOTO steps, such as locking out three energy sources, while tracking compliance in real time.
To implement this, organizations can input NFPA 70B schedules and OSHA LOTO procedures into the software, set alerts for upcoming tasks and generate reports showing the completion of both. This integration strategy ensures maintenance and LOTO happen in sync, preventing energized work during repairs. It also reduces manual errors like missed LOTO steps with automated tracking and using software offers real-time compliance visibility to simplify audits and prove adherence to both standards
Equipment assessment
Condition monitoring and inspection
Identifiying all energy sources
Documentation Maintenance records and history Energy control procedures
Planning Maintenance scheduling LOTO preperation and notification
Execution Testing and repair procedures Energy isolation and verification
Verification Equipment performance testing Return-to-service procedures
Training Maintenance practice competency LOTO procedure proficiency
Continous improvement Maintenance program updates Energy control plan revisions
3. Implement cross-training programs
Training maintenance and safety staff together on NFPA 70B’s testing protocols and OSHA LOTO requirements blends skills like equipment maintenance and energy isolation into a unified skillset. Hands-on sessions ensure workers grasp how these standards interrelate and apply them together.
Implementing this strategy involves partnering with trainers, such as NFPA or the OSHA Training Institute, for annual workshops featuring practical drills, like de-energizing a panel while assessing its condition, followed by competency tests in both areas.
4. Use NFPA 70B assessments to inform OSHA control plans
Using NFPA 70B’s condition assessments from Chapter 6 to update OSHA 29 CFR 1910.147(c)(4)
FIGURE 1: Four strategies to integrate NFPA 70B with OSHA 1910.147 requirements. Courtesy: Tradesafe
TABLE 1: Comparing the focus points of NFPA 70B and OSHA 29 CFR 1910.147 regulations. Courtesy: Tradesafe
ENGINEERING SOLUTIONS
(i)’s energy control plans ensures that LOTO procedures reflect the equipment’s current state. Maintenance findings, like degraded components or new energy sources, directly refine these plans for accuracy. To implement, organizations can conduct NFPA 70B assessments such as thermography or visual checks per schedule, then revise OSHA LOTO plans accordingly, like adding a lockout step if a hidden power feed is found and review updates with teams during safety briefings.
This strategy keeps LOTO procedures precise and current, preventing surprises like unlisted energy sources. It also links equipment health directly to worker safety and strengthens compliance by grounding OSHA plans in NFPA 70B’s real-time data.
Training employees to comply with codes and standards
Equipping workers with the integration strategies discussed above requires training that seamlessly combines electrical maintenance practices with hazardous energy control procedures. These
‘The goal is to instill a proactive mindset so that workers maintain systems systematically rather than react to breakdowns.’
three training components will help organizations implement the best training methodologies for workers to learn them.
1. Understanding NFPA 70B maintenance best practices
This component teaches workers the fundamentals of electrical equipment maintenance to prevent failures that could lead to hazards like fires or shocks. It covers NFPA 70B’s core practices: inspection, testing and repair. Trainees learn why regular maintenance matters, such as using thermographic scans to spot overheating breakers or testing insulation to catch degradation early, ensuring equipment remains reliable and safe for operation or repair.
The goal is to instill a proactive mindset so that workers maintain systems systematically rather than react to breakdowns.
Training method: Hands-on demonstrations: Setting up stations with real equipment offers the most effective way to teach NFPA 70B maintenance. Guided by instructors, trainees can perform tasks such as torquing connections, testing a relay’s functionality or conducting work with electrical personal protective equipment, simulating realworld maintenance.
2. Mastering OSHA’s 29 CFR 1910.147 LOTO procedures
This component focuses on training workers to execute LOTO procedures with precision, ensuring they can identify and isolate hazardous energy sources, apply locks and tags and verify a zero-energy state before maintenance begins. Based on OSHA 29 CFR 1910.147(d), it should teach the step-by-step process: shutting off power, securing energy points, releasing stored energy and confirming de-energization. Mastery here is critical because missing a step can expose workers to live circuits.
The aim is to make LOTO second nature, protecting workers during every maintenance task.
Training method: Step-by-step procedure simulations: Using a mock control panel with multiple energy feeds — such as alternating current power and a battery backup — provides the strongest training for OSHA’s LOTO process. Instructors can guide trainees through the LOTO steps.
FIGURE 2: The three training components to integrate NFPA 70B with OSHA 1910.147 requirements. Courtesy: Tradesafe
For instance, trainees might isolate a simulated conveyor motor, locking out two feeds and testing for voltage, repeating the drill until they perform it flawlessly. This repetition in a controlled setting builds proficiency and confidence, making sure that workers can handle complex energy systems safely.
3. Applying
integrated worker safety scenarios
This component ties NFPA 70B maintenance and OSHA 29 CFR 1910.147 LOTO together, training workers to assess equipment condition and de-energize it safely in realistic, combined contexts. It emphasizes the standards’ synergy, which is that maintenance reveals faults that inform energy control, while LOTO enables safe repairs based on equipment state.
Trainees practice holistic scenarios, such as inspecting a motor for wear and then locking it out before fixing it, learning to see these tasks as interconnected rather than separate. This prepares them to address both equipment health and worker safety in one fluid process.
Training method: Simulated maintenance and LOTO drills: Setting up a scenario like an overheating pump motor offers the most effective way to train integrated compliance. Trainees begin with an NFPA 70B inspection, then execute OSHA LOTO by locking out the main and backup feeds, tagging them and verifying de-energization before repairing the issue.
For example, a technician might spot degraded insulation during a drill inspection, adjust the LOTO plan to isolate an overlooked circuit and complete the task using both standards seamlessly. This hands-on simulation mirrors workplace realities, reinforcing how maintenance and energy control interlock to prevent hazards.
Common NFPA and OSHA implementation challenges and solutions
When it comes to training, there are some challenges when it comes to implementing both NFPA and OSHA standards. Here are some ways to resolve those challenges that will allow workers to incorporate both organizations’ standards.
1. Conflicting priorities
Maintenance teams often struggle to balance
Challenge Solution
Conflicting priorities between maintenance and production
Lack of worker awareness or training on NFPA ans OSHA standards
Inconsistent documentation across NFPA and OSHA requiements
Schedule maintenance during planned outages
Conduct cross-training sessions to clarify overlapping rules
Use integrated software to track compliance tasks
TABLE 2: The common challenges in implementing integrated NFPA 70B with OSHA 29 CFR 1910.147 and their solutions. Courtesy: Tradesafe
keeping equipment running while also doing necessary repairs and compliance checks. Production departments may push to minimize downtime, which can lead to deferred maintenance and increased risks of equipment failure.
Solution: Schedule maintenance during planned outages to meet both standards. Prioritize certain jobs and define the critical path.
One effective way to address this issue is by aligning maintenance schedules with planned production downtimes. This ensures that essential maintenance work gets done without disrupting operations. Preventive maintenance planning, predictive analytics and coordination between departments can help optimize scheduling, reducing conflicts and improving equipment reliability.
2. Lack of worker awareness or training on dual standards
Maintenance personnel often need to comply with multiple regulatory standards, such as NFPA and OSHA. Without proper training, workers may misunderstand overlapping rules, leading to non-compliance, safety risks or inefficiencies.
Solution: Conduct cross-training sessions to clarify overlapping rules.
A structured training program that covers both NFPA and OSHA standards helps workers understand their responsibilities. Cross-training ensures that employees are aware of best practices, reducing the risk of violations. These sessions can include handson training, case studies and regular refresher courses to keep everyone updated on changing regulations.
3. Inconsistent documentation across NFPA and OSHA requirements
Many organizations struggle with maintaining consistent documentation, especially when
Insightsu
NFPA 70B insights:
uNFPA 70B plays a critical role in electrical safety by establishing proactive maintenance practices that prevent equipment failures and reduce hazards like arc flashes, complementing OSHA 29 CFR 1910.147’s lockout/tagout requirements to control hazardous energy.
uIntegrating NFPA 70B’s maintenance guidelines with OSHA’s energy isolation standards is essential for preventing deadly workplace incidents and ensuring compliance.
ENGINEERING SOLUTIONS
‘When safety standards remain kept rather than integrated, what unseen vulnerabilities might we be creating in our workplaces?’
complying with multiple standards. Variations in reporting formats, missing records or outdated logs can lead to compliance issues during audits or inspections.
Solution: Use integrated software to track compliance tasks and follow through with responsible persons and completion dates, storing evidence or documents to ensure closure.
Implementing a centralized compliance tracking system ensures all maintenance records are accurately logged and updated. Integrated software can automate documentation, generate reports and send alerts for upcoming inspections.
By addressing these challenges with the right solutions, maintenance teams can work more effectively, ensure compliance and contribute to a safer, more productive work environment.
Moving beyond NFPA 70B compliance
As workplace safety becomes an increasingly complex landscape, the integration of NFPA 70B and OSHA 29 CFR 1910.147 represents more than regulatory compliance, it shows commitment to preserving human life. When safety standards remain kept rather than integrated, what unseen vulnerabilities might we be creating in our workplaces? Perhaps the most crucial conversation isn't about compliance at all, but about how we build systems where protection becomes instinctive rather than procedural to protect workers' well-being. PE
Herbert Post is the vice president of health and safety at TradeSafe.
SOLUTIONS
Shannon Chiles, WEG Electric Corp., Duluth, Georgia
Use VFDs with integrated PLCs for safe and reliable pumping systems
VFDs with built-in PLCs offer an efficient and effective method to create processes for pumping systems.
Variable frequency drives (VFDs) with integrated programmable logic controllers (PLCs) and specialized pumping software are revolutionizing the operation of pumping systems. By guaranteeing effective operation to satisfy fluctuating demand, these integrated solutions offer a simplified method of protecting equipment.
Complex pumping applications are made more reliable and efficient by these systems, which combine the power of intelligent automation and superior motor control into a single device, the VFD.
Integrated PLCs are becoming a common element of many contemporary drives as VFD technology develops further. Because the user can program these PLCs to direct the functions of VFD, they can be customized for a variety of uses. Additionally, many vendors offer preprogrammed setups for particular use cases, such as multiplex pumping systems.
These preprogrammed application wizards simplify the VFD-to-PLC integration and allow for precise control and coordination of multiple pumps, enabling systems to respond dynamically to changing demands. This capability is particularly important in sectors where demand changes are frequent and operational efficiency is crucial, like water and wastewater treatment, oil and gas and HVAC.
Advantages of VFDs with integrated PLCs
Simplified setup and operation: Traditionally, PLCs separate from the VFDs were used for these types of systems. Having a separate PLC often leads to an increase in complexity and costs. Creating systems like these from scratch requires engineers, users and installation technicians to have knowledge of the VFDs, PLCs and the details involved in creating safe and effective pumping systems.
Additionally, when the system is designed using a separate PLC, this creates a single point of failure situation. If the PLC were to fail or stop operating for any reason, the system would be inoperable until the PLC was repaired or replaced.
In comparison, modern VFDs with integrated PLCs can transfer primary control of the system to one of the other VFDs and the system can continue to operate and effectively eliminate a single point of failure scenario. In terms of installation ease, the
FIGURE 1: A typical multiplex pumping system using variable frequency drives with integrated programmable logic controllers. Courtesy: WEG Electric Corp.
VFDs feature intuitive setup wizards and pictorial graphics that guide users through the configuration of the pumping system, taking into consideration the number of pumps, pump speeds, pump protections and proportional-integral-derivative loop tuning. This reduces the complexity typically associated with programming and commissioning, making these systems accessible even to those with limited technical expertise.
In terms of hardware, the analog and digital input/output that are part of the VFD are used instead of additional PLC equipment. The analog inputs on the drive served as input for the process signal (flow, pressure, level) and the digital inputs can be used with auxiliary switches.
The primary drive accepts the process signal, controls the process and directs the other drives when to run and at what speed. The connection between the primary drive and the other drives is via a communication protocol.
For backup redundancy, a duplicate process signal can be connected to one of the other drives so that if there is a loss of signal to the primary drive or the drive faults, the second drive can take over immediately as primary to run the system.
Enhanced equipment protection: These systems offer a variety of configurable protection features to safeguard both pumps and the overall system. Among the primary protection features are:
• Preventing pump cavitation: Making sure pumps run without air gaps that can damage pumps due to low pressure at the pump's suction end.
• Water hammer mitigation: Increasing the system's longevity by lowering pressure surges that harm pipe elbows and fittings.
• Suction/discharge pressure loss detection: preventing dry running and guaranteeing stability of operation.
• Seal water and check-valve integration: Supporting auxiliary components to maintain reliable operation.
• Seamless control transfer: Allowing standby VFDs to take over system control without interruption.
• Optimized efficiency: To optimize energy efficiency, these VFD/PLC systems run pumps at the most effective speeds depending on realtime data from sensors. This minimizes environmental effects and lowers energy usage, which not only lowers operating expenses but also helps sustainability programs.
Additionally, by proper use of pump curves and affinity laws, minimum pump speeds can be determined to maximize flow and reduce wasted energy. In the above example, we can use the affinity law relating head to speed. That formula is:
H1/H2 = (N2/N1)²
Because we are looking for N2, the formula can be rewritten as:
N2=N1/√(H1/H2)
Where:
H = head
N = speed
By plugging in our values, we find that two pumps running at 1,409 revolutions per minute (rpm) pumping the same volume as 1 pump running at 1,800 rpm at the point of intersection with the system curve. When the minimum speed value for two pumps running is entered into the integrated VFD pumping system, the system then operates
FIGURE 2: Wizard screen capture example. Courtesy: WEG Electric Corp.
• Understand how programmable logic controllers (PLCs) are integrated into modern variable frequency drives (VFDs).
• Learn the added advantage associated with a system using these VFDs
• Know that additional pumping system protections and efficiencies available with these types of VFDs, integrated PLC and setup wizards.
ENGINEERING SOLUTIONS
‘A major advancement in pumping system technology
is represented by the combination of VFDs with integrated PLCs and sophisticated pumping software.
at maximum efficiency without a decrease in volume. The same type of calculation can be done for the above to find out the minimum speed required when running three pumps.
Applications of VFDs with integrated PLCs
Water and wastewater management is one of the most well-known uses for VFDs with integrated PLCs. Municipalities rely heavily on pumping systems for city water treatment and distribution as well as wastewater processing. These systems are subject to varying flow demands, which makes efficient and reliable operation crucial. Integrated VFD-PLC systems provide:
• Demand-based control: Adjusting pump speeds to match real-time demand, reducing energy waste.
• Leak detection and prevention: Monitoring system pressure and flow to identify potential leaks or blockages.
• Redundancy management: Coordinating multiple pumps for seamless transitions in case of equipment failure.
High-rise building water booster pumps: Maintaining adequate water pressure for occupants of high-rise buildings is common use for VFDs with integrated PLCs. These buildings could be hotels, office buildings, dormitories or a variety of commercial use structures. Systems in this application provide:
• Water pressure consistency: By monitoring system water pressure, the number of pumps running and the speed that they are running can change to maintain a set pressure throughout the building.
• Energy efficiency: Since pumps only run at the required rate to maintain pressure, energy is saved and lowers electricity consumption.
• Remote monitoring: Allowing operators to monitor and adjust operations from central control rooms or remote locations.
In the oil and gas sector, VFD/PLC systems play a vital role in upstream, midstream and downstream operations. From extraction to refining, these systems ensure:
• Flow control: Maintaining precise flow rates to optimize production and processing.
• Pressure regulation: Preventing over-pressurization in pipelines and equipment.
• Remote monitoring: Allowing operators to monitor and adjust operations from central control rooms or remote locations.
Heating, ventilation and air conditioning systems also benefit significantly from VFD-PLC
FIGURE 3: Typical connections in multiplex variable frequency drive setup. Courtesy: WEG Electric Corp.
integration. These systems are used in commercial buildings, data centers and industrial facilities to:
• Regulate airflow: Adjust fan and pump speeds to maintain desired temperature and humidity levels.
• Improve energy efficiency: Minimize energy consumption during periods of low demand.
• Enhance system longevity: Reduce wear and tear on components by operating at optimal speeds.
Challenges and considerations of built-in PLCs
Although VFDs with built-in PLCs have many benefits, there are also some challenges to their deployment. Organizations should consider technical expertise and compatibility and integration. Although modern systems are designed to be user-friendly, organizations may still require
skilled personnel for programming and troubleshooting. Procuring training and support services from the manufacturer is essential in bridging this gap.
Ensuring compatibility with existing equipment and systems is critical. Careful planning and
25_003416_Plant_Engineering_JUN Mod: March 31, 2025 1:43 PM Print: 04/24/25 page 1 v2.5
FIGURE 4: Multiplex pump curve example. Courtesy: WEG Electric Corp.
ENGINEERING SOLUTIONS
Insightsu
PLC insights
uVFDs with integrated PLCs are transforming pumping systems by combining intelligent automation with advanced motor control, ensuring efficient operation while protecting equipment from common failures.
u As PLC technology becomes more integrated into modern VFDs, these systems simplify setup, enhance redundancy, and optimize energy efficiency across industries such as water treatment, oil and gas and HVAC.
uThe associated setup wizards make these VFDs excellent choices for safe and reliable systems that are easy to commission.
consultation with manufacturers can help mitigate potential issues during installation.
Future trends in VFD-PLC technology
Future developments in digitization and connectivity will influence the use of VFDs with built-in PLCs. Among the new trends are:
• Internet of things integration: Enabling realtime monitoring and control via cloud-based platforms.
• Advanced analytics: Leveraging data to predict maintenance needs and optimize system performance.
• Sustainability features: Incorporating renewable energy sources and energy recovery mechanisms as well as AI learning to optimize system usage.
A major advancement in pumping system technology is represented by the combination of VFDs with integrated PLCs and sophisticated pumping software. These systems offer a dependable and economical solution for a variety of applications by fusing energy-efficient operation, strong protective features and ease of use. This technology is a great option for today's pumping problems because it can result in improved operational performance, less downtime and long-term savings.
A key component of dependable system design is the capacity to adjust to shifting needs while safeguarding vital assets, whether in industrial operations or water management. VFDs with integrated PLCs are expected to become even more crucial in promoting efficiency and innovation in pumping systems as a result of continuous technological breakthroughs. PE
Shannon Chiles is manager of LV Product Marketing and Management at WEG Electric Corp.
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Why the future of Logging and Control systems are defined by you, often without you realizing it.
It’s all about the focus
Focus is defined by many things. One of them is ‘paying particular attention to.’ At DEWESoft we pride ourselves on using that word to describe two key aspects related to our approach to designing and developing data acquisition and control systems. We focus on what you tell us you need or want, then we focus our attention on delivering it, how you wanted or needed it. DEWESoft design devices for you and wholly based on you.
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Engineering Excellence, Manufactured in the USA
For more than 60 years, FS-Elliott has led the centrifugal compressor industry, delivering reliable, energy-efficient, oil-free air systems engineered for demanding environments. Headquartered in Export, Pennsylvania, we proudly uphold the highest performance, durability, and American manufacturing excellence standards.
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Nominated for the 2025 Plant Engineering Product of the Year Award, the P650 delivers 5,000 to 10,100 CFM at pressures up to 145 PSIG, making it an ideal solution for various industries.
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R3000 Control Panel: Intelligent Operation with Built-In Optimization
Designed for facilities prioritizing uptime, control, and energy savings, the R3000 combines robust PLC technology with advanced system intelligence. Also a 2025 Product of the Year nominee, the R3000 empowers operators with actionable insights and seamless remote access.
Built with a Siemens S7-1500 PLC and 12” color touchscreen HMI, the R3000 includes:
• Pressure Band Optimization (PBO) to match output to demand in real-time.
• Energy Advisor and Maintenance Notification System to minimize unplanned downtime.
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Housed in a rugged NEMA 4/IP66 enclosure, the R3000 delivers flexibility, insight, and control, ideal for modern plants requiring maximum efficiency and operational visibility.
Trusted Partner. Proven Performance.
At FS-Elliott, innovation means more than technology; it means delivering solutions that drive measurable value. With decades of engineering experience and a focus on customer outcomes, we help plants worldwide increase productivity, reduce lifecycle costs, and operate with confidence.
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In Plant User Lubrication Training Programs
Lubriplate Lubricants Company Newark, NJ 07105 / Toledo, OH 43605
Phone: 800-733-4755 • LubeXpert@lubriplate.com www.lubriplate.com
Seamless Support: The Strength Behind Our Conveyance Services
Motion Conveyance Solutions keeps your business moving with extraordinary service. From precision belting solutions to reliable rubber products, we deliver the support, expertise and dependability you need to stay on track.
Three real-world examples demonstrate our commitment:
1. A Texas ship terminal faced critical downtime due to a needed 2,000’ heavy-duty conveyor belt replacement and resplicing of two 72” ship loaders. Delays threatened shipping schedules and productivity, compounded by an unexpected arctic blast. We quickly dispatched experienced crews despite harsh weather. The team safely transported equipment, replaced the conveyor belt, and respliced both ship loaders, restoring full operations. This swift response minimized downtime, reinforced equipment reliability and ensured schedules stayed on track—even in challenging conditions. motionind.biz/4lpeffK
2. A Southeastern cement company previously purchased belting from us but had not used our field services until a critical path belt issue arose. Seven Motion technicians restored operations in under 30 hours. The following month, the customer trusted us again during a scheduled kiln outage, requesting the vulcanization of critical path belts within a tight 12-hour window. We successfully replaced both belts on time. This continuing partnership highlights Motion’s reliable field services that earn long-term customer trust and satisfaction. motionind.biz/3XTtnrz
3. A major East Coast building materials manufacturer faced frequent belt failures in their shingle production facility. Shingle grit was wearing out mechanical fastener plates. We installed Volta FEZ Homogeneous Green belts, eliminating mechanical fasteners by using a durable butt weld. These belts withstood rigorous production demands, requiring no retension or rewelding over the seven-month timetable; the previous belts lasted only a week. The reduced maintenance time and increased production saved the customer $80,000 annually. Impressed, the manufacturer expanded the use of these high-abrasion-resistant Volta belts to additional production facilities. motionind.biz/44eE3F5
Do you need help keeping your production moving?
Let Motion Conveyance Solutions step in with problemsolving expertise, value-driven solutions, and reliable, unmatched service.
VP, Sales
Matt Waddell
Sales Director
Allen Basis
Advertisers' Index
Automation Direct. C2, 1 www.automationdirect.com
Citgo 29, 42 www.citgo.com
Clayton 11 www.claytonindustries.com
Dewesoft 13, 43 www.dewesoft.com
EASA 2025 41 www.easa.com/convention
FS Elliott 4, 44 www.fs-elliott.com
Hydro-Thermal 17 www.hydro-thermal.com
Jax 21 www.jax.com
Lubrication Engineers 20, 45 www.LElubricants.com
Lubriplate .................. C1, 2, 46, C3 ....... www.lubriplate.com
Mapcon ........................ 34 ........... www.mapcon.com
Marshall University .............. 21 ........... www.mfg.marshall.edu/apprenticeships
Motion ........................ 35, 47 .......... www.motion.com
Proline 40 www.1proline.com
Royal Products 48 www.mistcollectors.com
SEW Eurodrive C4 www.seweurodrive.com
Uline 39 www.uline.com
Weldbend 6, 7 www.weldbend.com
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abasis@wtwhmedia.com 609-664-1451
Sales Account Manager
Brian Gross BGross@WTWHMedia.com 847-946-3668
Sales Account Manager
Richard Groth
Sales Account Manager
RGroth@WTWHMedia.com 774-277-7266
Robert Levinger RLevinger@WTWHTMedia.com 516-209-8587
Sales Account Manager
Judy Pinsel
847-624-8418
JPinsel@WTWHmedia.com
Publication Services
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YOUR SOURCE
Lubriplate’s ultra-high-performance, 100% synthetic lubricants have been engineered to provide unsurpassed performance in the most demanding plant environments. They provide a wide range of benefits designed to make your plant run better. Benefits include: extended lubrication intervals, lubrication consolidation through multiple application capability, reduced friction, extended machinery life and reduced downtime. Products include...
HIGH-PERFORMANCE SYNTHETIC GEAR OILS
SYNTHETIC AIR COMPRESSOR FLUIDS
SYNTHETIC HYDRAULIC FLUIDS
HIGH-PERFORMANCE SYNTHETIC GREASES
NSF H1 REGISTERED FOOD GRADE LUBRICANTS
ECO-FRIENDLY SYNTHETIC LUBRICANTS
SPRAY & SPECIALTY LUBRICANTS
At SEW-EURODRIVE, we engineer the highest quality drive automation solutions. What truly sets us apart is our unwavering commitment to customer support, long after the sale. We go above and beyond to ensure your business stays on the move with exceptional service at every turn. Upgrade everything.