2012 - 11 - plant engineering

71 Remote monitoring 81 Rugged flexible enclosures 89 Oil contamination

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www.plantengineering.com PLANT ENGINEERING November 2012 • 3

What’s INsideWhat’s INside

6 Interactive

9 In Focus

23 In Practice

93 Product Mart

94 Internet Connection

95 Advertiser Contacts

96 In Conclusion

November 2012Volume 66, No. 9

76 Enhancing systems

2012 Product of the Year Finalists

The next wave of innovation

PLANT ENGINEERING (ISSN 0032-082X, Vol. 66, No. 9, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2012 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and addi-tional mailing offices. Circulation records are main-tained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: [email protected]. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: [email protected]. Rates for nonqualified subscrip-tions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regard-less of whether such errors result from negligence, accident or any other cause whatsoever.

What’s INside

30 Automation & Controls36 Apps for Engineers37 Compressed Air38 Electric Motors & Drives40 Electrical Controls41 Energy Management42 Environmental Health43 Fluid Handling

44 HVAC45 Lighting47 Maintenance Tools & Equipment49 Material Handling Systems51 Power Transmission53 Productivity Training Software54 Safety

There are more than 100 finalists in 15 categories vying for your approval in this year’s Product of the Year voting.

PLE1211_TOC_V3msFINAL.indd 3 11/7/12 4:34 PM

Analyze power quality and calculate energy loss. Poor power quality. It affects how your facility operates. It affects your bottom line. Fortunately, there’s the new Fluke 435 Series II Power Quality and Energy Analyzer. It features the most advanced waveform and power effi ciency functions available and calculates the cost of wasted energy. So don’t settle for half the job–do the whole job with Fluke.

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CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager 630-571-4070, x2212, [email protected]

AMANDA MCLEMAN, Project Manager 630-571-4070, x2209, [email protected]

MARK HOSKE, Content Manager 630-571-4070, x2214, [email protected]

PETER WELANDER, Content Manager 630-571-4070, x2213, [email protected]

AMARA ROZGUS, Content Manager 630-571-4070, x2211, [email protected]

CHRIS VAVRA, Content Specialist 630-571-4070, x2219, [email protected]

BRITTANY MERCHUT, Content Specialist 630-571-4070, x2220, [email protected]

PUBLICATION SERVICES JIM LANGHENRY, Co-Founder and Publisher, CFE Media 630-571-4070, x2203; [email protected]

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

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

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

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

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

MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 [email protected]

KARIE BURT, Account Director, mardevdm2 212-584-9374; [email protected]

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

LETTERS TO THE EDITOR Please e-mail your opinions to [email protected] or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity.

INFORMATION For a 2012 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected].

REPRINTS For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco Phone: 877-652-5295 ext. 102 Email: [email protected]

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

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

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

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

Richard A. Groth Jr. NJ/ E. PA [email protected] 12 Pine Street Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432

Stuart Smith, International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588 fax

Automation Solutions

71 Remote monitoring technologies lower costs, improve operations The latest remote communication technologies allow experts to monitor and control multiple plants from any location.

76 Using sensors to enhance systems Recognize the limitations, then plan for redundancy.

Maintenance Solutions

81 Smaller, more flexible enclosures still need to be rugged Cabinets allow for safe and accesible storage, but can generate dangerous heat.

Mechanical Solutions

89 Particulates, liquids, oxidation contribute to oil contamination Oil discoloration should be addressed with high importance for optimal operation performance.

9 In Focus � Get Skills to Work formed to address skills gap, veterans training � Georgia Tech study: Sales, Lean, skilled worker help needed � Data center management more than cooling � Hope is not an effective safety strategy � Measuring quality through software � Fine turning your preventative maintenance schedule

CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager 630-571-4070, x2212, [email protected]

AMANDA MCLEMAN, Project Manager 630-571-4070, x2209, [email protected]

MARK HOSKE, Content Manager 630-571-4070, x2214, [email protected]

PETER WELANDER, Content Manager 630-571-4070, x2213, [email protected]

AMARA ROZGUS, Content Manager 630-571-4070, x2211, [email protected]

CHRIS VAVRA, Content Specialist630-571-4070, x2219, [email protected]

BRITTANY MERCHUT, Content Specialist630-571-4070, x2220, [email protected]

PUBLICATION SERVICES JIM LANGHENRY, Co-Founder and Publisher, CFE Media

630-571-4070, x2203; [email protected]

STEVE ROURKE, Co-Founder, CFE Media630-571-4070, x2204, [email protected]

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

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


PAUL BROUCH, Web Production Manager630-571-4070, x2208, [email protected]

MICHAEL ROTZ, Print Production Manager717-766-0211, Fax: 717-506-7238

[email protected]

KARIE BURT, Account Director, mardevdm2212-584-9374; [email protected]

RICK ELLIS, Audience Management Directornagement Directornagement Phone: 303-246-1250; [email protected]

LETTERS TO THE EDITOR Please e-mail your opinions to

[email protected] or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity.

INFORMATION For a 2012 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected].

REPRINTS For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco

Phone: 877-652-5295 ext. 102 Email: [email protected]

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

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

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

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

Richard A. Groth Jr. NJ/ E. PA [email protected] 12 Pine Street Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432

Stuart Smith, International International International [email protected] SSMGlobal Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588 fax

PlantEngineering.com1111 W. 22nd St. Suite 250, Oak Brook, IL 60523Ph 630-571-4070, Fax 630-214-4504

CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager 630-571-4070 x2212, [email protected]

AMANDA MCLEMAN, Project Manager 630-571-4070 x2209, [email protected]

MARK HOSKE, Content Manager 630-571-4070 x2214, [email protected]

PETER WELANDER, Content Manager 630-571-4070 x2213, [email protected]

AMARA ROZGUS, Content Manager 630-571-4070 x2211, [email protected]

CHRIS VAVRA, Content Specialist [email protected]

BRITTANY MERCHUT, Content Specialist 630-571-4070 x2220, [email protected]

BEN TAYLOR, Content Specialist 630-571-4070 x2219, [email protected]

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

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

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

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


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

MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 [email protected]

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

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

LETTERS TO THE EDITOR Please e-mail your opinions to [email protected] or fax us at 630-214-4504. Letters should include name, company, and address, and may be edited for space and clarity.

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

REPRINTS For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco Phone: 877-652-5295 x102 Email: [email protected]

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

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

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

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

Richard A. Groth Jr. NJ/ E. PA [email protected] 12 Pine St. Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432

Stuart Smith, International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588

PLANT ENGINEERING November 2012 • 5

PLE1211_TOC_V3msFINAL.indd 5 11/7/12 4:34 PM

WHITE PAPER

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Fleet management programs help navigate hidden opportunities to reduce your materials handling spending. As you are confronted with difficult economic hurdles, the need to shed cost for sustainability is a must if you are to emerge from these economic times leaner, stronger and poised to take advantage of economic recovery.Visit www.plantengineering.com/media-library/white-papers to view the white paper.

VIDEO

Energy management trendsin manufacturing

CFE Media content manager Amara Rozgus sat down for an exclusive one-on-one interview with Jeff Drees, North Ameri-can president for Schneider Electric, to discuss trends in manufacturing, including the increasing use of energy man-agement and energy audits to identify and reduce the cost of energy to a plant.

Scan the QR code above with your Smartphone or visit www.plantengineering.com/videos

WHAT 2 CLICK 2Here are this month’s online highlights

at www.plantengineering.com. Type the keyword into our exclusive search engine and find full details on each article:

� Keyword: SME student assessment: The Society of Manufacturing Engineers (SME) has been granted $292,000 from the U.S. Dept. of Energy to partner SME Student Chapters with existing Industrial Assessment Centers at universities nation-wide.

� Keyword: Compressed dew points: Sampling is needed when direct measure-ment of the air is undesirable or is simply not feasible. This may be due to a high pro-cess temperature, the need to protect the sensor from water spikes, the added conve-nience of installing and removing the instru-ment from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location. This paper shares tips on how to get a representative sample of the process gas and avoid potential sources of error caused by incorrect sampling practices.

� Keyword: Industrial wireless market: New research study from Frost & Sullivan projects massive growth for the wireless industrial automation market. While rev-enues are expected to more than double over the next four years, implementation of wireless technology still is lagging. Analysts attribute this to a lack of understanding about the full potential of wireless.

� Keyword: AME Hall of Fame: The Association of Manufacturing Excellence named four 2012 Hall of Fame inductees at its annual conference. The honor recognizes individuals who have distinguished them-selves in the manufacturing community in a manner that is consistent with AME’s mis-sion to inspire a commitment to enterprise excellence through shared learning and access to best practices.

6 • November 2012 PLANT ENGINEERING www.plantengineering.com

INTERACTIVEwww.PlantEngineering.com

Smartphone or visit www.plantengineering.com/videos

20122012

PRODUCT OF THE YEAR

Cast your voteAs a qualified subscriber to Plant Engineering,

you are eligible to vote for the best products in this year’s Product of the Year program. Voting is open until Jan. 15, 2013, and the winners will be announced at the 2013 Awards in Manufacturing Event on March 18, as well as in the April 2013 issue of Plant Engineering.

Turn to page 29 or visit www.plantengineering.com/POY to read about this year’s finalists and cast your vote.

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A new survey finds that veterans returning from military service believe their skills will translate well into the private sector, but don’t believe the private sector

feels the same way.GE and the Institute for Veterans and Military Families at

Syracuse University released the results of their “Voice of Veterans” survey to coincide with the announcement of the coalition between GE, Alcoa, Boeing, and Lockheed Martin. The four companies, working with the Manufacturing Insti-tute, have developed the Get Skills to Work program to help train and deploy returning veterans for manufacturing jobs.

The survey found that 76% of U.S. veterans and active duty military preparing to transition to civilian life are confi-dent they can be successful in their private-sector careers. But 66% said they believe the skills they gained in military service are undervalued by private sector employers.

More than 1,000 veterans and active duty personnel under the age of 45 took part in the survey. They said they want the same kind of training they received in the military, and believe their background and existing skills will trans-late well into private sector employment.

“What stands out in this data is that veterans are moti-vated to make a difference beyond their military careers. Given their contributions, we must pay attention to the

unique challenges and opportunities they face as they navi-gate the transition to civilian life,” said Mike Haynie, founder and executive director, IVMF. “There is a lot we can do to match the desire to work in dynamic, rewarding industries with training that creates a pathway for success.”

“The U.S. manufacturing industry is growing, and we stand ready to provide our military veterans with the train-ing, education, and mentorship they are seeking to build long-term, well-paying careers that make a positive differ-ence in the world,” said Frank Taylor, chief security officer of GE. “The skills earned in the U.S. armed forces translate to today’s sophisticated, highly technical manufacturing industry, and we are confident that working together with America’s heroes, we are poised to drive American com-petitiveness.”

The Get Skills to Work coalition’s goal is to bolster the tal-ent pipeline, enhance American competitiveness, and give our nation’s veterans the skills and tools they need to com-pete for the jobs of the future. Coalition partners include The Manufacturing Institute, GE, Boeing, Lockheed Martin, Alcoa Inc., LinkedIn, Futures Inc., Atlantic Council, the Gary Sinise Foundation and Techshop.

For more information about the Get Skills to Work coali-tion, visit www.getskillstowork.org.

Study: Returning vets say they have the skills to help manufacturing

Four major American manufactur-ers recently announced the creation of a coalition to fund and encourage military veterans to get the training needed to fill the manufacturing jobs shortage.

The Get Skills to Work coalition will focus on accelerating skills train-ing for U.S. veterans; helping veterans and employers translate military skills to advanced manufacturing jobs; and empowering employers with tools to recruit, onboard, and mentor veterans. It will be managed by the Manufacturing Institute and supported through financial and in-kind commitments from GE, Alcoa Inc., Boeing, and Lockheed Martin.

“These initial investments will help 15,000 veterans translate military expe-rience to corresponding advanced man-ufacturing opportunities and gain the

technical skills needed to quali-fy for careers in this growing sector,” the group said.

“A strong manu-facturing industry is central to the long-term health and success of our economy,” said Jeff Immelt, chairman and CEO of GE. “But as technology advances, skill sets must be upgraded to ensure companies have the talent to continue to fuel innovation. Today, many veter-ans are out of work, despite the nation’s growing industrial sector and increased demand for skilled workers. Through this initiative, we have an opportunity to help veterans with extraordinary leadership capabilities better compete for good pay-ing jobs with a long-term future.”

Reportedly 600,000 high-tech manufacturing jobs remain

open in the U.S., and more than 82% of manu-facturers report they cannot find people to

fill their skilled production jobs. Meanwhile, one million

veterans are expected to exit the armed forces over the next four

years and will be transitioning to civil-ian careers.

The coalition commissioned an online survey of more than 1,000 veterans and active duty military members preparing to transition to the private sector. The sur-vey found that while 76% of respondents are confident they will be as successful in their careers as they were in the mili-tary, one-third do not feel equipped to


Get Skills to Work formed to addressskills gap, veterans training

INFOCUS

PLE1211_INFOCUS_V6msFINAL.indd 9 11/7/12 4:36 PM

overcome the challenges of the transition to civilian life; the percentage rises to nearly 48% when surveying active duty military who are scheduled to transition in two years or less.

“Veterans offer the technical, lead-ership, and critical thinking skills that advanced manufacturing demands,” said Paula Davis, president of the Alcoa Foundation. “Forming the Get Skills to Work coalition and coordinating with nonprofits to train, recruit, and develop veterans is an exciting model that has the potential to change lives and produce a significant competitive advantage for U.S. manufacturers.”

“We believe the Get Skills to Work initiative could have a major impact on the hiring of veterans nationwide,” said Rick Stephens, Boeing’s senior vice president of human resources and administration, and a U.S. Marine Corps veteran. “Using many of the same tac-tics and tools, such as a website for transitioning veterans that includes a military-to-civilian skills translator, we have hired and trained nearly 3,000 veterans in the past 21 months for jobs at Boeing. It’s a proven approach for matching the skills of those who have served our country to the hiring needs of American businesses. We’re honored to be part of Get Skills to Work, and look forward to integrating our efforts with the coalition.”

“America’s veterans want and deserve the opportunity to contribute to our soci-ety and provide for their families,” said Bob Stevens, Lockheed Martin Chairman and CEO.

The program will consist of three ele-ments:

n Accelerating skills training To help prepare veterans whose mili-

tary service experience doesn’t immedi-ately qualify them for available manufac-turing jobs, coalition partners will work with local community and technical colleges to establish the Manufacturing Institute’s Right Skills Now program, which fast-tracks industry-recognized certifications and offers training in core manufacturing technical skill areas. Part-ners will engage their regional supply base to ensure the certifications being offered meet the immediate skill needs of local employers, and will work with the U.S. Depts. of Defense and Veterans Affairs, as well as local military transi-tion offices and bases, to recruit veteran participants.

n Translating military experience into civilian opportunities

Many veterans and employers have dif-ficulty recognizing and translating the skills gained through military training and experience into civilian workforce skill sets. The Manufacturing Institute, working with Futures Inc., has created a digital badge system to help translate

INfOCUS

Mark Huber (from left) of Alcoa Inc., Gabriele P.M. Tyler, Deputy Director of Transition Strategic Outreach for the U.S. Army, and actor and veterans activist Gary Sinese discuss the formation of the Get Skills to Work coalition. Courtesy: GE

Among the findings of the “Voice of Veterans” study conducted by GE and the Institute for Veterans and Military Families at Syracuse University:

n 76% of young veterans are confident they can be successful in their careers, despite the many challenges faced when transition-ing to civilian life, and this confi-dence level increases with age.

n 66% feel their skills are under-valued. Unparalleled work ethic, leadership, teamwork, discipline, and dedication are translatable skills they have to offer the civilian workforce.

n 70% believe the skills they earned in the military align with a job in the manufacturing industry.

n 79% are motivated to find educational opportunities to help them find and advance their civilian career.

n Work/school balance (48%) and financial burdens (35%) pose barri-ers to their pursuit of education.

n 76% want a civilian career that makes a positive difference in the world.

n 78% seek a career that fills them with a sense of pride.

n 62% believe companies have a responsibility to provide veterans with opportunities to enter and suc-ceed in the civilian job market.

applicable Military Occupational Spe-cialty (MOS) codes, the U.S. military’s system for identifying jobs, to civilian positions in advanced manufacturing.

n Empowering employers GE and the Institute for Veterans and

Military Families at Syracuse University (IVMF) will develop and deploy a toolkit for employers focused on creating mean-ingful, lasting career opportunities for veterans in the advanced manufactur-ing sector. The toolkit will be available to employers participating in the U.S. Chamber of Commerce’s Hiring Our Heroes initiative and the 100,000 Jobs Mission, as well as the broader business community. PE

For more information visit www.getskillstowork.org.

10 • November 2012 plant engineering www.plantengineering.com


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12 • November 2012 plant engineering

The 2012 edition of the Georgia Manufacturing Survey,conducted by Georgia Tech University, points to four areas of concern for manufacturers in that state. Topping the list is a need for more help in sales and marketing, with 36% of manufacturers citing this as a significant need.

Manufacturers also want more help with the Lean manufac-turing operation, cited by 32% of manufacturers, and worker skills, with 24% needing more technical workers and 16% needing more workers with basic skills. Energy cost manage-ment is cited by 21% of manufacturers as an area of concern. That percentage has doubled since 1999.

The study also noted a significant increase in re-shoring of jobs to the state. According to a press release issued by Georgia Tech, nearly 16% of the companies responding to the survey said work had been transferred to them from outside Georgia, compared to slightly more than 14% that lost work to out-of-state facilities.

“We have finally seen a crossing of the lines so that more companies are benefiting from in-sourcing than are los-ing to outsourcing,” said Jan Youtie, director of policy research services in the Enterprise Innovation Institute at

Georgia Tech. “It’s not a huge difference at this point, butit is a positive and consistent trend for the manufacturing community.”

Plant Engineering spoke with Youtie about the implications for manufacturers in Georgia and elsewhere.

PE: What are Georgia manufacturers able to offer

right now that seems to be attracting manufactur-ing investment? Is this occurring in specific sectors or across the board?

Youtie: Science-based manufacturers (those in medical device, chemicals, and petroleum industries) and large manufacturers are more apt to be engaged in in-sourcing.

PE: The study also focuses on the relationship between technology and employment. Has the skills gap emerged as a problem for Georgia manufacturers, and how are they addressing the issue?

Youtie: This survey highlighted a reemergence of manufactur-ers’ concerns about technical skills, but we continue to see that investment in training is relatively low ($100 per respondent on average).

PE: What are the barriers to sustainability? Is it more profitable today to run a sustainable plant?

Youtie: Although we do not ask about the barriers to sus-tainable manufacturing, we do see that the vast majority of manufacturers are engaged in some aspects of sustainable manufacturing, such as eliminating waste materials sent to landfills, and more than half have a goal to eliminate air or water pollution. Both of those areas appear to have their 2010 plans implemented by 2012. Other areas such as using renewable energy to run the plant still are not very common at all (set by only 7% of manufacturers in 2012), however, although the percentage with this goal has risen slightly from 2010 to 2012. PE

Georgia Tech study: Sales, Lean, skilled worker help needed

While Georgia manufacturers still cite marketing and sales their biggest area that they need help with, the need for more technical skills, energy management and basic worker skills all rose in 2012 from 2010, the last time the study was con-ducted. Source: Georgia Manufacturing Study, Georgia Tech

Manufacturing Problems/NeedsProblems/needs 2012 2010 Change

Marketing and sales 36.0% 39.1% -3.1%

Manufacturing process/Lean

31.6% 31.6% 0%

Technical skills 23.5% 18.8% 4.7%

Energy costs management 21.4% 18.9% 2.5%

Basic skills 16.4% 13.9% 2.5%

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Myth: Building my own data center is expensive, inefficient, and time-consuming—but worth it to meet my specific IT needs.

Due to advances in data center technol-ogy, modular and containerized data cen-ters are now often a better alternative to customized data centers. For data center managers looking to increase their ROI, modular or containerized data centers are not only faster to deploy, but they’re also signifi-cantly more affordable and can offer better operational, effi-ciency, and processing benefits.

The most obvious benefit to modular data centers is a drastic reduc-tion in installation time. Traditional data centers take months or even years for construction, compared to just 10 to 16 weeks for a modular data center. This is in part because they’re already verified for compliance in safety, energy efficiency, compatibility, and security.

Cost savings is another major benefit. Not only will the upfront cost of instal-lation be drastically lower than that for a traditional data center, but mainte-nance and operating expenses are also reduced over time. A modular approach can deliver capital expenditure cost sav-ings anywhere from 10% to 20%, and operating expenditure cost savings from 20% to 35%.

Because of their manufacturing process and predictability, modular facilities also have a lower risk of operational human error. Systems have factory-verified operation and are tuned for maximum energy efficiency. Product defects are limited and software is preprogrammed, allowing technicians to spend less time troubleshooting and more time devoted to other critical IT issues.

Myth: Sustainability in my data cen-ter is unattainable within my budget constraints.

Sustainability isn’t just for big bud-gets. Using the right equation of afford-able, widely available services and

technologies to manage a data center’s energy supply and demand, businesses of all sizes can meet and exceed green and sustainability goals—without breaking the bank. Below are a few examples.

� Energy procurement: To ensure the most reliable and affordable clean energy is being sourced, data centers now have the option to work with outside sustainability service providers. These providers can help data centers with the

full-time job of energy planning, monitoring, and reporting. These partners can also help reduce complexities involving price volatility, and control costs.

� Energy use: Just as we’re reminded to consume energy

intelligently in our homes, data centers also need to be mindful of how and when they’re consuming energy. Some methods to reduce energy usage include:

� Natural cooling: Instead of an expensive HVAC system, use a free resource to cool your racks: outside air. While this is clearly best for data centers located in colder climates, it’s an ideal way to slash cooling costs and reduce energy use.

� Air containment strategies: Data centers routinely mix hot and cold air, limiting how effectively a system oper-ates, as well as its overall capacity. An air containment system can be imple-mented by placing air tiles in the cold aisle, installing supply vents in the cold aisle and return vents in the hot aisle, and physically dividing the hot and cold aisles with a curtain or hard enclosure. This can return up to 25% in savings.

And as the connecting element in a smart data center equation, demand response helps data centers get the most value out of their utility budget. By tak-ing advantage of their utility’s demand response programs, businesses have the ability to determine when to best con-sume electricity, in conjunction with low rates. Plus, companies can also sell back unused energy (gleaned from efficiency and smart sourcing) to their utility at peak times, generating entirely new streams of revenue.

Myth: Updating cooling is the only way to lower data center energy costs.

There are many other tactics to be considered for lowering data center energy costs. Though cooling is a tre-mendous energy consumer, there are equally important areas you should be paying attention to if you want to slash your energy bills as much as possible, including air containment, higher voltage power distribution, more efficient UPS, redundancy requirements, and power architecture. Also consider:

� Power equipment efficiency: Data centers often fail to account for the heat produced by critical devices within a data center, such as UPS, transformers, transfer switches, and wiring. By cooling the heat generated by these devices, data centers maintain optimal conditions but also consume far more energy.

Data centers should consider switching to more energy-efficient equipment, such as high-efficiency UPS, which have up to 70% less loss than legacy UPS at typical loads, servers, and CRAC/CRAH units, which can be programmed to reduce or cease demand fighting entirely.

� Centralized management system:Advancements in data center infrastruc-ture management (DCIM) software now allow data center managers to easily integrate and prioritize all IT equipment and functions into one application. This centralized point of control allows data center managers to holistically monitor temperatures, operations, security, and power utilization.

While cooling should not be over-looked, data centers would do well to look at energy usage holistically. By implementing a variety of tactics, data centers can slash energy bills in a way that works best for the organization. PE

Kevin Brown is Vice President, Data Center Global Solution Offer for Schnei-der Electric’s IT Business.


INFOCUS

Data center management more than cooling

5Fifthin a series

GO TO: www.PlantEngineering.com

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INDUSTRIAL EFFICIENCY: DEBUNKING THE MYTHS

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It basic nature that businessesdon’t want incidents to occur. And, at the same time employ-ees don’t want to be hurt. Busi-nesses generally, some only when confronted, don’t wish for exposure to unneeded regulation, un-scheduled machine downtime, employee injuries, costly liabilities or the cost bur-dens associated with these issues. Yet, these are some of the negative results a business can expect as consequences of avoiding the required risk assessments for their machinery operations.

Some of the potential liabilities of exposure (avoidable consequences) might be:

� Timing: Too many businesses still avoid the issue of compliance to the risk assessment requirement which extends to existing, new or modified equipment. The sooner the better to meet compli-

ance requirements and avoid citations.

� Misapplied devices: Quite often safety devices are provid-ed but are miss-applied because a hazard level was not properly assessed. For example, a Cat 4 hazard could require a control

reliable solution involving a Cat 4 safety rated switch with redundant contacts. A miss-applied device in this example could include; a single standard interlock switch, safety rated devices below Cat 4, or an application which is not control reliable.

� Foreseeable misuse: A properly con-ducted machine guarding risk assessment will typically uncover misuse situations like; equipment malfunction, unauthor-ized process material, operating tooling beyond its useful life, unexpected loss of power, and reach over, under, around, or through guarding.

� Misapplied procedure: Lockout/

Tagout (LOTO) is frequently misun-derstood and/or not always followed as prescribed by OSHA. LOTO incidents are preventable via frequent training, documenting procedures, not permitting shortcuts, and by establishing employee penalties for non compliance.

� Unidentified modes: All modes of operation and their related tasks need to be identified in order to reveal their related hazards. Unidentified modes include; setup, cleanup and preventive maintenance.

The advice of industry experts is to not become aware of the importance of risk assessments only after a serious incident and the resulting OSHA citation, or the legal engagement, or the sever financial expenses which fall directly to your bot-tom line. “Hope” is not an effective strat-egy – proactive engaged machine safety leadership is! PE

Read J.B. Titus’ blog, Machine Safety,at www.plantengineering.com/blogs.

INFOCUS

Hope is not an effective safety strategyBy J.B. Titus


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LNS Research has released itsEnterprise Quality Management Software Selection Guide, which looks at 18 major vendors in the spaces and offers comparisons on performance and applicability to individual industries. Matthew Lit-tlefield, president and principle ana-lyst at LNS Research, discussed with CFE Media the value of measuring quality with software, and how the acceptance of such tools is growing throughout the plant.

Plant Engineering: In evaluating the top vendors for Enterprise Quality Management Software, what crite-ria would you say is most critical for an effective system for end users?

Littlefield: There are a number of factors that determine how well suited a particular vendor is for a particular client. First and foremost I think comes industry experience, some vendors have experience in life sciences, others have experi-ence in discrete manufacturing like automotive or aerospace and defense, still others have started to develop experience in consumer products or food and beverage. The drivers and needs are very different in all these industries and very few vendors have expertise across all these industries.

Second, I would say existing IT infrastructure, some com-panies are heavily invested in ERP, others have a large PLM footprint, still others have disparate systems at the enterprise level, again different vendors have different strengths in this regard. Finally I would recommend looking at the technology itself. Originally EQMS vendors were very form based, over time many have updated their technology to be work-flow based that has a more solid data model and ability to inter-operate with other systems through web-services.

Finally, is the vendor continuing to invest in areas like BI, Mobility, and an enhanced user-experience. Some companies are and others are still behind the curve.

PE: Why is software the best measuring tool for qual-ity? What industries might benefit the most from such a system? Conversely, which industries are not a good fit for EQMS?

Littlefield: Software is an important tool for a number of reasons but I think one that stands out the most is our changing business environment. Companies are continuing to expand globally, products are continuing to increase in complex-ity, regulations continue to expand, and consumer demands continue to increase.

Companies that don’t specifically invest in a platform to manage how quality impacts the entire value chain and how

Enterprise Quality Management Software Selection Guide, which looks at 18 major vendors in the spaces and offers comparisons on performance and applicability to individual industries. Matthew Lit-tlefield, president and principle ana-lyst at LNS Research, discussed with CFE Media the value of measuring quality with software, and how the acceptance of such tools is growing throughout the plant.

18 • November 2012 PLANT ENGINEERING

INFOCUS

Measuring quality through software

Matthew LittlefieldLNS Research


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quality addresses all these market drivers will be at a distinctcompetitive disadvantage.

From an industry perspective, industries that have high risk products, high risk processes, a deep impact on con-sumers, or a restrictive regulatory environment are all can-didates for EQMS, including life sciences, consumer prod-ucts, discrete manufacturing, and process manufacturing.

PE: You mentioned the education process is critical in a successful deployment of EQMS. How far into the orga-nization does this training need to go?

Littlefield: For a quality culture to take hold, it truly has to go to the operator level. Continuous improvement, non-conformance management, compliance, and more all have to be managed at the most granular level possible. We are now seeing some companies that have 10,000-plus users on EQMS systems.

PE: What are the leading causes of failure for EQMS, or any operating system for that matter?

Littlefield: Very rarely is the technology to blame itself, although that could be the case with some vendors that have not kept based with investments in their products. Most likely that failure comes from executive leadership not promoting and believing in a quality culture. If executives do not walk the walk it can be very challenging to have the right culture and technology adoption flow through the organizations

PE: What’s the potential ROI for a successful imple-mentation?

Littlefield: ROI is tough to measure in the EQMS world and many companies don’t. Although there are two ways we are starting to see companies measure ROI. First is around the Cost of Quality and second is around risk reduction. Both are viable ways for measuring business success and companies that invest in EQMS can often see major improvements in these metrics, often providing an ROI in less than 1 year.

PE: Why might this be a good time for manufacturers looking to upgrade their quality management process?

Littlefield: We have seen companies be most successful with EQMS in two major ways. One if there is a major quality issue or compliance issue at your company, adopting software maybe a very prudent step for correction.

Second, if your company is focused on a new (or improv-ing an old) operational excellence initiative, EQMS can help in the success of these initiatives and building quality into operational excellence. PE

“For a quality culture to take hold, it truly has to go to the operator level. Continuous improve-ment, non-conformance management, compli-ance, and more all have to be managed at the most granular level possible.”


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What comes first: corrective or pre-ventive maintenance? Well, the industrial engineers would say “PM,” of course. But the reality of busy schedules and a

reduced labor force often set in and best laid plans slip.

Example: Company X has older, inef-ficient ventilation in one of its produc-tion facilities. The HVAC breaks down frequently, is expensive to run, and finally

management agrees to replace it with abrand new, more energy efficient sys-tem. Since the conversion, air quality and temperature have never been better, and the cost savings is tangible.

During installation, the manufacturer strongly advises Company X to follow a recommended maintenance plan. The maintenance supervisor asks her admin-istrator to make sure the PM calendar is set up in the CMMS. The team is so happy to not be dealing with the older, often malfunctioning system they won-der, “Why bother doing anything; the system is brand new!”

PMs are dutifully set up and the auto-mated reminders/PM work orders churn out every month. The challenge begins when the technician assigned tries to balance PM work orders on a combina-tion of assets, including a shiny, new ventilation system and other antiquated, poorly-running systems that should be replaced.

The reality is that technicians will likely continue to “MacGyver” older systems to keep them running and the new system will be ignored since it is humming along nicely. There are just not enough hours in the day. Reality forces us to make compromises.

Sometimes these choices have to be made. If all of a sudden the CMMS issues an actual corrective maintenance work order for this system, it indicates that the team has to get back to a more frequent schedule, but it may not need to be as frequent as the manufacturer’s recom-mendations.

A good CMMS system can deliver the information users need to better fine-tune their PM schedules. If a less-rigorous PM schedule gets the maintenance team slapped with a corrective work order, it’s time to adjust. Sometimes it is the other way around. If the CMMS system tells the maintenance manager ‘all is well’ with an asset, that may be a signal to shift resources to other equipment in greater need. PE

Paul Lachance is president and chieftechnology officer for Smartware Group, which produces Bigfoot CMMS. Contact Paul at [email protected].

INfOCUS

Fine tuning your preventive maintenance scheduleBy Paul Lachance, Smartware Group


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INPRACTICE

I frequently pose this question to managers: “How much time do you spend on the floor?” I get responses that run the gamut from “I don’t need to go to the floor” to “I’m on the floor all the time.” Of course, the amount of time that you

spend on the floor is directly proportional to where you sit in your organization’s hierarchy.

You’ve probably heard the phrase “Go to the gemba.” From what I can ascertain, this means go to where the work is being done. I absolutely, wholeheartedly, agree with this concept. However, the amount of time you spend there and what you get accomplished are not always pro-portional to each other.

So, how do you make your time in the work area more productive? First, let’s talk about the inverted pyramid. This is not a new concept, and it can be used in a myriad of ways. The pyr-amid that I am talking about stands on its point, and like the traditional pyramid, the head of the organization resides at the point. The difference here is that now the point supports the entire organization instead of the rest of the organization supporting the point.

Ask yourself a question, no matter where you sit on the pyramid. How much time do you spend making sure that daily customer demand is met? And how do you know that it is being met? Can you walk into the workplace and understand where you stand in meeting daily customer demand? In most places that I have worked, it is not easy to determine. That information is usually communicated at the morning production meeting. And where do these meetings usually take place? If you said “the floor,” you are in a small minority.

Meeting customer demandWhose job is it to meet daily customer demand? The opera-

tors who are in the trenches every day making the equipment/processes operate. About 90% to 95% of the time, they need to be focused on meeting daily customer demand. And what should they do with the other 5% to 10%? Teach them to solve problems in order to create greater stability and increase effi-ciency. With the operators taking on the biggest burden in order to meet customer demand, what does everyone else do? Everyone else supports the operator; thus the inverted pyramid.

A typical structure could include operators, team leaders, group leaders, assistant managers, and managers, with each lower level of the pyramid supporting the level above it. Visual

controls are what will allow you to see what is happening on the shop floor. It is how the operator communicates to the management team what is happening in their process. Things like progress control boards, color coding, and having spe-cific locations for tools, work in process, raw materials, and finished goods will help you to identify the current condition of satisfying customer demand for that particular day. Even if you are producing an item that gets completed only once every 45 days, it can still be broken down into weekly, daily, and even hourly targets.

One of the foundational visuals is the progress control board. It can dis-play everything about an area that is required to understand what is being done to satisfy customer demand. It will always contain a temperature of where the area stands in meeting customer demand. Some will call it an hour-by-hour chart; I call it a feeling. When you look at it, you get a feeling for whether the process is

performing well or not.Another integral part of the progress control board is the

Pareto of reasons for missing target (or capacity). As the opera-tors understand what is causing the line to be unstable, they will take action to constantly reduce the variation. This could be problem solving and implementing the solutions themselves, thus the 5% to 10% dedicated to improving the line, or it could be listing items on an action item log for someone else to handle.

This brings us to the final mandatory item on the progress control board—the action log. When the operators run into an item that they themselves cannot solve, they will put it on the action log. It is then the responsibility of the people that are lower on the pyramid to review these action items and act on them.

Allocating timeHow much time should you spend on the floor? If you can

adhere to the 90%-95% rule for the operators, the team leads (or supervisors, or assistant general foreman) will spend 70%-80% on daily demand and 20%-30% looking ahead. They will look one week to a month out and see what is coming up. What do they have to do with manpower? Are temps required? Are there any tests that will need to be run that require special attention? What is required of the team lead to support the operator in making the line more stable and efficient?

Make your plant floor timeproductive

By Kimo Oberloh, Life Cycle Engineering

As the operators understand what is causing the line to be unstable, they will take action to constantly reduce the variation. This could be problem

solving and implementing the solutions themselves, thus the 5% to 10% dedicated to improving the line.

PLE1211_INPRACTICE_V5msFINAL.indd 23 11/7/12 4:37 PM

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INPrACTICEThe next level down (group leader, assistant manager, fore-

man) should spend 50%-60% of their time satisfying customer demand and the remainder of the time looking ahead at what is happening this month or this quarter. Each level needs to ask what it can do to support the operator.

As we progress another level down, managers should allocate 25% of their time to meeting daily demand, and 75% to plan-ning for the year. Are you starting a new line? What needs to be done in the holiday shutdown? How are we going to staff for the summer peak, what do I need to do to satisfy the targets and objectives for the year and, of course, what can I do to support the operator? At the bottom of the pyramid (CEO, COO, plant director), leaders focus 5% to 10% on daily demand and 90% to 95% on looking ahead.

When we look at these percentages more closely, if the bot-tom of the organization were to spend 10% of their day making sure that customer demand is met, that would be one hour per day (assuming that most management teams usually work a 10-hour day). This would entail walking the floor, observing the progress control boards, and seeing what items on the action list require their attention. This would also include walking the floor with the team members that report to you.

The content on the rest of the progress control board is up to you. Remember, you have the daily progress sheet, Pareto of reasons for not meeting plan (or capacity), and the action list of what is being done to solve the issues. Be careful that the action log does not become a whine sheet. There should only be about two to three actions on the list. This is because in large plants with a lot of progress control boards you need

the ability to make sure that the actions identified are being solved.

Other items that you could place on the board are items that will roll up to the overall metrics of the company. These usually fall into the categories of quality, cost, safety, and, of course, delivery. All metrics should roll up and down to support policy deployment.

So while the question, “How much time do you spend on the floor?” is very relevant, because no one is excused from spending time on the floor, maybe the real ques-tion should be, “How productive is the time that you spend on the floor?” PE

Kimo Oberloh is a Lean manufacturing subject matter expertat Life Cycle Engineering (www.lce.com). Kimo can be con-tacted at [email protected].

How much time do you spend making sure that daily customer demand is met?

And how do you know that it is being met? Can you walk into the workplace

and understand where you stand in meeting daily customer demand?

PLE1211_INPRACTICE_V5msFINAL.indd 24 11/7/12 4:37 PMPLE121101-MAG_Ads.indd 24 11/8/2012 12:19:22 PM

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Four Things You Need to Know About Compressed Air Dew Point Sampling

Sampling is needed when direct measurement of the air is undesirable or is simply not feasible. This may be due to a high process temperature, the need to protect the sensor from water spikes, the added convenience of installing and removing the instrument from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location.

To get a representative sample of the process gas and avoid potential sources of errorcaused by incorrect sampling practices, the following aspects should be considered. • Changing the pressure of the gas changes the dew point• To avoid condensation the dew point must be below the ambient temperature in the sampling line• A leak-tight sampling system construction is essential• Sampling in still air should be avoided, however low air flow is okay

www.vaisala.com/compressedair [email protected]

Download the White Paper at knowledge.vaisala.com/SampleCell

ple201211_whtPprHLF_vaisala.indd 1 10/12/2012 10:17:06 AM

Energy Consumption: How it Relates to Performance in Refrigerated Compressed Air DryersTimothy J. Fox | Research and Development, SPX

Those in charge of specifying and purchasing equipment for industrial com-pressed air systems have many decisions to make. The design of a proper compressed air system does not end after determining the quantity of air required (i.e., the air compressor and receiver tank); the user must also pay particular attention to the quality of the air that his or her process needs. Today’s optimal air systems demand less moisture, less particulates, less oil aero-sols, and less oil vapor than ever before. For most users, a refrigerated-type compressed air dryer will satisfy their

requirements for moisture removal. With so many manufacturers offering “equivalent products”, each with promises of delivered pressure dew point, pressure drop and consumed electrical power, how does one make an intelligent selection?

This paper will address power consumption, and how it relates to a refrigerated dryer’s ability to remove moisture. It will explain how a potential buyer can determine if the stated performance is possible with the power consumption that is published in the manufacturer’s literature.

an SPX Brand For more information please contact: [email protected] or visit our website at www.hankisonintl.com

ple201211_SPX_whitePprHLF.indd 1 10/29/2012 3:22:28 PM




Maximize Uptime and Profits Through Effective Fleet Management PracticesPat DeSutter | Director NMHG Fleet Management

This paper from Hyster Company discusses lift truck fleet management. From planning and use strategy to understanding total cost of ownership, this white paper helps any operation with a fleet of lift truck equipment to understand how to effectively and efficiently manage that fleet. Topics included in this paper are challenges to fleet management, key elements of fleet management, total cost of ownership, replacement planning, telemetry and outsourcing.

One central challenge presented to lift truck fleets is hidden cost. Multiple service providers can add an unexpected financial and administrative burden to the fleet’s operation. With only an estimated 20 percent of an operation’s materials handling costs going to the initial purchase of the lift truck, the remaining 80 percent is composed of maintenance, operator and fuel costs. A proper understanding of total fleet man-agement from purchase to operation helps a company to review all associated costs and asset utilization.

Several key element of true fleet management are also outlined, including proper planning, which is essential as lift trucks have an economic life of approximately 10,000 to 12,000 hours as a general rule.

While that life varies depending on main-tenance practices and operational conditions, it is a reminder to plan not only the usage of the trucks, but also their replacement, to avoid costly downtime or increased maintenance expenses.

Hyster’s FleetSmart web-based reporting system allows managers to monitor and measure the fleet’s utilization, specific truck cost per hour and overall operating expenses. After reviewing many of the factors necessary to effectively manage and maintain their fleet, some operations choose to sign agreements with lift truck manufacturers or dealers to provide expertise and management as-

sistance. Capitalizing on years of experience, a strong dealer network and utilization of latest technology, Hyster Fleet Services can deliver unmatched results in reducing costs and maximizing productivity.

Download the paper at:http://www.hyster.com/AMERICAS/EN-US/FLEET SERVICES/FleetManagementWhitePaper.htmx

1-888-FLT-SVCS www.hyster.com/Americas/en-US/FleetServices

ple201211_whitePpr_HysterPg.indd 1 10/22/2012 4:31:25 PM




2012 Finalists

If innovation is one of the best indications of a strong manufacturing economy, the final-ists for the Plant Engineering 2012 Product of the Year awards are pointing the way to a bright future.

Entries in this year’s contest were up by more than 35%. This year’s crop of finalists covers 15 categories, includ-ing our newest category—Apps for Engineers. This points toward a great-er use of handheld and Smartphone devices on the plant floor, and we expect this to be a very large category in future years as more widespread adoption of apps and mobile devices continues.

Just as exciting this year are the two categories with the most entries. Automation & Controls is a category that highlights the desire of manu-facturers to measure and manage their manufacturing process in the most effi-cient fashion possible. The Safety cat-egory highlights that the most impor-tant asset on the plant floor is still the human one.

This year’s 116 finalists stretch across all areas where a plant manager’s influence is felt and his knowledge is required. From

motors and drives to maintenance and light-ing, the things a plant manager must specify and purchase perform very different func-tions. They all have one common element: they must help him or her do the job better, smart-er, safely and more efficiently. That has been

the hallmark of Plant Engineering’s Product of the Year program for thepast 25 years.

It might have been tempting to make a bigger deal out of the 25th anniver-sary of Product of the Year. People tend to like anniversaries and birth-days, especially a silver anniversary year. But Product of the Year is impor-tant each year, on its own merits. We certainly hope the cumulative effect of Product of the Year has helped improve your operation each year. But each year, our task is simple: We showcase the best in innovation each year, and then put it in the hands of our readers to determine the best of that best.

In 2012, for the 25th time, we again give the decision of this year’s Prod-uct of the Year winners to you. We hope you vote, and we hope you make use of this year’s outstanding inno-vations in manufacturing products.

–Bob Vavra, Content Manager


By Brittany Merchut, Content Specialist

facturers to measure and manage their manufacturing process in the most effi-cient fashion possible. The Safety cat-

the hallmark of Product of the Year program for thepast 25 years.

a bigger deal out of the 25th anniver-

tend to like anniversaries and birth-days, especially a silver anniversary year. But Product of the Year is impor-tant each year, on its own merits. We certainly hope the cumulative effect of Product of the Year has helped improve your operation each year. But each year, our task is simple: We showcase the best in innovation each year, and then put it in the hands of our readers to determine the best of that best.

PLE1211_POY_01_V6msFINAL.indd 29 11/7/12 4:42 PM


Product of the YearProduct of the Year2012


Automation & Controls

Wireless network access pointThe 802.11 WiFi Access Point for Industrial M2M Applica-

tions provides users with wireless networking capabilities. The access point appears as an embeddable module, which allows original equipment manufacturers to Wi-Fi-enable their products. The access point also appears as an external Ethernet access point, which provides the same functions as a stand-alone box. The access point technology allows the access point device to become its own Wi-Fi network communicating with other devices. The 802.11 WiFi Access Point contains an Ethernet port with two serial ports, providing more port configuration and connectivity tools.

B&B Electronics Mfg.www.bb-elec.com

Wireless sensor network

The SureCross Q45 is a wireless photo-electric sensor solu-tion developed for industrial automation applications. The Sure-Cross Q45 improves efficiency in control and monitoring appli-cations through the integration of a scal-able, wireless sensor network infrastructure. The SureCross Q45 can be used for applications such as cable replacement, moving applications, remote applica-tions, and productivity solutions.

Banner Engineering Corp.www.bannerengineering.com

Communication cardsThe C441 Ethernet series of

communication cards allows customers to select Ethernet/IP, HTTP web services, Modbus RTU communication protocols, and Modbus in a single card. The series contains added communications including options to configure, control, and monitor systems. Users have the ability to use one network for control and another for monitoring. The available Web services provide a Web-based graphical user interface. The series is compatible with Eaton C440, XTOE, and C441 electron motor protec-tion relays, and S611 soft starters.

Eaton Corporationwww.eaton.com

Fan controlBAFWorks is a fan application that allows users to con-

trol an unlimited number of Big Ass Fans products from a particular location. This application eliminates individual controls in large facilities by providing access to real-time fan speed and status of all fans. The BAFWorks applica-tion is available for all industrial overhead Big Ass Fans products. The application was designed specifically for the new industrial line of fans but is also compatible with previous generations.

Big Ass Fan Co.www.bigassfans.com


www.plantengineering.com plant engineering November 2012 • 31

Panel wiring system solutionThe SmartWire-DT System replaces

multiple wires used to connect motor control components with a single cable. The system allows users to easily inte-grate with the original equipment manu-facturer’s preferred industrial network. The SmartWire-DT system uses an eight-conductor, flat cable located in the control cabinet to connect motor starters, pushbutton actuators, and indicator lights.


I/O expansion seriesThe I/O Expansion Module is a new set of products to

help customers achieve optimal performance, faster ROI, and customization for communication networks. The I/O Expansion Module offers an increased degree of moni-toring, control and optimization, and flexible wired and wireless I/O. The I/O Expansion Module provides faster access time for up to 192 I/O points. The new module’s products carry the same measurement accuracy of ana-log inputs and can snap directly onto FreeWave radios or connect to other serial communication devices. With the I/O Expansion’s flexibility, the module can be used for a range of applications.

FreeWave Technologies www.freewave.com

Operator interface and controllerThe XV Series HMI-PLC incorporates programmable

logic controller functionality and integrates with the Eaton SmartWire-DT system. The XV Series HMI-PLC combines control, visualization, and data management tasks in one device. The design of the XV Series removes the physical PLC, incorporates logic into the operator interface, and provides a single software package. The series has an optional integrated SmartWire-DT master, eliminating the need for a gateway. The SmartWire-DT device connects directly into the back of the panels.







Lighting controlpanels

The 16- and 24-relay CX Commercial Light-ing Control Panels can be ordered as Master and Secondary Panels enabling two panels to be connected together on one project. There is an LCD user interface located in the door with scrolling menus to pro-gram, check status, or update the pane. The CX Commercial Lighting Control Panels are available in relay sizes of 4, 8, 16, and 24 with four types of relays. The programming capabilities of the panel include 365-day programming with astronomical and real-time clock.

Hubbell Building Automation Inc.www.hubbell-automation.com

Recorder/controller

E u r o t h e r m Nanodac recorder/controller’s latest edition includes greater storage flexibility for lon-ger loca l data archiving, store and forward data retrieval, and con-nectivity to Inven-sys’ Wonderware Historian. The nanodac record/controller is best used as a local historian to third-party equipment, but it can be used as a stand-alone device. The nanodac recorder/controller has 50 MB of flash memory for data storage, an on-screen help system, and remote viewing functionality. The device also offers the option to provide two high-stability PID looks with the unique Eurotherm Autotune facility.

Invensys Operations Managementiom.invensys.com

Wall switchsensors

The LightHAWK Wall Switch Occupancy Sen-sor line has expanded to include a suite of wall switch occupancy sensors with neutral connections. The line has sensors avail-able in passive infrared, ultrasonic, and dual-tech models with single or dual relays, several override options, and a complete palette of architectural finishes. All of the sensors come with a built-in photocell with SuperSaver mode.

Hubbell Building Automation Inc.www.hubbell-automation.com

Control and simulation software

The I/A Series is a control system with an Intelligent Marshalling solution and high-performance Foxboro Control Software and Simulation Soft-ware. The I/A Series features a Universal Fieldbus Module that eliminates the need for mar-shalling. Designed to improve user experience, the software embeds Invensys’ ArchestrA System Platform and Wonderware InTouch HMI in the system. This allows for integration of plant devices, sys-tems, databases, and software applications. The software has the ability to simulate, including dynamic control of time, alarms, and trends using the same configuration files used in a live I/A Series DCS.

Invensys Operations Managementiom.invensys.com




Automation communications platformThe KEPServerEX 5.9 industrial automation commu-

nications platform has new electronic flow measurement capabilities and Wellsite Information Transfer Specification Level 0 drivers. The new solutions ensure that systems and devices supporting pipelines, wells, and drilling rigs can gather and share vital operational information. The new drivers with EFM capabilities have the potential to tap into stored data to manage, collect, monitor, and distribute information. The WITS Level 0 drivers provide quick and easy access to real-time drilling and mud logging data to offshore drilling platforms, onshore rigs, well sites, and other geographic sites.

Kepware Technologies Inc.www.kepware.com

Modular HMIThe GP-4000M Series Modular HMI allows users to

easily monitor conditions and the operating environment in real time. The series offers a full graphics touchscreen with a selection of serial or Ethernet connections. The series design is energy saving with its on-board LED backlight, and a dimmer setting used to stand-by the display after being idle. The GP-Viewer EX software provides remote monitoring functions such as checking the screen from a remote office.

Pro-facewww.pro-face.com

Compact gearheadThe Nexen Harmonic Gearhead has a short

and rigid design combined with a large, rug-ged, crossed-roller output bearing that can handle all combinations of radial, axial, and overturning moment loads in a compact enve-lope. The Harmonic Gearhead is available with Nexen’s Roller Pinion System through the integration of the gearhead into the pinion without any added length. This allows for the maintenance of zero backlash from the driving motor shaft through to the driven load. The RPS has a unique roller pinion/rack combina-tion that can be adapted to any application.

Nexen Group Inc.www.nexengroup.com






Wireless monitoring system

VIBCONNECT RF is a wireless condition moni-toring system for machine compo-nents. The sys-tem monitors the condition of roller bearings and other rotating compo-nents, and detects damage caused by cavitation. The VIBVONNECT bridge acts as the central receiver as it processes the data from the sensor units, transmitting it through the operator’s network. Operators can assess machine vibration, bearing condition, and temperature through the variety of analytical functions available.

Prüftechnik Groupwww.prueftechnik.com

Virtual image templates

The PlantPAx Vir-tual Image Templates deliver the core sys-tem elements as pre-configured, drop-in templates on a USB hard drive. Delivered in an open, virtual-format file, and sup-ported and tested for use with VMWare vSphere, the Engi-neering Workstation, Operator Workstation, and Process Automation System Server templates are provided. The pre-installed and pre-configured Virtual Image Templates help reduce validation costs and initial engineering time, simplify upgrades, and patch management and enhance scalability.

Rockwell Automation Inc.www.rockwellautomation.com

Programmable automation controllersThe Allen-Bradley CompactLogix 5370 programmable

automation controllers include 5370 L1, L2, and L3 control-lers. These controllers have enhanced performance and motion capabilities while leveraging the common design and networking environment of Rockwell Automation’s Integrated Architecture system. The CompactLogix 5370 offers performance and cost competitiveness for machine builders requiring up to 16 axes of complex motion on EtherNet/IP. The series offers the same processing speed upgrades as the ControlLogix 5570 series, but with more than twice the processing speeds.


Power monitoring softwareStruxureWare Power Monitoring 7.0 Software is a soft-

ware application that tracks real-time power conditions to improve efficiency, availability, and reliability. The soft-ware has a Web-based interface allowing users to monitor, analyze, and report on energy usage and power quality information. The software includes several new libraries for common real-time values, alarm views, and reports. StruxureWare Power Monitoring can function as a stand-alone software application and can connect easily to other StruxureWare software within suites, developed to address the unique needs of key market segements. suites.

Schneider Electricwww.schneider-electric.com




Comfort panels The SIMATIC HMI Comfort Panels feature the

same functionality and performance across the entire product range. The panels come in differ-ent size of displays, including high-resolution, brilliant, and widescreen, and can be adapted for any application. The SIMATIC HMI Comfort Panels can switch off the displays of the units in break times. The panels are configured using TIA Portal based SIMATIC Step 7 and SIMATIC WinCC engineering software.

Siemens www.siemens.com

Sales resourceplanning software

Atlatl-Sales Resource Planning Software is designed to support manufacturing and industrial sales and streamlines the engineer-to-order sales process. The software merges all elements of manufac-turing sales processes including client data input, product dem-onstration, and configuration, as well as specification gathering engineering, and drafting.

SixAxis LLCwww.sixaxisllc.com

Compact CPUThe SIMATIC S7-1215C is equipped with 100

kb of user memory, a second PROFINET inter-face, two analog outputs, and fast outputs for controlling as many as four stepper motors. The controller offers 14 digital inputs, 10 digital out-puts, two analog inputs, and two analog outputs. The SIMATIC S7-1215C can replace relays and contactors, convey systems, and pump control and energy management through to distributed tasks in a complex automation network.



Now the vote is yours…

Plant Engineering subscribers with a valid e-mail address will receive the 2012 Product of the Year ballot. Simply fill it out, click ‘Submit,’ and let your vote for this year’s best products be counted. Then, in the April 2013 issue of Plant Engineering, meet the 2012 Product of the Year award winners honored at our 2013 Awards in Manufacturing Event in Chicago.

20122012




Apps for Engineers

Software platform applicationaPriori 2011r2 is a software platform that offers func-

tionality and enhancements that expand a platform’s cost-optimization capabilities for companies with high-tolerance machining requirements. The software platform has upgraded its abilities to create detailed tooling cost estimates for components. A flexible and powerful costing engine allows for instant and precise determination of the cost of a part or product from a CAD model. aPriori 2011r2 has the capability to reassess and provide updated product costs as design changes are made or new product specs are introduced. With the software platform, companies are able to make better design and production decisions while reducing costs.

aPriori Inc. www.apriori.com

HMI software application The Wonderware InTouch 2012 software is the primary

application of the company’s InFusion Enterprise Control System. The software offers users the ability to quickly and easily create standardized, reusable HMI and real-time decision support applications. The application’s graphics, ease of use, efficiency, and support allow users to help drive business optimization.

Invensys Operations Managementwww.invensys.com

Data processing applicationThe iQagent is an application that enables users to dis-

play live process data, documents, and resources about a given point of interest (POI) while connected to the plant wireless network. POIs are configured on the plant floor and then are tagged using a QR Code. POIs contain a Data View showing live process values and Info View containing links to documents and resources. On the plant floor, users can scan the QR Code and view data or other resources.

iQuestwww.iquest.net


Product and technicalinformation application

The POWEREDGE mobile application provides real-time access to Eaton’s electrical catalogs, videos, and training. Electrical products can now be searched, selected, and located from an Apple device. The application is created to engage, educate, and enable users to find the product and technical information. Through the POWEREDGE mobile application, users can learn more about Eaton’s products with direct access to the electrical product catalog. The design of the application helps users find information on solutions to improve reliability, efficiency, and safety of systems they manage.




Compressed Air

Air nozzleEXAIR’s Stainless Steel Super Air Nozzle offers 6.6 lbs of

blowing force for blow-off, cooling, and drying applications in corrosive, high-temperature, food and pharmaceutical environments. The air nozzle has an aerodynamic design that directs compressed air to a single point of conver-gence, allowing a concentrated stream of high-velocity airflow. The nozzle contains applications including ejection of heavy parts, drying, part and machinery cleaning, chip removal, liquid blow-off, and cooling hot parts.

EXAIR Corporation www.exair.com

Rotary screw air compressors

Ingersol l Rand’s R-Series range of rotary screw air com-pressors is available in fixed speed and Nir-vana variable speed drive. The new range of compressors comes with the Xe-Series controller, fea-turing a high-resolution LCD color display. The controller provides access and remote control of the compressor from any tablet, smartphone, or PC. The compressors have an integrated Total Air System dryer and filtration option that provides clean, dry air in a single package. The new design of the compressors reduces maintenance and allows for easy service with the swing-out separator covers, longer life consumables, and easy-access hinged doors.

Ingersoll-Rand plcwww.ingersollrand.com

Portable air compressorSullair Corporation’s E900H Portable Air Compressor is

designed to combine the clean, quiet efficiency of electric drive technology with the Sullair legacy of rugged air ends and portable compressor designs. The compressor delivers 900 cfm at operating pressures up to 150 psig. The E900H portable compressor features the Sullair AF System that allows the compressor to process equipment and other industrial applications. The compressor comes equipped with a built-in high-capacity after-cooler and efficient fil-tration. The E900H portable compressor is powered by a 214 hp premium efficiency TEFC electric drive motor with Wye-Delta starter.

Sullair Corporationwww.sullair.com


HOC dryersIngersoll Rand’s

new line of heat-of-compression (HOC) dryers provides flex-ibility, reliability, and energy efficiency in a low-profile pack-age. The dryers use heat produced during the compression pro-cess, which allows for instrument-quality air to be delivered using virtually no energy. The dryers contain Smart Control technology, which adjusts dryer operation to minimize dew point and temperature spikes. To prevent wasting compressing air, the dryers feature no-loss drains. The HOC dryers by Ingersoll Rand can be used with mul-tiple compressors, reducing footprint requirements.

Ingersoll-Rand plcwww.ingersollrand.com




Electric Motors & Drives

Tapered rollerbearings

Baldor ’s Dodge Type EXL tapered roller bearings pro-vide misalignment and expansion capa-bility, while maintain-ing industry standard Type E mounting d imens ions . The design of the Dodge Type EXL incorpo-rates a cartridge-style inner unit into a split ductile iron housing, which allows the inner unit to swivel freely in the hosing. The Dodge Type EXL offers a new bearing design with a 13% to 14% increase in load ratings. The roller bearings come in two- and four-bolt pillow blocks and utilize the same inner unit for expansion and non-expansion housings.

Baldor Electric Co.www.baldor.com

Soft starter solutionsThe S811+/S801+ Soft Starters provide smooth accelera-

tion and deceleration of the load with advanced monitor-ing, protection, and communication. The soft starters are designed for constant torque and variable torque applica-tions. The soft starters come equipped with power and power factor monitoring capabilities, analog input, fault warnings, and integrated Modbus RTU communication. With the digital interface, users can configure, monitor, and enable protection. The soft starters are available in open and packaged control configurations with five frame sizes for currents ranging from 11 A to 1,000 A.


Split universal mounting kitThe Split uKIT version of the AEGIS SGR Bearing Pro-

tection Ring protects the bearings of VFD-driven motors from electrical damage, and allows quick and easy retro-fitting of the ring on virtually any ac motor shaft without decoupling attached equipment. The AEGIS Split uKIT is ideal for HVAC service contractors and plant maintenance departments. Designed to accommodate slingers, shaft shoulders, and other end bell protrusions, the kit comes with a split AEGIS ring, the halves of which are held together with a unique hinge. This hinge design allows the split AEGIS ring to be opened on one side, then closed and fastened together with built-in adhesive-backed aluminum tabs, providing rigidity to the assembled ring.

Electro Static Technology Inc.www.est-aegis.com

Adjustable frequencydrives

Eaton’s H-Max Series of adjust-ab le f requen-cy dr ives are equipped with HVAC software and hardware features, includ-ing an industry-leading energy control algorithm. The H-Max Series has new technologies such as advanced dc capacitors and latest generation insulated gate bipolar transistors, with real-time clock and calendar. This gives customers the ability to design and operate efficient HVAC systems. The drives are available in 1.5 hp to 250 hp at 480 V and ¾ hp to 125 hp at 230 V. The H-Max Series comes with Ethernet, Modbus, N2, and BACnet built-ins.



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Line of actuatorsThe Tritex II dc pow-

ered line of actuators integrates power and control electronics with brushless servo motors and actuators in one package. The actuators combine electric power with advanced thermal management modeling and maximize power in smaller packages without sacrificing performance. The Tritex II dc offers continuous forces of 1,000 lbs and 1,300 lbs peak and speeds reaching 33 in./sec. The actua-tors have a wide range of I/O capabilities including digital I/O, analog I/O, and communication buses including Eth-ernet/IP, Modbus TCP, and PROFINET IO. With a wide range of applications including demanding environments, the actuators provide motion control in linear and rotary applications.

Exlarwww.exlar.com

EtherNet/IP enabled servo drive

The Allen-Bradley Kinetix 350 single-axis EtherNet/IP servo drive offers a cost-effective entry in the Rockwell Automation Inte-grated Architecture system. This system scales from 200 to 10,000 I/Os, allowing machine builders portability to migrate existing machine designs into new, higher-end machine designs. The drive comes equipped with safe, torque-off functionality allowing for tasks such as machine setup, cleaning, removal of jams, and other main-tenance tasks. The Kinetix 350 servo drive has 400 W to 3 kW of power range to meet global machine requirements.


3 hp and 5 hp motorsNovaTorque’s Gen2.0 PremiumPlus+ Electronically Com-

mutated Permanent Magnet (ECPM) Motors are packaged in standard NEMA frame sizes and mounting dimensions for easy substitution. The motors are driven by variable fre-quency drives and boast motor-only rated point efficiencies of 93% and 92% for 3 hp and 5 hp versions. NovaTorque motors are available in the mounting frame size typical for induction motors in addition to one frame size smaller. The motors are compatible with readily available frequency drives from many leading manufacturers.

NovaTorquewww.novatorque.com

Base drive solutionThe SINAMICS DC

Master Base Drive is a prewired solution that comes with all the neces-sary components mounted onto a back panel. The drives are designed for end users and third par-ties such as system inte-grators and Siemens solu-tion partners. Features of the SINAMICS DC Base Master Drive include input fuses, output dc fuses, a control transformer, ac line contractors, PROFIBUS, BOP20, UL508A certifications, and 65 kA SCCR rating. The new drives offer more power per panel in the same footprint compared to the previous two generations.

Siemenswww.siemens.com





Electric Motors & Drives Electrical Controls

Base drive panels expansion The SINAMICS S120 drive system’s expansion includes

PROFINET, Ethernet TCP/IP, and EtherNet/IP connectivity allowing for industrial Ethernet communication while offer-ing innovative concepts for users wanting a single network for an entire plant. PROFIBUS DP and PROFINET are sup-ported by the SINAMICS S120 drives to ensure seamless communications between all the components involved in an automation solution. The drives are designed to handle any drive requirement and facilitate vector, serve, and variable-frequency drive application with single or multi-axis offerings.


CNC operator panelThe SINUMERIK OP 019 is a CNC operator panel with

advanced technology that enables seamless design inte-gration to the SINUMERIK Operate graphical user interface. The design features a touchscreen operation including the new Power Control Unit 50.5 allowing high-speed key actuation. The OP 019 also features wide LEDs, which allow the user to clearly visualize every key actuation. The OP 019 panels provide basic machine display with three or four channels showing up to 13 axes.


Cabinet cooler systemThe Dual High Temperature Cabinet Cooler Systems

purge and cool overheated electrical control panels in harsh environments. The cabinet coolers eliminate high-temperature malfunctions and protect sensitive electronics from hot, dirty locations by keeping electrical enclosures cool with air as cold as 20 F. With high cooling capacity of up to 5,600 Btu/hr, the cabinet coolers are designed for large electrical enclosures and high heat loads. The cabi-net cooler applications include variable frequency drives, programmable controllers, industrial computers, motor controls, microprocessors, and robotics.

EXAIR Corporation www.exair.com

Sensing switch and transducerThe ATS Current Sensing Switch and Transducer is a

one-piece solution combing a limit alarm with an analog output signal transducer to monitor produced and con-sumed ac current up to 1,200 A while isolating outputs and input to maximize safety. The rotary switch makes it easy for operators to set the trip point. With an analog signal available at all times, increases or decreases in current can be detected. The switch also provides limit alarm contacts for over- or under-current conditions.

NK Technologies www.nktechnologies.com




Energy Management

Device and data management The Foreseer X-Class software is designed to monitor,

track, and analyze data from more than 100,000 devices at the same time across an enterprise. The software collects data and status information from power, environmental, safety, and security systems to help companies reduce energy consumption. The Foreseer X-Class software has a customized executive dashboard to help track and pre-dict power usage trends and events, and improve energy efficiency. The software is designed for companies with global operations and a vast array of devices.


Consolidatedcomplex data

P o w e r X p e r t R e p o r t i n g 3 . 0 enables users to make sense of exhaustive power monitoring data and identify important statistics to improve efficiency and reli-ability. This software was designed for energy, healthcare, information technology, and facility managers to track and compare systems within facilities and across the enterprise. Power Xpert Reporting is equipped with 13 ready-to-go report templates with graphics and charts to help users understand and control critical power systems and energy flow. The new version of Power Xpert Reporting allows users to create custom reports with user-selectable or virtual attributes and complex formulas for custom data.


Data logger EXAIR’s Digital Flowmeter is designed to monitor com-

pressed air consumption and waste. With EXAIR’s newly added USB Data Logger, users can maintain a history of the Digital Flowmeter’s measurements for analysis. The information from the data logger can be removed from the Digital Flowmeter and plugged into a computer where the data can be viewed. The Digital Flowmeter comes with an optional Summing Remote Display to allow for easy monitoring of compressed air consumption in any location.

EXAIR Corporationwww.exair.com

information technology, and facility managers to track and

Gateway solution The Power Xpert 200E gateway is a solution that collects

energy usage data from meters, allowing customers to benchmark energy usage, set energy management goals, determine the effectiveness of energy management initia-tives, and reduce energy costs. The Power Xpert 200E gateway is designed to be used as a data acquisition tool for serially communicating energy meters via an embedded Web server or connecting to Ethernet-based applications. Eaton’s gateways can be used with the Power Xpert Energy Viewer, which provides a simple way to gather key energy parameters and display them in reports.






Energy Management Environmental Health

Dock sealThe Insulator Dock Seal with Light-Blocking Header is a

durable dock seal that closes small light gaps caused by trailer protrusions. The design of the Insulator Dock Seal features rows of layered, horizontal pleats that conform to the protrusions as a trailer backs in. All of Frommelt’s dock seals are reinforced with high-strength Durathon fabric over a flexible vinyl base fabric to protect against wear and tear. The corners of the Insulator Dock Seal are also reinforced with layers of Durathon fabric and flexible high-molecular weight polyethylene sheeting to prevent damage and are attached with industrial Velcro for quick replacement.

Frommelt Products Corporation www.frommeltsafety.com

Power protectorThe 300 kW VDC-XE with

High Current (HC) option is a solution for protecting power-dependent applications in facili-ties that do not have the floor space for multiple backup units. Compatible with all major brands of 3-phase UPSs, the VDC-XE with HC option connects to the dc bus of a UPS. The system includes patented technology consisting of a flywheel hub formed from aerospace-grade steel, a high-speed permanent magnet motor generator, a con-tact-free magnetic levitation sys-tem, and a touchscreen graphi-cal display. VYCON’s flywheels incorporate a host of advanced features that make the systems easy to use, maintain, and monitor.

VYCON Inc. www.vyconenergy.com

Ultra-fine atomized misting systemThe AirGo Misting System fan is available with high-

filtered misting, producing a cooling effect equivalent to 22 tons of air conditioning. The system’s design features an ultra-fine atomized mist that absorbs heat in the air and allows for a safe cooling zone in hot outdoor settings. The fan produces the cooling power of air conditioning in any setting. The AirGo Misting System provides a cooling breeze measured at 140 ft and about 6,000 sq ft of floor coverage area.


Mercuryadsorbent

The VaporLokCapture is a breakthrough technol-ogy that adsorbs mercury vapors from broken lamps within lamp storage, ship-ping, or recycling contain-ers. The VaporLokCapture is featured in VaporLok’s fluorescent lamp shipping and recycling system. The design minimizes the risk of exposure to mercury by reducing 95% of the vapor within a container. The Vapor-LokCapture is manufactured with powdered activated carbon and inert chemicals, which immediately capture mercury vapor when lamps or compact fluorescent lamps (CFL) break. The product will be incorporated into indus-trial products of VaporLok and consumer CFL packaging solutions.

VaporLok Productswww.vaporlokproducts.com




Fluid Handling

Fluid recycling solution

T h e m o b i l e SumpDoc by Eriez provides complete, inline fluid recycling for machine tools operating in three simple steps. The operator selects each mode start-ing with Sump Vac mode, moving to F i l t r a t i on Mode and then to Cool-ant Makeup Mode. When the sump tank reaches the desired concentration level, the process is complete. The SumpDoc is completely portable, allowing operators to drop in the hoses, complete a full cycle, and move on to the next machine tool sump or parts washer to be cleaned.

Eriezwww.eriez.com

Inline vortexflowmeter

The VLM10 combines an inline vortex meter, a built-in flow computer, and an integral tem-perature sensor giving users an elegant all-in-one solution for their metering needs. The VLM10 is precise and reliable with a steam or gas mass flow accuracy of ± 1.5% over a wide 20:1 flow range. The fully welded, no-gasket design ensures safe measurement of steam and allows the sensors and RTD to be removed without having to shut down the line first. The built-in Web server allows customers to monitor flow and monitor meter health through the Internet.

Spirax-Sarco Inc.www.spiraxsarco.com

Siphon fed spray nozzles

EXAIR’s Atomizing Spray Nozzles atom-ize fluids in a range of spray patterns by combining liquid and compressed air to create a mist of atom-ized liquid that can be easily adjusted to vari-ous applications. The siphon fed nozzles require no liquid pres-sure and can be used with gravity fed liquids or lift liquids from a siphon height as much as 36 in. Siphon fed nozzles can be used on liquids with a viscosity up to 200 cp. The nozzles are fully adjustable with a stainless steel construction for durability and cor-rosion resistance.

EXAIR Corporationwww.exair.com

Threaded port connectors

FasMate FN Series connectors allow for quick, easy connec-t ions to threaded por ts , de l i ve r ing results in many appli-cations. The con-nectors feature easy actuation and a split collet design. The versatile connectors have the capacity to perform three styles of actuation: squeeze level, pneumatic pilot, and pneumatic thumb valve. The new series offers additional features and benefits for better performance and durability. The FasMate FN Series provides increased application compatibility through the connectors that offer an extensive threaded port sealing range of 1/8 in. to 1/2 in. NPT. The connectors are equipped with pressure-assisted sealing technology to eliminate the risk of separation.

FastEST Inc.www.fastest-inc.com





HVAC

Airfoil fan system Big Ass Fans’ Powerfoil X2.0 system combines patented

airfoils and winglets with AirFence technology to increase the overall coverage. The winglet improves airfoil effec-tiveness through the elimination of turbulence at the tip, while the AirFence is able to capture air that would have slipped off the end of the airfoil. The Powerfoil X2.0 offer-ing a 28% increase in coverage area is available in 8 ft to 24 ft diameters.


Portable and adjustable fan

The Renegade Series of HVLS fans are designed for improving air circu-lation in areas with overhead obstruc-tions or limited ceiling access with a floor-mounted configura-tion. The HVLS fans are portable and can be moved when nec-essary and are also adjustable from 10 ft to 15 ft in height. The Renegade fans are designed with Rite-Hite’s Propell-Aire custom aluminum blades with a single unit circulating air covering up to 7,850 sq ft. The fans are available in 8 ft, 12 ft, and 16 ft diameters with optional SureStop Safety Barriers to protect against accidental contact.

Rite Hite Holding Corp.www.ritehite.com

Steam system softwareSteam DesignPro 6.1 was designed to meet the demands

of mechanical engineers, designers, and contractors in the HVAC market. The software was created as a visual design tool through an easy, drag-and-drop method for designing and modeling HVAC steam systems. The Windows-based software allows for easy modeling of steam generation, steam distribution, steam utilization, and condensate-handling systems. Steam DesignPro supports compiling of equipment schedules based on the Spirax Sarco cata-log. Additional features include the ability to select relief valves, flowmeters for steam and hydronic applications, and control valves.

Spirax-Sarco Inc. www.spiraxsarco.com

Modulation infrared heaterThe MP Series of modulation infrared

heaters allow users to select a desired operation for their specific needs through the incorporation of three performance curves, as well as a Blast Mode. The Blast Mode allows users to temporarily lock the heater into its highest input with an extra 5,000 BTU for extreme environ-mental demands. The models available in the MP Series range from 80,000 BTU to 200,000 BTU. The MP Series features full gas modulation with corresponding airflow modulation to allow for optimal fuel utilization.

Detroit Radiant Products Co.www.re-verber-ray.com




Lighting

Color-consistent LEDColumbia Lighting’s e•poc LED uses precise standards

to maintain superior color consistency within each fixture throughout its lifetime. The luminaires are passed through a test booth where each receives a QR code capturing the exact initial color, lumen rating, and module serial number creating the best quality and the most traceability of LED lighting. The e•poc LED is constructed from 70% recycled steel and has a 50,000-hr, mercury-free lamp life. The e•poc LED provides reduced energy consumption when higher light levels are not necessary through the two lumen output configurations available.

Columbia Lightingwww.columbialighting.com

Architectural LED

The Serrano LED delivers high effi-cacies up to 101 lumens per watt and a fixture life of up to 50,000 hours at 80% lumen main-tenance. Serrano LED is compatible with a variety of controls and can be ordered with wiHUBB capability to easily integrate with Hubbell Building Automa-tion’s wireless mesh network. The modular plug-and-play design allows for components to be easily swapped out as technology advances. To ensure color consistency, each Serrano LED is tested to maintain a three-step MacAdam ellipse.


Architectural luminaire As part of Columbia Lighting’s createchange series,

the Serrano Architectural Luminaire is a three-element diffuser combining a performance-optimized center optic with two high-transmission, lenticular side lenses to pro-vide efficiency. Serrano delivers energy savings of up to 40% while maintaining lighting quality and light levels. The Serrano is compatible with a variety of controls and has a wiHUBB-enabled option to integrate with Hubbell Building Automation’s wireless mesh network.


Emergency LED lighting The EV Series LED emergency light utilizes two high-

powered long-life LEDs to produce superior light output with optimized fixture spacing of 27 ft. The EV Series emergency lights require less than 2 W to power and utilize an envi-ronmentally friendly nickel metal hydride (NiMH) battery. The EV Series measures only 8.5 in. wide by 5 in. high with fast wall mount installation. The LEDs are mounted inside a die-cast housing, utilizing precious components to offer adjustability and thermal stability.

Dual-Litewww.dual-lite.com





Lighting

Heavy industrial LEDHubbell Industrial’s LED Highbay is engineered for

tough industrial environments, offering a customized solution in an eco-smart and retrofit-ready package. The design features a rugged cast aluminum housing design with a hinge and latch-mounting system. The LED Highbay’s design also features custom engineered LED optics for evenly distributed 5,000 K light in aisle, nar-row, and wide distributions for use in up to 45 C ambient temperature environments. The LED Highbay comes standard with 0 V to 10 V dimmable drivers and can produce up to 100 lumens per watt with a life span of 100,000 hours.

Hubbell Industrial Lighting www.hubbellindustrial.com

Commercial, industrial LED luminaires The AccuLite Highbay and Lowbay LED Luminaires are

low-profile industrial LED luminaires ideal for large commer-cial and industrial spaces. The fixtures are equipped with several innovative features including the large-format LED chip technology, hybrid TIR/reflector optics, and an ultra-thin efficient housing design. These features offer higher efficacy with improved thermal performance and ability to drive the LED more efficiently at higher currents. The LED luminaires produce up to 34,000 lumens of uniform area illumination and efficacies approaching 100 lumens per watt. The fixtures provide 57% energy reduction with a 100,000-hr lamp life.

Juno Lighting Group www.junolightinggroup.com

Surface mount luminaire Hubbell Industrial’s Sedona LED Surface Mount luminaire

is designed to provide a unique, high-performance illumina-tion solution for surface ceiling mount and parking garage applications. The Sedona LED features a hexagonal LED cluster design that provides optical flexibility and light level scalability. The packages available in this luminaire provide 92 to 100 lumens per watt with an ambient temperature of 40 C. The Sedona LED is wet-location listed and offers complete on/off dimming operation.

Hubbell Industrial Lighting www.hubbellindustrial.com




Maintenance Tools & Equipment

Heavy-dutygear oils

T h e M o b i l S H C G e a r Oil Series are heavy-duty gear oils designed for enclosed gear-ing, as well as plain and rolling element bear-ings. The series is designed to provide service in equipment protection, oil life, and prob-lem-free operation, enabling increased customer produc-tivity. The lubricants are formulated from synthetic base fluids with exceptional oxidation and thermal properties. The Mobil SHC Gear Series covers a viscosity range from ISO VG 150 to 6800, which allows the series to meet the lubrication needs of very slow speed and high-load/high-temperature gears and bearings.

Exxon Mobil Corp.www.exxonmobil.com

Vibrationscreening tool

The Fluke 805 Vibration Meter is a portable multi-function vibration screening tool, providing quantifiable information on the bearing and health of motors and other rotating equipment. The Fluke 805 has the abil-ity to measure overall vibra-tion, bearing condition, and surface temperature. The design of the Fluke 805 features a unique sensor tip that minimizes measure-ment variations caused by device angle or contact pressure, reducing operator error and improving accura-cy. The vibration meter also has a severity scale for overall vibration and bearing condition.

Fluke Corp. www.fluke.com

Power qualityanalyzers

The Fluke 430 Series II three-phase power quality analyzers use patented algorithms to measure energy waste and quantify costs. By providing the ROI jus-tification to mitigate power quality distor-tion, the 430 Series II helps reduce electrical power consumption and improve the performance and lifespan of electromechani-cal equipment. With the Unified Power function of the 430 Series II, electricians, utility technicians, electrical engi-neers, field service technicians, and energy consultants can determine how much power is being wasted and calculate the extra consumption costs. The improved screen qual-ity and battery life on the 430 Series II gives users more options to analyze power quality and power consumption.


Infrared camerasFluke’s Ti Series of infrared

cameras or thermal imagers offer a broad range of easy-to-use capabilities, capturing images of infrared energy or temperature. Fluke infrared cameras combine the power of infrared images with vis-ible light images on the same display. The thermal imaging detects heat patterns or tem-perature changes in objects, allowing users to discover problems or monitor develop-ing problems. Common appli-cations of the Ti Series include electrical, mechanical, process, and building inspection.






Maintenance Tools & Equipment

Machinery alignmentROTALIGN Ultra iS is a system designed by

Prüftechnik for machinery alignment, combin-ing sensALIGN intelligent sensor technology with ROTALIGN Ultra computer for fast acquisition and real-time results display. sensALIGN calculates mis-alignment from collected measurement points while monitoring the rotating angle, speed, acceleration, and environmental vibration. This eliminates external influences and coupling backlash, ending in accurate readings in harsh conditions. With ROTALIGN Ultra iS, users can accomplish alignment in three steps: enter dimension, measure, and view results.

Prüftechnik Groupwww.prueftechnik.com

Warning beacon The wireless aisle-way beacon is a pushbutton and

motion sensing technology providing users with the flex-ibility to position aisle-way beacons when and where they are needed. This allows plant operators to signal for parts, material refills, or machine maintenance in a timely man-ner. The design of the beacon allows for one, two, or four wireless pushbuttons to be linked. The motion sensor can be linked to the beacon for visible warning of approaching industrial vehicles, and the ultrasonic sensor can be linked for blind doorway applications.

Schneider Electric www.schneider-electric.com

Inspection systemThe SeeSnake MAX rM200 Camera System combines portabil-

ity and versatility to provide plumbing professionals with a solu-tion for inspecting longer and tighter lines up to 200 in. in length and 1-1/2 in. to 6 in. in diameter. The camera system features improved reel mechanics for easier passage through tight turns, an ultracompact camera capable of providing optimal lighting through narrow spaces, and an upgraded cable. This provides greater abrasion resistance and allows users to push further with less effort. The system comes equipped with a built-in docking system for attaching viewing monitors and is compatible with RIDGID SeeSnake CS10 and CS1000 digital recording monitors.

RIDGIDwww.ridgid.com




Materials Handling Systems

Air casterThe LoadRunner makes it safe for one operator to easily

move loads up to 2,500 lbs on air by utilizing an on-board compressed air caster to float a load across the floor. The self-contained unit features a low-profile deck with a 2–in. insertion height and throttle-style fingertip controls. The LoadRunner can assist or replace traditional equipment such as hand trucks, pallet jacks, and forklifts. The Load-Runner unit is emission free and designed for manufac-turing, cleanrooms, assembly, testing, and warehouse applications requiring load movement.

AeroGo Inc. www.aerogo.com

Chain hoistThe Lodestar Electric

Chain Hoist incorporates features that provide steady lifts for a vari-ety of applications. The hoist is designed with a lightweight, durable cast aluminum housing and a powder-coasted finish for high visibility. The Lode-star Electric Chain Hoist has a capacity range of 1/8 to 3 tons and a wide range of speeds creating versatility. The control panel of the hoist allows for quick voltage change, access to terminal strips, and simple fuse installation. The adjustable limit switch prevents the load from over-travel and built-in overload protection helps prevent lifting of dangerous overloads.

Columbus McKinnon Corporation www.cmworks.com

Tire lift trucks Cat Lift Truck’s 2EPC5000-2EP6500 Series is equipped

with powerful ac technology, featuring improved energy efficiency, performance levels, and premium operator ergonomics. The model gives users the ability to run up to two shifts on one battery charge in most applications. The 2EPC5000-2EP6500 Series is equipped with sealed wet-disc brakes, electrical components, and connectors, providing added protection for harsh environments. The enhanced operator control features an adjustable com-partment and standard fingertip hydraulic control with an optional enclosed cabin for protection in cold or wet envi-ronments.

Cat Lift Trucks www.cat-lift.com

Electric end riderThe Jungheinrich ECR 327/336 Series of electric end

rider pallet trucks, available in 6,000 lbs and 8,000 lbs, incorporate a variety of applications including order picking, long distance transporting, and loading/unloading trailers. Designed for durability, the ECR Series features thick forks with a cast steel frame and sealed electrical components. The riders come equipped with standard features such as an electromagnetic brake, advanced regenerative braking, and adjustable casters. An optional corrosion protection package provides a galvanized coating on key components, resulting in durability in wet and corrosive environments.

Jungheinrichwww.jungheinrich-lift.com





Materials Handling Systems

Eco-performancetruck series

The 7000 Series Reach-Fork Trucks feature economic and ecological benefits, maximizing the number of pallets that can be moved per hour. This includes regenerative lowering that produces energy when the forks are lowered to increase battery shift life. The trucks were designed with an A-frame suspension with strong steel springs to provide a strong connection between the wheels and frame. They also feature an exclusive steered idler wheel, eliminating caster snap, and full-time traction and steering.

The Raymond Corp. www.raymondcorp.com

Material handling workhorses

The 8000 Series pallet trucks are material han-dling workhorses that stand up to tough appli-cations while maximizing productivity and con-tributing to sustainable operations. The design of the pallet trucks fea-tures increases in mate-rial strength, enabling them to meet heavy-duty application needs. With PowerSteer, the trucks reduce steering efforts by up to 90% and provide speed-sensitive steering for smooth control at all speeds. The trucks offer a number of user-friendly features includ-ing roomy operator compartments, accessory bars, large storage totes, and additional caster options.

The Raymond Corp. www.raymondcorp.com

Galvanized pallet trucksToyota’s three models of ac electric pallet trucks and

walkie riders feature a Galvanized Chassis option to pro-tect the vehicles while operating in wet environments. The three models include the 8-Series ac electric walkie pallet truck, 8-Series end-control walkie rider, and 7-Series elec-tric walkie pallet truck. The chassis is designed for users who move materials in and out of cold storage facilities, the chemical, salt and brine industries, or in areas where frequent wash-down is required. Other features include heavy-duty Teflon coated Polytube bushings; galvanized metal frames; corrosion-resistant linkage pins; and gal-vanized lower linkages, pull rods, and connecting links.

Toyota Industrial Equipment www.toyotaforklift.com




Power Transmission

Operator safety switchgear

Eaton Corporation’s Arc-Resistant Front-Accessible Switchgear provides cen-tralized control and protec-tion for low-voltage power distribution equipment and is engineered to enhance operator safety. The front accessible design mini-mizes equipment footprint for utility, industrial, data center, institutional, hospi-tal, and water facilities. The design also allows the equipment to be installed against the wall and eliminates the need to meet the National Electri-cal Code requirement of 36 in. of rear clearance. With an optional ANSI Type 2B rating for the front-accessible arc-resistant switchgear, the operator can be protected while the low voltage control or instrumentation compartment doors are open.

Eaton Corporation www.eaton.com

Utility-scale inverterThe Power Xpert Solar 1,500 kW Inverter is designed to

improve plant levelized cost of energy, maximize energy harvest, operate in harsh environments, and adhere to safety standards. The inverter for utility-scale, solar appli-cations converts dc power into clean ac. Eaton created the inverter to use an MV pad-mount transformer, which is connected to the inverter via a direct-coupled throat connection, reducing cable requirements, pad size, and commissioning time. The Power Xpert Solar 1,500 kW features a wide Maximum Power Point Tracking voltage range, which maximizes inverter operation time to boost energy harvest.


Drawout switchboard, panelboardEaton Corporation’s 2- and 3-pole molded case circuit

breakers (MCCB) provide front-accessible and front-connected equipment with ease of maintenance. Drawout feeder MCCBs are available in 20 A to 600 A. The drawout MCCB switchboard and drawout MCCB panelboard may be submitted for almost any application. Breakers on the drawout MCCB units are inserted and removed through a mechanical removal system similar to other drawout designs associated with switchgear. For greater density and reduced space, the breaks are horizontally mounted in a traditional panelboard group mounted way.


Grid-connect inverters

Eaton Corpora-tion’s Series 6001 Energy Storage G r i d - C o n n e c t Inverter features proprietary elec-tronics and pro-vides improved stability for wind and solar energy customers. The inverter is designed to allow users to achieve full battery storage potential because of a large dc operating voltage window. With a 20-year life for utility applications, the Series has rated magnetic, liquid-cooled power modules with over seven million hours mean time between failure and a rugged enclosure for harsh envi-ronments. The Series inverter provides the required grid support, including low-, zero-, and high-voltage range, stand-alone/black start operation, islanding detection, utility communication, and full four quadrant operation.






Power Transmission

Mid-size bevel speed reducersThe new upgraded series is a mid-sized family of right

angle spiral bevel speed reducers and gearmotors. The Cyclo BBB4 has a combination of features that results in a highly reliable, efficient, and durable gearbox. The all-steel internal construction, featuring Cyclo or planetary inputs and the ductile iron housing, provides unmatched ruggedness. Interchangeable with the Cyclo BBB3 series, the redesigned Cyclo BBB4 series has been optimized for increased power ratings. A new F size yields higher torque and accommodates larger shaft diameters. Sumitomo also introduces 46 new standard ratios, along with 87 optional ratios with this generation of Cyclo BBB4.

Sumitomo Machinery Corp. of Americawww.smcyclo.com

Electric linear actuator Thomson WhisperTrak Electric Linear Actuators maximize

design flexibility and improve performance and user comfort in personal mobility, rehabilitation, and medical equipment applications where reliability, small size, and low noise are design considerations. The actuators comply with all relevant certificates and are built in accordance with ISO 9000. A sealed, IP67 enclosure allows the electric linear actuator to provide maintenance-free operation throughout its lifetime. The actuators are rated to provide at least 10,000 cycles at maximum load. The actuators operate at 12 Vdc or 24 Vdc and can handle static and dynamic loads up to 2,000 N at speeds up to 5.8 mm/sec.

Thomson Industries Inc. www.thomsonindustriesinc.com

Bevel speed reducersThe new Cyclo BBB5 series is a compact, energy-effi-

cient family of right angle spiral bevel speed reducers and gearmotors. This series has been optimized for direct shaft-mounted applications. Similar to the Cyclo BBB4 Series, the Cyclo BBB5 has a combination of features that results in a very reliable gearbox. The all-steel rotating components, featuring Cyclo or planetary, exclusive bevel outputs, and compact housing design provide top performance without thermal limitations. To enable customers to precisely define operating speeds, Sumitomo introduces more than 100 ratios with this new 5 series of Cyclo BBB.

Sumitomo Machinery Corp. of Americawww.smcyclo.com




Productivity Training Software

Blended learning solutions

GPAl l ied ’s inspired Blend-ed Learning is designed to allow partici-pants to take control of their learning experience through instructor led-classes, online curriculum, and skill applications within their facility or industrial environment. The training is a three-step process including a learning project kickoff, eLearning, and practical application. GPAllied inspired Blended Learning enables organizations to expand the capabilities of existing maintenance and reliability engineers and develop new maintenance and reliability engineers to meet growing needs. GPAllied employs its Rapid Improvement Process throughout the blended learning experience to ensure retention, alignment, and lasting change.

GPAllied www.gpallied.com

Performance and visibility software FactoryTalk VantagePoint 4.0 Software is designed

to simplify the end-user experience, include connectivity to additional Rockwell Automation products, and provide native integration to Microsoft SharePoint 2010. The soft-ware lets users expose plant floor data to the enterprise and provides capabilities like business intelligence, collabora-tion, and communications. The software connects real-time, historical, relational, and transactional data sources to create a single resource that can access, aggregate, and correlate information into a common, unified model. The Web-based dashboards and reports monitor key perfor-mance indicators and help empower users at every level of an enterprise to better manage their operation in real time.


Test question scrambler

The newly devel-oped Scramblizer by Ramsay Corpo-ration allows online administration of test questions in a randomized order, so each test taker sees a different ar rangement o f test questions. The scrambling of test questions discourages cheating while allowing the use of computers in close proximity. With each test showing the questions in a different sequence, memorization of answers is discouraged in order to avoid communicating those answers to others. The tests are machine-scored without the possibility of hand-scoring errors. With the answers on each item reported in their original order, test administrators can easily compare test-takers’ results.

Ramsay Corporation www.ramsaycorp.com

Systemmonitoring mobile application

Ta n g o M o b i l e Rounds Logging soft-ware designed for a smartphone or tab-let allows reliability information manage-ment to take place in real time and in pro-cess. Tango Mobile Rounds Logging is an economical way to involve operators and mechanics in a plant’s reliability program. Numeric readings can be set for low and high alarm levels. Tango QR codes can be installed on equipment by plant personnel, contractors, or repair vendors. Users can quickly scan a QR code with Tango Mobile and instantly view condition monitoring his-tory, equipment repair history, equipment design details, and linked documents.

24/7 Systems Inc. www.tf7.com





Safety

GE AK-1/2-50 remote racking systemCBS ArcSafe offers a single application Remote Racking

System for GE AK-1/2-50 extraction-style power circuit breakers. The RRS-3 AK-1/2-50 system enables operators to install and remove GE AK-1/2-50 equipment from up to 150 ft away with the wireless remote control. Installation of the RRS-3 AK-1/2-50 requires no modifications to the breaker or switchgear. This lightweight and portable system is ideal for hard-to-access areas including mezzanines, basements, and other areas with space restrictions.

CBS ArcSafe www.cbsarcsafe.com

Rotary remoteracking system

The CBS ArcSafe RRS-4 Remote Racking System is an upgraded version of the RRS-1 for rotary-style power circuit breakers. The RRS-4 boasts many of the same components as the RRS-1 unit, making it portable, adjustable, and user-friend-ly. The RRS-4 is operated using a dual mode, source programmable, PLC-based control system. This PLC-based control system offers two operating modes: CCM Mode, allowing users to monitor the drive motor run-ning current, and SEK Mode, allowing users to monitor the drive motor revolution count. Users have an option of which control mode to choose and can switch between the two.


Square D VR remote racking system

CBS ArcSafe has developed a single application Remote Racking System for Square D VR-style power circuit breakers. The RRS-3 VR system allows operators to install and remove this style of circuit break-er from up to 150 ft away using a wireless remote control. The user-friendly RRS-3 VR requires no modifications to the breaker or switchgear and may be installed by one person in a matter of seconds. This lightweight and portable system is ideal for mezzanines, basements. and other locations with space restrictions.


DHP remote switch actuatorThe RSA-11A is a remote switch actuator for Westing-

house DHP power circuit breakers. This product allows operators to remotely close and/or trip the circuit breaker. Installation of the lightweight and portable RSA-11A may be performed by one person in a matter of seconds and requires no modification to breaker or switchgear.





DS remote switch actuatorThe RSA-12A is a remote switch actuator that remotely

operates all styles of DS power circuit breakers. The RSA-12A is designed to operate on equipment with either manual or electric charging mechanisms and is compatible with all manufacturers and sizes of DS breakers. This product enables operators to charge, close, and/or trip the cir-cuit breaker. Installation of the lightweight and portable RSA-12A requires no modification to existing breaker or switchgear.


Bidirectional disconnect switches

Eaton’s bidirection-al disconnect switches incorporate the latest switching technology to enhance opera-tor safety, extend equipment life, and reduce installation costs in grounded and ungrounded systems. The bidirectional disconnect switches can switch one circuit per pole and remove polarity limitations. The switches are available at 30, 90, and 100 A, with either 600 Vdc or 1,000 Vdc configurations. These new switches are avail-able for either grounded or ungrounded PV systems and are capable of breaking up to six circuits with one switch. Grounded system switches include individual, isolate ter-minals for landing the grounded conductors.


GE AK-1/2-25 remote switch actuator The RSA-29 is a remote switch actuator for GE AK-1/2-

25 power circuit breakers. This product allows operators to remotely charge, close, and/or trip the circuit breaker from up to 150 ft away when using a wireless remote con-trol. Installation of the lightweight and portable RSA-29 may be performed by one person in a matter of seconds and requires no modification to breaker or switchgear. The RSA-29 is powered and operated by a CBS ArcSafe Remote Switch Operator (RSO-IIID).


Medium-voltage vacuum circuit breaker

T h e W- VA C i M B medium-voltage vac-uum circuit breaker is designed for mining applications and engi-neered to provide reli-able and robust circuit protection in a compact and reliable package. The breakers are also designed to protect transformers, capacitor banks, motors, busbar sections, and cable. To protect from demanding environmental conditions, the breakers are sealed from dust and contaminants prevalent in the mining industry and are suitable for high altitude, shock, vibration, and high temperatures. The 17.5 kV circuit breakers make and break power in a sealed environment with no external arcing.






Safety

Dock warning signal alarm

The Safety Sentry Warning Signal Alarm improves loading dock safety by alerting those nearby a vehicle backing into the dock position. The Safety Sentry uti-lizes a 105 dB siren and strobe light combination system with industrial motion sensing technol-ogy. The patent-pending design is rated NEMA 4 and constructed with UV-resistant polycarbonate using liquid tight strain relief connections.

Erich Industries Inc.www.erichindustries.com

Swing arm systemThe Tether Track Swing Arm Fall Arrest System protects

workers from injures due to falls. The system provides workers with a high degree of mobility and freedom, while preventing falls to lower levels. The Swing Arm System provides circular or semicircular fall protection with a compact footprint. The swing arm can be positioned over the workspace when needed and moved out of the way when not in use. The track can be wall mounted, column mounted, or stand alone and is available in standard arm lengths from 8 ft to 30 ft.

Gorbel Inc.www.gorbel.com

Automated barrier doorThe Guardian Defender combines safety interlock

switches/controls capable of achieving up to PLe, Category 4 level safety with a movable physical barrier restricting access to dangerous machine movement. At the same time, process driven hazards such as weld flash, sparks, flying debris, mist, spray, and smoke are contained. The Guardian Defender’s switches/controls provide clear visual communications with two signals, green for safe and red for unsafe. The machine is designed with a 9-in. foam soft bottom edge and Armorplex curtain material.

Frommelt Safetywww.frommeltsafety.com

Safety valveCormack Propane Safety Valve helps prevent LPG

escaping when changing forklift cylinders. When the Cor-mack valve is closed, it shuts off LP Gas next to the coupler to prevent it from coming through if the seal fails. If the Cormack valve is open, the foolproof handle design covers the coupler so the operator cannot disconnect it in the open position. The Cormack valve fits almost all forklifts and increases LPG cylinder exchange safety. With installation only taking minutes, LPG cylinder changes are quicker.

Liftow Limitedwww.liftow.com




Metal detectablecomponents

DETEX Belt Dressing is a metal detectable plastic aerosol component for the food indus-try, designed to assist food pro-cessing plants in meeting strict HACCP requirements. Blue colored caps, actuators, and extension tubes signify the com-ponents, which are metal detect-able and can help prevent food from being contaminated. All metal detectable plastic compo-nent ingredients are GRAS listed, meeting the FDA requirements as an acceptable material for use in food processing plants. The aerosol can is in compliance with the Food Safety Net Services and contains lithographed labels.

LPS Laboratories www.lpslabs.com

Water-resistantlubricant

DETEX Food Grade Chain Lubricant is a water-resistant lubricant designed primarily for the effective lubrication of all types of chains and conveyors operating in food environments. Food Grade Chain Lubricant is NSF Registered H1 No. 132899 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as pro-tect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufactur-ing, processing, and packaging facilities.


Versatile lubricantDETEX Clear Penetrating

Grease is a high-performance, versatile lubricant fortified with PTFE additives for enhanced lubrication. Clear Penetrating Grease is NSF Registered H1 No. 143804 and packaged with DETEX, metal detectable plas-tic components. DETEX com-ponents can be identified using standard metal detection equip-ment should they become loose in the processing area. DETEX chemicals protect vital machin-ery, as well as protect against expensive recalls, costly down-time, and damaged reputations. DETEX products are ideal for use in food manufacturing, process-ing, and packaging facilities.


Lubricant andpenetrant

DETEX Food Grade Machine Oil is a lubricant and penetrant that minimizes friction, extends equipment life, and penetrates to provide complete surface cover-age protection against wear and corrosion. Food Grade Machine Oil is NSF Registered H1 No. 129000 and packaged with DETEX, metal detectable plas-tic components. DETEX com-ponents can be identified using standard metal detection equip-ment should they become loose in the processing area. DETEX chemicals protect vital machin-ery, as well as protect against expensive recalls, costly down-time, and damaged reputations. DETEX products are ideal for use in food manufacturing, process-ing, and packaging facilities.






Anti-stick agent DETEX Food Grade Silicone

Lubricant is a nonstaining, high-quality lubricant designed espe-cially for the food industry for use as an anti-stick agent for chutes and slides. Food Grade Silicone Lubricant is NSF Registered H1 No. 113815 and packaged with DETEX, metal detectable plas-tic components. DETEX com-ponents can be identified using standard metal detection equip-ment should they become loose in the processing area. DETEX chemicals protect vital machin-ery, as well as protect against expensive recalls, costly down-time, and damaged reputations. DETEX products are ideal for use in food manufacturing, process-ing, and packaging facilities.


Nonchlorinatedelectric cleaner

K2 Electronic Cleaner is a non-chlorinated, plastic-safe cleaner that is engineered to rapidly clean and restore electronic compo-nents. K2 Electronic Cleaner is NSF Registered K2 No. 146516 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as pro-tect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufactur-ing, processing, and packaging facilities.

LPS Laboratorieswww.lpslabs.com

Water-based lubricant DETEX Heavy-Duty Silicone

Lubricant is a unique water-based formulation that contains a high percentage of silicone for better and longer lubrication. Heavy-Duty Silicone Lubricant is NSF Registered H1 No. 01519 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as pro-tect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufactur-ing, processing, and packaging facilities.


Nonflammableelectronic cleaner

K2 NF Electronic Cleaner is a nonflammable, heavy-duty electronic cleaner that is engi-neered to rapidly clean and restore electronic components. K2 NF Electronic Cleaner is NSF Registered K2 No. 146517 and packaged with DETEX, metal detectable plastic components. DETEX components can be identified using standard metal detection equipment should they become loose in the processing area. DETEX chemicals protect vital machinery, as well as pro-tect against expensive recalls, costly downtime, and damaged reputations. DETEX products are ideal for use in food manufactur-ing, processing, and packaging facilities.

LPS Laboratorieswww.lpslabs.com

Safety




Rescue kitThe Miller QuickPick

Rescue Kit delivers peace-of-mind during unexpected, peer-res-cue situations involv-ing those working at height. The rescuer can attach the sys-tem to the suspended worker while remaining securely anchored on the working surface. All rescue compo-nents are included in an easy-to-store kit with no required assembly. The kit is available in two con-figurations: the Premium Miller QuickPick Kit designed for workers whose job is not normally rescue, and the Stan-dard Miller QuickPick Kit designed for those experienced in rescue situations. The kits are a professional solution that enhance worker safety and comply with corporate fall protection plans.

Miller Fall Protection www.millerfallprotection.com

Vehicle restraint The RHR-4000 Dok-

Lok Vehicle Restraint adds another layer of safety by securing over-seas container chassis, which can have a plate of obstruction above the rear impact guard. The RHR-4000 offers a water- and dust-resistant IP66 rated motor and a longer lasting, corro-sive-resistant finish that meets the ASTM B117 testing standard. Like previous Dok-Loks, the RHR-4000 helps prevent all types of trailer separation accidents, including early departure and landing gear collapse, as well as trailer creep, pop-up, upending, and tip over. The Dok-Lok rotating hook restraints are designed for impact and to withstand the loading dock environment.


Safety gateThe GateKeeper Mez-

zanine Safety Gate is a reciprocating barrier that creates a controlled access area where work-ers can safely load and unload from the edge of a mezzanine, pick mod-ule, or other elevated platforms. The barrier designed with the Gate-Keeper is interconnected and cannot be open at the same time. When the outer gate opens to allow pallets to enter the mez-zanine level, the inner gate automatically closes, keeping workers out. The exclusive link bar design ensures that both gates always work in unison, without relying on the chains or cables. Also featured with the GateKeeper is a Saf-T-Latch, preventing workers from raising the outer gate while inside the work zone.


Virtual main system Schneider Electric offers

an arc flash mitigation solu-tion to upgrade Unit Substa-tion equipment with the addi-tion of a virtual main system. The system reduces arc flash energy on low-voltage switchgear, including the main incoming section. The virtual main system features a switching device with fault interruption capability on the high-voltage side of the ser-vice transformer. The system provides maintenance mode for arc flash reduction, improv-ing the overcurrent protection of unit substation. The virtual main system is equipped with a built-in fault recording and event reconstruction technology in the digital relay.

Schneider Electric www.schneider-electric.com





Nowthe voteis yours…

Plant Engineering subscribers with a valid e-mail address will receive the 2012 Product of the Year ballot. Simply fill it out, click ‘Submit,’ and let your vote for this year’s best products be counted. Then, in the April 2013 issue of Plant Engineering, meet the 2012 Product of the Year award winners honored at our 2013 Awards in Manufacturing Event in Chicago.

20122012

Safety

Fail-safe programSiemens introduced the SIMATIC STEP 7 Safety

Advanced V11 option as a part of its Totally Integrated Automation (TIA) Portal, providing end users with all con-figuration and programming tools required for generating a fail-safe program. The TIA Portal integrates product and production engineering via one interface, linking all of Sie-mens automation software packages and platforms. The framework of the TIA Portal enables all Siemens Program-mable Controllers, HMI operator panel, and drives to be configured in the same development environment. The new Safety Advanced feature allows for intuitive operation and quick entry into the generation of fail-safe programs.


Fire suppressionsystem

The Victaulic Vortex 500 Fire Suppression System is designed specifically for informa-tion technology spaces such as data rooms and server spaces. This tech-nology utilizes both water and nitrogen in a com-bined suspension to both cool the hazard area and remove oxygen that sus-tains the fire using high velocity and low pressure. The swirling distribution fills the hazard space at 40 mph and extinguishes the fire with little to no water. The Victaulic Vortex 500 system provides supreme protection and fire suppression with limited resid-ual moisture, no toxic chemicals, and full design flexibility.

Victaulicwww.victaulic.com

Braided hoseThe Series AH2 Braided Hose is an extension of the

VicFlex Sprinkler Fitting System. The hose is 100% kink resistant, offering a tight bend radius at 2 in., as well as a new level of installation ease and advantage. The VicFlex hose also offers an improved hydraulic performance with a 50% lower friction loss over corrugated systems. The improved corrugation and braided technology reduce the effort needed to bend the hose, allowing for better shape retention. The Series AH2 Braided Hose is cULus Listed and FM Approved in combination with the Style AB1 Bracket.

Victaulicwww.victaulic.com




Company Product Category Page

24/7 Systems Inc. Tango Mobile Rounds Logging Productivity Training Software 53AeroGo Inc. LoadRunner Material Handling Systems 49aPriori Inc. aPriori 2011r2 Apps For Engineers 36B&B Electronics Mfg. 802.11 WiFi Access Point for Industrial M2M Applications Automation & Controls 30Baldor Electric Co. Dodge Type EXL Electric Motors & Drives 38Banner Engineering Corp. SureCross Q45 Wireless Photoelectric Sensor Automation & Controls 30Big Ass Fan Co. AirGo Misting System Environmental Health 42Big Ass Fan Co. BAFWorks Automation & Controls 30Big Ass Fan Co. Powerfoil X2.0 HVAC 44Cat Lift Trucks 2EP5000-2EP6500 Electric Pneumatic Tire Lift Trucks Material Handling Systems 49CBS ArcSafe RRS-3 AK-1/2-50 Safety 54CBS ArcSafe RRS-3 VR Safety 54CBS ArcSafe RRS-4 Safety 54CBS ArcSafe RSA-11A Safety 54CBS ArcSafe RSA-12A Safety 55CBS ArcSafe RSA-29 Safety 55Columbia Lighting e•poc LED Full Distribution Luminaire Lighting 45Columbia Lighting Serrano Architectural Luminaire Lighting 45Columbia Lighting Serrano LED Architecturally Styled Luminaire Lighting 45Columbus McKinnon Corp. Lodestar Electric Chain Hoist Material Handling Systems 49Detroit Radiant Products Co. MP Series ‘Modulating Plus’ Overhead Infrared Heaters HVAC 44Dual-Lite EV Series LED Lighting 45Eaton Corporation Arc-Resistant Front-Accessible Switchgear Power Transmission 51Eaton Corporation C441 Ethernet Series of Communications Cards Automation & Controls 30Eaton Corporation DC Disconnects Safety 55Eaton Corporation Drawout MCCB Pow-R-Line Panelboard and Switchboard Power Transmission 51Eaton Corporation Foreseer X-Class Software Energy Management 41Eaton Corporation H-Max Series Adjustable Frequency Drives Electric Motors & Drives 38Eaton Corporation Power Xpert 200E Gateway Energy Management 41Eaton Corporation Power Xpert Reporting v3.0 Energy Management 41Eaton Corporation Power Xpert Solar 1,500 kW Inverter Power Transmission 51Eaton Corporation POWEREDGE Mobile Application Apps For Engineers 36Eaton Corporation S811+/S801+ Soft Starters Electric Motors & Drives 38Eaton Corporation Series 6001 Energy Storage Grid-Connect Inverter Power Transmission 51Eaton Corporation SmartWire-DT System Automation & Controls 31Eaton Corporation W-VACiMB Medium-Voltage Vacuum Circuit Breaker Safety 55Eaton Corporation XV Series HMI-PLC Automation & Controls 31Electro Static Technology Inc. AEGIS Split uKIT Electric Motors & Drives 38Erich Industries Inc. Safety Sentry Warning Signal Alarm Safety 56Eriez SumpDoc Fluid Handling 43EXAIR Corporation Dual High Temperature Cabinet Cooler System Electrical Controls 40EXAIR Corporation Siphon Fed Atomizing Nozzles Fluid Handling 43EXAIR Corporation Super Air Nozzles Compressed Air 37EXAIR Corporation USB Data Logger for Digital Flowmeter Energy Management 41Exlar Tritex II DC Powered Actuators Electric Motors & Drives 39Exxon Mobil Corp. Mobil SHC Gear Oil Series Maintenance Tools & Equipment 47FastEST Inc. FasMate FN Series Fluid Handling 43Fluke Corp. Fluke 430 Series II Three-Phase Power Quality and Energy Analyzers Maintenance Tools & Equipment 47Fluke Corp. Fluke 805 Vibration Meter Maintenance Tools & Equipment 47Fluke Corp. Fluke Ti Series Thermal Imagers Maintenance Tools & Equipment 47FreeWave Technologies I/O Expansion Module Automation & Controls 31Frommelt Safety Guardian Defender Automated Barrier Door Safety 56Frommelt Safety Insulator Dock Seal Energy Management 42Gorbel Inc. Tether Track Swing Arm Fall Arrest System Safety 56GPAllied inspired Blended Learning Productivity Training Software 53Hubbell Building Automation Inc. CX Commercial Lighting Control Panels Automation & Controls 32Hubbell Building Automation Inc. LightHAWK Neutral Wall Switch Occupancy Sensors Automation & Controls 32Hubbell Industrial Lighting HBL LED Highbay Lighting 46

Product Index




Product Index Company Product Category Page

Hubbell Outdoor Lighting Sedona LED Lighting 46Ingersoll-Rand plc Heat of Compression Dryers Compressed Air 37Ingersoll-Rand plc R-Series Rotary Screw Air Compressors Compressed Air 37Invensys Operations Management Eurotherm Nanodac Recorder/Controller Historian Automation & Controls 32Invensys Operations Management Intelligent Marshalling for Foxboro I/A Series DCS Automation & Controls 32Invensys Operations Management Wonderware InTouch 2012 Apps For Engineers 36iQuest iQagent Apps For Engineers 36Jungheinrich Warehouse Products ECR 327/336 Electric End-Rider Pallet Trucks Material Handling Systems 49Juno Lighting Group AccuLite Highbay and Lowbay LED Luminaires Lighting 46Kepware Technologies Inc. KEPServerEX 5.9 Automation & Controls 33Liftow Limited Cormack Propane Safety Valve Safety 56LPS Laboratories LPS DETEX Belt Dressing (2216) Safety 57LPS Laboratories LPS DETEX Clear Penetrating Grease (6716) Safety 57LPS Laboratories LPS DETEX Food Grade Chain Lubricant (6016) Safety 57LPS Laboratories LPS DETEX Food Grade Machine Oil (1316) Safety 57LPS Laboratories LPS DETEX Food Grade Silicone (1716) Safety 58LPS Laboratories LPS DETEX Heavy-Duty Silicone Lubricant (51516) Safety 58LPS Laboratories LPS DETEX K2 Electronic Cleaner (57116) Safety 58LPS Laboratories LPS DETEX K2 NF Electronic Cleaner (57016) Safety 58Miller Fall Protection Miller QuickPick Rescue Kit Safety 59Nexen Group Inc. Harmonic Gearhead Automation & Controls 33NK Technologies ATS Current Sensing Switch and Transducer Electrical Controls 40NovaTorque Gen2.0 PremiumPlus+, ECPM Motors Electric Motors & Drives 39Pro-face GP4000 Series Modular HMI Automation & Controls 33Prüftechnik Group ROTALIGN Ultra iS with sensALIGN Maintenance Tools & Equipment 48Prüftechnik Group VIBCONNECT RF Automation & Controls 34Ramsay Corp. Test Scramblizer Productivity Training Software 53RIDGID SeeSnake MAX rM200 Camera System Maintenance Tools & Equipment 48Rite Hite Holding Corp. GateKeeper Mezzanine Safety Gate Safety 59Rite Hite Holding Corp. Renegade Series HVLS Fans HVAC 44Rite Hite Holding Corp. RHR-4000 Dok-Lok Vehicle Restraint Safety 59Rockwell Automation Inc. Allen-Bradley CompactLogix 5370 PACs Automation & Controls 34Rockwell Automation Inc. Allen-Bradley Kinetix 350 Single-Axis EtherNet/IP Servo Drive Electric Motors & Drives 39Rockwell Automation Inc. FactoryTalk VantagePoint 4.0 Productivity Training Software 53Rockwell Automation Inc. PlantPAx Virtual Image Templates Automation & Controls 34Schneider Electric Aisle-way Beacon Maintenance Tools & Equipment 48Schneider Electric StruxureWare Power Monitoring 7.0 Software Automation & Controls 34Schneider Electric Unit Substation “Virtual” Main Circuit Breaker Solution Safety 59Siemens SIMATIC HMI Comfort Panels Automation & Controls 35Siemens SIMATIC S7-1215C Automation & Controls 35Siemens SIMATIC STEP 7 Safety Advanced V11 Safety 60Siemens SINAMICS DC Master Base Drive Electric Motors & Drives 39Siemens SINAMICS S120 Drive w/ Industrial Ethernet Electric Motors & Drives 40Siemens SINUMERIK OP 019 CNC Operator Panel Electric Motors & Drives 40SixAxis LLC Atlatl-Sales Resource Planning Software Automation & Controls 35Spirax-Sarco Inc. Steam DesignPro 6.1 HVAC 44Spirax-Sarco Inc. VLM10 Inline Vortex Mass Flowmeter Fluid Handling 43Sullair Corp. E900H Portable Air Compressor Compressed Air 37Sumitomo Machinery Corp. of America Cyclo Bevel Buddybox 4 (BBB4) Power Transmission 52Sumitomo Machinery Corp. of America Cyclo Bevel Buddybox 5 (BBB5) Power Transmission 52The Raymond Corp. Raymond 7000 Series Reach-Fork Trucks Material Handling Systems 50The Raymond Corp. Raymond 8000 Series Pallet Trucks Material Handling Systems 50Thomson Industries Inc. WhisperTrak Electric Linear Actuators Power Transmission 52Toyota Industrial Equipment Galvanized Chassis Material Handling Systems 50VaporLok Products VaporLokCapture Environmental Health 42Victaulic Series AH2 Braided Hose Safety 60Victaulic Victaulic Vortex 500 Fire Suppression System Safety 60VYCON Inc. VDC-XE with HC Option Energy Management 42




SPECIAL ADVERTISING SECTION

You’ve meet the finalists for Product of the Year. After you’vecompleted the electronic ballot, you can learn more about thefinalists and the products they offer. Our special Product of the

Year advertising section provides a way to make plantsrun more efficiently, safely and productively.

� � �

Companies interested in entering the 2013 Product of the Year competition may do so before the Sept. 2 7, 2013deadline. Details and entry forms will be available Apr. 15, 2013, at www.plantengineering.com/POY

2012


A VOTE FOR RAYMONDIS A VOTE FOR

PRODUCTIVITY.

★

Raymond® 8000 Series pallet trucks perform without

compromise–engineered with Eco-Performance, our design

philosophy that reduces energy consumption and increases

productivity. That means longer battery life with up to 33%

less energy used and a 6% increase in productivity over the

competition. Plus dramatically lower maintenance costs and

zero compromise on reliability and durability. Add it up, and

you’ll move more product per shift. And, achieve a lower

total cost of ownership.

For any questions or to learn more, please call 1-800-235-7200 or visit raymondcorp.com.

Raymond 7000 Series Reach-Fork® trucks leverage

Eco-Performance to deliver reduced energy consumption

and increased productivity. In fact, they use up to 21% less

energy and produce cycle times up to 9% faster than the

competition. With faster lift speeds, quicker acceleration

and longer battery life, you can move more pallets per hour

and minimize maintenance and labor costs. Bottom line, it’s

performance without compromise.

8000 SERIES PALLET TRUCK

7000 SERIES LIFT TRUCK

Vote for the 7000 series Reach-Fork® trucks and the 8000 series

pallet trucks as your Plant Engineering Product of the Year, in the

Material Handling category. They both represent great thinking.

As all leaders should.

2012

2012

Job Name: RAYC15606 PlantEngineering_spread_DBmec.indd

Trim: 15.75" X 10.5"

Bleed: 16.25” X 10.75”

Live: 15.25” X 10”

Colors: 4C

Scale: 100%

Publication: Plant Engineering

Other:

10-22-12

SPECS

RELEASE DATE

APPROVALS

PM:

MK:

PP:

QA:

AD:

CW:

CD:

ST:

QR Code Check iPhone DROID



What if you could use your iPhone® or iPad® to scan a QR Code on any piece of production equipment within your plant to:

•View Live KPIs, Process Values, Trends, Charts and Graphs?•Review Maintenance Procedures, Drawings, or Parts Lists?•Call or e-mail the Equipment Support line, Sales Rep or Vendor?•Enter a work order, PM Action, or Trouble Report?•Record MP4 movies with video, live data and annotations to send to offsite support personnel for quick analysis?

uest,Inc. uestwww.iQuestcorp.com

View Live Plant Data on Your iPad®!

With iQagent, You Can!(Try it Now with your IOS Device.)

Step 1: Download the Free iQagent App from the Apple App Store.Step 2: Launch iQagent on your iPad or iPhoneStep 3: Scan the Sample QR Codes below using iQagent.Step 4: Visit www.iQagent.com to watch our Product Video and learn more about the first true Process App for IOS Devices!

Production QR Codes (Scan with iQagent)

Line 1 Production Plant Environment Thermal Former 3



Ingersoll Rand has unleashed two products, nominated for Product of the Year, that optimize the efficiency and productivity of your compressed air system:

Long-Life, Contact-Cooled R-Series Rotary Compressors (55-160 kW) • Leak free, reliable components lower cost of ownership

• Integrated intelligent controls optimize airflow

• Flexible options such as fixed- and variable-speed motors, single- and two-stage airends and integrated Total Air Systems

Cost-Saving HOC Dryers • Uses heat generated by compression process to lower energy cost

• Low pressure drop design conserves energy

• Patented stainless steel heat exchangers provide optimal performance

Ingersoll Rand Efficiency...ingersollrandproducts.cominput #26 at www.plantengineering.com/information


Hubbell Building Automationinput #27 at www.plantengineering.com/information


Forget the pens. Think METER: fl uke.com/VibrationMeter

The new Fluke 805 Vibration Meter is more than a pen. It’s a Fluke meter that gives you results you can trust, time after time.

• Checks overall vibration, bearings and temperature • Ability to export and trend data • Four-leve l scale quickly assesses problem severity • Unique sensor design ensures accurate and repeatable measurements

4151036A_EN_805_PlantEng.indd 1 11/2/12 11:04 AM




AUTOMATIONSOLUTIONS

Remote monitoring isn’t new to the industrial automation world as over 25 years ago the first remote moni-toring systems were installed using

dial-up phone connections. In the 1990s, these early systems advanced to hardwired Ethernet/Internet connections that offered greater speed and reliability. Today, many plants are benefiting from technologies in which wireless networks and devices are used for easier and more economical remote moni-toring and control.

The advent of cellular technology has sig-nificantly expanded the ability to monitor plant operations from just about anywhere, while lowering costs and simplifying imple-

mentation. 4G technologies have made cel-lular connections much faster, often match-ing the speed of hardwired Ethernet/Internet connections.

Benefits of remote monitoring Once only found in significant numbers in

industrial applications that covered widely dispersed areas, remote monitoring is becom-ing a more integral part of daily operations in many manufacturing facilities, thanks to the lower costs and simpler implementation associated with the newest technologies.

Some of the factors driving remote monitor-ing proliferation have to do with lower upfront investment costs needed for implementation;

Remote monitoring technologieslower costs, improve operations

By Greg PhilbrookAutomationDirect

The latest remote communication technologies allow experts tomonitor and control multiple plants from any location.

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PLE1211_AUTOSOL_V6msFINAL.indd 71 11/8/12 9:28 AM

Some advantages, disadvan-tages of wireless networks

Advantages: n Flexibility for different hardware and software types n No cables or wiring n Faster and easier installation n Can provide greater visibility into operations.

Challenges: n Not a closed system as with wired networks n Early security standards not robust n Implementation of new security technologies can be challenging.

others are the result of leaner operations and fewer operators on the plant floor. Not only does remote monitoring enable operators to monitor conditions from just about anywhere, it also facilitates more effective monitoring by fewer personnel, a real differentiator in today’s tough economic climate.

The potential benefits of remote monitoring are significant: minimizing labor costs, filling the knowledge gap resulting from experienced operators retiring, prolonging equipment life, preventing unplanned downtime, and more. However, there’s no easy answer as to what type of remote monitoring is best.

While remote monitoring can greatly con-tribute to cost savings and improved opera-tions, there are considerations that must be addressed to ensure the security and practi-cality of implementing a remote monitoring system. Also required are definitions of what data can be accessed and by whom, and, most critically, what remote control options will be allowed.

Wireless advantages and challengesInstalling wireless networks for remote

monitoring systems is becoming a common way to reduce costs associated with installing and maintaining a network. Wireless networks offer significantly more flexibility than wired remote monitoring networks that have a fixed topology. The ability to mix and match equip-ment from different suppliers is also much easier with wireless.

Eliminating the need to purchase and install wires and cables is the most immediate cost savings associated with implementing a wire-less network. Another area for savings is the

ability to add sensors much faster and for very little cost versus the high price of adding a hardwired device.

Adding sensors improves visibility into a machine’s overall function, or to the overall performance of a batch or continuous process. The additional data gathered from new sensors enables operators to diagnose potential prob-lems faster and with better accuracy, which leads to improved efficiency and reduced maintenance costs.

While providing much lower installation costs, wireless networks aren’t a panacea for every situation or plant. The biggest concern with using wireless networks is security. Early wireless standards, such as wired equivalent privacy (WEP), were not as robust as they should have been, which has led to continuing concerns about data security over wireless networks.

Although security measures are vastly better today, it is still important to remember that wireless networks can be more vulnerable than their wired counterparts. However, wire-less networks have become far more secure through the use of encryption, and through standards such as the IEEE.802.11X-based Extensible Authentication Protocol, which requires clients to be identified in order to gain access to the network.

But implementing and maintaining wire-less network security requires certain IT knowledge, and smaller operations may not know how to implement these new security measures. Although wireless networks may pose a challenge for some users, wirelesses networking protocols and security features have advanced considerably, and wireless networks are definitely a viable option for reducing remote monitoring installation and maintenance costs.

Remote data accessRegardless of the type of remote monitoring

system, great strides have been made in terms of how and where the data from these systems can be accessed. In the late 1990s, PC-based access became the norm, later followed by Web-based access.

These developments not only lowered costs, but also improved efficiency and productiv-ity because plant operators could more eas-ily and frequently access data. In addition to easier data access, PC-based monitoring brought about significant improvements in alarming and alarm response times. Now, many plants are taking advantage of the


aUTOMaTIONSOLUTIONS

Remote monitoring is becoming a more integral part of daily operations in many manufacturing facilities, thanks to the lower costs and simpler implementation associated with the newest technologies.


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ability to use mobile devices suchas Smartphones to reduce costs and gain greater visibility into plant operations.

Whether as a result of the reces-sion or experienced operators retir-ing, most manufacturing plants have fewer operators to monitor plant conditions. Process monitor-ing requires extensive oversight, yet plant managers can no longer afford to operate isolated diag-nostics stations or assign certain operators to specific areas of the plant.

In today’s plants, many opera-tors must simultaneously monitor multiple machines or processes in various locations throughout a facility. Without remote moni-toring, potential problems may not be detected, quality can suffer, equipment can be damaged, and unscheduled downtime can occur.

More manufacturers are moving to consolidated monitoring models that

cover multiple plants. With these mod-els, highly experienced operators and engineers can access detailed, real-time information from each plant, as well as detailed historical information. Information from different plants can

be compared and analyzed, often leading to early problem detection.

Remote personnel can trouble-shoot issues, change an operat-ing parameter, and shut down a machine or process to avoid possi-ble problems. They can also advise on-site engineers and operators as to how best remedy a problem or improve performance.

This type of expertise combined with real-time visibility into daily operating conditions can extend the lifetime of machinery and process equipment. Maintenance schedules and historical data can more easily be used to determine maintenance and replacement intervals, all without having to be physically at the plant.

Cellular technology useSmartphones have replaced individu-

al devices that once seemed absolutely necessary. Watches, alarm clocks, cam-eras, maps, video recorders, calculators,

aUTOMaTIONSOLUTIONS

Remote monitoring via Smartphones

Web browser/VPN for remote monitoring: n May provide snapshot, not real-time data n May be read-only n Often not designed for small displays n Security challenges.

Smartphone app for remote monitoring: n Very low cost n Wide range of functionality n Fast loading of app n High-speed access n Seamless upgrades from the supplier n Designed for small displays n Security challenges.


recording devices, and much more nowfit into a typical user’s pocket. It’s no wonder that the advances in cellular technology are being taken advantage of in manufacturing environments.

Everyday more companies are using mobile devices such as Smartphones, tablets, and other handheld devices to cut costs, and to communicate informa-tion economically and quickly. While many manufacturers are enabling remote access via Smartphones and other handheld devices, implementa-tion isn’t quite as simple as checking e-mail online.

One of the main decisions to be made is how and when to implement browser-and app-based remote monitoring.

Web browsers: Pros and consThe logical progression for accessing

data remotely via a Smartphone is to use a browser to access plant automation systems via a company’s virtual private network (VPN). Many companies today offer remote connectivity via a VPN,

with users simply connecting to the company’s network and then interact-ing with the automation systems via a Web browser interface. This access is generally to a human machine inter-face (HMI) or a controller, although browser-based access can be used with any automation component equipped with Web-served capability.

This type of access can be very good and relatively quick when the browser is running on a PC, but can raise issues with Smartphone browsers. In many cases, the Web server screens don’t scale well to the smaller displays found in handheld devices, and screens often take too long to load.

Another consideration is that often remote browser-based access provides only a snapshot of the HMI screens, which can cause problems when moni-toring large amounts of data in operating conditions that change frequently.

Some Web servers and VPNs enable two-way access for remote control, but many just offer read-only access.

www.plantengineering.com/interact

Q: Does your plant implement browser-or app-based remote monitoring? What applications do you use?

INTERACT

Therefore, care must be taken whenselecting a supplier or implementing a VPN solution to make sure users can perform remote actions as necessary.

While Web browser access is essen-tially free, the costs of designing, deploying, and maintaining the VPN and the Web servers can be considerable and must be factored in when determining overall ROI.

Continued on pg. 86

PLE1211_AUTOSOL_V6msFINAL.indd 75 11/8/12 9:28 AMPLE121101-MAG_Ads.indd 74 11/8/2012 12:20:11 PM

You may not think of electrical components as a means to better productivity, but we have ways to help prevent costly downtime due to electrical system malfunction or failure, and ways to help extend the working life of electrical equipment. Our portfolio includes a vast array of power and low-voltage electrical products, T&B Engineered™ to optimize performance, reliability and safety in even the most challenging manufacturing and processing environments. To learn how our products can help you keep your operation running strong, visit www.tnb.com

Trust T&B Engineered ™ components to keep your

operation running.

Wire & Cable Management • Cable Protection Systems Power Connection & Control • Safety Technology • HVAC Building Solutions • Engineered Transmission Structures

Corrosion ResistanceT&B Superior PVC-coated

Conduit Systems fi ght corrosion and help to

avoid downtime

Ingress ProtectionT&B Sealed Power Connectors

prevent washdown shorts and shutdowns

Extreme TemperaturesT&B Extra High Temperature Cable

Ties with stainless steel locking device withstand temperatures

from -40° to 150° C

Continuous OperationT&B Motor Lead Disconnects allow faster replacement of

electrical motors

Your operation is only as strong as your electrical system.


ability to use mobile devices suchas Smartphones to reduce costs and gain greater visibility into plant operations.

Whether as a result of the reces-sion or experienced operators retir-ing, most manufacturing plants have fewer operators to monitor plant conditions. Process monitor-ing requires extensive oversight, yet plant managers can no longer afford to operate isolated diag-nostics stations or assign certain operators to specific areas of the plant.

In today’s plants, many opera-tors must simultaneously monitor multiple machines or processes in various locations throughout a facility. Without remote moni-toring, potential problems may not be detected, quality can suffer, equipment can be damaged, and unscheduled downtime can occur.

More manufacturers are moving to consolidated monitoring models that

cover multiple plants. With these mod-els, highly experienced operators and engineers can access detailed, real-time information from each plant, as well as detailed historical information. Information from different plants can

be compared and analyzed, often leading to early problem detection.

Remote personnel can trouble-shoot issues, change an operat-ing parameter, and shut down a machine or process to avoid possi-ble problems. They can also advise on-site engineers and operators as to how best remedy a problem or improve performance.

This type of expertise combined with real-time visibility into daily operating conditions can extend the lifetime of machinery and process equipment. Maintenance schedules and historical data can more easily be used to determine maintenance and replacement intervals, all without having to be physically at the plant.

Cellular technology useSmartphones have replaced individu-

al devices that once seemed absolutely necessary. Watches, alarm clocks, cam-eras, maps, video recorders, calculators,

aUTOMaTIONSOLUTIONS

Remote monitoring via Smartphones

Web browser/VPN for remote monitoring: n May provide snapshot, not real-time data n May be read-only n Often not designed for small displays n Security challenges.

Smartphone app for remote monitoring: n Very low cost n Wide range of functionality n Fast loading of app n High-speed access n Seamless upgrades from the supplier n Designed for small displays n Security challenges.


recording devices, and much more nowfit into a typical user’s pocket. It’s no wonder that the advances in cellular technology are being taken advantage of in manufacturing environments.

Everyday more companies are using mobile devices such as Smartphones, tablets, and other handheld devices to cut costs, and to communicate informa-tion economically and quickly. While many manufacturers are enabling remote access via Smartphones and other handheld devices, implementa-tion isn’t quite as simple as checking e-mail online.

One of the main decisions to be made is how and when to implement browser-and app-based remote monitoring.

Web browsers: Pros and consThe logical progression for accessing

data remotely via a Smartphone is to use a browser to access plant automation systems via a company’s virtual private network (VPN). Many companies today offer remote connectivity via a VPN,

with users simply connecting to the company’s network and then interact-ing with the automation systems via a Web browser interface. This access is generally to a human machine inter-face (HMI) or a controller, although browser-based access can be used with any automation component equipped with Web-served capability.

This type of access can be very good and relatively quick when the browser is running on a PC, but can raise issues with Smartphone browsers. In many cases, the Web server screens don’t scale well to the smaller displays found in handheld devices, and screens often take too long to load.

Another consideration is that often remote browser-based access provides only a snapshot of the HMI screens, which can cause problems when moni-toring large amounts of data in operating conditions that change frequently.

Some Web servers and VPNs enable two-way access for remote control, but many just offer read-only access.


Q: Does your plant implement browser-or app-based remote monitoring? What applications do you use?

INTERACT

Therefore, care must be taken whenselecting a supplier or implementing a VPN solution to make sure users can perform remote actions as necessary.

While Web browser access is essen-tially free, the costs of designing, deploying, and maintaining the VPN and the Web servers can be considerable and must be factored in when determining overall ROI.

Continued on pg. 86


The network edge is continually expand-ing into new applications and new industries, and network-enabled sen-sors are leading the way. Metcalfe’s

Law tells us that every time you add another device to a network, whatever that device’s function may be, you increase the value of the network.

Sensors demonstrate that point every day. Whether they’re measuring deformation errors in a tire plant, geo-fencing an oil pipeline, or monitoring well water quality for the U.S. Geological Survey, sensors lower costs and enhance productivity.

Each new application presents its own set of new problems. Sensors must function in a wide array of environments, and they must be able to report their data. This article will describe system design techniques that anticipate issues like brownouts and equipment failure, and prepare for them by employing solutions

like local decision-making and controls, and redundant backhaul paths.

The myth of 100% uptimeAll data communications installations have

vulnerabilities. Fiber optic cable, for example, the option with by far the greatest range and bandwidth, is used by the telecommunica-tions companies to move data across entire continents.

Uptime is excellent, but the system isn’t perfect. The cables are either run through sew-ers, where backhoes break them with annoying regularity, or they’re strung along telephone poles, where they’re knocked down by every-thing from windstorms to sleepy truck drivers. Indoor fiber optic connections have problems of their own. Transceivers and receivers even-tually fail. Cables can be bent or broken by anything from careless forklift drivers to the cousins of the raccoons that get into power substations and shut down the grid.

Copper cable adds additional weaknesses. Any strong magnetic field can induce current on a copper cable, which will lead to power surges that can burn out sensors, integrated circuits, and connectors. Industrial machinery isn’t the only thing that can generate those strong magnetic fields. For example, a 1989 solar flare famously produced a magnetic storm that took out the power grid for all of Quebec. Lightning strikes will also produce damaging electrical events, as will the ground loops that occur when connected devices have different ground potentials.

Wireless connections are subject to fail-ure, too. Interference from other devices on the same frequencies can lead to data loss. And radio signals attenuate with the square of distance. Merely doubling the range would require a four-fold increase in power.

No system is perfect. And the harder you try to achieve perfection, the faster your costs will rise. It’s cheaper and easier to eliminate the need for 100% uptime from the very beginning.

Rugged devices and isolation While 100% uptime is a mirage, at least for

a price that any reasonable person would be willing to pay, that doesn’t mean you shouldn’t try to do your best. Industry-hardened network devices that will stand up to off-the-desktop,

aUTOMaTIONSOLUTIONS


Using sensors to enhance systems

By Mike Fahrion B&B Electronics

Recognize the limitations, then plan for redundancy.

Solar kits allow accurate monitoring and control of processes or equiment without a power infrastructure. Courtesy: B&B Electronics


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real-world conditions can minimize many potential problems.

Their copper connecting cables can be equipped with isolators. Unlike surge suppres-sors, which only try to limit spikes between the signal and ground line, isolators allow the lines to float while keeping the local side at the proper ground and signal level. USB connec-tions, which are becoming ubiquitous because of their usefulness, also have an unfortunate proclivity for permitting ground loops. They should be isolated as a matter of course.

Planning for downtimeOccasional glitches and communications

failures are a fact of life. After you’ve done your best to eliminate the potential problems caused by equipment failure, human error, solar flares, and pesky raccoons, it’s time to start planning for what will happen when commu-nications fail anyway.

You can solve many problems by placing enhanced intelligence and local decision mak-ing at the end point, rather than calling for unbroken connectivity with the central control-ler. Autonomy at the sensor’s end is a great way to get around connection glitches and varia-tions in bandwidth. Monitoring can be done in a “store and forward” scheme where the local sensor has the ability to store data and send/resend it as needed. That is becoming easier and easier to implement. Processors keep growing more powerful, yet their power requirements keep dropping. Sensors can now be equipped with powerful internal processors as well as sig-nificant quantities of internal memory. That’s a great substitute for perfect uptime.

One good example would be the U.S. Geo-logical Survey (USGS) mentioned earlier. The USGS monitors well and surface water condi-tions at sites all over the country and uses the data to make ongoing updates to its website. As you might expect, many of its sensors are deployed in very remote locations, and in places where there is no access to the power grid and no Internet infrastructure. Data communica-tions are handled by low-power radio transmit-ters. Because the transmitters have low power but must broadcast across large distances and overcome interference, there will be ongoing fluctuations in bandwidth and link quality.

Trying to achieve 100% uptime in such circumstances would be absurd. Instead, the sensors use localized intelligence to record and store data, and they send/resend until they are satisfied that the information has been passed along.

Redundant backhaulCable of one kind or another, with its built-in

security, bandwidth, and reliability, normally forms the basic infrastructure of an industrial LAN. But what happens if you’d like to estab-lish redundant backhaul and nudge your uptime rate that much closer to 100%? Cable instal-lations involve a lot of labor and materials; they aren’t cheap. If the main infrastructure is already wired, you might consider using wireless as the backup. (It’s what the tele-coms did while they were rebuilding their fiber optic networks in the aftermath of Hurricane Katrina.)

There are a number of ways to go about it, depending on what you need to accomplish. With advances in multiple-in, multiple out (MIMO) technology and associated develop-ments, Wi-Fi now has very serviceable range and bandwidth capabilities. It uses license-free frequencies, which presents a financial advantage, and it is inherently interoperable with off-the-shelf wireless network adapters, laptops, tablets, and even Smartphones. For many applications Wi-Fi would be a very cost-effective and uncomplicated way to establish redundant backhaul.

Wi-Fi does have range limitations. You’ll need another wireless option if you need to establish M2M communication over long distances and the connections must be under your own control. Companies like Conel, in the Czech Republic, specialize in enabling users to maintain data communications over the cel-lular telephone network. The packet transfer system lets users employ any station in the network as an end station or as a retranslation station, allowing for networks with complex topology and vast size. Data transfer can be encrypted, and the system will support your choice of protocols.

The technology is mature enough that 3G often serves as the backhaul for telecommu-nications and broadband services in countries like Belize, where a fiber build-out in difficult terrain like jungles and mountains would be far too expensive.

The goal of 100% connectivity remains elusive. But industrial-grade installations, alternative power, and redundant backhaul combined with smart sensors can get you very, very close. PE

Mike Fahrion, the director of product man-agement at B&B Electronics, is an expert in data communications with 20 years of design and application experience.

aUTOMaTIONSOLUTIONS

Monitoring remote assets via discrete analog and digi-tal sensors and controlling remote control equipment from a central SCADA/PLC can both be accomplished with a single compact, rug-ged unit. Courtesy: B&B Electronics

Each new application presents its own set of new problems. Sensors must function in a wide array of environments, and they must be able to report their data.


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MAINTENANCESOLUTIONS

Technology advancements are result-ing in electronics playing a greater role in the daily activities of busi-ness and manufacturing plants than

ever before. A direct effect of the addi-tional network and electronics is the grow-ing demand for connectivity and network equipment to be relocated from centralized data centers—where conditions can be care-fully monitored and controlled—to localized network and wireless applications, plac-ing them at the point of control or activity.This increases the potential for exposure to the often harsh manufacturing conditions or environmental elements. To accommo-date these changing needs, enclosure solu-tions have had to adapt to provide moreflexible and controlled access, enhanced protection, durability, and performance ver-satility.

As component size decreases, PCB den-sity increases, allowing more electronics and networking equipment to fit into small-er spaces. Now, control, networking, and security monitoring equipment that once filled full-size electronic enclosures eas-ily fit into a smaller enclosure that can beaffixed to a wall or mounted directly onto a machine—freeing up valuablefloor space.

Wall-mount cabinets allow manufacturers to safely store electronics where they are needed most, without exposing them to industrial con-ditions. However, these small, highly dense electronics generate a significant amount of heat. Therefore, the ideal wall-mount enclo-sure will offer thermal management capabili-ties, adapt to changing networking require-ments, and accommodate a wide variety of applications.

Smaller, more flexible enclosuresstill need to be ruggedCabinets allow for safe and accessible storage, but can generate dangerous heat.

By Brian MordickHoffman

Courtesy: Hoffman

PLE1211_MAINTSOL_V3msFINAL.indd 81 11/7/12 4:41 PM


Along with selecting enclosuresto complement equipment size and location, cabinet specifiers must also consider the application challenges and environmental conditions that can compromise an enclosure’s integrity. Exposure to extreme temperatures, corrosive agents, or impact can dam-age enclosures.

Wall-mount enclosuresWithin industrial facilities, floor

space is valuable, and many companies measure productivity and efficiency by dividing the amount of floor space by dollars generated. Consequently, install-ing a full-size electronics enclosure can take up valuable floor space that could otherwise be designated for equipment or machines and becomes detrimental to plant productivity. Wall-mount cabinets house and protect a variety of electron-ics and networking devices, convenient-ly mounting on walls or machines.

To accommodate the demand for net-working flexibility, wall-mount enclo-sures can be used to extend the data cen-ter via intermediate distribution frame (IDF), which further supports remote access points (AP) for wireless appli-cations. An IDF is a free-standing or wall-mounted rack used to manage and interconnect cables between end-user devices and a main distribution frame (MDF).

AP applications utilize dedicated hardware devices that act as a central transmitter and receiver for wireless sig-nals. By supporting both IDF and AP networking applications, wall-mount

enclosures aid in extending networks to remote locations to handle a broad scope of activities, such as industrial controls, access control, HVAC, monitoring, secu-rity/cameras, communications, building automation systems, and more.

When selecting the ideal wall-mount solution, users should take multiple factors into consideration, such as space limitations, enclosure size, cable management, and any thermal issues. Wall-mount cabinets should provide easy access to equipment. For instance, single-door cabinets offer a cost-effec-tive solution for protecting, securing, and cooling a host of equipment, while double-hinged door cabinets facilitate easy front and rear equipment access, enhancing access to cabling and reduc-ing time to install and connect system components.

Wall-mount cabinets are available in standard sizes and with custom options to support all types of networking and industrial electronics—both 19-in. rack-mounted and traditional back panel mounted. In addition to the enclosure size, users must also consider how far the cabinet will extend from the wall or machine on which they intend to mount the unit. To avoid collisions in public aisle ways, cabinets should typically extend less than 12 in., but requirements can vary depending on application.

Cable managementCable management is a crucial aspect

in cabinet selection. Proper, efficient cable management provides organization and support. For applications requiring

mAINTENANCESOLUTIONS


Ideal wall-mount enclosures will offer thermal management capabilities andaccommodate a wide variety of applications. Courtesy: Hoffman

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a simple solution, cable knock-outsallow cables to easily enter and exit the cabinet. Alternatively, in demand-ing applications where the enclosure’s rating integrity must be maintained, gland plates, which are removable sections of the enclosure, offer an outlet for cable egress. Gland plates not only provide cable management without compromising the enclosure, but they also accommodate evolving network needs by allowing cables to be frequently changed or added.

Along with providing environment protection and management for cables entering or exiting a cabinet, internal cable organization minimizes stress points while still supporting frequent cable moves, additions, and changes (MACs). To accommodate these needs, wall-mount enclosures contain vertical and horizontal cable managers. This allows the cabinet to support all cat-egories of networking cables, providing flexible cable management capabilities.

Thermal management is another critical factor when selecting enclosure solutions. Electronics and networking equipment generate heat, requiring ther-mal management to protect components from overheating. Ranging from simple, passive cooling to complex solutions, thermal management capacities should correspond to the amount of heat gener-ated by equipment being housed. The most advanced wall-mount cabinets combine protection, support, and access with integrated thermal management for a comprehensive enclosure solution.

Enclosure materialsProtecting electronics and equip-

ment from harsh industrial conditions requires enclosure and cabinet solutions that isolate and secure devices and con-nections from the surrounding environ-ment. Non-metallic enclosure solutions provide rugged durability and enhanced longevity for applications repeatedly exposed to caustic chemicals or tem-perature changes, offering an alternative to traditional steel enclosures.

Two prevalent non-metallic options include fiberglass and polyester. Also, non-metallic cabinets allow Wi-Fi sig-nals to freely exit, protecting the equip-ment without impeding signals.

FiberglassFiberglass is a common non-metallic

material used in networking applica-tions, due to its capacity to resist chemical exposure and extreme tem-perature changes—providing a cost-effective alternative to stainless steel for corrosive environments. Com-posed of a high-performing, engi-neered composite resin, fiberglassenclosures are typically formed in one of two ways: compression molding or spray-up process.

Compression molding incorporates precision-designed molds to deliver superior part uniformity and material consistency, and utilizes a material known as SMC, which is a long-glass-fiber pigmented polyester resin. These long fibers provide superior strength and, when formulated with UV inhibi-tors and aluminum trihydrate, they resist material degradation.

Further, this combination enables the enclosure to achieve the UL 94 5V flam-mability rating, which classifies the rate of burning, time to extinguish, ability to resist dripping, and whether or not the drips are burning. This rating is the highest performance requirement for a UL 508 enclosure.

The second method of fiberglass enclosure forming, the hand lay-up or spray-up process, also delivers similar advantages. The molding used in this process also ensures part uniformity and material consistency, as well as achieves the UL 94 5V flame-resistance rating. Plus, its heavy, unfilled pigmented outer gel coat layer provides rugged protec-tion against environmental contami-nates or exposure.


Q: How does your plant maintain continual network function, improve overall efficiency, and increase productivity?


INTERACT


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PolyesterThe use of hybrid polycarbonate/polyester blends for non-

metallic enclosures is a relatively new development. Pro-viding an alternative to traditional non-metallic enclosures, its thermoplastic material delivers high impact resistance, enhanced electrical properties, and superior chemical and moisture resistance.

Unlike fiberglass enclosures, which eventually break under extreme pressure, polyester is engineered to absorb tremendous amounts of pressure without shattering. With its inherent durability, polyester is also less susceptible to scratches and abrasions. Featuring flame-retardant properties,

mAINTENANCESOLUTIONS

Cabinet design must address the application challenges and environmental conditions of the space. Courtesy: Hoffman


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polyester performs well in extreme temperatures andwill not ignite when in contact with fire. Further, poly-ester’s corrosion and chemical resistance enables these units to withstand the highest range of solvents, alkalis, and acids without failure.

Additionally, since polyester produces virtually no dust, it can be easily drilled and punched for holes and cutouts—even in the field—without contamination. By lacking glass par-ticles, polyester is not susceptible to fiber bloom, minimizing the risk of product contamination and skin irritation, as well as reducing wear on tools. Plus, constructed of recyclable, thermal molded components, polyester is an eco-friendly enclosure material.

ConclusionBy understanding the available enclosure options, their

advantages and performance capabilities, cabinet speci-fiers can select the ideal solution to perform in virtu-ally any application, from limited spacing to damaging environments. Implementing the proper enclosure is instrumental in maintaining continual network func-tion, which, in turn, improves overall efficiency and productivity. PE

Brian Mordick is senior product manager for the Hoffmanbrand of Pentair Technical Products.


input #40 at www.plantengineering.com/information86 • November 2012 plant engineering www.plantengineering.com

Using apps for monitoringand control

A different approach for using Smart-phones and handheld devices to moni-tor and control operations remotely involves the use of apps specifically designed for these devices. Extremely economical, with some costing as little as five dollars, Smartphone apps can be an optimal method for accessing data. Some of these apps may offer the ability to view and control operations as if the user were in the control room in front of the HMI screen. However, as with the VPN/Web browser combination, care must be taken.

To create fully functioning remote monitoring apps for Smartphones, devel-opers must increase hardware, software, and protocol per-formance levels to reduce the latencies that can occur over remote connections. If not, users can become frustrated by slow or poor per-formance. To opti-mize performance, developers must also reduce the amount of data transfer from the automation compo-nents, typically HMIs and controllers.

When done correctly, using an app to access data via a Smartphone can be very cost-effective and reliable. Joel Froese, owner/operator of the Red Bank Hydro Plant in Columbia, S.C., uses his Smartphone for remote access as depicted in Image 2. “I can access data anytime and anywhere to ensure I have optimal operating conditions. I can start or stop the plant just as if I were stand-ing in front of the HMI. The screens are scaled correctly, safety features are included, and I can quickly access the data I need.”

Not only is app access often supe-rior in terms of performance, but it’s also easier to load. Browser access via a Smartphone requires a user to load up the browser, then enter the address

and wait for a screen to load. By con-trast, app access is much quicker and requires fewer steps. Finally, app access typically requires much less IT support than VPN/Web browser remote access.

Security issuesJust as with implementing a wireless

remote monitoring system, new security measures must be implemented when accessing sensitive data via a Smart-phone or handheld device. Regardless of whether a Web browser or Smartphone app is used, remote access must be pro-tected from unauthorized personnel, and access levels must be controlled.

Methods and technologies exist to make remote wire-less connections more secure. These security measures are similar to those used for other wireless communi-cations: encryption, password authoriza-tion, and device iden-tification.

The required secu-rity settings and pro-cedures can be too time-consuming or difficult for some plant managers and control engineers. To a l levia te th is situation, neophyte users should select

a company that provides a high level of service, and has a deep under-standing of both the security require-ments and the technologies needed to make access via handheld devices feasible and smart.

Not every manufacturing plant will employ the same remote monitoring systems, as each system has its own pros and cons, and as each plant has different needs. But regardless of the type of access used, remote monitoring will become more the norm as tech-nologies advance and as the need to accomplish more with fewer resources continues. PE

Greg Philbrook is HMI/Communica-tions product manager for Automation-Direct.

aUTOMaTIONSOLUTIONS

Everyday, more companies are using mobile devices to cut costs and to com-municate information

economically and quickly. While many manufactur-ers are enabling remote access via Smartphones

and other handheld devic-es, implementation isn’t quite as simple as check-

ing e-mail online.

Continued from pg. 75


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MECHANICALSOLUTIONS

Maintaining proper oil quality is essen-tial for satisfactory operation and longevity of oil film bearings. Oil discoloration is a sign of potentially

harmful contamination or degradation. There are three main causes of oil discoloration in oil film bearings: particulate contamination (external and internal), liquid contamination, and oxidation. Each cause has some unique characteristics, but discoloration is often a combination of the three.

Particulates, external and internalExternal particulate contamination refers to

particles that are ingested from the surround-ing environment. In an oil film bearing there is a radial clearance between the bearing liner and shaft to allow for shaft movement as the

oil film develops. There are also axial shaft movements due to thrust loads and shaft expan-sions/contractions.

These shaft movements, inherently, make completely sealing the bearing around the shaft a challenge. Without special sealing, small particulates in countless forms (lime and coal dust, sand/silicon, soot, metal chips, etc.) can work their way into the bearing and discolor/darken the oil.

During maintenance and installation, when the bearing housing is open, the bearing is exposed to large scale particu-late contamination. For this reason it isrecommended to thoroughly clean and flush the bearing with clean oil after it hasbeen opened.

In addition to particulate contamination coming from external sources, there are inter-nal sources of particulate contamination that come from inside the bearing. To begin with, there will naturally be some wear particles generated each time a hydrodynamic bear-ing is started or stopped. These wear particles are created when the shaft is rotating below the minimum speed required to develop a full oil film. Without a full oil film, the shaft rubs against the white metal (babbitt) in the bearing liner. This is commonly referred to as boundarylubrication.

The babbitt is a soft metal alloy designed to protect the shaft and will generate wear par-ticles primarily in the form of tin, lead, and antimony. The babbitt also protects the shaft by embedding contaminates, but this has its limitations. If particulates are too large, they will not fully embed in the babbitt and will begin to score the shaft.

A large concentration of small particles can also build up in the babbitt and lead to shaft scoring. Shaft wear particles (iron, chromium, etc.) will then further contaminate the oil and propagate the wear. Internal wear particles, just

Particulates, liquids, oxidation contributeto oil contaminationOil discoloration should be addressed with high

importance for optimal operation performance.

By Andrew MyersBaldor

Three oil contamination examples: The left-most sample contains a new premium grade industrial mineral oil — no contami-nation. The center sample contains the same oil grade after five years of inter-mediate service in an oil film bearing with minimal external contamination. The oil is notably darker and has visible metallic particles suspended. The last sample con-tains the same oil grade with water con-tamination. Notice the cloudy appearance. Courtesy: Baldor

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like external particulates, willgenerally cause the oil to darken.

Shaft surface finish plays a critical role in controlling the amount of wear developed dur-ing starts and stops. Minor scor-ing, pitting, or sharp edges on the shaft should be smoothed out as much as possible. For most applications, shafts should have a surface finish of 32 micro in. or better.

Iron wear particles may also be generated in the contact areas between the bearing housing and liner. A minor amount of con-structive wear in these areas can be expected when a new housing or liner is installed and the new surfaces mate or “seat” together.

However, if the liner is not clamped securely in the housing, or if there is vibration in the system, the contact surfaces can begin to abnormally wear or fret and produce iron particulates. A visual inspection of these contact areas

for wear should be performed during rou-tine maintenance to rule out this source of contaminates.

Oil rings and seals are other sources of internally generated wear. Oil rings, usually made of bronze, rest freely on the shaft and can rub against the oil ring grooves and produce copper and tin

particles. However, during operation, oil rings are continu-ously coated in oil and should not cause significant wear. Shaft seals come in many different configurations and materials including aluminum and nitrile elastomer. A well-designed shaft seal, if properly installed and maintained, should not gener-ate significant amounts of wear particles.

One last source of internal par-ticulate contamination is actually from new oil. Studies have been conducted to show that new oil can contain a large quantity and wide variety of contaminates

ranging from metallic wear particles to large organic debris. It is a good practice to filter the oil using a 10 µm, or finer, fil-ter before ever pouring it into the bearing. If a circulating oil system is to be used, then the standard practice is to filter the new oil with a finer filter than the filter used in the circulating oil system.

mechanicalSOLUTIONS

Oil film bearings can be found in just about every typeof industrial environment and are therefore exposed tocountless forms of contaminates. Courtesy: Baldor

PLE1211_MECHSOL_V6msFINAL.indd 90 11/8/12 9:32 AMPLE121101-MAG_Ads.indd 90 11/8/2012 12:28:08 PM



Q: How often are you checking on the oil quality for your systems? How often SHOULD you check it?

INTERACTLiquids

Liquid contaminates are simply con-taminates in the liquid state. The most common liquid contaminate in oil film bearings is water. Water or water vapor, just like external particulates, may enter the bearing through the clearances around the shaft seals and migrate into the oil. The presence of water in oil will make it appear cloudy or milky in appearance.

Water has many harmful effects in bearings including rust/corrosion, accel-erated oil oxidation, depletion of oil additives, and dilution of oil viscosity properties. Too much water can degrade the oil properties to a point to which the oil film will not develop at all. For these reasons, it is recommended to keep the water content less than 500 ppm (1,000 ppm maximum).

Other forms of liquid contaminates can be cleaners, lubricants, assembly chemicals, assembly greases, process chemicals, and detergents. These can cause a wide range of oil discolorations and changes in chemical composition.

Care should be taken to prevent these contaminates from entering the bear-ing, and extra precautions should be in place to ensure that oils are not mixed during installation or during routine oil checks/refills.

The same oil used for lubrication (during operation) should also be used for cleaning and assembling. Simply knowing the color of the correct oil is an important step in preventing and identifying this type of contamination.

OxidationOil oxidation is one last source of oil

discoloration. Oil oxidation is a process of chemical degradation that naturally occurs in oil over time when it is exposed to air. Some of its by-products are sludge, varnish, and acid, which cause the oil to thicken and darken. Higher temperatures (above 160 F for mineral oils) accelerate oxidation, as well as other contaminates such as water, iron, and copper. Synthet-ic oils are available which have better oxidation resistance than conventional

oils and can be considered to extend oil change intervals.

Oil analysisThere are many types of oil analysis

tests available today. The most informa-tive tests for oil film bearings show oil viscosity, water content, total acid num-ber (oxidation indicator), and parts per million for each contaminate type. Due to reasons described previously, some




small (less than 10µm) particulate is tobe expected under normal operation; therefore, keeping a trend of particle count is more helpful than a single par-ticle count for assessing bearing perfor-mance. A spike in particle count during steady operation (few starts and stops) is indicative of external contamination

or abnormal wear. Particles of 10µm or larger are on the same magnitude as the oil film thickness, and should be kept to a minimum in order to prevent abnormal wear.

A very practical tool for analyzing oil samples in the field is an oil patch test kit. An oil patch test can be used to

get quick test results of the contamina-tion level in the oil without waiting for results from a laboratory.

In addition to oil sampling, monitor-ing the bearing operating temperature can detect changes in oil conditions. High levels of contamination and deg-radation result in increased friction and oil film breakdown, which will lead to a rise in operating temperature.

Oil typeThe recommended oil for oil film

bearings is a premium grade, industrial mineral oil or turbine oil, with rust and oxidation inhibitors and anti-foaming agents. Extreme pressure (EP) addi-tives are not recommended. Oil vis-cosity is determined individually for each application and is based on bear-ing clearances, loads, temperatures, and speeds. For units operating in hot or cold climates, synthetic oils can be considered which will not thicken as much at low temperatures and which will have better oxidation resistance at high temperatures.

ConclusionOil discoloration in oil film bearings is

a visible indication of oil contamination or degradation. Contamination comes in two main forms: particulates and liquids. Particulates can either be ingested from the environment or come from inside the bearing. Liquid contaminates can come from the environment, but they can also be inadvertently added to the bearing in the form of incompatible cleaners and lubricants.

Oil degradation will naturally occur over time through oxidation. Regard-less of the source, significant oil dis-coloration should be addressed with high importance. Slight discoloration does not necessarily indicate a problem. The lubricant supplier ultimately determines the acceptability.

Oil is the lifeblood for oil film bear-ings, and maintaining proper quality through regular oil replacement and analysis will greatly increase the lon-gevity and reliability of the bearings. PE

Andrew Myers is a Baldor appli-cations engineer for Dodge Sleeve Bearings.

mechanicalSOLUTIONS


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PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.

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Veterans can deliver skills to manufacturing

Last month’s launch of the Get Skills to Work program by the Manufactur-ing Institute and four major American manufacturers is to date the highest

profile attempt by American manufactur-ing to bridge its ever-widening skills gap. Its stated goal is to link the hundreds ofthousands of existing and projected American manufacturing jobs to the t ide of mili tary personnel returningfrom wars in Asia or from the end of their tours of duty.

The link between veterans and manu-facturing is the key to the program, and so the first four companies to sign up—Alcoa, Boeing, GE and Lockheed Martin—fully understand the relation-ship between a strong military and a strong manufac-turing environment. They also see the strong connection between the two, especially at this pivotal time in manufacturing. All have a long tradition in American manufacturing; all of them also are major defense contractors or suppliers.

There is an unquestioned need for skilled manufacturing workers, and enlisting military personnel is both a strong political and stra-tegic move. Reaching out to reemploy veter-ans in the private sector after their service to their country was completed has long been a patriotic concept. More than at any time since World War II, Americans value the service of our military personnel, and this program is yet another attempt to recognize and honor that service.

American military personnel are trained on some of the world’s most sophisticated equipment. They understand discipline, commitment to hard work and an abil-ity to apply critical thinking to solve prob-lems. This skill set is exactly what manymanufacturing employers want and need as they address a technological evolution inmanufacturing. Plant managers need this kind of skill set to be able to remaincompetitive in a global manufacturing envi-ronment.

“Veterans offer the technical, leadership and critical thinking skills that advanced manufac-turing demands,” said Paula Davis, president

of the Alcoa Foundation, in a press release announcing the formation of the coalition. “Forming the Get Skills to Work coalition and coordinating with nonprofits to train, recruit and develop veterans is an exciting model that has the potential to change lives and produce a significant competitive advantage for U.S. manufacturers.”

The timing of this announcement comes as wars are winding down in Afghani-stan and Iraq and military personnel will be returning to civilian life. Get Skills to

Work estimates that one million vet-erans will leave the Armed Forc-

es over the next four years,while 600,000 high-tech manu-

facturing jobs remain unfilled.

The return to civilian life from the military often is

not easy. No one associated with the program underestimates that

reality. We also can see the value of worker in our manufacturing ranks. For those who may struggle with what to do on their return from military service, Get Skills To Work offers a tangible direction and a clear path to the future.

Manufacturing needs this influx of skilled talent. Manufacturing leaders need to deliv-er the same level of service to our return-ing veterans that they have delivered to us during their time in the military. We would have this obligation even if there were not a skills gap. The fact that one exists is allthe more reason to get moving on this initia-tive today.

The roster of manufacturers involved in Get Skills to Work current stands at four. I expect that roster to grow rapidly. But even without the formal involvement in thisprogram, manufacturers around the country can and should tap into this resource without delay.

Our soldiers are coming home, and a warm greeting and a parade is one way to welcome them home. But after the parade is over, let’s make sure we have a job training program and a job in manufacturing wait-ing for them. It’s good for manufacturing, it’s good for our veterans and that has to begood for America. PE

Bob VavraContent Manager

Manufacturing leaders need to deliver the same level of service to our returning veterans that they have delivered to us during their time in the military. We would have this obligation even if there were not a skills gap.

INCONCLUSION

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YA S K AWA A M E R I C A , I N C .D R I V E S & M O T I O N D I V I S I O N

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©2012 Yaskawa America Inc.

WHAT YOUALWAYS WANTED

Our customers tell us that quality means no product hardware failures. Now, that’s a gift that keeps on giving.

When you take Yaskawa drives out of the box, you can count on them to work. In fact, Yaskawa products have a meantime-between-failure rate (MTBF) of up to 28 years. That means your engineers can spec Yaskawa and never have to worry. Just program, plug and play.

Get what you want, every time. Call Yaskawa.



DC On Demand

• The Most DC Choices

• Unmatched Quality

• Superior Reliability

• Quickest Delivery Available

• American Made Since 1920

While other manufacturers have chosen to leave the DC motor market, ABB and Baldor continue to invest in product development and U.S. manufacturing in order to offer the widest variety of permanent magnet and wound field industrial DC motors in the world. DC motors continue to provide the right solutions to many application requirements. We now can supply IEC or NEMA frame motors, stock motors from 1/50 to 500 Hp or custom-designed motors to 3000 Hp to meet your specific application. If you need a DC motor anywhere in the world, call Baldor!

baldor.com 479-646-4711

©2012 Baldor Electric Company

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