plant engineering april 2013

8/12/2019 Plant Engineering April 2013

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41Selective coordination 47Pipe joining systems 54Fall arrest solutions


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Motion Industries understands that machines

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3/86

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4/86

Buy direct and save on high-quality components

Best prices on pneumatics

The NITRA Pneumatics F-Series non-repairable round body stainlesssteel cylinders includes bore sizes from 3/4 to 2 and stroke lengthsfrom 1/2 to 18 to meet a broad range of applications includingwashdown and corrosive environments.

All Stainless Steel PneumaticCylinders - F Series

Also

Available

All Stainless Steel Pneumatic Cylinders - F Series

- start at: $66.00 (F12005DN)

Cylinder bore sizes from 3/4 to 2

Air Cylinder stroke lengths from

1/2 to 18

Double-acting cylinders

Three pneumatic cylinder mounting

configurations

Tubing and Hose

Also available is the A series non-repairablecylinders, with stainless bodies and aluminum end caps.In bore sizes from 7/16 to 2, the A series starts at just $10.50.

Dual Rod Guided

Pneumatic Cylinders - "E" Series

- start at: $94.00(E12M010MD-M)

90 sizes available Eight bore sizes from 12mm

to 63mm

Cylinder stroke lengths from 10mm

to 250mm

Double-acting cylinders

Compact Pneumatic

Cylinders - "C" Series

- start at: $34.50(C090025D)

Cylinder bore sizes from 9/16" to 3"

Cylinder stroke lengths from 1/4" to 4"

Double-acting mini air cylinders

Interchangeable with other mini actuator, flat cylinder or pancake cylinder brands

Heavy Duty NFPA Tie Rod

Pneumatic Cylinders - "D" Series

- start at: $96.00(D24010DT-M)

Cylinder bore sizes: 1-1/2", 2", 2-1/2", 3-1/4", 4"

Cylinder stroke lengths

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Double-acting

cylinders Flange, pivot and

clevis cylinder

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More cylinder series also interchangeablewith popular brands

Fittings and

Air Couplings

Solenoid Valves

and Manifolds Air Preparation

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Switches/Transmitters

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Valve Cables

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Blow Guns

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1-800-633-0405

Go online or call to get complete information,request your free catalog, or place an order.

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input #2 at www.plantengineering.com/information


5/86

Miniature Infrared TemperatureSensor With Optional High-AmbientSensing Head and Touch Screen

Display"

Ideal for Tight Spaces" Miniature Sensing Head and

Configurable Electronics Module

Screen Color Change IndicatesAlarm Mode

Optional Touch Screen for TemperatureIndication and Configuration

Optional High-Ambient Sensing HeadWithstands Up to 180C (356F)Without Cooling

Visit omega.com/os-mini

omega.com

Plant Maintenanceand Operations

COPYRIGHT 2013 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

OS-MINISeries

Starts at$302

iBorescope for iPad/iPhone

for WiFi-Enabled Real-TimeVideo Capture and Displayon iPad/iPhone

Platforms

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$299

Visit omega.com/hhb-iscopeVisit omega.com/hx400

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Compact Thermal Imager



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www.plantengineering.com PLANTENGINEERING March 2013 3

Whats INside

6 Interactive

9In Focus

25In Practice

56 Innovations

61Product Mart

62Internet Connection

63Advertiser Contacts

64In Conclusion

30

March 2013Volume 67, No. 2

17 Energy management

The average impact of unplanned downtime in process industries is $20 billion,or almost 5% of production, according to a 2011 ARC Advisory Group report.With every 10 workers retiring, only five will take their place, which meansfewer skilled people will be trying to support ever more advanced and technical-ly interconnected plants. A strategic plan is in order, and it is in order right nowif any facility is expecting to survive the continued national and internationalcompetitive pressures.

32 Selecting a maintenance vendor

35 Providing a saner approach to maintenance

36 Is your plant a profit center or a profit eater? 38 The evolution of work processes can deliver revolutionary results

Cover Story

Maintenance

as a profit center

PLANT ENGINEERING (ISSN 0032-082X, Vol.

67, No. 2, GST #123397457) is published 10x

per year, monthly except in January and July,by CFE Media, LLC, 1111 W. 22nd Street, Suite

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Whats INside

Courtesy:RockwellAutomation


8/86

Bag-in Bag-out Filter Change

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9/86


CONTENT SPECIALISTS/EDITORIAL

BOB VAVRA,Content Manager 630-571-4070 x2212, [email protected]

AMANDA MCLEMAN,Project Manager

630-571-4070 x2209, [email protected]

BEN TAYLOR,Project Manager


MARK HOSKE,Content Manager


AMARA ROZGUS,Content Manager


PETER WELANDER,Content Manager


BRITTANY MERCHUT,Content Specialist


CHRIS VAVRA,Content Specialist


PUBLICATION SERVICES JIM LANGHENRY,Co-Founder & Publisher 630-571-4070 x2203, [email protected]

STEVE ROURKE,Co-Founder 630-571-4070 x2204, [email protected]

TRUDY KELLY,Executive Assistant 630-571-4070 x2205, [email protected]

ELENA MOELLER-YOUNGER,Marketing Manager 630-571-4070 x2215, [email protected]

MICHAEL SMITH,Creative Director 630-779-8910, [email protected]

PAUL BROUCH,Web Production Manager 630-571-4070 x2208, [email protected]

MICHAEL ROTZ,Print Production Manager

717-766-0211, Fax: 717-506-7238 [email protected]

MARIA BARTELL,Account Director, Infogroup Targeting Solutions 847-378-2275, [email protected]

RICK ELLIS,Audience Management Director 303-246-1250, [email protected]

LETTERS TO THE EDITORPlease e-mail your opinions to

[email protected] or fax us at 630-214-4504.Letters should include name, company, and address,

and may be edited for space and clarity.

INFORMATIONFor a 2013 Media Kit or Editorial Calendar,e-mail Trudy Kelly at [email protected].

REPRINTSFor custom reprints or electronic usage, contact:Wrights Media Nick Iademarco

Phone: 877-652-5295 x102 Email: [email protected]

PUBLICATION SALES Tom Corcoran,West, TX, OK [email protected] 1111 W. 22nd St., Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax 484-631-0598

Karen Cira,Southeast [email protected] 879 Autumn Rain Ln. Tel. 704-523-5466 Charlotte, NC 28209 Fax 630-214-4504

Patrick Lynch,AL, FL [email protected] 1111 W. 22nd St., Suite 250, Tel. 630-571-4070 x2210 Oak Brook, IL 60523 Fax 630-214-4504

Kerry Gottlieb,N. Central [email protected] 1111 W. 22nd St., Suite 250, Tel. 312-965-8954 Oak Brook, IL 60523 Fax 630-214-4504

Richard A. Groth Jr.,NJ/ E. PA [email protected] 12 Pine St. Tel. 774-277-7266

Franklin, MA 02038 Fax 508-590-0432 Stuart Smith,International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588

9In Focus New wave of technology moves beyond theory

Checklist for robotics survival

Putin to open Hannover Messe 2013 on April 7

ARC president: Pick up the pace of technology adoption

Training, mentoring needed to address skilled worker shortage

Innovative energy management strategies help a Maine paper mill

stay competitive

Reduced corrective maintenance is found money Staying ahead of the curve

In Practice

25 Benchmark your manufacturing performance to deliver results Manufacturing leaders must establish production schedules, optimum workflows, effective maintenance procedures, and continuous improvement programs that will keep the organization

moving forward.

Electrical Solutions

41 Achieving effective selective coordination design The concept of full selective coordination has changed the way engineers must think when designing electrical distribution systems.

Mechanical Solutions

47 Pipe joining systems get in the groove Of all the pipe joining methods available, maintenance on HVAC systems installed using

grooved piping products is the fastest, most efficient, and simplest to perform.

Maintenance Solutions51 Fall arrest solutions require attention to detail, not scale Big or small, implementing a fall protection system requires considering a number of factors. The project size is not one of those factors.

53Making sense of process safety A Process Safety Management (PSM) program and a more focused National Emphasis Program (NEP) are relatively new to U.S. manufacturing. While PSM-NEP makes sense, we must begin to make sense of it.

PlantEngineering.com1111 W. 22nd St. Suite 250, Oak Brook, IL 60523

Ph 630-571-4070, Fax 630-214-4504

CONTENT SPECIALISTS/EDITORIAL

BOB VAVRA,Content Manager 630-571-4070 x2212, [email protected]

AMANDA MCLEMAN,Project Manager


BEN TAYLOR,Project Manager


MARK HOSKE,Content Manager


AMARA ROZGUS,Content Manager


PETER WELANDER,Content Manager


BRITTANY MERCHUT,Content Specialist


CHRIS VAVRA,Content Specialist


PUBLICATION SERVICES JIM LANGHENRY,Co-Founder & Publisher 630-571-4070 x2203, [email protected]

STEVE ROURKE,Co-Founder 630-571-4070 x2204, [email protected]

TRUDY KELLY,Executive Assistant 630-571-4070 x2205, [email protected]

ELENA MOELLER-YOUNGER,Marketing Manager 630-571-4070 x2215, [email protected]

MICHAEL SMITH,Creative Director 630-779-8910, [email protected]

PAUL BROUCH,Web Production Manager 630-571-4070 x2208, [email protected]

MICHAEL ROTZ,Print Production Manager

717-766-0211, Fax: 717-506-7238 [email protected]

MARIA BARTELL,Account Director, Infogroup Targeting Solutions 847-378-2275, [email protected]

RICK ELLIS,Audience Management Director 303-246-1250, [email protected]

LETTERS TO THE EDITORPlease e-mail your opinions to

[email protected] or fax us at 630-214-4504.Letters should include name, company, and address,

and may be edited for space and clarity.

INFORMATIONFor a 2013 Media Kit or Editorial Calendar,e-mail Trudy Kelly at [email protected].

REPRINTSFor custom reprints or electronic usage, contact:Wrights Media Nick Iademarco

Phone: 877-652-5295 x102 Email: [email protected]

PUBLICATION SALES Tom Corcoran,West, TX, OK [email protected] 1111 W. 22nd St., Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax 484-631-0598

Karen Cira,Southeast [email protected] 879 Autumn Rain Ln. Tel. 704-523-5466 Charlotte, NC 28209 Fax 630-214-4504

Patrick Lynch,AL, FL [email protected] 1111 W. 22nd St., Suite 250, Tel. 630-571-4070 x2210 Oak Brook, IL 60523 Fax 630-214-4504

Kerry Gottlieb,N. Central [email protected] 1111 W. 22nd St., Suite 250, Tel. 312-965-8954 Oak Brook, IL 60523 Fax 630-214-4504

Richard A. Groth Jr.,NJ/ E. PA [email protected] 12 Pine St. Tel. 774-277-7266

Franklin, MA 02038 Fax 508-590-0432 Stuart Smith,International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588


10/86

6 March 2013 PLANTENGINEERING www.plantengineering.com

Exclusive blogs at www.plantengineering.com/blogsCMMS horror stories: Five reasons a CMMS implementation can fail

Machine Safety: Serious machine guarding issues

Machine-tool industry limiting growth in the motion control marketGovernment in the power business

LinkedIn: Plant Engineering ProfessionalsPlant Engineerings LinkedIn audience has more than 2,200 manufacturing professionals from six conti-

nentsand were working on finding our first manufacturing professional from Antarctica. Join the discus-

sion in the Plant Engineering Professionals group at www.linkedin.com.

Industry newsHere are the top stories for this month on www.plantengineering.com:

PMI surges to highest point in almost two years

Automation project road map: Advice for the journey

ARC study: Additive manufacturing creates powerful incentive

Hot technology jobs: artificial intelligence, robotics

ABB to fund 40 global research projects

To keep up with important industry news, go to www.plantengineering.com/industry-news.

Point, click, watch

SPECIAL REPORT:The electrical

infrastructure businessDon Rickey, senior vice president for the U.S. Infrastructure

Business at Schneider Electric discusses the medium-voltage

electrical distribution business and a host of other items. Scan the

QR code or visit www.plantengineering.com/videos .

www.plantengineering.com

Connect with us!

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and news with our weekly Plant Mail and topic-

specific electronic newsletters.

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system integrators. You can find a specific company

or run a seven-way multi-parameter search.

Digital editionPlant Engineeringis delivered every month in a

digital format, with enhanced features to bring the

print product alive on your screen.

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Deadline is Sept. 16, 2013.

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MARCH

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11/86

Facts about BlowersEnergy conscious plants might think ablower to be a better choice due to its

slightly lower electrical consumptioncompared to a compressor. In reality, ablower is an expensive capital expenditurethat requires frequent downtime andcostly maintenance of filters, belts andbearings. Here are some important facts:

Filters must be replaced everyone to three months.

Belts must be replaced everythree to six months.

Typical bearing replacement is at least once

a year at a cost near $1000.

Blower bearings wear out quickly dueto the high speeds (17-20,000 RPM)required to generate effective airflows.

Poorly designed seals that allow dirt andmoisture infiltration and environmentsabove 125F decrease the one yearbearing life.

Many bearings can not be replaced inthe field, resulting in downtime to sendthe assembly back to the manufacturer.

Blowers take up a lot of space and oftenproduce sound levels that exceed OSHAnoise level exposure requirements. Airvolume and velocity are often diffi cult tocontrol since mechanical adjustments arerequired.

To discuss an application, contact:

EXAIR Corporation

11510 Goldcoast DriveCincinnati, Ohio 45249-1621(800) 903-9247Fax: (513) 671-3363email: [email protected]

www.exair.com/79/423.htm

See the Super Air Knife in action.www.exair.com/79/akvideo.htm

ompare these Blowoffsere are a variety of ways to blow the water from the bottles shown in the photo below,

ut which method is best? To decide, we ran a comparison test on the same application

ing four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (eaching compressed air as a power source), and a blower supplied air knife (using an electricotor as a power source). Each system consisted of two twelve inch long a ir knives. ellowing comparison proves that the EXAIR Super Air Knife is the best choice forur blowoff, cooling or drying application.

e goal for each of the blowoff choices was to use the least amount of air possible tot the job done (lowest energy and noise level). e compressed air pressure requiredas 60 PSIG which provided adequate velocity to blow the water off. e blowered had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM.

e table at the bottom of the page summarizes the overall performance. Since yourtual part may have an odd configuration, holes or sharp edges, we took sound level

easurements in free air (no impinging surface).

The Super Air Knife is the low cost way

to blowoff, dry, clean and cool.

If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

The Truth About Compressed Air!

Drilled Pipeis common blowoff is veryinexpensive and easy to make. For thistest, we used (2) drilled pipes, each

with (25) 1/16" diameter holes on 1/2"centers. As shown in the test resultsbelow, the drilled pipe performedpoorly. e initial cost of the drilledpipe is overshadowed by its high energyuse. e holes are easily blocked andthe noise level is excessive - both of

which violate OSHA requirements.Velocity across the entire length

was very inconsis tent with spikesof air and numerous dead spots.

Flat Air NozzlesAs shown below, this inexpensiveair nozzle was the worst performer.It is available in plastic, aluminumand stainless steel from severalmanufacturers. e flat air nozzleprovides some entrainment, but suffersfrom many of the same problemsas the drilled pipe. Operating cost

and noise level are both high. Somemanufacturers offer flat air nozzles

where the holes can be blocked -an OSHA violation. Velocity wasinconsistent with spikes of air.

EXAIR Super Air Knifee Super Air Knife did an exceptional

job of removing the moisture on one passdue to the uniformity of the laminarairflow. e sound level was extremelylow. For this application, energy use wasslightly higher than the blower but can beless than the blower if cycling on and offis possible. Safe operation is not an issue

since the Super Air Knife can not be dead-ended. Maintenance costs are low sincethere are no moving parts to wear out.

Blower Air Knifee blower proved to be an expensive, noisyoption. As noted below, the purchase priceis high. Operating cost was considerablylower than the drilled pipe and flat airnozzle, but was comparable to EXAIRsSuper Air Knife. e large blower withits two 3" (8cm) diameter hoses requiressignificant mounting space compared tothe others. Noise level was high at 90 dBA.ere was no option for cycling it on and off

to conserve energy like the other blowoffs.Costly bearing and filter maintenance alongwith downtime were also negative factors.

Blowoff Comparison

Comp. Air Horsepower

Required

SoundLevel

dBA

Purchase

Price

AnnualElectrical

Cost*

Approx. AnnualMaintenance

Cost

FirstYear

CostType of blowoff PSIG BAR SCFM SLPM

Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478

Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227

Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288

Super Air Knife 60 4.1 55 1,557 11 69 $534 $1,417 $300 $2,251

*Based on national average electricity cost o f 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.



12/86

Dual Bulk Bag Weigh

Batch Eductor conditions,discharges by weight, andblends into a liquid stream

Bulk-Bag-To-Bin Weigh

Batching System discharges,de-lumps and feeds materialgravimetrically

Continuous Loss-of-Weight

Bulk Bag Unloader allowscontinuous gravimetricdischarging

Bulk Bag Unloader for

Pneumatic Conveyors hassurge hopper with rotaryairlock feeder for metering

Sanitary Bulk Bag

Discharger with patentedUSDA-accepted flow controlvalve cleans rapidly

BB-0470

Now save time, money and spacewith BULK-OUTmulti-function dischargers

Condition, de-lump, screen, feed, weigh batch, combine with liquids, and convey as you discharge,with a custom-integrated, performance-guaranteed discharger system from Flexicon

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See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners,Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

2013 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

*Patent(s) granted and/or pending.

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Bulk Bag Unloader forPneumatic Conveyors hassurge hopper with non-flow-through pick-up adapter

Bulk Bag Conditioner-Unloader loosens solidifiedmaterial, then discharges,de-lumps and conveys

Half Frame Unloaderswith Conveyor or Airlockrequire forklift, eliminatingcost of upper frame

Combination Bulk BagDischarger and ManualDumping Station has multi-purpose hopper interface

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Unlimited configurations:All Flexicon dischargers are available

as fully enclosed, dust-free systems withdurable industrial finishes or in stainless

steel finished to food, dairy, pharmaceuticalor industrial standards, and as weigh

batching systems complete with automated

controls and pneumatic or mechanicalconveying systems.

Flexicon innovations: SPOUT-LOCK clamp ring*: forms high-integrityseal between clean sides of bag and equipment

TELE-TUBE telescoping tube: maintainsconstant downward tension on spout as bagempties/elongates, promoting complete discharge

POWER-CINCHER flow control valve*: allows

retying of partially empty bags dust-free bycinching spout concentrically.



13/86


The fourth wave of innovative technol-

ogy jobs will involve computers, tele-

communications, biotechnology, artificial

intelligence, and robotics, according to

Dr. Michio Kaku, American theoretical

physicist, best-selling author, TV host,

and Feb. 21 keynote speaker at the 2013

Robotics Industry Forum, held in Orlan-

do, Feb. 20-22. He also praised engineersin general and physicists in particular,

credited for inventing the transistor, laser,

computer, Internet, World Wide Web, TV,

radio, x-rays, radar, the microwave, PET

scans, the space program, and GPS satel-

lite, among other innovations.

Kaku, who is continuing work started

by Einstein on a grand unified theory of

the universe, has made the New York

Times best seller list twice, with Physics

of the Future, citing 300 top scientists,

and Physics of the Impossible, a look

at life and science 500 to 1,000 years in

the future.

Even so, in his keynote presentation,

The Future of Technology, Kaku cited

Yogi Berra, credited with explaining that

prediction is very hard to do, especially

if its about the future.

Even so, hindsight is marvelous, show-

ing that many economic downturns came

after unsustainable economic speculation

that followed waves of engineering inno-

vation. Engineering innovation, he said,

is the origin of all wealth.He called the first wave of economic

innovation the rise of steam power in the

1800s, which was followed by the crash

of 1850, resulting from more than 200

stocks on the London exchange related to

steam poweran unsustainable number.

The second wave resulted from inno-

vations from electricity, magnetism, and

the internal combustion engine, leading

to speculation surrounding utilities and

automotive stocks on the NYSE, a bubble

that burst in 1929, Kaku said.The third wave came 80 years later,

with high technologies, such as lasers,

computers, satellites, telecommunica-

tions, and the Internet, which led to the

real estate bubble and what Kaku called

the unsustainable Mediterranean lifestyle

of Europe, leading to the 2008 recession,

still felt in Europe today.

The fourth wave, Kaku said, will be

telecommunications, computers, bio-

technologies, artificial technologies, and

nanotechnologies, driven and supported

by motion control, machine vision, and

robotics.

In each wave, there are those who

resist, Kaku observed, and those who

have resisted often faced bankruptcy and/

or unemployment. The automobile put

many blacksmiths and stable hands out

of work, but new jobs were created. Kaku

challenged attendees, noting that recent

negative coverage of robots is the latest

in this nay-saying trend: Who will define

your industry? Will you define yourself or

will you allow your competitors to do so?Kaku said, Robotics and other auto-

mation replace dull and dangerous jobs,

and we should celebrate that. Innova-

tion is the source of jobs. Dont let bad

press by 60 Minutes define you, he

said, talking about the piece that sug-

gested use of robots results in fewer jobs,

when examples and research suggest

otherwise.

The progression of Moores Law is

tied to the wealth and power of nations,

Kaku said: Now, we have more comput-

ing power in our pocket cell phone than

all of NASA did in 1969 to put men on

the moon. PE

Next wave of technology moves beyond theory2013 Robotics Industry Forum speaker takes a long look into the future of everything.

By Mark T. Hoske,CFE Media

INFOCUS

Robotics and otherautomation replace dull and

dangerous jobs and we should

celebrate that. Innovation is

the source of jobs. Dont let

bad press by 60 Minutes

define you.Dr. Michio Kaku

Robot design-

ers who ignore

one or more

of three principles

are doomed to fail,

according to a roboti-cist with 22 patents

who has worked for

three robot com-

panies and MIT

Robotic Lab. Joseph

L. Jones, co-founder

and chief technology officer, Harvest

Automation, told attendees at the

Robotics Industries Forum about a

checklist for robot survival.

How are robots like sea turtles?

For each 1,000 sea turtles hatched,only one lasts to adulthood. Its about

the same statistic for robots. Robot

designers need to

be really careful

in choosing which

robots to build,

Jones said. He also

worked at iRobot

(which has sold

9 million Roomba

robotic vacuums) and

at Denning Mobile

Robotics. In 30 years

of watching the robotic industry, hes

observed three key elements that

need to be present with any robot

project for success.

1. Do something that lots of peo-

ple want done

2. Be built with existing technol-

ogy, and

Checklist for robotics survival


14/86input #8 at www.plantengineering.com/information

INFOCUS

3. Be cost-competitive

with current solutions.

While this seems perfect-

ly logical, when in the thickof things, roboticists usu-

ally ignore one and often

all three, Jones said. In his

talk, Small Mobile Robots

for Agriculture, Jones dis-

cussed his current efforts at

Harvest Automation, found-

ed in 2007,

now with 40

employees.

Hes making

robots foragriculture. A

nursery and

greenhouse

robot is the

companys first product.

Plants sold in garden stores often are grown in pots in

open fields that extend to the horizon. Armies of hard-

to-find workers manually space pots in the field after the

pots are unloaded from

wagons.

After I observed that,

I thought, If we cannot

build a cost-effectiverobot to do this, were

in the wrong business,

Jones said.

The first model,

Harvest Automa-

tion HV100, costs

about $30,000, with

return on investment

after 12-18 months

of use, Jones said.

Addressing labor scar-

city issues, Harvestsrobots are designed

to work alongside

people, not replace

them, in a growers

operation, to create a

sustainable workforce combining robots and people

to increase efficiency, reliability, and plant quality, he

noted. PE

The Harvest Automation HV100 nursery

and greenhouse robot is flexible andscalable, fault tolerant, inherently safe

for operation near people, and easy and

intuiti ve to set up and operate. All

photos courtesy of Harvest Automation.


15/86

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12 March 2013 PLANTENGINEERING

Russian president Vladimir Putin will help open Han-

nover Messe 2013 as part of Russias status as

partner nation at this years event, April 8-12 in

Hannover, Germany.

The Russian head of state will be in the Hannover Con-

gress Centrum for the opening ceremony on Sunday, April

7, and will also take part in the traditional opening tour of

Hannover Messe on Monday, April 8. On both occasions,

President Putin will be accompanied by German Chancel-

lor Angela Merkel, who this year will again officially open

the worlds most important technology event.

We are delighted to have received confirmation of

President Putins visit, said Dr. Jochen Kckler, member

of the Board at Deutsche Messe AG. His presence offers

convincing evidence of the international status enjoyed

by Hannover Messe and at the same time underlines the

importance of the Partner Country program.

Every year a different country is invited to step into

the spotlight and act as the Partner Country at Hannover

Messe. This year, the Russian Federation will be the

focus of attention, not only within the exhibition itself but

also throughout the entire program of forums, conferenc-

es, and events that traditionally accompanies the worlds

leading trade show.

The lead theme of Integrated Industry signals Hannover

Messes strong focus on the current trend toward integration

across all areas of industry. Integrated Industry is about

making industrial production smarter and more efficient. Its

also about multidisciplinary cooperation between different

industries and different enterprises, Dr. Kckler said.

Hannover Messe 2013 will comprise 11 flagship fairs:

Industrial Automation; Motion, Drive & Automation (MDA);

Energy; Wind; MobiliTec; Digital Factory; ComVac; Indus-

trial Supply; IndustrialGreenTec; Surface Technology; and

Research & Technology. PE

For more information, go to www.hannovermesse.de.

Photo courtesy of Hannover Messe.

INFOCUS

Putin to open Hannover

Messe 2013 on April 7


17/86

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18/86

Its not about the productsIts not about the productsIts not about the products

on our shelves.on our shelves.on our shelves.

Its what we do withIts what we do withIts what we do withour productsour productsour products thatthatthat

makes the diference.makes the diference.makes the diference.

The speed of manufacturing informa-

tion adoption is accelerating, and those

who stay on the sidelines will find them-

selves falling farther and farther behind

a fully optimized plant.

That was the keynote message from

ARC Advisory Group president Andy

Chatha at the 2013 ARC Forum in Orlan-

do Feb. 12. All of you have data, gather-

ing information in real time. The chal-

lenge is that we havent had good tools to

analyze that data, Chatha told more than600 attendees at the ARC event. Now

we do have powerful analytical tools. We

think information-driven manufacturing

is the way to leverage the information.

You have to be able to make sense out of

the information.

Chatha noted that the accelerated use

of smart devices, the pervasive influ-

ences of Wi-Fi and cloud computing,

and the connective nature of devices all

have created enormous opportunities

to leverage the data now available on

the plant floor.

Its much easier now to get devices

connected and add intelligence, Cha-

tha said. In my view, one thing that

is happening is that the cost of adding

intelligence is coming way down. Com-

panies should be adding intelligence to

all equipment. Data should be moving

toward some sort of cloud.

But the key for manufacturing to take

advantage of this technology is speed,

and Chatha noted manufacturing is slow

to embrace speed.Technology constantly is changing.

Most manufacturing companies are very

conservative. They only employ technol-

ogy when it has been well-proven, he said.

That strategy worked fine in the past. New

technologies are more disruptive, and they

are moving faster. Now you have to start

testing technologies faster. If you are not

testing technologies, it may take you too

long to catch up. Youve got to start moving

a little faster to develop new technologies.

Chatha sees a continuing evolution ofplant floor processes. With powerful

tools, you can look at all processes in the

plant and information outside the plant

in your supply chain, for example, Cha-

tha said. Look at how analyzing much

larger amounts of information can opti-

mize the performance of the plant.

Developing such a plan will require

new relationships from existing suppli-

ers. The automation business already is

moving toward being more of a service

business, Chatha said. One model is

looking at signing some sort of perfor-

mance-based service agreement with sup-

pliers, based on key metrics. Systems are

becoming more complex, and it is more

difficult for manufacturers to upgrade

them and manage them. PE

INFOCUS

ARC president: Pick up the pace of technology adoptionRapid growth of devices, technology use requires faster implementation on plant floor.

By Bob Vavra, CFE Media

With powerful tools, youcan look at all processes in

the plant and information out-

side the plantin your supply

chain, for example.

Andy Chatha,ARC Advisory Group


19/86

Get more from your MRO products provider.

Experience the independent diferencewith your local IDC Distributor atwww.IDC-USA.coop/diference


Respondents to Plant Engineerings2012 Salary

Survey again placed workforce development on top

of their list of plant floor issues. Attracting that next

generation of workers requires not just a need to attract

skills, but also to satisfy the changing nature of these

workers.

That was the conclusion of a panel of experts at the ARC

Advisory Group World Forum in Orlando Feb. 12. There

is a skills gap, but also a generational gap in how workers

operate and how they use technology.

Dick Hill of ARC Group, who moderat-

ed the session, noted that workers on

the cusp of retirement may walk away

with more than a pension or a 401K.

Experienced workers know how

the plant runs, and know when its not running well, but its

not written down, Hill said.

Citing a Pew Research report that called the millennial

generation digital natives, Hill noted that the next genera-

tion expects modern technology and progressive corporate

culture to greet them on their arrival in the workplace.

Have you built necessary training tools and training

environment? Hill said. Do you have a mentoring pro-

gram? Is your plant equipment ready for them? Is your

software application smart, because knowledge of your

current workers is going to go away?

That reality has forced companies such as Momentive

Specialty Chemicals to change the way they train and

deploy employees. New employees are learning the right

way to operate the plant, and we want them to be able to

train cross-functionally. We can share resources between

plants, said Brooke Robertson, project manager for

Momentive Specialty Chemicals. At Momentive within 5

years just in engineering, 17% of our workforce will be eli-

gible for retirement. How are we going to be able to retain

all of this information?

Mike Resetarits of Fractional Research Inc., a company

that does distillation research for chemical and engineering

companies, cited estimates of 10,000 workers a day for the

next 20 years leaving the workforce.

That means were losing 400,000 years per day of

experience, Resetarits said. The boomer generation puts

their job high on their list of priorities.

It allows them to achieve all the other

goals they have set for their lives.

Confronting a transition in the

workforce at Fractional Research

took some soul searchingand some

tough choices. We had a problem. We were on the verge

of losing our best engineers and best technician opera-

tors, Resetarits said. There were several things we did to

prepare. It took us about a year.

The company put its experienced engineers and tech-

nicians into a room and programmed all of the plants

start-up and shutdown operations into the system. When

new operators came on, the procedures were already pro-

grammed, but Resetarits said it didnt change the opera-

tional knowledge in the department.They embraced it, he said. They never stop thinking.

They dont just push the button. They think about the pro-

cess, and the computer program corroborates what they

were going to do anyway.

Within that transition were some veteran workers who

were unwilling to change. We had some people who

Training, mentoring needed to address skilled worker shortage

By Bob Vavra, CFE Media

Were losing 400,000 yearsper day of experience.

Mike Resetarits,Fractional Research Inc.


20/86

put #13 at www.plantengineering.com/information

16 March 2013 PLANTENGINEERING

INFOCUSproved to me that they did not want to work with us.

Theyre gone, he said. We released 11 people and

none of those were easy, but now we have a group of

engineers who are as good. Change is an every-minute

experience in our control rooms, Resetarits said. We

decided to hire happy people. There are people whowake up angry every day, and they infect the entire

organization. When we interviewed, we looked for

people who liked to smile. We looked for people who

like people. The number one thing we looked for was

attitude.

One strategy was for Momentive to take a fresh look

at its control system. Modernizing your control system

will attract new workers but also will capture knowl-

edge, Robertson said. Implement global DCS stan-

dards. It makes modernizations quick, and the benefit

for the operators is they can now switch between units.

Theyre not about learning the control systems. All theyhave to pick up is the process.

She noted that many of the problems of data capture

and system modernization are fixable through system

alignment. When your engineering resources are low,

your DCS vendor likely has a solution for you, Robert-

son said. You need to train operators on how to run

operations, but a key is to run simulations. But you also

need to keep simulators up to date. But all of the chal-

lenges we were faced with, there were solutions out

there.

In search of Gen X-ers

While the discussion in the workforce development

issue revolves mostly around retiring baby boomers

and up-and-coming millennials, a third group may

actually hold the key to filling a widening Skills Gapif

they can be found.

The Generation X group, generally born between

1960 and 1980, normally would be the next in line to

fill in the jobs currently occupied by baby boomers, but

fewer of those people took manufacturing jobs in the

period from 1985 through 2005, when they most likely

would have been heading into the workforce.

One thing that is not discussed is that if we look at

workforce issues, as baby boomers retire, theres a big

hole of Gen X-ers not there to fill in, said Peter Zornio

of Emerson Process Management during the panel

discussion. If you look at the timing, it was at a time

when many of us werent hiring.

In the modern market, where Facebook profiles for

both employers and job seekers are now the norm,

the challenge seems to be getting manufacturing

careers a seat at the kitchen table when careers are

discussed.

How do we make what we do attractive to young

people? asked Maurice Wilkins of Yokogawa. Do we

need to bring apprenticeships back? We need to make

young people believe what we do isnt boring. PE


21/86

Call. 800-526-9328

Click. www.motionindustries.com

Visit. Over 500 Locations

For more vendors,see our full line catalog.

INDUSTRIALSOLUTIONSCATALOG

pg 2

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pg 3 pg 4 pg 5

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pg 8

pg 10-11

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02567974 MRO350-DP 30" X 150 ft 1/case

LABELING / SECURITY / ABSORBENTS
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BatteriesAlkalineProfessionalProcell

Dependable, long-lasting powerwith up to a seven-year freshnessguarantee; date coded toguarantee freshness

Operates reliably in temperatureextremes of -20C to 54C

Economical bulk packaging forprofessional applications

Contains no added mercury Priced per each

Lantern Battery6 VoltAlkalineCopperTop

Alkaline lantern batteries last up to twice aslong as super heavy duty zinc carbon batteriesand provide an extra measure of leakageresistance for critical applications

Reliable performance at temperature extremes Date coding to ensure freshness and a long

shelf life No added mercury

BatteriesAlkalineULTRA Power

Seven-year guarantee in storage High battery output

Watch Batteries1.5 VoltSilver Oxide

High capacity, low self-discharge for longer service life Longer lasting to increase productivity

Mercury-free

Coin Cells3 VoltLithium

For electronic devices including memory back-ups and testing meters High capacity, low self-discharge for longer service life Longer lasting to increase productivity Mercury-free

Lithium Photo Battery3 VoltULTRA Photo

For applications with a high current pulse and continuous drain Reliability with more consistent performance Longer lasting to increase productivity Wide operating temperature extremes (-40F to 140F)

Item # Mfr Part # Battery Size Pkg Count

02537658 PC2400 AAA 24

02537657 PC1500 AA 2402538037 PC1400 C 1202452561 PC1300 D 1202537659 PC1604 9 Volt 12


03113128 MN-908 6 Volt 1

Item # Mfr Part # Battery Size Package

03279851 MX2500 AAAA Double Blister Pack


04784725 384/392 1.5V 384/5R41/KSingle Blister Pack

03139362 303/357 1.5 Volt


04291799 DL2032 3 Volt Single Blister Pack03044852 DL2450


03844857 DL1233 Volt Single Blister Pack

05396741 DLCR2

BATTERIES
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EnergizerIndustrialAlkaline Batteries

Offers the longest lasting power source of all primary batteries

over a range of sizes No mercury addedspecial disposal is not required Operates well in temperature extremes (-30C to 55C) Excellent shelf lifealkaline cells are ready for use even

after 7 years of storage Priced per each

EnergizerIndustrial3 LED Headlight

Two light modes: Whitespot / red for night vision

Light pivots up to 90 Shatter-proof lens On/Off switch Adjustable head strap Packed with 3 AAA

EnergizerMAXbatteries Run time: 28 hours

EnergizerIndustrial6 LED Headlight

Four light modes: Area, spot, flood and red (for night vision) Light pivots up to 90 Easy On/Off push button switch Adjustable head strap with two built-in pencil holders Grips to safety helmets

Packed with 3 AAA EnergizerMAXbatteries


02952094 EN92 AAA 24

02952092 EN91 AA 24

02952096 EN93 C 12

02952097 EN95 D 12

02952090 EN22 9 Volt 12

Item # Mfr Part # Light Output Beam Distance

02952099 HD33A1EN 30 Lumens 23 Meters

Item # Mfr Part # Light Output Beam Distance

03462021 HDL33AINE 48 Lumens 33 Meters

BATTERIES / LIGHTING
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1/2" 20V High-TorqueImpact WrenchCordlessImpactool

780 ft-lbs of maximum reverse torqueand 1100 ft-lb of nut-busting torquefromcordless impact wrench that weighsonly 6.8 lbs

High-power rare earth magnet(neodymium) motoroffers a long lifeand high power

Steel-lined aluminum hammer casedesigned to be strong andlightweight for maximum protection of the internal components

All-metal drive train and hammer mechanismrobust, durable,and optimized for maximum power and efficiency

2,300 impacts per minute at 1,900 RPM Variable speed switch with electronic brakeprovides maximum

control of the tool Patent-pending metal reinforced housingready to work even

after repeated drops Patent-pending soft touch over-molded gripminimizes vibration,

reduces fatigue, and enhances user comfort during extended use Best-in-class short length9.4" from tip to tail W7150-K2 Standard Anvil Two Battery Kit includes: One W7150

Impactool, one IQV20 Charger, two 20V Li-ion 3.0 Ah batteriesand one blow-molded case

Vibration Reduced Air HammerLong Barrel

Great for exhaust and front-endjobs, general bolt cutting, pindriving and body shearing work

Anti-vibration feature reduces toolvibration by over 30% whencompared to standard airhammers in its class, plus anergonomic grip that provides comfort for extended use

15% increased in impact force over standard air hammers Quick-change retainer allows for faster chisel changeovers, so you

can get the job done

Air Angle Die Grinder300 Series

Features a composite grip for superior ergonomicsand comfort, and can be used in various

applications including porting, weld breaking,de-burring, polishing and grinding

Durable ball-bearing construction improvesbalance, reduces vibration, and ensures a longer life

Built-in lubricating wick increases angle gear life Lightweight, durable, ergonomic composite

housing protects tool from cold air and offersgreater operator comfort

Integral safety-lock throttle lever prevents accidental start up Rear exhaust directs air away from the operator, piped-away

exhaust kit optional Tool comes with 1/4" and 6 mm collets and two wrenches

Air Chain HoistCLK Series

Meets ASME B30.16 specifications Rugged, lightweight and compact design Disc brake is non-asbestos and spring engaged

with air release Quiet operation


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Synthetic Air Compressor Fluids

SynXtreme AC Series

100% Polyol Ester (POE)-based, high performance fluids ECO-friendly; readily biodegradable (Pw1) Extended drain intervals up to +10,000 hours, monitored by

Lubriplates complimentary fluid analysis program

Syn Lube Series

100% Synthetic, Polyalphaolefin (PAO)-based fluids Fully compatible OEM fluid replacement Extended drain intervals up to 8,000 hours, monitored by


Synac Series

100% Diester-based synthetic air compressor fluids High temperature fluids eliminate varnish buildup Extended drain intervals up to 8,000 hours, monitored by


Syncool

100% synthetic, Polyglycolester-based fluid ECO-friendly; readily biodegradable (Pw1) Superior heat transfer properties

SFGO Ultra Series

NSF H-1 registered food machinery grade For food processing and bottling operations 100% synthetic, (PAO) based compressor fluids

Item # Mfr Part # Container Viscosity

Grade

SynXtreme AC Series03450190 L0939-060 5 gallon Pail ISO 32

03450191 L0939-062 55 gallon Drum ISO 32

03450192 L0940-060 5 gallon Pail ISO 46

03450193 L0940-062 55 gallon Drum ISO 46

03450194 L0941-060 5 gallon Pail ISO 68

03450195 L0941-062 55 gallon Drum ISO 68

SynLube Series04398031 L0968-062 5 gallon Pail ISO 22

02338479 L0970-060 55 gallon Drum ISO 2202318930 L0970-062 5 gallon Pail ISO 32

05067620 L0971-057 55 gallon Drum ISO 32

05067619 L0968-060 1 gallon Jug ISO 46

02309842 L0971-060 5 gallon Pail ISO 46

02338480 L0971-062 55 gallon Drum ISO 46

02338481 L0972-060 5 gallon Pail ISO 68

02338482 L0972-062 55 gallon Drum ISO 68

02248199 L0973-060 5 gallon Pail ISO 100

02248200 L0973-062 55 gallon Drum ISO 100

Synac Series01467844 L0932-060 5 gallon Pail ISO 32

01467846 L0932-062 55 gallon Drum ISO 32

01467847 L0933-060 5 gallon Pail ISO 46

01467848 L0933-062 55 gallon Drum ISO 46

01467849 L0934-060 5 gallon Pail ISO 68

01467850 L0934-062 55 gallon Drum ISO 68

05067611 L0935-054 1 quart Bottle ISO 100

04229150 L0935-057 1 gallon Jug ISO 10001467851 L0935-060 5 gallon Pail ISO 100

01467845 L0935-062 55 gallon Drum ISO 100

Syncool03720571 L0964-060 5 gallon Pail ISO 32/46

03855067 L0964-062 55 gallon Drum ISO 32/46

Item # Mfr Part # Container Viscosity

Grade

SFGO Ultra Series03068409 L0912-057 1 gallon Jug ISO 7

02338483 L0912-060 5 gallon Pail ISO 7

05067605 L0912-061 16 gallon Drum ISO 7

02338484 L0912-062 55 gallon Drum ISO 7

04255094 L0930-057 1 gallon Jug ISO 15

02946753 L0930-060 5 gallon Pail ISO 15

05067607 L0930-061 16 gallon Drum ISO 15

04371475 L0930-062 55 gallon Drum ISO 15

05067608 L0931-057 1 gallon Jug ISO 2204745440 L0931-060 5 gallon Pail ISO 22

05067609 L0931-061 16 gallon Drum ISO 22

05067610 L0931-062 55 gallon Drum ISO 22

03941473 L0915-057 1 gallon Jug ISO 32

01277054 L0915-060 5 gallon Pail ISO 32

02338485 L0915-061 16 gallon Drum ISO 32

01302652 L0915-062 55 gallon Drum ISO 32

05067606 L0916-057 1 gallon Jug ISO 46

01303055 L0916-060 5 gallon Pail ISO 46

02338486 L0916-061 16 gallon Drum ISO 46

01303065 L0916-062 55 gallon Drum ISO 46

02462236 L0917-057 1 gallon Jug ISO 68

01303472 L0917-060 5 gallon Pail ISO 68

02338487 L0917-061 16 gallon Drum ISO 68

01303480 L0917-062 55 gallon Drum ISO 68

02462231 L0983-057 1 gallon Jug ISO 100

02475058 L0983-060 5 gallon Pail ISO 100

02462238 L0983-061 16 gallon Drum ISO 10002475059 L0983-062 55 gallon Drum ISO 100

LUBRICANTS
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