1. technology and computing
2. enterprise technology
3. enterprise resource planning

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How to
recondition
motor
controls
P E R F O R M A N C E | R E L I A B I L I T Y | E F F I C I E N C Y | A S S E T M A N AG E M E N T
Them
Back
DE C E M BE R 2 0 0 8
IT Undergoing Convergence
PS0812_01_Cover.indd 1
p.13
Coating Exposed Equipment
p.31
Energy: Are We Getting It?
p.42
Embrace Aging Workers
p.23
12/8/08 4:57:16 PM
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©20
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STRATEGIC PLANNING I ENGINEERING I FACILITIES MAINTENANCE I ENERGY MANAGEMENT I SUPPORT SERVICES
PS0812_FPA.indd 4
12/4/08 9:23:36 AM
Volume 29, Number 12
features
26
COVER STORY
Bring Them Back
How to recondition motor controls
31
COATINGS
Ensure Good Coverage
Strategies for maintaining coatings of exposed equipment
specialists
23
Asset Manager
Aging Workers
How to make the most of tough demographics
25
Technology Toolbox
Valves Evolve
Advances in valve-control materials, design and construction
improve performance, reduce costs and simplify maintenance
37
Web Hunter
Potpourri XI
The annual collection of cyberspatial oddities
42
Energy Expert
Do We Get It?
It might be time for energy evangelists to move on
PlantServices.com
WEB-ONLY
ARTICLE: THE EFFECTIVE SAFETY AUDIT
PlantServices.com
A well-prepared and well-executed safety audit program can
make a substantial difference in helping companies prevent
accidents and injuries. Use these five simple tips to develop
a program that will produce success and increased safety at
www.plantservices.com/articles/2008/249.html.
WEB-ONLY ARTICLE: REPLENIShING
A WELDING SHORTFALL
A Texas-based training center rapidly builds a skilled worker
base for the welding industry. Find out how they did it at
www.plantservices.com/articles/2008/250.html.
columns and departments
7
December 2008
PS0812_05_TOC.indd 5
Rally ’Round
19
Expand your definition of
extended family
CRISIS CORNER
Beyond the Boob Tube
Skill TV proves to be a crucial
tool to fix the crisis
9
LETTERS
• Hands-On Careers
• Restoring Our Past
21
WHAT WORKS
11
THE PS FILES
34
IN THE TRENCHES
Of Greed and Giving
Bearing manufacturer gets
the generosity ball rolling
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FROM THE EDITOR
13
UP AND RUNNING
Software strategists raise
emphasis on integration
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Chemical Plant Boils
With Hydrogen
Killing Time
Acme employees respond
to accusations of submitting
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39
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PS0812_FPA.indd
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FROM THE EDITOR
Rally ’Round
Expand your concept of extended family
L
Personally, I’d be foolish to stop my home remodeling
ike many of you, I have lived and worked through
projects designed to improve energy efficiency, or suspend
the economic stagflation of the 1970s and the
my investments in raising and educating my children, or
recessions of the early 1980s, 1990s and the oughts.
run my car on worn-out tires just because my retirement
We’ve seen the Dow plunge, unemployment rise, bankaccount has tanked.
ruptcies flourish and GNP sag. But this time, for me at
Simply put, those of us who are still solvent must not
least, the speed, breadth, depth and reasons behind this
stop spending, even if we easily could. Instead, we must
particular economic debacle have made it much more, shall
disburse our funds carefully, with an eye to how our investwe say, engaging.
ments will support our fellows and the economy we want
I’m not saying it’s happening yet, but there’s nothing like
so much to turn back in the right direction.
an imminent global economic collapse to remind us of how
For me, that means an emphasis on services, because
powerless we are as individuals. In aggregate, we dominate
dollars spent there are likely to help the most people. Next
the world, but we remain pretty pathetic little hunks of
come locally produced goods and those with significant
meat when we perceive our personal livelihoods as threatlabor content, then the businesses whose failures I believe
ened in ways over which we have no control.
would be the greatest losses to me and my
Our instincts are to curl up around what we
community. I put a higher value on domestic
have, hoard it and protect it for the benefit of
our immediate families – those closest to us
Those of us who goods, but I also plan to buy imports that are
and dearest to our hearts. It’s a fine instinct
are still solvent the strengths of their countries of origin and
don’t compete with local products.
for surviving a drought or famine, where food
must not stop
Think about how your dollars not only
or water is scarce. There’s only so much to go
spending.
can make their way locally from your wallet
around and once it’s gone, it’s gone. No need
to your local suppliers, their employees, the
to help the weak – better that the fittest surmarket and back to you by being used to buy
vive to ensure continuity of the species.
your company’s products, but also can go around the world,
But those instincts have no place in our industrialized
help many people, and then come back to you.
society, where the very definition of “survival” has come to
It’s also a good time to remember the local food banks
mean plenty of gas in the tanks of cars to drive on smooth
and charities that will allow those who have lost their jobs
roads among well-stocked supermarkets, centrally heated
to remain in the community so they will be available to
homes and workplaces, where our efforts are appreciated
help you when times turn better.
and rewarded with riches beyond the imagination of anyI see it as extending my family in this time of need. Inone who battles the elements for subsistence.
stead of focusing just on myself and blood relations, I need
If we want to survive this recession, it means emerging
to consider how every expenditure can do the most to help
not just alive, but with a support system of suppliers, serothers weather the economic storm and, in turn, feel confivice providers, distributors and OEMs with the resources
dent enough to do the same for their extended families.
and personnel we need to flourish in the vacuum created by
From where I’m sitting, it looks like the best way out.
our less wise, failed former competitors.
Projects and plans that made sense before the banks ran
aground are still likely to be solid winners as soon as things
pick up. During the past few weeks we’ve spoken with
leaders of many major manufacturers who understand this
PAUL STUDEBAKER, CMRP
and don’t intend to curtail the investments they planned
EDITOR IN CHIEF
for improving their products, efficiency, growth potential
pstudebaker@putman.net
and competitiveness.
(630) 467-1300 ext. 433
December 2008
PS0812_07_Editorial.indd 7
www.PLANTSERVICES.com
7
12/8/08 4:55:15 PM
PS0812_FPA.indd 8
12/4/08 9:25:42 AM
PERFORMANCE | RELIABILIT Y | EFFICIENCY | ASSE T MANAGEMENT
Putman media, inc.
555 W. Pierce Rd., Ste. 301, Itasca, IL 60143
BACKTALK
Phone: (630) 467-1300, Fax: (630) 467-1120
mike brenner,
group publisher
mbrenner@putman.net
editorial staff
paul studebaker , cmrp
editor in chief
pstudebaker@putman.net
russell l . kratowicz , p. e. cmrp
executive editor
russk@putman.net
lisa towers
managing editor
ltowers@putman.net
stephen c. herner
group art director
sherner@putman.net
jennifer dakas
art director
jdakas@putman.net
david berger , p. eng.
contributing editor
peter garforth
contributing editor
sheila kennedy
contributing editor
joel leonard
contributing editor
bob sperber
editor at large
publication services
carmela kappel
assistant to the publisher
ckappel@putman.net
jerry clark
v. p., circulation
jclark@putman.net
jack jones
circulation director
jjones@putman.net
rita fitzgerald
Hands-On Careers
M
y father spent 22 years in the Navy in the dataprocessing field (“The Trades’ Secret,” October,
p. 11, www.plantservices.com/articles/2008/212.
html). After he retired, he was offered jobs that paid very
well in that field, but he always turned them down. I used
to ask him why would he turn down a job that paid so
well, and he always told me, “I spent 22 years of my life in
the field of computers, and I don’t want to do it anymore.”
Instead, he went back to school, earned a master’s degree in divinity, and
promptly went to work with his brother-in-law to build houses. After that,
he worked in a sawmill. He used to joke that he was probably the only man
with a master’s degree who liked to pack lumber. Growing up, I never could
understand why he did these types of jobs when he could earn more money
doing something else. Now that I’m grown, I understand. My father loved to
work with his hands. Doing what he loved to do liberated him.
My mother wanted me to become a CPA. Instead, I studied electronics
and machining at a community college, and operated heavy equipment in the
Army. My father instilled in me a love of working with my hands. I am teaching my two sons to work with their hands and I tell them that whatever fields
they decide to go into, they need to learn how to fix stuff. Most anybody can
operate machinery, but not everybody can repair it. Our country needs to get
back to its vocational roots. In my home state, there is a candidate running for governor who wants to bring vocational training back to our high
schools because, in his words, “Not everybody wants to go to a four-year
college.” We have pushed our children into thinking that the only way to
get a well-paying job is to earn a four-year degree. As a maintenance mechanic, I might not have the most glamorous job in the world and I might
not make the highest salary, but I love my job. I think my father had it all
figured out after all.
Eric Hobernicht, maintenance mechanic
ASMO Appalachian Corp., Mt. Airy, N.C.
production manager
rfitzgerald@putman.net
claudia stachowiak
reprints marketing manager
Foster Reprints
(866) 879-9144 ext. 121
claudia@fostereprints.com
administrative staff
john m. cappelletti
president/ceo
julie cappelletti - lange
vice president
keith larson
v. p., content
rose southard
it director
December 2008
PS0812_09_Talk.indd 9
Restoring Our Past
I just had to drop you a line after seeing that you attended the Southeast
Threshers Reunion (“What I Did on
My Vacation,” September, p. 19, www.
plantservices.com/articles/2008/183.
html.) I used to go to that event every
year, but I have not been for several
years now. Isn’t it amazing how many
of the old engines and tractors have
survived and how many look as good,
if not better, than they did when they
were brand new? I still have about
half a dozen old gas engines and some
www.PLANTSERVICES.com
other old farm equipment, but I have
not attended any shows lately. I am in
the process now of setting up an old
Meadows sawmill at my grandmother’s old home where the log house that
my great-great grandfather built still
stands. I want to make somewhat of a
museum out of the place where people
can come and see some of the ways
people used to live. Thanks for reminding me of the good times I used
to have at Denton Farm Park.
Michael Garren, engineering supervisor
Hickory Printing Group, High Point, N.C.
9
12/8/08 1:01:44 PM
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K en S c h nep f
THE PS FILES
Of Greed and Giving
One bearing manufacturer gets the generosity ball rolling
I
Months of newscasts delivering details of unimaginable
f your boss handed you a check for $35,000 – in addicorporate greed have stoked our collective cynicism and
tion to your regular paycheck – what would you say?
grown a sense of panic. Government bailouts, handouts and
Employees of Peer Bearing Co. in Waukegan, Ill.,
help for seemingly everyone but the average worker threaten
were speechless when the company’s owners, the Spungen
to dull our sympathies and crush our faith.
family, did just that. Back in September, the company was
Many wonder whether American manufacturing as we
sold to SKF, and to celebrate, the owners threw a party for
know it will continue to exist. We question whether we’ll
their 230 employees. Handing out an extremely generous
be able to maintain our high standard of living. We wonder
bonus check to each employee, commensurate with how
if anyone is thinking about those who work hard to keep
long each had worked for the company, was the family’s
our facilities running. People still want to
way of saying thank you for each person’s
believe in something good, if they could just
loyalty and dedication. They enclosed the
find it among the reports of so much being so
gifts in hand-written thank-you notes.
The trick is not in bad. “It’s because there’s so much greed going
“The employees were in total shock,” says
making money; on,” Spungen says. “People have called to
Laurence Spungen, former owner of the
thank me, saying this generosity has restored
company. “They thanked me. Many people
the trick is in
their faith in mankind.”
were so joyous and so surprised. You can tell
giving it away.
It seems the Spungen family would have
they have a warm feeling toward our family.”
made the same decision to take care of the
When the Spungen family began to plan
people who have helped take care of their
for the eventual sale of the company more
company, recession or not. “It’s the mentality of sharing,”
than a year ago, they collectively decided to set aside more
he says. “What makes anyone successful? You have to have
than $6 million just for these bonuses, out of revenues of
a team. Sharing is a good thing. The trick is not in making
$100 million they made last year. The result was tearymoney; the trick is in giving it away.”
eyed employees who appreciated not just the money, but
Bonuses are not the only vehicle the Spungen family has
the benefactors behind it. “We’ve always tried to make the
used to distribute some of their good fortune. Several years
working environment comfortable and clean,” Spungen
ago, they established the Florence and Laurence Spungen
says. “We try to bring up people’s morale. Here, feelings
Family Foundation, and one of their favorite charities is
are important. People are treated like family.”
One Step at a Time (www.onestepcamp.org), which is a
These are sentiments you don’t hear from management
camp for children with cancer. A lymphoma survivor for
very often, and they’re certainly not backed up with hefty
28 years, Spungen can easily relate to the families of chilbonus checks. Consequently, the Spungen family’s method
dren with cancer. “We lose kids every year at the camp,” he
of giving back to their employees has made big news. More
says. It’s taught him to “be thankful for what you have.”
than 400,000 hits to Peer Bearing’s Web site and countWhen he was diagnosed with lymphoma at age 50,
less media interviews later, Laurence Spungen says he was
his doctors said he’d live just seven months. Now, at 78,
just doing the right thing. “I do what I think is necessary,”
Spungen thinks of himself as being a young guy with
he adds. “That’s my only read on it. There was no other
many more adventures ahead of him. He has several other
agenda. Just do what you think is the right thing to do.”
business interests, including being the owner of Peer Chain
That he did the right thing during a recessionary year
Co., and his family still works with the SKF-owned comand while financial alarm bells are sounding at thousands
pany that Spungen’s father started in 1941. “Every day is
of manufacturing facilities across the country is partly what
important,” he says. “So let’s not be so selfish.”
has given this story wings. Like most Americans, Spungen
says he had no idea that the subprime mortgage mess was
about to hit our economy – and the world economy – hard.
E-mail Managing Editor Lisa Towers at ltowers@putman.net.
December 2008
PS0812_11_PSfiles.indd 11
www.PLANTSERVICES.com
11
12/8/08 4:17:15 PM
PS0812_FPA.indd 12
12/4/08 9:26:08 AM
UP AND RUNNING
Call It Convergence
Software strategists raise emphasis on integration
By Paul Studebaker, CMRP, Editor in Chief
A
Head (feet)
Head (feet)
llowing information to flow freely among applications and between offices and plant floors
isn’t a new concept, but it appears to be reaching
a new level of reality, especially for maintenance and assetmanagement purposes. Recently, it seems that everywhere
software is spoken, the emphasis is on what’s being done
to make connections, build custom dashboards, enable
automatic alarms and notifications, and empower individuals with the information they need when, where and in the
context required to help them squeeze out higher productivities, reliabilities and efficiencies.
At the ARC Forum, Oct. 13-15 in Houston, Dow
Chemical’s Kevin Bauman pointed out that 42% of
company knowledge resides in people’s brains, 26% on
paper and 20% in electronic documentation. Only 12% is
accessible to software systems as e-knowledge to support
decisions, a proportion that needs to be improved through
better interaction among systems.
But it’s
not easy, thanks in part to “the morass of stan120
dards we’re
110 in right now, due to people not doing the hard
120
Pump curve
100
work of110
building
consensus and instead, just writing their
Pump curve
90
100
own,” said
Alan
Johnston,
president, Machinery Informa9080
8070
tion Management
Open Systems Alliance (MIMOSA), as
7060
part of his
6050 Open O&M Initiative and MIMOSA session
5040
at the ARC
Forum. The many disparate and legacy systems
4030
and vendors
that have grown over time make the job com3020
System curve
plex (Figure
1). System curve
2010
0
There10are
too
of stan2000many
4000 standards
6000 8000 and
10000fractions
12000
0
2000 Volumetric
4000 6000
8000
10000 12000
flow rate
(gal/min)
dards. Johnston
suggested
that
implementers
reference the
Volumetric flow rate (gal/min)
standards’ use cases and project them forward (Figure 2).
“By the time we’re actually doing the job the standards will
hopefully simplify and combine, but to get them to change
in the best way, we have to use them now,” he said. “Develop your requirements based on the road map and vendors
will comply. They have been watching and are ready.”
At Rockwell Automation’s recent Automation Fair, they
called it convergence, which Chairman and CEO Keith
Nosbusch defined as merging manufacturing and production systems with the rest of the corporate enterprise.
The drivers are globalization, productivity, innovation
and sustainability. The enabling megatrend, Nosbusch said,
December 2008
PS0812_13_17_UpRun.indd 13
Complexity Reigns
Complexity Reigns
Enterprise business system ERP
Enterprise business system ERP
Services-oriented architecture (SOA)
Services-oriented architecture (SOA)
Manufacturing
data
Manufacturing
data
Integration
Engineering
registry
Integration
data
Engineering
(ontology)
registry
(STEP)
data
(ontology)
(STEP)
Open O&M
Open
O&M
Schema
Schema
Meta
Data
Plant data
historian
Meta
Data
Master
Data
Plant
data
historian
Master
Data
MIMOSA
MIMOSA
Distributed information
Other
manager
Distributed
information
data
Other
manager
data
Design &
engineering
Design &
engineering
Distributed
control
Distributed
system
control
system
PM PLM SM
PM PLM SM
Business process
engine
Business
process
engine
Integration
server
Integration
server
Integration engine
Integration engine
Adapter engine
Adapter engine
O&M
decision
O&M
support
decision
support
MIMOSA
Asset
XML
health
MIMOSA
Asset
messages
manager
XML
health
messages
manager
Human
Manufacturing
machine
applications
Human
interface Manufacturing
machine
applications
interface
Physical asset control-real-time systems
Physical asset control-real-time systems
Figure 1. Convergence depends on accessing, analyzing and
presenting information at every level of a typical manufacturing
organization. Source: SAP.
The Open O&M Initiative To-Be State for Asset Excellence
The Open O&M Initiative To-Be State for Asset Excellence
Control systems,
operational
data,
Control
systems,
historians
and
HMIs
operational
data,
historians and HMIs
OPC XML and
MIMOSA
OPC XMLOSA-EAI
and
MIMOSA OSA-EAI
Order and material
Operational forecasting, management, personnel
Order and material
planning
and
Operational
forecasting,
and financialpersonnel
systems
management,
scheduling
systems
planning and
ERP, CMMS
and financial
systems
scheduling systems
ERP, CMMS
ISA-95, OPC XML and
ISA-95
MIMOSA
ISA-95,
OPC OSA-EAI
XML and
ISA-95
MIMOSA OSA-EAI
Open operations and maintenance enterprise information bus specifications
Open operations and maintenance enterprise information bus specifications
MIMOSA OSA-EAI MIMOSA OSA-EAI MIMOSA OSA-EAI MIMOSA OSA-EAI
MIMOSA OSA-EAI
MIMOSA
OSA-EAI
MIMOSA
OSA-EAI
Periodic
and
Diagnostic
and MIMOSA
EAMOSA-EAI
asset
Asset capability
online
Periodic
and
condition
online
monitoring
condition
monitoring
prognostic
Diagnostic
and
asset health
prognostic
asset health
registry
and
EAM
asset
maintenance
registry andwork
management
maintenance
work
management
forecasting
and
Asset
capability
optimization
forecasting
and
optimization
Physical asset resource management systems
Physical asset resource management systems
Figure 2. The quest for standardized interfaces is heating up . Here is
MIMOSA’s vision for a physical asset resource management system.
Source: MIMOSA
www.PLANTSERVICES.com
13
12/8/08 4:18:34 PM
is convergence of control, communication, information and power technologies on the manufacturing floor.
“Imagine a highly linked environment enabled by modern technology
and global standards that can flexibly
combine and leverage information,”
he said.
Nosbusch suggested that the future
holds universal acceptance for Ethernet and a resolution to the age-old
IT-versus-production culture clash.
Maintenance and asset management
will benefit from increased access to
plant-floor variables such as loads,
cycles and speeds, as well as condition information such as temperature,
vibration and power signatures.
CMMS/EAM software suppliers
also spoke volumes on the subject of
information exchange and integration
at several user group meetings this
fall. “If I have to have information
from a work order in an ERP system,
that information is going to flow,”
said Eric Miles, president and CEO,
AssetPoint (TabWare).
David Kotrady, AssetPoint director, product development, is on a road
map that calls for pre-built connectors and a standard integration approach for automation systems, GIS
and engineering content.
Like many others, AssetPoint is
harnessing MIMOSA standards,
using “Mtelligence” to aggregate
plant floor information and serve it
up to the asset-management system
to track, for example, run time (as
opposed to calendar time) and equipment health. Conversely, the maintenance-management system is being
made visible to operators so they can
see existing work orders and work in
progress, and enter new orders.
Arguably positioned to benefit
significantly from the packages of its
many acquisitions working together,
Infor is reducing complexity through
a new Open SOA for networks.
14
PS0812_13_17_UpRun.indd 14
www.PLANTSERVICES.com
“Open SOA lets components be
added via open, standard interfaces,”
said Jim Shafer, Infor chairman and
CEO. Making the connections via
standard interfaces lets users easily
connect to non-Infor applications.
“They write XML and Infor
manages the flow of information,”
Shafer said. Standard interfaces let
the packages themselves be updated
independently. “Updates can be made
continually without disruption,” he
added. “Infor includes them as part of
an annual service contract.”
Maintenance planning can be integrated into the supply chain schedule,
“what we call ‘advanced scheduling,’”
said John Murphy, director, global industry and product marketing, EAM
for Infor. Real-time and historical
energy information can be factored
into repair/replace decisions, help determine what equipment to procure,
and be used to compare energy effects
of various capital planning scenarios.
IFS put open architecture at the
top of its list of key trends in EAM
software at its customer summit.
Other trends include integration with
enterprise software, mobile and wireless, and proving ROI.
The EAM gives costs of material,
labor and inventory, but you need
more, said IFS Cofounder and Global
Industry Director Ulf Stern. To calculate OEE and revenue information,
you need to know if the equipment
is running or not, or is running slow,
or producing poor quality. IFS’s
MaxOEE module adds operator and
corporate dashboards, automatic data
input via MIMOSA/OPC/S95 and
integration with EAM systems.
Whatever the cause for underperformance, MaxOEE defines results
in terms of lost revenue in dollars.
“People react much more to the figures when there are dollar signs,” he
observed, “even when they know how
much the hours are worth.”
December 2008
12/8/08 2:09:06 PM
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
12/4/08 9:26:27 AM

UP AND RUNNING
First Lube Company Certified for Food Safety
N
SF International (www.nsf.
org, formerly the National
Sanitation Foundation) an-
nounced that synthetic lubricant
company KL Texas, L.P. (dba Summit
Industrial Products, www.klsummit.
Establishing Reliability Excellence
for Lean Implementation
(Lean Reliability)
com), is the first company in North
America to receive certification to ISO
21469: Safety of Machinery – Lubricants With Incidental Product Contact
– Hygiene Requirements.
ISO 21469 specifies hygiene
requirements for the formulation,
manufacture, use and handling of lubricants that might come into contact
with food products during manufacturing or processing. The international standard applies to lubricants for
food production as well as cosmetic,
pharmaceutical and animal feed.
“Certification to ISO 21469 by
an independent third party provides
lubricant manufacturers with a means
to obtain international acceptance for
their products,” says Sarah Krol, NSF
business unit manager.
Resources
Is clean air a luxury?
Air filtration system and parts manufacturer Donaldson Co. answers that
question in the white paper, “HighQuality Compressed Air Filters: Is
High-Quality Filtration a Luxury?” The
paper outlines the methods and cost
savings associated with filtering compressed air in industrial applications
to remove dust, prevent formation of
corrosive and flow-restricting sludge
deposits, and avoid damage to pneumatic machinery. Access the paper at
www.donaldson.com/en/compressor/
support/datalibrary/061913.pdf.
Teach proper hearing protection
A new poster from Howard Leight
details the care and maintenance of
earplugs and earmuffs. Designed for
posting on worksite bulletin boards or
in other high-traffic areas, the colorful
display provides clear instructions
for each type of hearing protection
device in a clear, concise fashion while
serving as a reminder to wear hearing
protection on the job. Download a
free PDF of the poster at www.howard
leight.com/bestpractices/commit.
16
PS0812_13_17_UpRun.indd 16
www.PLANTSERVICES.com
December 2008
12/8/08 2:09:22 PM
U.S. Workers Taking Chances
U
.S. workers are risking workplace injuries by not complying with important safety
procedures, according to a survey by
Kimberly-Clark Professional (www.
kcprofessional.com). The survey
found that 89% of safety professionals polled at the 2008 National
Safety Council (NSC) Congress
have observed workers failing to wear
personal protective equipment (PPE)
when they should have been.
“We fi nd it disheartening that
people continue to put themselves
at risk by failing to wear PPE when
undertaking hazardous tasks,” said
Randy Kates, general manager of the
safety business for Kimberly-Clark
Professional. “Despite the importance of PPE, there is still an unacceptably high rate of noncompliance
in the workplace.”
Th is is the third consecutive year
that the Kimberly-Clark survey
revealed a high rate of PPE noncompliance. In 2007, 87% of respondents said they had observed PPE
noncompliance in the workplace,
whereas 85% answered yes to this
question in 2006.
Given the high rate of noncompliance during the past three years, it
is not surprising that when asked
to name the top workplace safety
issue in their facilities, one-third of
respondents cited worker compliance with safety protocols. Next was
insufficient management support and/
or resources for health and safety
functions (27%). Under-reporting of
workplace injuries and illnesses was
third (14%), followed by training a
multilingual, multicultural workforce
(7%) and escalating worker compensation costs (5%).
The study also investigates the
eff fects of the economy, the environDecember 2008
PS0812_13_17_UpRun.indd 17
ment, supplier relationships, and
what respondents were doing to
improve compliance. For more on
this topic and a link to the full survey
results, see www.plantservices.com/
industrynews/2008/150.html.
Here You GO!
Introducing the GO, a new
mid-range laser alignment
tool from Fixturlaser.
The new GO is designed to offer the dedicated functionality of the
Shaft Hog, while applying the measurement technology of the XA.
It fits right into Fixturlaser’s “Express Alignment” philosophy, with large
detectors, line lasers, built-in inclinometers, and USB connectivity.
Customers have been asking for it, and we’re pleased to reply “here you go”.
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www.PLANTSERVICES.com
17
12/8/08 2:09:41 PM
“
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Hackensack University Medical Center, Hackensack, NJ
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#2022 Facility Ad Final.indd 1
PS0812_FPA.indd 18
7/18/08 10:20:22 AM
12/5/08 12:12:53 PM
CRISIS CORNER
Beyond the Boob Tube
Skill TV proves to be a crucial tool to fix the maintenance crisis
T
featuring the issues and challenges regarding the maintehe negative television portrayal of skilled trades
nance crisis online.
contributes to the stigmas that prevent future
For a whole year, I nurtured this idea, developed potenworkers from developing the skill sets necessary
tial content and made a list of interviewees but without
to enter the field of maintenance. I’ve written much about
a sponsor, I knew this project wasn’t going to get off the
this topic because it’s something I’m passionate about. This
ground. Then, Plant Services’ editors asked me to write
passion, combined with my personal experiences, helped
a blog about the maintenance crisis. I said, “Everybody
me find a way to help take the some of the panic out of the
writes blogs, but no one has his own online TV show about
maintenance crisis.
the maintenance crisis.” I shared with them some of the
Before my father died from cancer a few years ago, I
videos I paid a production studio to protook him to record his legacy chronicles. At
duce on a fast-track apprentice program we
the time, he was in the final stage of his life.
Looking back, I was lucky to get him up
Even though he developed at the MPACT Learning Center.
Several of Plant Services’ leaders said, “Let’s
the three flights of stairs to the production
had more than give it a try.” That was all I needed to hear. I
studio, much less get him to open up in front
100 channels,
later purchased my own production-quality
of a camera. He was a proud man who, as
video camera and am now enjoying the crea physician, delivered thousands of babies.
there still was
He also served as county coroner and was
nothing to watch ative process of producing videos for, as well
as being the host of, Skill TV.
involved in solving hundreds of murders. He
on TV.
Skill TV just marked its first anniversary,
was known for his intelligence and his ability
and in this year we’ve achieved so much. We
to provide accurate diagnoses of common
filmed the EuroMaintenance Conference, the
and obscure ailments. In his later years, he
Council on Competitiveness Workforce briefing on Capitol
became withdrawn and suffered from painful internal
Hill, the PEMAC MainTrain Conference and the National
damage caused by esophageal cancer.
Competitiveness Summit. We interviewed students from a
Before hiring pros to record his video, I wondered if he’d
Youthbuild HVAC class, attendees of the Southeast Threshopen up and provide a record of his reflections on his life.
ers Reunion and numerous other industry events. We’ve interMy fears quickly dissolved when the video director brought
viewed government leaders, business leaders and technicians
in a cute, curious young lady who nurtured my father’s
to explore the challenges of the maintenance crisis.
sizeable ego and coaxed this normally shy man to unload
My father never got to watch Skill TV, but I know he’d
his life’s dreams, fears, concerns and frustrations.
be proud to know that he played a part in providing sociThis video is something I cherish and look forward to
ety’s real heroes – workers – with the tools to fight stigmas,
watching with my grandchildren. They’ll get an accurate
stereotypes and ignorance.
idea of who their progenitor was and recognize him as
We’re busy editing 40 additional Skill TV episodes and
much more than just a name listed on their family tree.
hope to soon upload them to SkillTV.net. We also will be
During the interview, my father, who once spent most
featuring videos from my adventures in Amsterdam, Milan
of his time watching cable TV, said that even though he
and Dubai. We’ll be dedicating more energy to potential
had more than 100 channels, there still was nothing to
maintenance crisis solutions, and I would love to hear your
watch. As I listened to him ridicule TV, I saw the creative
suggestions and get your input about what you would like
process at work in the recording studio, and I realized
to see on Skill TV during 2009. I look forward to receiving
that online videos could be a powerful tool to help the
all of your ideas!
world realize the challenges we face in maintenance. The
concept for Skill TV was born. However, I had no funding, no partner, no Web site and just a crazy idea about
E-mail Contributing Editor Joel Leonard at Joel@SkillTV.net.
December 2008
PS0812_Crisis.indd 19
www.PLANTSERVICES.com
19
12/4/08 1:30:23 PM
25 PUMP
INTERNATIONAL
th
USERS SYMPOSIUM
PS0812_FPA.indd 20
12/4/08 9:28:24 AM
WHAT WORKS
Chemical Plant Boils With Hydrogen
Multi-fuel steam-generation system reduces fuel bill and carbon footprint
F
or years, Olin Chlor Chemicals relied on a neighboring facility to supply steam to its manufacturing operations in Niagara Falls, N.Y. But in 2001,
Olin’s steam supplier announced that it would be closing
its facility.
This posed a significant problem for Olin, a division of
Olin Corp., Clayton, Mo. As a manufacturer of chlorine
and caustic soda, hydrochloric acid, hydrogen and bleach
products, the company relies on steam for manufacturing
processes and heating. Olin’s facility managers quickly set
out to find a supplier for a new boiler system.
At the time, Olin was producing an excess of hydrogen
as a byproduct. They used part of that hydrogen in the
process, and were selling some of it. But because it’s difficult to store, excess hydrogen was vented. The Olin team
realized they could substantially reduce their annual fuel
costs and be more environmentally friendly by burning the
wasted hydrogen because hydrogen combustion doesn’t
produce carbon dioxide.
Olin can use the steam produced with the hydrogen for
the manufacturing process and for building heat. This is
more beneficial as costs of natural gas and oil rise.
After researching boiler manufacturers, Olin’s facility
engineers decided to contract with C-B Nebraska Boiler and
C-B NATCOM, the watertube boiler and burner divisions
of Cleaver-Brooks (www.cleaverbrooks.com) to install two
industrial watertube boilers, each capable of 75,000 pounds
per hour (PPH) with operating pressures of 150 psig.
Because the hydrogen is process byproduct, its availability isn’t constant, so Olin wanted a system that could fire
hydrogen and natural gas or #2 oil. The boiler burners also
needed to be efficient at both low fire and high fire.
A flow-control valve is typically used to reduce available flow and pressure for reduced firing, but the available
hydrogen pressure was limited to 7 psig. To fire hydrogen
safely, it’s essential to maintain a minimum velocity at the
hydrogen injectors, so conventional flow and pressure control isn’t sufficient. C-B NATCOM designed a burner that
uses multiple hydrogen injection zones that are opened and
closed to keep the fuel pressure within usable limits. A system of six zones meets the targeted 20:1 turndown ratio.
Conventional systems use high differential pressure
December 2008
PS0812_21_Works.indd 21
Two 75,000-lb/hr, 150-psig-output boilers can efficiently fire
hydrogen, natural gas, #2 fuel oil or combinations at 20:1 turndown.
to generate a representative flow signal throughout the
turndown range, but with such low hydrogen supply pressure and high turndown ratio, the flow elements had to be
designed to minimize pressure drop. C-B worked with the
instrumentation supplier to develop a split-range strategy
for the flow elements to ensure safe, accurate flow signals
with minimal pressure loss throughout the firing range.
Finally, the burner management system (BMS) and
combustion control system (CCS) were developed to safely
and efficiently manage five individual firing modes: natural
gas only, #2 oil only, hydrogen only, hydrogen with natural
gas and hydrogen with #2 oil. The system has an 8-in. hydrogen main train and a 3-in. low-flow bypass for partialload hydrogen flow measurement.
Hydrogen is a clean fuel, but it also burns rapidly, which
produces high levels of thermal NOX. Olin’s targeted NOX
when firing hydrogen was 0.1 lb/MMBTU (110 ppm). The
burner injects steam around the periphery of the hydrogen
injectors to shield the fuel from immediate contact with
the combustion air, giving NOX emissions of 72 ppm.
Firing hydrogen usually means high burner maintenance. The rapid combustion often allows the flame to contact the burner components, leading to quick degradation.
To date, Olin hasn’t needed to change a single hydrogenfiring burner component.
www.PLANTSERVICES.com
21
12/8/08 1:02:30 PM
“Our business changes
every six months.
Our systems take a year
to catch up.”
Customer mandates, regulation and
market conditions are changing faster
than ever. How do you keep pace? By the
time you implement most enterprise
applications your needs have already
changed. The answer is IFS.
IFS – first in enterprise agility
s The first software package built from
the ground-up on a Ser vice-Oriented
Component Architecture (SOCA), combining the agility of ser vice orientation
with the proven benefits of components
s IFS’ seventh generation of components
and second generation of SOA -- the
most stable platform on the market
s Roll out functionality in stages,
addressing your needs in priority order
s Easily integrate with legacy systems
or other third-par ty software
s ERP, EAM, SCM, CRM, PLM
Read our white paper on Design, Operate, Maintain for valuable insight on
how your maintenance activities can play a greater role in the success of
your business. Call 1.888.437.4968 today to get your copy.
SEE US ON PLANT SERVICES’ ONLINE CMMS COMPARISON TOOL.
I F S – T H E G L O B A L E N T E R P R I S E A P P L I C AT I O N S C O M PA N Y
w w w. I F S W O R L D . c o m
PS0812_FPA.indd 22
12/4/08 9:28:46 AM
ASSET MANAGER
Aging Workers
How to make the most of tough demographics
A
n aging workforce presents challenges to managThe new old
ing asset count and complexity. According to the
According to the United Nations Population Division
United Nations report, “International Plan of Ac(“World Population Prospects: The 2000 Revision,” New
tion on Aging 2002” (Second World Assembly on Aging,
York, 2001), by 2050, average life expectancy will rise to
Madrid, 2002), by 2050, the proportion of persons aged 60
82 years in developed countries, from 75 in 2000. Attitude
years and older is expected to double, and will account for
surveys point overwhelmingly to a new definition of “old”
21% of the global population. Birth rates are expected to
such that those retiring don’t view themselves as old and
fall. In 2050, children are expected to represent 21% of the
are perfectly willing and able to work.
population, a drop of 9% from 2000. These trends are proA recent study conducted by Monster.com, a career and
nounced in developed countries, resulting in a
recruitment Web site, found that 70% of
shortage of young workers to replace retirees.
2,000 workers between the ages of 50 and
As the U.S. economy faces uncertainty, the
70 planned to continue working past age 65.
Your policies
fact that 77 million workers are approaching
felt compelled to delay retirement for
must somehow Most
retirement age might sound like good news.
financial reasons. Other reasons included
ensure the right needing health insurance, mental activity,
However, companies need to do a better job
of assessing the implications of much knowlbeing productive and having interesting jobs.
people are
edge and experience disappearing during a
Many baby boomers reject the linearity of
retained.
short period of time. Numerous studies point
life: education then work then leisure. They’re
to the level of apathy among company execugoing back to school and continuing work
tives in the face of this potential crisis. The majority have
and education on a part-time basis throughout their lives.
no plans in place to deal with the expected brain drain.
These workers are looking for employers with the flexibility
to accommodate more creative retirement options.
Ageism prevails
A more disturbing trend is the prevalence of ageism. It’s
generally accepted that as one nears retirement age, it’s
more difficult to find a new job. Furthermore, older workers are pressured to accept lower salaries because of their
age. Finally, when older workers take their employers to
court to fight age discrimination, the amounts the courts
award tend to be lower than those for younger workers.
In part, age discrimination is the result of a more experienced worker’s expectation of greater compensation. In
many cases, ageism is the result of unfair stereotypes and
biases, including the idea that older people are less productive, more rigid in their ways and less likely to adapt
to new technologies.
There’s no evidence to support these biases. According to
“Challenges of an Aging Workforce,” published by Human
Resources Development Canada, “In almost every study,
variations within an age group far exceed the average differences between age groups.” This implies there are no
productivity differences.
December 2008
PS0812_23_24_Asset.indd 23
Leverage the statistics
The following steps are recommended for the transitioning
of maintenance management and workers:
Analyze workforce demographics: The first step in
understanding the depth of the problem (or whether one
exists) is to determine the demographics of your work
environment. What is the age, experience and skill set of
the workforce at every level of the maintenance organization? When are they eligible to retire? During career path
planning sessions, have those eligible to retire expressed
any desire to stay on, and if so, under what conditions?
Then, prepare a spreadsheet showing the gaps that will
arise in each year for each position as a result of retirement.
Overlay employee turnover projections onto the spreadsheet based on historical values.
Develop and implement a workforce plan: Based on
the analysis and your asset-management strategy and overall corporate goals and objectives, develop a long-term plan
to ensure having adequate resources during the next three
www.PLANTSERVICES.com
23
12/8/08 1:03:05 PM
ASSET MANAGER
to 10 years, depending on when the greatest staff turnover
is anticipated. The plan should encompass the retention
and recruitment policies as follows. Carefully monitor the
maintenance area resource needs and make adjustments
based on changes in supply of and demand for resources.
Develop a retention policy: Armed with data about
who is likely to leave and when, be ready with tactics for
keeping the more desirable staff, technicians, supervisors
and managers. Early retirement incentives, for example,
have resulted in organizations losing the more marketable
employees, who know they can pocket the money and get
a job elsewhere. The less-stellar employees are more likely
to stay. Encouraging early retirement doesn’t retain the
knowledge about assets and best practices.
Your policies must ensure the right people stay. This
might require a combination of retention bonuses, parttime work, reduced workload, job sharing, consulting
opportunities, changing bosses and more interesting
work programs. It might require innovations such as
adjustments to medical coverage, pension and other
elements that matter to potential retirees. Poll your
workforce and benchmark the approaches used by other
companies to identify the best approach to keeping the
right individuals.
Capture the knowledge of your senior employees
through training and mentorship programs, and document
the knowledge through training videos, work study, job
plans, maintenance practices and populating your CMMS.
Develop recruitment policies: Look for ways to attract
the right people to fill any gaps. Because of the squeeze on
technical resources, sell candidates on the benefits of your
maintenance operation over competitive opportunities.
Understanding the candidate’s needs is critical. Consider
short-term options where appropriate, such as hiring older
workers, contract workers or consultants.
(Editor’s note: The Plant Services CMMS/EAM Software Review, at www.PlantServices.com/cmmms_review,
provides a side-by-side comparison of more than a dozen
popular software packages.)
E-mail Contributing Editor David Berger, P.Eng., partner, Western
Management Consultants, at david@wmc.on.ca.
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PS0812_23_24_Asset.indd 24
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www.PLANTSERVICES.com
December 2008
12/8/08 1:03:15 PM
TECHNOLOGY TOOLBOX
Valves Evolve
Control valve advances boost performance, cut costs and simplify maintenance
W
fer long life through a controlled, short-stroke balanced
hat’s changing are the ways operators recogpoppet design. The valves are lubrication-free, tolerant of
nize valve positioning, says Ed Hardin, owner
impurities and have achieved multimillion cycle capability
of Hardin Consultants in Charlotte, N.C. “It’s
with rapid cycling, positive sealing and flow characteristics.
not enough to expect a valve to open or close. You need to
The valves can be mounted inline or inserted into Humknow whether the open or close happened. According to
phrey’s valve manifolds.
Murphy’s Law, the most critical valve will have a problem
Improved temperature control: A three-way valve can
of indicated position most frequently.”
control temperature and pH. The Fisher GX 3-Way valve
“Too often the indicator is a direct-action micro switch,
and actuator from Emerson Process Management, availwhich is subject to physical change or damage causing loss
able with integrated Fieldvue digital valve
of reliability,” Hardin explains. “Secondcontroller technology, offers good temperaary operator devices often can resolve this
ture control in a rugged, compact, highproblem but introduce secondary reliability
Fieldbus
capacity design.
concerns. Visual or light transmission devices
networks allow
Suited for heat exchangers and lubricating
can mitigate some of these concerns, but then
continuous
skids, the valve features a flow cavity engiprotection from blockage, dirt, trash and
alternate sources become critical.”
access to device neered for linear stability. It accommodates
mixing and splitting applications without exFieldbus networks continuously access
positioning,
tra parts. It has both side-port and bottompositioning, performance and condition
performance
port common trim, unlike other three-way
information so that quick action can be
and condition
valves. Its internal trim, seat ring, one-piece
taken. Metso Automation introduced a
plug-and-stem design and actuator matched
Foundation Fieldbus safety valve controller.
information.
to the valve make for easy maintenance.
Its Neles ValvGuard VG9000F uses FoundaEasy installation and repair: Flowserve’s
tion Fieldbus to monitor changes and issue
Durco PlugSeal valve can be repaired without removing it
alarms, without external wiring or I/O cards.
from a desalination unit. The corrosion-resistant, PFALower-cost materials: Polymers are an alternative to
coated plug design eliminates the need for a sleeve. Worn
metal for flow regulation. Festo’s technopolymer-based,
plugs can be replaced and adjusted in-line. To prevent
one-way flow control valves, solenoid-operated valves and
leakage, the stem-sealing system uses a reverse-lip PFA
valve terminals are for high-volume industrial markets. The
diaphragm that is self-adjusting and self-energized under
VB12 valves use a 50% glass-fiber reinforced polyarylamline pressure. The Durco PlugSeal can be welded directly
ide compound. The R&D program used X-ray and thermal
in the pipeline or the internals can be removed first.
analysis to demonstrate high strength, rigidity and dimenValves should always be tested, particularly when
sional stability. The products also exhibit creep resistance
venturing into uncharted territory. “Before you commit
under stress, low leakage, good environmental resistance
to a large number of unknown valves for a new or unusual
and electrical properties. Festo’s injection-molded valves
application, test them first to ensure they will indeed be
supply 200 liters to 1,000 liters of air per minute reliably at
functional and serviceable,” Hardin advises.
temperatures to 122°F. The valves are available as individual components or as fully assembled manifolds.
Extended life: Humphrey’s 320 Series ¼-in. ported
E-mail Contributing Editor Sheila Kennedy, managing director of
three-way direct-acting solenoid valves are said to ofAdditive Communications, at Sheila@addcomm.com.
For more information, see:
www.pdhengineer.com/Authors/
ed_hardin.htm
December 2008
PS0812_25_TechTool.indd 25
www.metsoautomation.com
www.festo.com
www.humphrey-products.com
www.PLANTSERVICES.com
www.emersonprocess.com
www.flowserve.com
25
12/8/08 1:03:45 PM
Bring Them Back
How to recondition
motor controls
By David Rosenfield, Malcom Frederick and Winn Hardin
lectric motors come in countless sizes and shapes
spread among various types. Each is available in a
range of speeds, enclosures and mounting configurations. One common theme is that each requires a control
system with separate power and control circuits.
Newer NEMA-rated controls are robust, which makes
them suited for reapplication if they’re no longer needed for
their current use. They’re usually good candidates for repair
and reuse when reconditioned by qualified technicians following qualified standards. Qualified service shops follow
reconditioning standards promulgated by the Electrical
Apparatus Service Association Inc. (www.easa.org). You
should inspect and qualify a service shop before you
send your equipment for repair. Be sure that you
know the vendor and its capabilities.
Recondition versus test-and-inspect
The Professional Electrical Apparatus Recyclers
League (PEARL, www.Pearl1.org) standards
are split into three categories: full reconditioning (Blue
Seal), test and inspection (Green Seal) and inspectonly (PEARL Stamp). Test and inspect (Green Seal)
standards include procedures for testing and inspecting
equipment to a minimum quality standard to ensure
it’s safe and in operable condition. This standard was
developed to meet the need for quick shipments and to
maintain the equipment validation process for used electrical equipment. Reconditioning standards include Test
& Inspect procedures as well as equipment reconditioning
steps and additional testing.
The inspect-only standard (PEARL stamp) applies to
items where no reconditioning or testing is to be done, other
than cleaning or applying surface coating on the product.
For example, enclosures, fittings, conduits and terminals
undergo little reconditioning and virtually no testing other
26
PS0812_26_30_Motors.indd 26
than visual inspections. Most dealers in
these markets only trade in
unused product. PEARL standards allow for quick transactions
between reconditioners, enabling one
shop to buy product needed for its customer
with the comfort and knowledge that the product has already cleared major function and conformity
hurdles and is ready for a full reconditioning.
Respect a control’s history
Let’s focus on the key steps in reconditioning a motor-control
bucket (Figure 1), as well as tips to consider if you’re performing the reconditioning in-house or selecting a qualified vendor
www.PLANTSERVICES.com
December 2008
12/8/08 2:53:16 PM
to perform the service. You should know about the reconditioning standards for an autotransformer-reduced voltage
(ATRV) starter, a common form of motor control for AC
induction motors 60 hp and larger.
The first step a PEARL-qualified technician takes when
reconditioning a control system is to remove visible dirt and
debris from the interior of the enclosure as a prelude to careful
inspection of the wiring harness and its connections to other
components. The technician takes special care when removing the dirt and debris and looks for broken parts and wear
debris among the dirt, cracked and frayed wires, and cracked
component cases, especially at terminal or connection points.
The technician seeks out discoloration that might indicate
overheating, arcing and shorts. Often, there are maintenance notes about previous problems or settings
that can provide valuable data. Many
times you’ll find the equipment is
being used outside its design
capability or contains underrated devices.
December 2008
PS0812_26_30_Motors.indd 27
After visually and mechanically inspecting each and every
component, inspect the circuits, treating each as a single
device. Energize and test them to ensure operational integrity.
A system test verifies every component is functioning in coordination with others and ensures the system’s integrity.
Follow standard procedures
Reconditioning begins with choosing the correct PEARL
technical standard; they are available as free downloads
from www.Pearl1.org. These standards include forms for
documenting test results, comprehensive reconditioning
procedures, specification tables, and inspection, observations and procedures for each component or circuit.
PEARL reconditioning standards have two sections:
evaluation and procedures. Both require specific calibrated
test equipment (megohmmeter, digital low-resistance ohmmeter (DLRO), millivoltmeter, etc.), which are listed at the
beginning of each standard. Both sections require PEARL
members to use the provided forms to record test values and
technician observations. Comprehensive test results are kept
on file for future reference and supplied with each device. This
is a vital part of reconditioning electrical equipment safely.
If the procedures are followed diligently, the reconditioned
device will operate as well or better than it did when new. We
say better because new electrical equipment typically is tested
in batches, whereas reconditioned equipment is 100% tested
and fully documented. This ensures it exhibits its highest
performance level and can protect the vendor, electrician and
end user. If the technician is PEARL-certified, follows the
recondition standards, records all data, and documents
the work, then a device will merit the PEARL
reconditioned Blue Seal.
For the purposes of this article, the technician should be interested in the following standards:
• 1110 Low-Voltage Disconnect
Switches Manually Operated Air
Non-Fusible (for the 3-ph motor
disconnect)
• 1420 Low-Voltage Transformers
Control Power (for the control
transformer)
• 1430 Low-Voltage Transformers
Instrumentation Voltage (for the
auto transformer)
• 1 620 Low-Voltage Starters Magnetic (for the starter with overload
protection)
• 1841 AC Contactor (for the wye, run and
start contactors)
• Components not yet covered by PEARL
standards include pneumatic timer and pilot
(start/stop) switches.
www.PLANTSERVICES.com
27
12/8/08 2:53:33 PM
H
M
Reliability
Motors
Know the details
From left to right, the power circuit schematic shows a
three-phase motor disconnect, a three-coil autotransformer
and a contactor/starter, including three-phase overload
protection. The circuit permits two stages of acceleration
rather than one high-current start at full line voltage.
PEARL publishes 12 reconditioning standards for lowvoltage disconnects in its 1100 series, including manually
operated, air-fusible and non-fusible; manual trip power
fusible and non-fusible; and high-pressure electric trip
fusible and non-fusible. The 2100 series includes a similar
number of standards for medium-voltage, manual and electrically operated, and air and vacuum disconnects of both
the fused and non-fused varieties.
Because the number of motors installed varies inversely
with motor size, we’ll use the low-voltage, non-fusible
disconnect switches (Standard 1110) as our example for
reconditioning them. Because this disconnect offers no circuit protection, a feeder device in a nearby panel will likely
provide the necessary protection.
Section I lists the required calibrated test equipment,
including insulation resistance test set (Megohmeter,
1,000 Vdc minimum) and digital low-resistance ohmmeter
(DLRO, minimum of 10-amp capability) or a DC current
source and a millivoltmeter.
Section II covers the recondition evaluation, which is
broken down into two sections: inspection and test. Standard 1110 lists eight parts of the disconnect that require
inspection, including frame/enclosure, insulation system,
current-carrying components, stationary contacts or blade
clips, moving contacts or blades, arc extinguishers, operating mechanism and interlock.
PEARLs of Wisdom
EASA standards cover maintenance and repair of electric motors and transformers, but they don’t cover reconditioning motor
controls or distribution systems. Realizing there was a gap in the
electrical standards regarding reconditioning electrical equipment
other than motors, The Professional Electrical Apparatus Recyclers
League (PEARL, www.Pearl1.org) formed in 1996. Its mission is to
develop reconditioning standards for other common electrical
devices, subassemblies and systems. It was founded by industry
leaders throughout the United States to fill this void in the electrical
industry. Since that time, PEARL has developed 104 reconditioning
standards for a variety of common electrical devices, including disconnects, transformers and overload devices, among others.
As you might expect, the inspection procedures for
each standard are device-specific. For instance, the initial
evaluation for a low-voltage, non-fusible disconnect
switch – Sections 1.2.1 through 1.2.5 – requires the technician to check the insulation for dust and foreign materials, chips, cracks and deterioration, signs of overheating,
missing or defective insulation, and missing or defective
interphase barriers.
At the end of the component inspection evaluation, the
technician records relevant observations on the 1110 evaluation report. Section I guides the inspection through the
remaining seven components in the low-voltage disconnect,
namely frame/enclosure, current-carrying components,
stationary contacts or blade clips, moving contacts or blades,
arc extinguishers, operating mechanisms and interlocks. The
technician records inspection observations for each component group on the PEARL evaluation report. These written
records provide a device history, allowing more in-depth
evaluation and trend analysis. These steps relate to making
sure this device is safe for service.
After recording the observations,
Circuit rehab
the technician performs insulation and
contact-resistance tests on the disconR
L1
L1
nect. Insulation resistance measures the
2S
degree of isolation between the device’s
L2
L2
R
current-carrying and non-current2S
carrying materials. Contact resistance
L3
L3
R
2S
indicates the degree of free flow of
current along the current-carrying
TB
path. This test identifies loose connecX2
1
2
tions, pitted and misadjusted contact
3
surfaces, and damaged current-carrying brades. Contact resistance requires
R
Run contactor
1S
Star contactor
2S
WYE contactor
measurements with the DLRO,
TR
Pneumatic timer
TO
Time opening contact
whereas insulation resistance needs a
TC
Time Closing contact
OL
Thermal overload relay
OTT Over temperature thermostat
megohmeter or megger. The insulation
AT
Autotransformer
FU
Fuse
tests require checking values line-toload while the disconnect switch is
Figure 1. Every switch gear component, including overload protection components
open, and phase-to-phase, phase-toshown here, are individually cleaned, inspected, tested and documented to ensure
frame or phase-to-enclosure resistance
reliability based on PEARL technical standards and documentation forms.
measurements in the closed position.
5D 100%
65%
0%
O/L-1
T1
O/L-2
T2
O/L-3
T3
1S
Auto-transformer
5D 100%
65%
0%
1S
0%
1S
Auto-transformer
5D 100%
65%
Auto-transformer
F1
6A
F2
6A
1 KVA
480/120 CPT
X2
F3
12A
1
Stop
2
Start
3
R
1S
2S
Neutral
TR(T.O)
X2
Start
R
TR(T.C.)
O–L
1S
Run
R
28
PS0812_26_30_Motors.indd 28
www.PLANTSERVICES.com
December 2008
12/8/08 2:53:47 PM
RELIABILITY
Motors
Where the contact resistance of the disconnect switch is
tested in the closed position, it’s line-to-load.
The results are recorded from both test and observations
on the 1110 PEARL evaluation report. Optional contactresistance tests include millivolt drop or Watt-loss, which
determine resistance values line-to-load on each phase of
the closed switch, with the test points at the line and load
lug landing. Again, the values are recorded and checked
against manufacturer specifications. Unless the contact
resistance for the three phases is within 50% of each other,
the device is considered out of specification by PEARL
reconditioning standards 2.2.3.
Down to piece parts
Correct, clean and lube
After recording observations and resistance values,
correct any disconnect switch problems and completely
clean and lubricate it. Standard 1110 specifies 10 reconditioning procedures related to the frame/enclosure,
missing or defective parts and hardware, operating
mechanism, insulation system, arc extinguishers, contacts or blades, and current- torque and fi nal disconnect
operation. At the completion of each section, record on
the 1110 inspection and test report form any reconditioning actions performed on the device.
Reconditioned equipment that bears the PEARL seal has
been reconditioned by a certified technician working to
PEARL’s standards, which protect the end user.
After completing the PEARL reconditioning, operate
the disconnect switch 10 times to verify its proper operation. If the unit passes the PEARL recondition standard
guidelines set forth in Section 1110 – Low-Voltage, NonFusible Disconnect Switch, final testing may be repeated
and recorded on the insulation and contact resistance tests
described in section 2.1 and 2.2.
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PS0812_26_30_Motors.indd 29
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29
12/8/08 2:54:01 PM
Reliability
Motors
The device is eligible for a blue
PEARL reconditioning seal only if
the reconditioning procedures, testing
and documentation are carried out
by a certified technician working at a
licensed PEARL member company.
This seal guarantees that the device
has been evaluated, reconditioned
and tested to the PEARL standards,
thereby producing a safe, high-quality, reliable disconnect switch.
Then, the autotransformer, starter
and other components to complete
the motor control and power circuit
are subjected to the PEARL reconditioning procedures. PEARL takes
reconditioning seriously. Placing a reconditioned device back in service can
save downtime and untold costs, and
help save the environment by reducing
scrap, waste and energy consumed in
manufacturing a new device.
Between rebuilds, polish skills
Standards are critical, but by themselves
they aren’t enough. PEARL-qualified
technicians must have a full understanding of the workings of the components
and how they integrate with the larger
electrical system. Major manufacturers
offer courses in applications and maintenance of their products. Electrical trade
associations such as NEMA, NETA,
NECA, EASA and PEARL provide
training and materials for the continuing education of field service and
maintenance technicians. Standards
organizations such as OSHA and
inspection organizations such as IAEI
do as well. Private training organizations
such as AVO Institute provide valuable
and up-to-date training.
Over time, such training and handson experience makes for a technician
who can perform value-added services
The endorsement
Reconditioned equipment that
bears this seal performs safely.
that help keep the lights on and the conveyors running. n addition to their technical knowledge, experienced PEARL
technicians are savvy about the common
causes of control system malfunction.
For instance, contactors exhibiting a
humming noise often have missing
shading coils or worn armatures. They
can size motor overload protection in the
absence of OEM data. Most of us don’t
have a $100,000 dynamometer to test an
electric motor. Savvy maintenance and
repair technicians know that standard
AC motors draw about 1.25 amp per
horsepower at 480V.
Associating with organizations
like PEARL or EASA can help keep
your maintenance department in the
loop. It also helps you compile an
ever-growing library of information
to help keep your electrical systems
online more of the time and safely.
David Rosenfield is president of ROMAC
Supply in Commerce, Calif. Malcom Frederick is president of Coastal Switchgear in
Richwood, Texas. Winn Hardin is marketing director of PEARL, Neptune Beach, Fla.
Contact them at winnhardin@pearl1.org
and (904) 246-8958.
More resources at www.PlantServices.com
Single-line diagrams - “Toe the line”
Power distribution safety - “Caution: High voltage”
Lubrication - “Smooth breakers”
For more, search www.PlantServices.com using the keywords arc, inspection and switch.
30
PS0812_26_30_Motors.indd 30
www.PLANTSERVICES.com
December 2008
12/8/08 2:54:34 PM
Good
Coverage
Ensure
Strategies for
maintaining coatings
of exposed equipment
T
he pressure to keep equipment running continuously is greater than ever. As demand for output
continues to grow, a facility’s maintenance engineers, who wear many hats in their day-to-day duties, must
walk a fine line when it comes to scheduled maintenance.
Taking a section of a plant down, even for a few hours,
can have major financial implications. At the same time,
this cost has to be balanced with the what-if scenarios of
unscheduled maintenance.
In a perfect world
Ideally, a program of scheduled maintenance exists; in
some cases, such maintenance might have to wait until a
mechanical shutdown, for any reason, occurs.
When it comes to coatings maintenance procedures,
there are no hard and fast rules for maintenance decisionmakers to follow. Depending on the facility and its
requirements, coatings maintenance might fall far down
the list. But without careful monitoring of facility assets, the full value of equipment investment might not be
December 2008
PS0812_coatings.indd 31
realized, and maintenance costs could rise dramatically as
unplanned shutdowns occur.
There are several factors to consider when putting
together a coatings maintenance checklist and timetable.
Obviously, the assets essential to daily operation must
receive priority attention. Likewise, the funds invested
in a particular asset might determine where it falls on a
coatings maintenance schedule. In other cases, such as
with lower-cost, commodity equipment, it might be more
economical to simply schedule asset replacement, say,
every five years, than to include it on a coatings maintenance schedule.
Part of the equation regarding scheduled maintenance
might involve the facility’s location. If a plant is located in
a salt-air, damp environment, for example, facility assets will require more frequent monitoring because of the
atmosphere’s corrosive nature. The facility’s age and level
of depreciation also might be factors; an older, nearly fully
depreciated facility might not receive the maintenance attention that a newer, more efficient plant receives.
www.PLANTSERVICES.com
31
12/8/08 1:27:58 PM
Reliability
Industrial Coatings
Much farther down the list but still relevant are overall
aesthetics. If a plant has high visibility – for example, if it’s
easily seen by passers-by on a highway or an interstate –
the areas most visible will most likely receive more regular,
scheduled attention.
Today’s reality
More often than not, coating maintenance is done during
mechanical shutdowns. It’s at that point, when a section of the
refinery is taken off line, that a maintenance team has the opportunity to perform several tasks. So a fast return to service
and the ability to withstand high temperatures are two critical
components of most coatings under consideration.
Specifying the proper coatings,
however, is only one part of the equation.
In new construction, appropriate coating specifications
are crucial to maintaining equipment’s useful life. In existing plants, proper selection can add years to the life of coatings, especially in areas where they are covered by insulation.
A high percentage of the coatings in a refinery are
concealed under piping insulation. If these pipes move extremely hot product only sporadically, it generates a cyclical wet/dry condition. This combination of heat and severe
chemicals with, in many cases, a harsh overall environment
because of weather and salt air, provides the potential for
corrosion if the proper coatings haven’t been specified. One
of the most common refinery coatings challenges occurs
when corrosion develops behind insulation. This condition
is sometimes not obvious until the insulation is stripped
away, and, at that point, the pipe might already be corroded beyond use.
Problems like this can be prevented by selecting the
proper coating:
Like x-ray vision
Figure 1. The topcoat is applied over epoxy with optically
active pigment, as viewed under ambient light (left). Viewed
under fluorescent light, the fluorescing blue primer indicates
a holiday around the rivet (right).
32
PS0812_coatings.indd 32
• Non-insulated structures (piping, vessels, tanks and
furnaces), temperature between 200°F and 400°F:
inorganic zincs, silicone acrylics, epoxies, urethanes
• Non-insulated, high-temperature equipment (piping, stacks, mufflers), temperature between 400°F and
1,000°F: inorganic zincs, silicones
• I nsulated, fireproofing or cementitious, heat limits to
250°F: epoxy phenolics
• I nsulated piping, vessels, towers, storage tanks,
exchangers, furnaces, stainless steel surfaces, temperature between 400°F and 1,000°F: high-temperature
coatings
•N
on-insulated stainless steel equipment, temperature
between 400°F and 1,000°F: Chloride-free, hightemperature coatings
•G
alvanized structural appurtenances, temperature less
than 200°F: epoxy/urethanes
•C
hemical-resistant linings and containment, heat
limits vary with commodity and use: epoxies, epoxy
phenolics, epoxy phenolic novolac, vinyl esters
Experience counts
Specifying the proper coatings, however, is only one part of
the equation. Making certain that the coatings are properly
applied is just as important for long-term success.
Experience in refinery and petrochemical projects ranks
high on the short list of requirements for selecting an applicator. The contractor should certainly have a résumé, a documented safety plan and a list of references that prove he knows
his way around a facility. If the applicator is being selected
using a bid process, each bidder should demonstrate that it
can perform in a refinery and petrochemical environment.
Beyond insisting on a demonstration of the knowledge
and technical expertise to do the job, a maintenance engineering staff should consider a short list of qualifications
when reviewing potential applicators:
•O
verall capabilities and record-keeping procedures.
•E
xperienced and properly trained personnel who have
worked in a petrochemical environment.
•C
ompliance with state and federal health and safety
requirements.
•W
illingness to work with an independent inspection
company.
The final point listed – that of working with an independent company that will provide final inspection – is the key to
ensuring that a coatings project has been completed properly.
The inspector, the applicator and the coatings supplier must
be willing to work together, along with the maintenance engineering staff, throughout the project to ensure success.
Perhaps the best resource for guidelines in selecting the
proper applicator and inspection company is the Society for
Protective Coatings (SSPC) in Pittsburgh (www.sspc.org).
SSPC’s Qualification Procedure No. 1 is the Standard Procedure for Evaluating Painting Contractors (Field Application
www.PLANTSERVICES.com
December 2008
12/5/08 3:59:15 PM
RELIABILITY
Industrial Coatings
to Complex Industrial Structures). Qualification Procedure
No. 5 is the Standard Procedure for Evaluating the Qualifications of Coating and Lining Inspection Companies.
Products that extend lining lives
In any industry, once a tank is returned to service, the
last thing an owner wants is to have to take it back offl ine
before the next scheduled maintenance period because
of incomplete coating or improper fi lm thickness. Proper
application and inspection are musts, and the product itself
can help. Coatings technologies, at least in tank linings,
have advanced to the point where they can help applicators
and inspectors assure proper fi lm thickness.
For example, optically activated pigments (OAP) in
chemical-resistant glass flake-filled epoxy novolac lining, were
originally developed for use in marine ballast tanks. Coating
inspection requires LED illumination (Figure 1). The pigment itself fluoresces and glows. Pinholes and holidays appear
black in contrast to the fluorescing lining in a one-coat system, and blue in a two-coat application. Improper film thickness appears less bright than the properly applied fluorescing
lining. This allows corrections to be made while the coating
is still wet. Inspection even can be done during application,
saving time while identifying areas in need of attention.
Having a coatings maintenance schedule in place and
adhering to it is always the best policy. However, given
today’s environment, such maintenance often is done when
other factors force a mechanical shutdown. In either case, a
maintenance engineering staff can guarantee coating success by remembering and embracing to three basic tenets:
• Proper coatings specifications.
• Experienced industrial plant applicators.
• Final inspection before return to service.
Thomas W. Burker is strategic account manager, petrochemical,
at Sherwin-Williams Protective and Marine Division in Cleveland.
Contact him at Tom.Burker@sherwin.com and (216) 566-2000.
More resources at www.PlantServices.com
Painting philosophy – “Maintenance painting”
Pipe coatings – “Buried treasure”
Quality in coatings – “Finding the right mix to protect
your equipment”
Coating inspection – “Ensure proper coating performance”
For more, search www.PlantServices.com using the keywords
coating, corrosion and inspection.
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33
12/5/08 3:59:31 PM
IN THE TRENCHES
The scenario presented here is based on a true story;
only the names have been changed to protect the innocent.
Killing Time
Acme employees respond to accusations of submitting fraudulent time cards
T
he Acme chemical plant was concerned about two
things. The first was terrorism. The production
crew routinely handled dangerous, flammable and
toxic materials. The second concern was health care costs.
Regardless of insurance carrier, premiums seemed to rise
faster than the inflation rate and the consumer price index.
Addressing the first concern was relatively easy. A
security guard opened the gate after inspecting a driver’s
identification and copying the details onto a form. Most of
the 600 Acme employees walked in, and the guard wrote
down as many employee ID numbers as he could during
shift changes. The second concern was more problematic.
Medical care was important to Petey and Geri Atrique,
a couple who worked at Acme. Petey had been there for 25
years and Geri about eight years. They worked at Acme for
one reason. The benefit package provided medical coverage
for Barry, their preteen son, who is a cancer patient.
Every year, Acme and its employees’ union discussed the
details, cost and performance of the health care plan, and
reached agreement about employee cost-sharing. Nevertheless, medical costs spiraled out of control. To minimize
its own costs and employee premiums, Acme had been
changing insurance nearly every year. But now the company couldn’t find coverage at a reasonable cost. The HR
department found that fewer than 20% of the employees
accounted for more than 80% of the medical claims. So,
Acme elected to become self-insured, which meant the
company would pay employee medical claims.
If this initiative was to be a success, Acme would need
to influence employee behavior. It conducted a series of
employee meetings to explain the health-care plan using
charts showing most medical claims were relatively small
and that many employees never filed a claim. Acme warned
that large medical claims would increase the cost of coverage and raise deductions from their weekly paychecks.
Barry suffered a relapse and his parents were advised
that he had entered the final stages. The oncologist recommended, and the paretns approved, an aggressive six-week
experimental treatment that would cost $10,000 per week.
About halfway through the treatment, Acme opened an
investigation into Petey’s time cards because it believed he
falsely reported the hours he was on-site during a recent cha34
PS0812_34_36_Trench.indd 34
otic shutdown. This was motivated by a discrepancy between
his time cards and the security guard’s entry log.
When his supervisor confronted Petey about the differences, he couldn’t recall the details and wasn’t sure about
the times shown on either set of records. He said that having a child with cancer was stressful. One week later, Acme
fired him, citing a dozen falsified time cards, equivalent to
about 20 regular hours and half a dozen overtime hours,
during the previous month.
Late one night, HR called Geri at her son’s hospital
room to ask about her time card discrepancies. Geri was
adamant that the guard’s logs weren’t accurate because
the guard knew her and many times didn’t require her to
display a gate pass when she entered the plant. During a
second call to her son’s room, Geri couldn’t convince Acme
that she had done nothing wrong. The next day, Acme
terminated Geri, citing falsified time cards totaling eight
hours of straight time and six hours of overtime.
This left them, and Barry, without coverage. Petey and
Geri sued, claiming Acme terminated them in violation of
the Americans with Disabilities Act (ADA) of 1974. Their
son died six months after they were terminated.
How could this situation have been avoided? How should
Acme have handled its transition to self-insurance? Should employees be forced to use time cards? Does a self-insured company
have an inherent conflict of interest? How does the Americans
with Disabilities Act of 1974 apply in this case?
www.PLANTSERVICES.com
December 2008
12/4/08 1:31:18 PM
An academician says:
There are two issues here. The first is falsifying time cards.
The second is the loss of medical benefits. The Atriques
think the two are related, with the medical cost their son
incurred as being the cause of the firing. The company
probably will argue that the time cards were the cause and
their son’s condition wasn’t a factor.
Let’s take falsification first. What is the most accurate
indication of the Atriques’ time – time cards or guard’s
records? In a recent case, a police officer had applied for
a lot of OT pay because of numerous court appearances
on arrests he had made. To go to court, the officer had to
notify a sergeant, who had the officer dispatched to court
in a patrol car and picked up again. The department said
the officer falsified much of the overtime and hadn’t been
in court on many of the days shown on his time sheet. The
department filed a motion to have him dismissed.
The department’s case was based on the sergeant’s records, many of which were incomplete or missing. The officer used the court records to show that he was in court on
the days under question. The hearing officer decided that
court records were more valid than the sergeant’s records.
Acme’s case against the Atriques is based on the security
guard’s records, which appear to be flawed. I’d push for
reinstatement, given that they were terminated by unreliable records.
Were the Atriques fired because
of their child’s health? That would
be tough to prove.
Were the Atriques fired because of their child’s health?
That would be tough to prove. The key is determining which employees were investigated and which were
terminated because of time card issues. If it was only the
Atriques, or only employees in a similar situation, then the
Atriques have a good case. Is it an ADA case? Yes, it is.
It falls under the “association clause,” in that the Atriques
were (allegedly) terminated because of their “association”
with their ill son.
I’m not a big fan of being self-insured, although it
might make economic sense in specific cases. Insurance
companies exist to take risk off of the backs of people and
companies. That especially makes sense in the medical area
where costs are skyrocketing. Some of the problems could
be caused by Acme’s attempts to control or cut medical
costs, which is something they are ill-equipped to do.
Better to focus energies on the core business and make
December 2008
PS0812_34_36_Trench.indd 35
solid profits. Let the insurance companies worry about the
medical issues.
The first problem could have been solved with a better
system for accounting for an employee’s time. The second
problem could have been solved by farming out their health
insurance to an outside insurance carrier.
Professor Homer H. Johnson, Ph.D.
Loyola University Chicago
(312) 915-6682
hjohnso@luc.edu
An attorney says:
The old 80/20 rule lives. Acme’s experience is far from
unique. Most employers face rising health-care costs, often
from large claims from a few employees. The solution,
however, isn’t to fire the employees responsible for increased health-care costs on a trumped-up charge of falsified time cards. Even worse were Acme’s insensitive calls
to Geri about her time cards when she was with her son in
the hospital. This kind of employer conduct causes juries to
award punitive damages.
Employers who go from group health coverage to selfinsurance often experience increased cost. Becoming selfinsured entails the same risk that not obtaining insurance
involves. If claims are low, the self-insured saves money. If
claims are high, the results can be disastrous.
Unfortunately, there’s nothing an employer can do to
prevent employees and their dependents from contracting
fatal diseases. No one asks to get cancer. What employers can do is offer incentives to adopt healthier lifestyles,
which, in turn, should minimize some health-care costs.
Many companies offer smoking cessation programs,
weight-reduction and exercise classes, and nutrition programs, all in an attempt to encourage employees to live in
a healthier fashion. Often, the incentive to participate in
these programs is a percentage reduction in the employee’s
share of health-care costs.
This kind of program wouldn’t have prevented Barry’s
cancer, but it might prevent strokes and heart attacks, and
minimize the effects of some diseases, like diabetes, with
a savings in health-care costs both for the company and its
employees.
Julie Badel, partner
Epstein Becker & Green, P.C.
(312) 499-1418
jbadel@ebglaw.com
A corporate consultant says:
RFID tags and a reader at the plant gates can eliminate
human error. Even without technology, and given the risk
www.PLANTSERVICES.com
35
12/4/08 1:31:23 PM
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36
PS0812_34_36_Trench.indd 36
of wrongful termination lawsuits, you’d think Acme would
have checked other employee attendance records against
pay records to test the guard’s inaccuracy. Acme used
private medical information to target high-cost employees.
This is illegal, though it might seem unfair that the average
health-care costs rise because of a handful of people.
A third party could manage the self-insurance plan
to insulate Acme from private medical information and
avoid being tempted to use it to reduce costs. Acme should
get stop-loss insurance to back up higher-than-expected
health-care program expenses.
The company must pay employees for their labor. Employees must monitor time logs and pay records to ensure
the company has accurately accounted for their hours.
Time card mistakes happen. In case of emergency, accurate
attendance provides a way to account for individuals.
Self-insurance is a risky statistical game with legal risk
and a risk of degrading the trust between the company and
employees if incidents aren’t handled correctly.
Self-insurance carries an implied conflict of interest because of the perception that a company self-insures to save
money. If there’s a disagreement about coverage, employees
will question the motives of the self-insured program.
I’m not an attorney; however, as I read the ADA, I’m not
sure it applies in Acme’s case. Employers can fire workers
with disabilities under three conditions:
1. The termination is unrelated to the disability, or
2. The employee doesn’t meet legitimate requirements
for the job, such as performance or production standards,
with or without a reasonable accommodation, or
3. The employee’s disability poses a direct threat to
health or safety in the workplace.
According to the Department of Justice, the ADA prohibits discrimination based on relationship or association
to protect individuals from actions based on unfounded
assumptions that their relationship to a person with a
disability would affect job performance, and from actions
caused by bias or misinformation concerning disabilities. For example, this provision protects a person with a
disabled spouse from being denied employment because of
an unfounded assumption that the applicant would need
excessive leave for spousal care. If the Atriques could prove
that the true reason Acme terminated them was for the
care of a person with a disability, they could have grounds
under the ADA. Any specific circumstances should be
checked with professional legal advice.
Tom Moriarty, P.E., CMRP
Organizational Reliability Professional Services Consultant
(321) 773-3356
tjmpe@alidade-mer.com
www.PLANTSERVICES.com
December 2008
12/4/08 1:31:35 PM
WEB HUNTER
Potpourri XI
Peruse our annual collection of cyberspatial oddities
I
t is with great pleasure that we present our annual collection of off beat Web sites. The 11 months of diligent,
intense Web research that produces this column often
uncovers sites that are totally irrelevant to the topic at
hand. These are saved for your winter solstice entertainment. The following sites adhere to the basic philosophy
we’ve followed for more than 12 years: real content that is
zero-cost, noncommercial and registration-free. I hope you
find something useful in this exploration of the off-thebeaten-path “sights” that don’t necessarily have a rational
relationship to the business life of the plant professional.
Honor thy craftsmen
Effective plant maintenance and engineering has its roots
in a worker taking pride in doing something correctly the
first time and fixing it so it won’t break that way ever again.
Most people recognize excellent craftsmanship when they
see it. It’s the little details and the precision with which
work is completed that define the difference between the
skilled cabinet maker in a studio and the typical wood
If you fancy yourself a craftsman with
a delicate hand, then you have an
opportunity to prove it in a virtual world.
butcher with a basement shop. To see a graphic example of
true craftsmanship, point your browser at http://eyecur
rent.com, scroll down to the archive listed on the rightand select the January 2008 entry. The 20-minute video
there shows how an amateur radio operator fabricates
triode vacuum tubes from scratch. And, yes, of course, this
craftsman uses several pieces of specialized tooling.
If you fancy yourself a craftsman with a delicate hand,
then you have an opportunity to prove it in the virtual
world. Our Technology Toolbox columnist, Sheila Kennedy, brought to my attention an online game posted by
National Geographic magazine. The idea is that you control
three tasks simultaneously using only your trusty desk rodent. As a crane lowers a rotor into a turbine housing, you
keep its axis horizontal and centered on the journal bearDecember 2008
PS0812_37_38_WebHunt.indd 37
ings while keeping workers out of the danger zone. Give it
a try the next time things get boring at the plant. Spin over
to www.nationalgeographic.com and click on “National
Geographic Channel” at the left. Then, click on “Shows”
near the top center and again on “World’s Toughest Fixes”
listed in the “Featured Shows” section. Finally, click on
“Can You Handle a Big Fix” near the top center. Warning:
It’s way too easy to overcorrect once things start moving.
Speaking of wheels
That fact we’re a mobile nation is intuitively obvious to
even the most casual observer. Those trusty vehicles upon
which we rely are subjected to different degrees of maintenance. Reactive people wait until the engine is about to
seize before they so much as refill the crankcase. Preventive people get an oil change every 3,000 miles or every
three months, whichever comes first, whether it’s needed
or not. Your vehicle probably needs other fluids, mainly
fuel. Even with the recent decline in gasoline prices, you
might want to optimize your ROI when you fill up that
gas hog. The Microsoft Web site is going to point you to
the least-expensive gas station in your area. Drive your
mouse over to www.msn.com, park on the “Autos” link at
the upper left and open the “Gas Prices” door in the lower
right. From there you need only enter your zip code to be
rewarded with the identity of your gas tank’s best friend.
Perhaps the best thing you can do now is dump that gas
guzzler and treat yourself to a new car. You deserve it. If
you agree, Edmund Publications Corp., Santa Monica,
Calif., wants you to get the best possible price, whether
you seek a new or used vehicle. Check out the offerings at
www.edmunds.com. There are so many drop-down menus
on this site and so many vehicular opinions out there that
I’ll leave you to explore in peace.
Verbal precision needed
The reason our economy has been suffering lately might
be related to imprecision in what passes for workplace or
Washingtonian communication. One can issue directives,
knowing full well what is intended, but if the transmission mode is muddled, the receiver won’t understand. Let’s
make a New Year’s resolution to clean up our language
www.PLANTSERVICES.com
37
12/8/08 1:31:27 PM
More
Moly
and More of Everything!
Our formulas are the
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Rope Lube has all the
Moly grease you need.
skills and avoid the BBC’s “50 office-speak phrases you love
to hate,” which will appear at http://news.bbc.co.uk after you
enter “50 phrases” in the search box.
Fill the iPod
35 industrial products were uniquely developed for
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Call 877-GO4-GUNK for local distributors www.gunk.com
It was William Congreve who penned that famous line:
“Musick has Charms to sooth a savage Breast.” It was the
opener to his 1697 poem “The mourning bride.” So, when
things get a bit dicey or hectic on the plant floor, grab your
trusty iPod and chill, dude. Ideally, you want to collect a
quantity of aural pleasure sufficient to last an entire shift.
Achieving that soothing, Nirvana-like state might be easier
if you’re not hearing the same old familiar songs repeatedly.
Something else might offer more of the desired calmative
effect. Explore that proposition at www.icompositions.com,
an Internet community for aspiring musicians. It is there
you’ll find hundreds of homebrew compositions in a variety
of familiar genres, some of which sound professionally orchestrated, nearly all of which can be downloaded at no cost.
You’ll end up with a one-of-a-kind collection.
Don’t waste your money
EMERGENCY
With many government entities operating on deficit budgets,
charities and nonprofit organizations can no longer expect
support from that quarter. It’s going to be up to the good
citizens of this great country make a financial contribution
where it’s needed. Revealing where you get the most bang
OVERHEAD PROTECTION FROM
for your buck is Charity Navigator, Mahwah, N.J., an indeROOF • PIPE • MACHINERY LEAKS
pendent evaluator of the financial health of more than 5,300
of America’s largest charities. The ratings the organization
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Protect Machinery
programs. You can see a tabulation of annual revenue and
and Stock!
expenses (and trends for both), total net assets and leadership
Perfect for offices,
compensation, among other metrics. Reach out your hand to
shops
& warehouses
2008
Industrial Ad #4 for Plant Services Mag. Size 3.25 x 4.75
www.charitynavigator.org to help you make your donation
101 USES!
before the end of the year so you can claim the tax write-off
Diverts water to
next April’s 1040 filing says you’re entitled to take. The orgawindow, drain or sink
nization doesn’t rate religious-based charities because they’re
not obliged to pay taxes. Before you leave the site, though,
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I’d recommend you locate “Top 10 Best Practices of Savvy
Price subject to change without notice
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Donors,” one of the articles on the site.
Solid brass
reinforced with
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3’ x 8’ – $68.16
6’ x 8’ – $82.86
3’ x 10’ – $70.20
6’ x 10’ – $89.22
Suspension and hose not included.
Other sizes available upon request.
Water — so essential to life, yet it can be your worst
enemy when you least expect it.
At last a product has been developed to make those
untimely leaks a little less frustrating.
polyester
attachment
grommets
It is better to have one and not need it then to need it
and not have it.
Water pails in the middle of the floor are not considered
Fire Protection.
Keep the buckets out of sight — liability claims are
there already.
Our Water Diverter protects valuable areas and
equipment from roof leaks until a permanent solution can be accomplished.
It is our opinion that every building that has a fire
extinguisher in case of a fire or a first aid kit in case
of an injury, should have a least one Water Diverter
in case of a disastrous roof leak.
38
PS0812_37_38_WebHunt.indd 38
1115 Main St., Holyoke, Mass. 01040
(413) 533-5347 Fax: (413) 536-4797
WWW.SUMLAC-DEWAY.COM
Without comment
www.peterrussell.com/Odds/WorldClock.php
See the unabridged version of this column on the Plant Services
Web site at www.plantservices.com/articles/2008/255.html.
E-mail Executive Editor Russ Kratowicz, P.E., CMRP, at
russk@putman.net.
www.PLANTSERVICES.com
December 2008
12/8/08 4:20:36 PM
MRO MARKETPLACE
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This new catalog details two-way bronze and
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READ US ONLINE
WWW.PLANTSERVICES.COM
Never miss an issue of Plant Services
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PS0812_39_AdLits.indd 39
WITH JOEL LEONARD
www.SkillTV.net
PS0811_01_cover.indd 1
December 2008
WATCH SKILL TV
See how professionals are
solving the maintenance skills
shortage. Watch videos, listen
to podcasts and read articles that
reveal the depth of this crisis ... and
what you can do about it.
NOV E M B E R 2 0 0 8
www.PlantServices.com
Magnatrol Valve Corp.
Seven Trends to Address With a CMMS
p.25
New NFPA 70E Clarifies Electrical Safety
p.43
Energy Versus Economics
p.66
11/5/08 12:16:59 PM
www.PLANTSERVICES.com
39
12/8/08 3:04:53 PM
CLASSIFIEDS
PERFORMANCE | RELIABILIT Y | EFFICIENCY | ASSE T MANAGEMENT
SALES OFFICES
MIKE BRENNER, GROUP PUBLISHER
AR, Northern CA, MN, OR, WA
Phone: (630) 467-1300, ext. 487
Fax: (630) 467-1120
e-mail: mbrenner@putman.net
Products and Services
JERRY BURNS, DISTRICT MANAGER
CT, DE, FL, GA, ME, MD, MA, NH, NJ,
NY, NC, RI, SC, VT, VA, DC, WV
Phone: (630) 467-1300, ext. 427
Fax: (630) 467-1120
e-mail: jburns@putman.net
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MIKE BALZANO , DISTRICT MANAGER
AL, AZ, Southern CA, CO, ID, IL, IA, KS,
KY, LA, MI, MS, MO, MT, NE, NV, NM, ND,
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Phone: (630) 467-1300, ext. 425
Fax: (630) 467-1120
e-mail: mbalzano@putman.net
ReadOz has the most dynamic features
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SCOTT WALTERS , DISTRICT MANAGER
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Phone: (630) 467-1300, ext. 805
Fax: (630) 467-1120
e-mail: swalters@putman.net
Visit ReadOz.com today to gain
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MICHAEL CONNAUGHTON,
ACCOUNT EXECUTIVE
Alberta/Canada, British Columbia/Canada,
New Brunswick/Canada, Quebec/Canada,
Literature Reviews
Phone: (513) 543-6432
Fax: (630) 467-1120
e-mail: mconnaughton@putman.net
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CUSTOM REPRINTS
Use reprints to maximize
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e-mail: pdickson@putman.net
Reprints are a simple way to put information directly into the hands of your
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ADVERTISER INDEX
Company Name
Page No.
Company Name
Apex Engineering
36
MACTek
ARC Advisory Group/Automation Research Corp.
12
Quincy Compressors
Baldor Motors and Drives
3
14
Radiator Specialty
Carrier Rental Systems
33
Ramsay
Flexitallic
10
Shepard Niles
Fluke
IFC,6,15
Page No.
IBC
38
8
36
SPX Dehydration and Process Filtration
24
IFS North America
22
Sulmac
38
Institution Solutions
30
Turbomachinery Laboratory
20
International Exposition Co.
18
Unicco
Kaeser Compressors
BC
University of Tennessee
16
Legris
29
VibrAlign
17
40
PS0812_40_41_Class.indd 40
4
www.PLANTSERVICES.com
PLANT SERVICES (ISSN 0199-8013) is published monthly by
Putman Media, Inc., 555 West Pierce Road, Suite 301, Itasca, IL
60143. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals
Postage paid at Itasca, IL and additional mailing offices. Canada
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SUBSCRIPTIONS:
Qualified reader subscriptions are accepted
from PLANT SERVICES managers, supervisors and engineers
in manufacturing plants in the U.S. and Canada. To apply for
qualified-reader subscriptions, please go to www.plantservices.
com. To non-qualified subscribers in the U.S., subscriptions are
$96 per year. Single copies are $15, except the September and
October issues which are $36. Canadian and foreign annual
subscriptions are accepted at $145 (Foreign airmail $200/yr).
Single copies are $81. © 2008 by Putman Media, Inc. All rights
reserved. The contents of this publication may not be reproduced
in whole or in part without consent of the copyright owner. In
an effort to more closely align with our business partners in
a manner that provides the most value to our readers, content
published in PLANT SERVICES magazine appears on the public
domain of PLANT SERVICES’ Website, and may also appear on
Websites that apply to our growing marketplace. Putman Media,
Inc. also publishes CHEMICAL PROCESSING, CONTROL, CONTROL
DESIGN, FOOD PROCESSING, INDUSTRIAL NETWORKING, THE
JOURNAL, PHARMACEUTICAL MANUFACTURING and WELLNESS
FOODS. PLANT SERVICES assumes no responsibility for validity of
claims in items published.
December 2008
12/8/08 1:33:21 PM
CLASSIFIEDS
Products and Services
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12/8/08 1:34:30 PM
energy EXPERT
Do We Get It?
It might be time for energy evangelists to move on
A
if a dilution of local energy productivity goals will put the
paradox that applies as much to energy productivEU energy technology leadership at risk.
ity as anything else is that the last thing an evanWith this political backdrop, the conclusions for busigelist might want is to finish winning converts. If
ness are becoming obvious to a rapidly growing group of
we all understand, do we need the evangelist?
industry leaders. First, energy prices will start to rise again
It has taken a roller coaster ride of oil prices, increases in
as soon as the immediate economic storm is over, making
gas and electricity costs, hurricanes, wars, major blackouts
investment in energy productivity a nonnegotiable priority.
and an economic meltdown to get there, but it seems that
Second, with so much public investment channeled into
the requirement for sound energy management is becomenergy infrastructure, these will be major opportunities in
ing a given. With nearly 7 billion people on the planet, we
what could be a pretty bleak market scene for some time.
are going to have to be a lot smarter about energy.
In my own work, I find less time is devoted
President-Elect Obama’s economic team
to justifying why we need energy productivhas “green collar” employment as a highity. Political and business leaders are making
priority route to 2.5 million new jobs. The
The next
it clear to their constituents and employees
stated focus is on efficiency, renewable
challenge will
that the energy equation will change. The key
energy, so-called “clean coal” and upgrading
be filling the
questions today are around how to execute
the electricity distribution system. Closely
growing need
effective energy plans, not whether they are
related are the efforts that the new U.S.
needed in the first place.
regime is willing to make to become a world
for energy
For example, while developing targets for
leader in mitigating global climate change.
practitioners.
a Community Energy Plan in Ontario, a
Clearly, the evangelistic phase is coming to
greenhouse gas per capita of about Sweden’s
an end, and the implementation phase might
level today was proposed as a reasonable 25-year target.
just be gathering steam.
This is no small goal because it means building a city two
China has announced a stimulus package that simito three times as energy efficient as today’s average. As
larly will focus on long-term infrastructure investments
recently as three years ago, there would almost certainly
in a classic example of Keynesian economics. Like the
have been strong resistance to such a dramatic change.
United States, China is setting a high priority on major
Instead, the proposed target was set 1 metric ton lower
investments in energy efficiency and efficient energy
than Sweden today on the basis that just being the same
sources. I was recently in China working on an energy
was unacceptable.
strategy for a major city. The newspapers were full of
The need for energy-efficiency evangelists might finally
articles about the economic stimulus program and the
be stabilizing. The next challenge will be filling the
role of energy for a competitive sustainable economy and
growing need for energy practitioners to fan out across
in reducing climate change.
the globe to help us meet business, social and environEurope is in the midst of an interesting debate. As an
mental energy imperatives. As U.S. and Chinese policy
early leader in adopting a more rigorous approach to minion employment suggests, we’ll need a lot more practitiomizing the effects of energy waste, the EU was lining up
ners than evangelists. To paraphrase Churchill, this is not
to accept another aggressive set of climate change targets.
the end, nor even the beginning of the end, but it might
The economic tsunami has definitely produced two camps.
just be the end of the beginning of a completely new
On one side there’s strong support from many members to
energy scenario for all of us.
stay the aggressive course; others are concerned this will
add costs to economies at a time of high fragility. European companies stand to benefit from the focus in Asia and
Peter Garforth is principal of Garforth International LLC, Toledo,
America given its strong green technologies. Time will tell
Ohio. E-mail him at garforthp@cs.com.
42
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December 2008
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