Don`t risk lives, reliability and profits just to save a

Transcription

WWW.PLANTSERVICES.COM
PERFORMANCE | RELIABILIT Y | EFFICIENCY | ASSE T MANAGEMENT
Dare to compare
air compressors
Flooring safety:
no skidding matter
How to ruin fan bearings
RE
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PERFORMANCE | R
Rise above firefighting
CO2 is not the only
greenhouse gas
J A N UA RY 2 0 0 8
Don’t risk lives, reliability and
profits just to save a buck
PS0801_01_Cover.indd 1
1/10/08 2:17:36 PM
L/C
1
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11:53:39 AM
Something New is in the Air...
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1/9/08 11:53:48 AM
‘Good enough’ flowmeters are cutting into
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©2007. Micro Motion, Inc. All rights reserved. The Emerson and Micro Motion logos are respective trademarks and service marks of Emerson Electric Co. and Micro Motion, Inc.
1/9/08 11:54:00 AM
Volume 29, Number 1
features
28
COVER STORY
Counterfeits can kill
Don’t risk lives, reliability and profits just to save a buck
34
COmpRESSORS
Dare to compare air compressors
Knowing operating characteristics and physical limitations will
help you select the best machine for your plant
39
FlOORing
No skidding matter
There is science behind preventing slips and falls
42
pOwER TRanSmiSSiOn
How to not ruin fan bearings
Five tips for installing and maintaining fan bearings to achieve
long-term reliability
specialists
23
aSSET managER
Rise above the
firefighting fray
Use people skills and your
CMMS to build a solid strategy
for management excellence
26
45
SMRPSURVEY
54
TEChnOlOgY TOOlbOx
Smaller and
self-powered
columns and departments
TRIMTURNOVER,INCREASEPROFIT
9
CHOOSETHERIGHTSEALS
Proper application of these principles can improve the life, dependability and operation of your process and mechanical machinery.
www.PlantServices.com/articles/2008/006.html
This paper describes why North America’s largest manufacturer and remanufacturer of transformer oil pumps retrofits
all ball bearing pumps with pump-specific bronze sleeve type
radial/thrust bearings and hardened steel thrust collars.
www.PlantServices.com/whitepapers/2008/001.html
January 2008
PS0801_05.indd 5
Business as usual?
13
Change only happens if you
want it
Contributing Editor Tom Moriarty explains what it takes to attract and
keep qualified workers, and how employee retention rates affect companies’ profitability. www.PlantServices.com/articles/2007/247.html
WHITEPAPER:TRANSFORMEROILPUMPRETROFITS
FROm ThE EDiTOR
10
lETTERS
• Manufacturing infrastructure is deteriorating
• Joined the maintenance
evangelists army • No
shortage of quality fade
in manufacturing • Author
provided a straightforward
look at VSD • Reasons for print
preference
planTSERViCES.COm
Top Web destinations
of 2007
Users are on a constant
search for information
www.PLANTSERVICES.com
EnERgY ExpERT
2008: The year
of energy
integration?
Combining forces leads to
breakthroughs in energy
productivity
plantServices.com
The
Society for Maintenance and Reliability Professionals (SMRP)
invites you to review the body of knowledge that practitioners master
to become certified as maintenance and reliability professionals
(CMRP). Offer your input via Internet survey, where you can rate and
comment on job tasks necessary for competence in maintenance and
reliability practice. Access the survey at www.smrp.org/BoKsurvey.
www.PlantServices.com/industrynews/2008/004.html
7
The power of
element number six
Carbon is a common, but not
the only, greenhouse gas
Watch for these advances
to come to a predictive
maintenance operation in
your town
PlantServices.com
wEb hunTER
ThE pS FilES
In adversity comes
opportunity
Recession or not, there are
bright spots in manufacturing
15
up anD Running
• “Super Boiler” technology
passing the test • Industry
briefs • Resources
48
in ThE TREnChES
Removing the thorn
Acme learns a lesson about
its strategy for paying off a
leveraged buyout
51
pRODuCT piCKS
52
ClaSSiFiEDS
53
FaST FaCTS
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1/11/08 1:41:10 PM
FROM THE EDITOR
mike brenner , group publisher
mbrenner@putman. net
editorial staff
paul studebaker , cmrp
editor in chief
[email protected]
russell l . kratowicz , p. e. cmrp
executive editor
lisa towers
managing editor
[email protected]
[email protected]
michael ermitage
[email protected]
dan hebert, p. e.,
[email protected]
stephen c. herner
[email protected]
senior web editor
senior technical editor
group art director
jennifer dakas
art director
[email protected]
david berger , p. eng.
contributing editor
peter garforth
contributing editor
sheila kennedy
contributing editor
joel leonard
contributing editor
r. keith mobley, cmrp
contributing editor
ricky smith, cmrp
contributing editor
publication services
carmela kappel
[email protected]
jerry clark
[email protected]
assistant to the publisher
v. p., circulation
jack jones
circulation director
rita fitzgerald
production manager
[email protected]
[email protected]
claudia stachowiak
Foster Reprints
[email protected]
reprints marketing manager
(866) 879-9144 ext. 121
administrative staff
john m. cappelletti
president/ceo
julie cappelletti - lange
vice president
keith larson
rose southard
v. p., content
it director
PLANT SERVICES (ISSN 0199-8013) is published monthly by Putman
Media, Inc., 555 West Pierce Road, Suite 301, Itasca, IL 60143. Phone
(630) 467-1300, Fax (847) 291-4816. Periodicals Postage paid at
Itasca, IL and additional mailing offices. Canada Post International
Publications Mail Product Sales Agreement No. 40028661. Canadian
Mail Distributor Information: Frontier/BWI,PO Box 1051, Fort Erie,
Ontario, Canada, L2A 5N8. Printed in U.S.A. POSTMASTER: Send
address changes to PLANT SERVICES, Putman Media, Inc., PO
Box 3435, Northbrook, IL 60065-3435. SUBSCRIPTIONS: Qualified
reader subscriptions are accepted from PLANT SERVICES managers,
supervisors and engineers in manufacturing plants in the U.S. and
Canada. To apply for qualified-reader subscriptions, please go to
www.plantservices.com. To non-qualified subscribers in the U.S.,
subscriptions are $96 per year. Single copies are $15, except the
August and October issues which are $36. Canadian and foreign
annual subscriptions are accepted at $145 (Foreign airmail $200/
yr). Single copies are $81. © 2008 by Putman Media, Inc. All rights
reserved. The contents of this publication may not be reproduced
in whole or in part without consent of the copyright owner. In an
effort to more closely align with our business partners in a manner
that provides the most value to our readers, content published in
PLANT SERVICES magazine appears on the public domain of PLANT
SERVICES’Website, and may also appear on Websites that apply to our
growing marketplace. Putman Media, Inc. also publishes CHEMICAL
PROCESSING, CONTROL, CONTROL DESIGN, FOOD PROCESSING,
INDUSTRIAL NETWORKING, THE JOURNAL, PHARMACEUTICAL
MANUFACTURING and WELLNESS FOODS. PLANT SERVICES assumes
no responsibility for validity of claims in items published.
January 2008
PS0801_07_Editorial.indd 7
Business as usual?
Change only happens if you want it
I
ter all, they’re paying for it.
’m old enough to think widespread
Established habits are tough to
use of bottled water is a recent and
break. At the start of this election year,
unnecessary phenomenon, so I
there’s more than the usual amount of
was heartened when the City of Chitalk about change, but talking, encago levied a five-cent-per-bottle tax,
couraging – even demanding – are
effective January 1. Mayor Richard
puny tools when you’re asking people
Daley stood by the stalwart managers
to behave differently.
of the city’s water works and sanitation
However, new habits
departments and spoke
are easy to make if you
of the excellent quality,
Talking,
like them enough. We’re
widespread availability
encouraging –
certainly going to need
and low cost of Lake
Michigan-sourced, lov- even demanding new habits to help solve
energy, environmeningly treated and reliably
– are puny tools the
tal, economic, staffing,
pumped tap water, and
when you’re
security and multitude
the excessive costs in both
asking people
of other problems facing
dollars and the environindustrial facilities.
ment for manufacturing,
to behave
Our new year’s resohauling and dealing with
differently.
lution is to introduce
the trash associated with
you to good new habits.
water bottles.
We’ll do a better job than ever of show“Score one for common sense,” I
ing you ways to improve your working
thought. “Surely people will see the
world. We’ll do it on the Web, in print
wisdom and want to help save the
and in person, and we’ll do it with the
world with the small sacrifice of rehelp of the best people in the field: our
turning to delicious tap water.”
readers and site visitors, our contribuNaive and silly me. Within days of
tors and experts, our professors, sponthe Chicago law taking effect, food and
sors and consultants. Maybe you.
beverage special interests filed lawsuits
If you believe that a strong and steady
claiming the tax is unconstitutional
flow of high-quality know-how and inand unfair. I think their real concern is
spiration can make a difference, think of
people being reminded of an environus as being on tap, and see if you don’t
mental effect at the store and foregoing
pick up some good new habits.
the purchase. But if they succeed, the
effect will be the same either way: business as usual.
And if they don’t and the tax
stands, will bottled-water chugPAUL STUDEBAKER, CMRP
gers change their habits? I doubt it
EDITOR IN CHIEF
– they’ll simply feel more justified in
[email protected]
their environmental stance since, af(630) 467-1300 ext. 433
1/11/08 11:19:43 AM
C o n s u l t i n g S e r v i c e s • C o m p r e s s o r P r o d u c t s • C l e a n A i r Tr e a t m e n t P r o d u c t s • C o n t r o l P r o d u c t s
The best energy efficiency.
Period.
The true measure of compressor efficiency is how much air
comes out per kW of energy that goes in. It's called specific
performance.
Compare our specific performance to the competition and
you'll find yet another clear reason to choose Kaeser. Our new
100 to 250 hp DSD series is in a class by itself.
But don't just take our word for it. The Compressed Air &
Gas Institute's (CAGI) performance verification program
independently confirms the information published on our CAGI
datasheets.
To learn more about Kaeser value and “built for a lifetime”
engineering, call us toll-free or visit www.kaeser.com/sigma.
COMPRESSORS
[email protected]
(866) 516-6888
Kaeser Compressors, Inc., P.O. Box 946, Fredericksburg, VA 22404 USA
Built for a lifetime is a trademark of Kaeser Compressors, Inc. ©2008 Kaeser Compressors, Inc.
1/11/08 1:41:22 PM
BACKTALK
Manufacturing infrastructure is deteriorating
T
hank you, Joel Leonard, for your
column “How are you fighting the
Crisis?” (November 2007, page 25,
www.PlantServices.com/articles/2007/223.
html). As an engineer for General Motors, and now Hewlett-Packard, I’ve seen
a significant deterioration in manufacturing infrastructure during the past
25 years. The pressure to cut costs by
eliminating products and people are
merely reactionary measures to systemic problems. To use operations as
a competitive advantage has significantly higher ROI, but requires long-term
vision and leadership.
PERF
ORMA
NCE
| REL
IA
As a compadre in the training industry, I just wanted to say
that I thought your recent article, “How are you fighting
the Crisis?” was very thought-provoking. We (and industry)
need to see more articles like this. I, too, am a member of
the maintenance evangelists army.
Robert M. Dombek, electrical trades program manager
National Technology Transfer, Inc., Englewood, Colo.
No shortage of quality fade in manufacturing
I recently read Paul Studebaker’s article “Quality fade,”
(September 2007, page 9, www.PlantServices.com/articles/
2007/197.html) and I share your views that quality fade
isn’t exclusive to China. I believe this is being practiced
throughout the manufacturing sector in the United States.
I have more than 18 years working experience on many
different products, which include sheet metal, gears, plastic and bearings in Southern California. I have seen many
subcontractor manufacturers chose to outsource many of
these jobs to sub-tiers because they’re able to produce the
parts with less vigilance.
Many of these sub-tiers are only qualified based on quality surveys, which are fi lled out and then reviewed by someone in quality, that their facility meets the intention of ISO
9000. In many cases, the subcontractors don’t have the resources to audit the sub-tiers, as long as their products are
shipped to the subcontractor on time and with no quality
problems. Many of these subcontractors impose the right
to visit the sub-tiers’ facilities, but never follow through because sub-tiers are able to produce the parts for less. The
PS0801_09_Backtalk.indd 9
BILIT
Y | E
FFIC
IENCY
| ASS
E
T MA
NA
plan tser
vices.
GEME
com
NT
Stephen J. Duey, engineer
Hewlett-Packard Company, Ft. Collins, Colo.
Joined the maintenance evangelists army
J 
Leadership in the MBA programs involves financial maneuvers and maximizing shareholder wealth as opposed to investing for solid
long-term growth. Most people in MBA
programs know nothing about how to make
anything, other than PowerPoint presentations. Because operations and infrastructure
aren’t as glamorous as investment banking, or
some other businesses, this area of the American economy will continue to deteriorate.
I have a BSEE, a MSEE in Solid State
Physics, and a MBA in Operations Management, all from the Big-10 schools.
www.
subcontractors are thinking that if they mess up the relationship with their sub-tiers, their on-time deliveries ratings
to their customers will be affected. This isn’t good news to
the investors and/or the subcontractors’ businesses.
Joe Barroso, quality control supervisor
Rancho Dominguez, Calif.
Author provided a straightforward look at VSD
I recently read Chris E. Beals’ article on www.Plant
Services.com, “A critical look at variable-speed-drive air
compressors” (October 2006, page 45, www.PlantServices.
com/articles/2006/278.html). His is the most straightforward article on the “spin” of VSD that I have ever seen in
my 30 years in this glorious business!
Rick Stein
Air Center, Inc.
Reasons for print preference
I have two reasons for continuing to receive your magazine
versus going on-line:
1. I work for a company that produces coated papers. We
also maintain sustainable forest practices, so we are maintaining our forests.
2. I like to thumb thru magazines when I’m away from
the computer/work. I spend a good portion of my day on the
computer and probably wouldn’t read your magazine on-line
if that was my only option.
So... keep cutting, planting and reading.
Les Pepper Jr., director maintenance training
International Paper, Jay, Maine
.PLANTSERVICES.
9
1/11/08 9:57:52 AM
PLANTSERVICES.COM
Top Web destinations of 2007
Users are on a constant search for information
P
lus ça change, plus c’est la même chose. – The more
things change, the more they stay the same, says
the proverb, originally coined by French novelist
Alphonse Karr. It’s terribly cliché nowadays, but, as I peruse our 2007 Web analytics for PlantServices.com, it floats
through my head. It seems that the more we change ourselves, the more predictable your Web behavior becomes.
Take a look at the site’s top five most visited URLs for 2007.
You may not be surprised, but you will find five links that
are extremely useful.
1. The Home Page
4. Digital Edition
Every monthly issue of Plant Services magazine is online as
a full digital edition. It presents everything you have in your
hands in the paper version, plus links to associated material on
the Web site. For example, if you’re reading this month’s “In
the Trenches” on our digital edition, you are one click away
from every “In the Trenches” we have published in the past
three years. Each print article that makes a reference to another article, or to an external reference site, has a live link in the
digital edition. Furthermore, you don’t have to go each month
to www.PlantServices.com to get the digital
edition – subscribe and we’ll send it to you.
It’s not
It probably doesn’t shock anyone that the most
surprising that
visited page on our Web site is our home page.
5. Best Practices Energy Wiki
our average
It serves as our table of contents and your inThe Energy wiki (www.PlantServices.com/
dex to a wealth of knowledge. While the main
visitor is on the wikis/best_practices_energy) wasn’t introportion of the page is dedicated to a cycling
duced until July, but still registered as one of
site for more
list of features, news, products and white pathe top five most popular destinations on our
than six minutes. Web site. It aggregates best practices for enpers, it’s the top and left navigation that provides the most value. It’s the gateway to the
ergy management, with primary sections covinformation you are seeking, it’s always up and running, and
ering energy efficiency, energy concerns and industrial enit’s easy to remember: www.PlantServices.com.
ergy sources. But, the direction of a wiki is entirely in your
hands – wiki technology allows you, as the user, to change,
edit and move content on the page. As a knowledge-sharing
2. Search Results Page
portal for our community, it’s as good as the participation,
Your peers like to search. It’s affectionately called, “The
and it allows you to share and learn from your colleagues.
Google Effect.” We are now trained to use search if we don’t
The common thread among these five popular items is that
immediately see what we are looking for, and the reason
they’re excellent Web starting points. From each of them,
we think that is because Google’s search algorithms have
you can tumble down a family tree of links that narrow and
served us well. PlantServices.com’s internal search has reexpand, as you choose, to give you exactly the information
cently been reengineered, and gives you the ability to sort
you are seeking. It’s not surprising that our average visitor
by date and relevance, as well as drill down by news, white
is on the site for more than six minutes, and many of our
papers, articles and products.
returning users spend more than 15 minutes a session.
To read more about what your peers are viewing, go to
3. CMMS Software Review
www.PlantServices.com/thismonth to get the top 10 most
If you’re looking to purchase a CMMS or learn more
popular items in each of the above categories for 2007.
about them, www.Plant Services.com/CMMS_Review
Please continue to peruse our content in any manner you
is the place to go. Fueled by the experience of CMMS exprefer, and feel free to comment on how we’re doing, either
pert David Berger and guided by working IT professionto me at the address below, or as a response on our blog at
als, the Review compares a variety of packages against a
www.PlantServices.com/plantperformance/?p=17.
comprehensive list of capabilities. You can use the tool to
do research, or even plug in your requirements and generate a score that tells you which vendor is the best fit.
E-mail Senior Web Editor Michael Ermitage at [email protected]
10
PS0801_10_PScom.indd 10
J 
1/11/08 11:38:21 AM
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PlantServices_0108_a320w.indd 1
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1/11/08 1:41:38 PM
KEN SChNEPf
THE PS FILES
In adversity comes opportunity
Recession or not, there are bright spots in manufacturing
I
f you were waiting for an official pronouncement
Midwestern manufacturers like Peoria, Ill.-based Caterpillar Inc. Strauss says that as a result of the expanding
about the state of the economy, it’s here: “Recession
in the U.S. ‘has arrived,’” the BBC News reported in
oil sands extraction business, the company is sold out on
early January, based on a study of economic indicators from
its heavy-duty 797B, the largest truck they manufacture.
“The companies that are buying these vehicles are able to
Merrill Lynch.
pay for them in about a month’s time with the return on
The economically chilling term crept back into the nainvestment,” he says.
tional consciousness around the time the U.S. mortgage
crisis began. Maybe we’re still in denial about it, for it’s not
Aviation is another hot field, and Chicago-based Boesomething that’s easy to accept for Americans who have
ing also is a manufacturer that “had a fantastic year and
been working harder and longer just to mainis booked out until the middle of the next
tain the status quo.
decade,” Strauss says. “They’re getting a lot
Whether you believe we’re in a recession or
Productivity has of foreign orders, though, and it’s softer for
not, one axiom certainly remains true: Crisis increased output U.S. business.”
– especially that of the economic kind – is a
silver lining to the economy is that
by 600% on 0% theOne
powerful motivator for change.
weakness of the dollar has helped U.S.
2008 promises to be a year of change on job growth since manufacturers. “Now that our currency has
many fronts, including economic, political and,
the post-World dropped about 22% from its peak, it makes
closer to home, manufacturing – and not all of
domestic goods less expensive,” Strauss says,
War II period.
it good. Layoffs, plant closings and outsourcboosting the market for exports.
ing aren’t news to anyone, but what impact will
“People think we haven’t been effective in
this latest economic news have on an already hard-hit sector?
creating manufacturing jobs, but growth has been steady at
William A. Strauss, senior economist and economic ad1%,” he says. “The number of jobs needed has been reduced
viser in the economic research department at the Federal
because we have become more productive.”
Reserve Bank of Chicago, is confident that the overall econU.S. manufacturing continues to show great output gains.
omy will continue to expand. Strauss analyzes the Midwest
Productivity has increased output by 600% on 0% job
economy and the manufacturing sector’s performance for
growth since the post-World War II period, beginning in
use in creating monetary policy. “We’ll still be weighed
1947. “We’ve driven inefficiencies out of production with
down by the housing sector, which many expect will modergreat technological improvements,” he says.
ate through 2008,” he says. “We’re looking for it to improve
To put the situation in context, “China has lost more jobs
and be less of a drag on the economy.”
in manufacturing than we have in manufacturing in the
The November 2007 Chicago Fed Midwest ManufacUnited States,” he adds.
turing Index (CFMMI) report backs up Strauss’ tempered
Jerry Szatan, founder and principal of Szatan Associates,
optimism. The CFMMI, which rose 0.5% in November, is
a business site selection and location strategy consulting
a monthly estimate by industry of manufacturing output
firm, says, “Even in a recession, not everyone is a loser. Not
in the bellwether manufacturing states of lllinois, Indiana,
every sector is seeing weakened sales. Companies are still
Iowa, Michigan and Wisconsin. The composite index of 15
investing in new opportunities.”
manufacturing industries uses hours worked data to meaMaybe recession is too harsh a term for many to swallow
sure monthly changes in regional activity.
when things aren’t as bleak as they seem. How are you feeling about the U.S. economy in general, and manufacturing
Despite what you might be hearing in the news about
in particular? Send me your thoughts.
the overall economy, there are several bright spots in
manufacturing. “Strength is in energy extraction,” Strauss
says. The oil sands market in Canada has been a boon to
E-mail Managing Editor Lisa Towers at [email protected].
January 2008
PS0801_13_PSfiles.indd 13
13
1/11/08 10:59:35 AM
From the most recognized manufacturers in industry to show
stoppers in arenas, nightclubs, and theatres, the CM Lodestar
is the brand of electric chain hoist that more workers trust.
For more than half a century, the CM Lodestar has tackled the
toughest jobs in the most stringent manufacturing environments
around the globe. In entertainment, many of today’s top
performers rely on the inverted CM Lodestar or “chain motor”
to delicately position lighting, scenery, and sound equipment.
The CM Lodestar has developed a following for its durability,
reliability, and ease of maintenance. With the introduction
of “next generation” features, the CM Lodestar
solidifies its reputation for years to come.
Quick Change Voltage Conversion Board – Takes
only seconds to move from low to high voltage.
Color Coded Jumper Harness – Permits easy
identification of functions and voltage.
All Electrical Components are “Finger Safe” – Helps
prevent accidental electrical exposure to repair
personnel during routine maintenance.
New Robust Control Pendant – Provides reliable
performance – Nema 4X suitable for outdoor use.
For complete information, visit www.cmindustrial.com
or call us at 800-888-0985
1/9/08 2:21:47 PM
UP AND RUNNING
‘Super Boiler’ technology passing the test
Three sites get positive results with more testing planned this year
“S
uper Boiler” technology is
up and operating at three
locations with the hopes of
adding additional sites before commercialization of the process in 12 to
18 months.
Successful operation of the technology for more than one year at Specification Rubber Products, Inc., a subsidiary of American Cast Iron Pipe
Company, in Alabaster, Ala. was recently recognized by the U.S. Department of Energy (DOE).
“It has operated virtually troublefree for the past 18 months and we’re
recognizing a savings in gas of about
13%,” says Philip Robertson, president, Specification Rubber. “Also,
we’re using considerably less water. It’s
been a very successful venture for us.
It’s doing what they said it would do
and saving us money.”
The Super Boiler can reportedly
deliver better than 94% thermal efficiency, while at the same time producing fewer pollutants than conventional boiler technology. By 2020, the
technology could save more than 185
trillion Btu, estimates DOE. This is
equivalent to the natural gas consumed
by more than 2 million households.
“Steam generation accounts for about
one-third of all the energy consumed in
U.S. manufacturing,” says Alexander
Karsner, assistant secretary for the Office of Energy Efficiency and Renewable
Energy. “The Super Boiler is expected to
help save energy, increase efficiency and
improve environmental performance
throughout the manufacturing sector.”
The Super Boiler is the culmination
of more than seven years of DOEsponsored research and development
by the Gas Technology Institute, Des
Plaines, Ill. and its partner, CleaverBrooks, Milwaukee. This work has also
been supported by Utilization Technology Development, Des Plaines, Ill.;
the Southern California Gas Com-
pany, Los Angeles; the South Coast
Air Quality Management District,
Diamond Bar, Calif.; the California
Energy Commission, Sacramento, Calif.; and the California Air Resources
Board, Sacramento, Calif.
In July, 2006, the Gas Technology
Institute and Cleaver-Brooks installed
a 300 hp high-pressure steam Super
Boiler which has been running 24
hours a day, five days a week with excellent results. After more than 6,000
hours of operation, fuel-to-steam efficiency has been consistently in the
93% to 94% range, and NOx levels
have been less than 9 ppm. Annual
gas savings have averaged nearly 13%.
Additional field tests are underway at
Clement Pappas & Co., Ontario, and
Third Dimension, West Jordan, Utah.
Cleaver-Brooks’ goal is to have five test
sites up and running before the product
goes to market. “Approximately 80% of
the boilers out there are 25 years old,” says
Dan Willems, vice president product engineering, Cleaver-Brooks. The company
hopes to be able to replace 25% of those
boilers with the new technology.
“It can be applied to existing boilers,” Willems says. “You can get very
close to 90% efficiency.”
A brief video about the Super Boilers is available at www.deangroup.com/
clients/superboiler/.
INDUstRy bRIefs
Syclo/IBM relationship redefined
Syclo recently updated and expanded its partnership with long-time ally IBM to give Syclo
direct responsibility for support, and Maximo
Mobile SE has been renamed SMART Suite for
Maximo. Organizations can now purchase Syclo
mobile software pre-integrated to Maximo versions 4, 5 and 6 (plus 7 and beyond when available) through either IBM or Syclo, and receive
January 2008
PS0801_15_18_UpRun.indd 15
services and support directly from Syclo, giving
them a closer relationship and better access. For
more information visit www.syclo.com.
Test confirms value of
FDT/DTM technology
WIB, the International Instrument Users’ Association, has completed its test comparing
the performance of FDT/DTM and EDDL technologies for asset management of intelligent
field devices in process automation systems.
FDT/DTM and EDDL are the two standard
technologies for integration of device information into process automation systems.
The test confirms the extended benefits that
FDT technology brings to configuration and
maintenance of intelligent field devices. The
15
1/10/08 4:58:42 PM
UP AND RUNNING
INDUstRy bRIefs
extensive testing, based on Foundation
fieldbus communication, was performed by
the Shell Global Solutions test laboratories
in Amsterdam on behalf of WIB.
StatoilHydro Ormen Lange is
2007 HART Plant of the Year
The StatoilHydro Ormen Lange natural gas
processing plant in Aukra, Norway, has been
selected by HART Communication Foun-
dation (HCF) as recipient of the 2007 HART
Plant of the Year Award. The award is given
annually to recognize the people, companies
and plant sites around the globe that are using the advanced capabilities of HART communication in real-time applications to improve operations, lower costs and increase
availability. The StatoilHydro Ormen Lange
facility produces natural gas that will provide
up to 20% of the natural gas for the United
Kingdom. The natural gas is shipped via the
What
happened...
Langled Pipeline, one of the world’s longest subsea gas pipelines—1,200 km from
the coast of Norway to the U.K. The Ormen
Lange project consists of 24 subsea wells in
four seabed templates with an onshore processing facility to clean up the gas before
pushing it into the pipeline to the U.K.
Grainger rolls into Windy City
The Chicago-area portion of Grainger’s market expansion initiative arrived a few weeks
before the city’s first snowfall. With the construction and grand opening of the Bensenville, Ill., warehouse and store front, Grainger
offers 23,000 SKUs to customers in the northwest suburbs. “We’re expecting to get a lot of
customers,” says Branch Manager John McDermott. “With the added SKUs, customers
no longer have to make the longer drive to the
larger warehouses.” One of the primary goals
of the five-year long market initiative is to make
more product available at more locations.
And, if a warehouse doesn’t have a particular
product, it has the capability to make a sameday order so the item will be available later in
the same business day. The 27,000-squarefoot warehouse hosted an open house with
25 vendors attending (including 3M, Westward, CRC, Fluke, Hubbell, Milwaukee, Dayton
and Stanley). Former Chicago Bear Keith van
Horne was available for autographs. In addition to establishing a larger brick-and-mortar
presence, Grainger is exploring improvements on the Web. The company maintains
a Web portal designed specifically for plant
managers at www.grainger.com/plant. The
Website offers easily downloadable PDFs such
as a plant shutdown checklist, and scheduled
Webinars on plant maintenance.
Advanced Mechatronics
Training Center opens
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Visit Vaisala at AHR2008 booth #564.
16
Suffolk County Community College (SCCC),
Brentwood, N.Y., in partnership with Festo
Corp., recently unveiled the Advanced Mechatronics Training Center. The new center
sports advanced, high-tech manufacturing
and process control equipment that reflects
world-class training capabilities. The hope is
to create greater awareness among students,
school systems, industry leaders, workforce
development agencies, economic development agencies and government officials
about the variety of career paths that exist in
the manufacturing field. As part of this mission to provide affordable higher education
and workforce development opportunities,
SCCC applied for and received a three-year
$2.4 million federal grant through the U.S.
Department of Labor Employment & Training
Administration to train workers for advanced
manufacturing. This resulted in a new curriculum – Mechatronics – that will give the manufacturing workforce more highly developed
skills increasing their employment opportunities and salary levels.
January 2008
1/10/08 4:58:48 PM
Ultra-Filter
™
Superior Compressed Air Filtration from Donaldson
HIGH PERFORMANCE
Flow-optimized filter design, paired with innovative
filtration technology, reduces pressure loss by 50%
compared to conventional filters.
GREATER EFFICIENCY
Achievement of compressed air quality meeting ISO 8573-1
with performance data validated according to ISO 12500-1.
EASE OF USE
The filter element and bowl are removed together.
All filters can be used as coalescing filters (inside to
outside flow) or particulate filters (outside to inside flow).
FLEXIBILITY
Rotatable, combinable, adjustable—fits into the
smallest spaces!
SAFETY
The bayonet lock ensures that the filter cannot
be opened under pressure.
SERVICE & SUPPORT!
Ready-to-ship filters within 48 hours.
Call today to learn more
about Donaldson Ultra-Filter.
Visit www.donaldson.com
Call 800.543.3634
E-mail us at [email protected]
© 2007 Donaldson Company, Inc., Minneapolis, MN U.S.A.
1/9/08 2:21:55 PM
UP AND RUNNING
INDUstRy bRIefs
FLIR systems to acquire
Extech Instruments
Extech Instruments, a major supplier of test
and measurement equipment and portable
receipt printers with distribution in more
than 90 countries, will be acquired by FLIR
Systems Inc. FLIR is a world leader in the design, manufacture and marketing of thermal
imaging and stabilized camera systems. The
Resources
Contributing author earns manufacturing award
Scotty Lippert Jr. of Clopay Corp., a contributing author to Plant Services, was recently
named the 2007 Kentucky Manufacturing Employee of the Year by the Kentucky Association of Manufacturers. He received the award at the organization’s Seventh Annual
Manufacturer of the Year Award Presentation and Annual Meeting Luncheon. For more
see www.PlantServices.com/KAM_award.
transaction, which is subject to standard
closing conditions, was expected to be completed within the fourth quarter. “This is an
exciting opportunity for Extech, our customers, our distributors, and our employees,” said
Jerry Blakeley, president and owner of Extech.
“This acquisition will create new opportunities in distribution, product development and
branding, which will extend and strengthen
Extech’s position in competitive markets.”
With this acquisition, Extech’s product portfolio will increase, bringing the addition of thermal imagers and Infrared (IR) cameras to the
company’s 15 current product categories.
Watch this space
Contributing Editor and
maintenance evangelist Joel Leonard is extremely busy working
on a special project,
to be announced
in his next “Crisis
Corner” column.
Equipment and supplies for industrial buyers online
SurplusTrack.com has launched version 3.0 of its online industrial exchange community,
which helps businesses buy and sell surplus industrial inventory and equipment. The improvements to the Web site include a completely redesigned user interface, more robust
search capabilities powered by Google, and PayPal online payment technology. These
advancements address the evolving needs of the company’s growing customer base. For
more information visit www.SurplusTrack.com.
INCREASE PRODUCTIVITY.
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Dependable Deltech compressed air dryers and filters deliver rugged durability to maximize productivity. Deltech can protect your products from
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HALF?PAGEINDD
18
www.deltech-spx.com
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January 2008
1/10/08 4:58:54 PM
Products.
Baldor and Reliance motors are synonymous with
Quality. Combined, we offer more solutions than
ever before with availability of more than 7,000
different stock motors and the quickest delivery
on custom motors to 15,000 horsepower.
Baldor-Reliance sets the standard.
Baldor also offers the most complete line
of industrial adjustable speed drives. From
a standard inverter, to closed-loop vector
technology or advanced motion control, look no
further than Baldor for the drive you need.
Baldor’s Dodge product line offers a wide
variety of power transmission products backed
by a reputation of superior reliability in rugged
applications. Baldor is your complete end-toend solution for industrial motors, drives, power
transmission products and generators.
www.baldor.com
Bringing the Best Together
©2007 Baldor Electric Company
1/9/08 2:22:45 PM
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1/9/08 11:57:27 AM
WHAT WORKS
PET project saves energy
Blow molding costs deflated by recycling high-pressure compressed air
P
ET bottle molders that use both high-pressure and
low-pressure compressed air in blow molding operations typically exhaust residual compressed air from
the high-pressure side to the atmosphere. But as cost for
power to run the compressors increases, “Many of these PET
container producers have begun to view air as the fourth utility, along with gas, water and electricity,” says Chris Gordon,
president, Blackhawk Equipment, Arvada, Colo. “So, you try
to save money on compressed air in plants like these because
they can theoretically net out some big energy savings.”
Three years ago, Blackhawk Equipment was introduced
to a new concept in recycling compressed air, the Air Recovery System (ARS). Developed by Technoplan Engineering SA of Geneva, the ARS recovers compressed air that
still has residual pressure. Gordon immediately saw that the
ARS concept could be advantageous to PET bottle production operations, so he began to work with the licensed U.S.
distributor of the system, Connell Industries (www.connellind.com/recycling.html).
“The PET molding process is a less than optimal one that requires ultra-high pressures, in excess of 580 psig,” Gordon says.
The ARS system is installed between a blow molder’s exhaust
system and the plant’s low-pressure air system, capturing, storing and returning almost 50% of the dry, oil-free air at a pressure of 12 bar (170 psi) to the plant’s low-pressure air system.
Gordon performed pre- and post-installation measurement and verification, and the energy savings were substantial. The total savings the ARS system generated enables a
payback period of eight to 12 months.
The potential for rebates on electric power consumption
can make the payback even more attractive. In New England, for example, where the kilowatt-hour rates are three
times those in much of the United States, the ARS system
can qualify for about one-third of the total purchase price.
“We have energy efficiency programs designed to help customers with electric power usage to take some of the load off
our system,” explains Craig Trottier, an account executive with
Public Service Co. of New Hampshire, the state’s major electric
power utility. “That helps defer the need for new investments
in infrastructure. But it also helps our customers manage their
energy costs better so that they are more competitive.”
Trottier recently evaluated the rebate qualification of an
January 2008
PS0801_21_Works.indd 21
The air recovery system captures almost half of the high-pressure air,
reducing compressor load and maintenance expenditures.
ARS system installed at Southeastern Container’s Hudson,
N.H. facility, where 1.5 million PET bottles are produced
per shift for Coca-Cola, its parent company.
“The results of the ARS installation were quite surprising,
even better than projected,” Trottier says. “This is a unique
system that we had never seen before, and is especially appropriate for PET bottle applications.”
“We have two ARS systems installed,” says John Fischer,
general manager, northeast region, Southeastern Container, “one on a two-liter bottle machine and one on a 20 oz.
Public Service of New Hampshire says we’re saving at least
5 million kilowatt-hours per year, and could possibly double
that depending on different production considerations. But,
in the first six months of this year we’ve saved approximately
$300,000. In fact, we’ve been able to speed up the machines
with some engineering work and software programming – so
we’re actually using less electricity and yet making about 6.5%
to 7% more bottles than we did before. Our per-thousandbottle costs have dropped dramatically. Based on that and the
utility’s rebate program, the payback period is less than a year
with roughly about $400,000 invested less the rebate.”
Fischer adds that the biggest bang for the buck is on the
two-liter machine. “We’re considering adding ARS systems
in other plants that produce those, especially in regions were
electric power is most expensive. But in reality, the days of
cheap electric power are evidently over, so we have to prepare for future rate increases even in areas where electricity
is comparatively inexpensive today.”
21
1/9/08 11:43:44 AM
1/9/08 11:57:38 AM
ASSET MANAGER
Rise above the firefighting fray
Use people skills and your CMMS to build a solid strategy for management excellence
F
• Promote diversity, respect for others, teamwork, and
rontline supervisors are critical for successful change
constant heath, safety and environmental vigilance.
initiatives. Numerous studies and surveys conducted
• Communicate expectations, provide constant feedback,
since the 1980s substantiate this claim. Of all the
and support the staff in their daily efforts.
means of communicating to frontline employees, the most
• Be a change agent, encourage creativity and reward inpowerful appears to be face-to-face communication through
novation.
the immediate supervisor. Research shows that frontline supervisors enjoy the highest level of trust and credibility with
their staff.
Breaking the firefighting mentality
Thus, to ensure the CMMS is implemented and used efFrontline leaders must rise above the firefighting mentality.
fectively, management must get buy-in from frontline superEasier said than done, but some tips might be helpful.
visors. In turn, this requires concerted management effort to
Think of four key strategic goals that can keep you foconvince frontline supervisors that the benefits
cused. For example, you might want to move
of a CMMS more than offset any perceived
to a planned environment, build a skilled,
It might also
pain and disruption. Convincing frontline suinnovative team, generate a learning organihelp to specify zation, implement RCM, form a partnership
pervisors that there’s something in it for them
and their staff maximizes CMMS value. If
with operations and engineering to share
what will not
there’s a perception this is an IT initiative that
and objectives, measure and reward
be part of your goals
benefits only management or that plant-floor
success, and so on. It might also help to specstrategic focus, ify what won’t be part of your strategic focus,
workers are being diverted from their real jobs,
and make that
the probability of success drops dramatically.
and make that clear to others. Get input and
clear to others. buy-in from management, frontline staff and
key stakeholders. Note that a CMMS will go
The frontline supervisor’s role
a long way in supporting a strategic change,
Observing frontline supervisors on a day-tobut only when the focal point is process change and, more
day basis, one might conclude their key role is chief firefighter,
importantly, a change in attitudes and behaviors.
coordinating staff on one urgent problem after another. That’s
Prioritize your actions by asking how much it will conno surprise, given the lack of training when one moves from
tribute to your goals. When you are pulled left and right
the line to supervision. Even if training is offered, where fireduring the day, determine which items can drop to the botfighting takes precedence, the perception is that there’s no time
tom because they add little value. Post your list where everyavailable to attend training sessions. Of course, this becomes a
one can view it. Let your staff know that you are looking for
circular argument, which maintains the status quo.
behaviors that help accomplish these goals. This is how you
Breaking this cycle requires knowing what needs to be
can influence the frontline staff into adopting the goals, and
done, a measurement system that won’t reward firefighters,
help them distinguish between value-adding and waste.
leadership providing the vision and drive to make it hapDo more leading and less crisis management. When a pypen, and evidence of management commitment to providing
romaniac comes to you with a fire, fight the urge to hop on
time and resources. The frontline supervisor should put less
the fire truck. Stop and think about the problem. Determine
emphasis on acting like a technician by getting down and
if this is urgent with respect to your priorities. Force your
dirty, or being an administrator hiding behind paperwork.
subordinates to stop and think strategically about the probThe supervisor’s role should encompass long-term thinking:
lem and force them to come to you with solutions, not just
• Lead and motivate the frontline staff to attain higher
problems. Ask if they’ve examined CMMS-based data to
performance achievable by using the CMMS.
understand the root cause of the problem. Think big picture
• Encourage skills development and career path planning,
and help others help themselves. Delegate responsibility to
satisfying the needs of both employees and employer.
January 2008
PS0801_23_24_AssetMan.indd 23
23
1/9/08 2:51:24 PM
ASSET MANAGER
teach strategic and critical thinking to
those on the front line. If nothing is
getting through, provide more aggressive skills development or reorganize
your team.
Set aside time each day to think,
plan, work on longer-term projects,
review KPIs and critical reports,
and take in the big picture. Using
the CMMS as a strategic tool for
analysis and planning. It’s difficult to
carve out quality time to rise above
it all. Find a quiet spot away from
telephones and people. Be part of the
solution, not the problem.
Take a carrot-and-stick approach
to influencing front-line behaviors.
Reward the behaviors you’re trying to
promote, and show little tolerance for
24
PS0801_23_24_AssetMan.indd 24
deviations. Celebrate when technicians
use the equipment history on your
CMMS to identify and eliminate recurring problems, or better anticipate
problems through condition-based
maintenance. If the fire bells ring,
call the key stakeholders into your office and discuss what should have been
done, and will be done, to prevent a
similar crisis from occurring.
What not to do
Be wary of the traps that typically undermine a supervisor’s credibility:
• Sending unclear, conflicting messages (encourage staff to be involved,
but not providing the time to do so)
• Over-promising and under-delivering (promising to upgrade the
CMMS, and then blaming management for not approving it)
• Stealing the limelight (accepting
praise from senior management without crediting the front line for helping
to make it happen)
• Acting disrespectful or unprofessional (reprimanding an employee in
the presence of peers)
(Editor’s note: The Plant Services CMMS/
EAM Software Review, posted at www.
PlantServices.com/cmms_review, provides a
side-by-side comparison of more than a dozen
popular software packages.)
E-mail Contributing Editor David Berger,
P.Eng., partner, Western Management Consultants, at [email protected].
January 2008
1/9/08 2:51:32 PM
1/10/08 2:55:56 PM
TECHNOLOGY TOOLBOX
Tiny, wireless and self-energized
A new generation of sensors is poised to revolutionize predictive maintenance
A
As vehicles vibrate the bridge, the generator produces elecpredictive maintenance program can be constrained
trical power for the wireless sensor. Each bridge uses several
if it relies on indirect or imprecise measurements,
sensors to monitor structural integrity and other variables,
if instrument batteries fail, or if data communicaand report changes that could indicate a potential failure.
tions are limited. Gradually such constraints are being overUsing self-powered sensors can eliminate communication
come by software and technologies that simplify condition
gaps caused by dead batteries. The concept also can be levermonitoring and streamline predictive maintenance.
aged for monitoring and maintenance of vibrating applicaMiniature sensors cozy up to bearings: Purdue University
tions, including lift trucks and rotating machinery.
researchers, working with the U.S. Air Force, are using microKCF Technologies is developing vibration-harvesting deelectromechanical systems (MEMS) technology to detect if jet
vices to power wireless sensors on industrial production lines,
engine bearings are close to failing. The miniaturized wireless
power generation systems, vehicles and buildsensors monitor bearing temperature, which inings. The company anticipates this will expand
dicates bearing condition and how long it will
The
the use of wireless sensors, thus reducing pollulast. The sensors detect bearing failure much
tion, energy consumption and battery issues.
earlier than sensors that monitor bearings via
hermeticallyData aggregation and analysis: Equipengine oil temperature. The wireless sensors are
sealed wireless
ment data is most useful if it can be aggrepowered through inductive coupling and handle
sensor
gated, analyzed and logged. The InFusion
temperatures to 300°C (572°F).
eliminates
Condition Manager from Invensys displays
MEMS combine microscopic electronic
equipment condition and maintenance inforand mechanical components. “The MEMS
the need for
mation on HMI workstations as well as the
technology is critical because it needs to
batteries.
Invensys Avantis.PRO enterprise asset manbe small enough so it doesn’t interfere with
agement system. InFusion v. 2.2 feeds data to
the performance of the bearing itself,” says
plant historian packages, making the data and actions availFarshid Sadeghi, Purdue professor of mechanical engiable to other plant and enterprise systems.
neering. “And the other issue is that it needs to be able
The system collects and analyzes real-time diagnostics
to withstand extreme heat.” Although the application is
from intelligent instrumentation, fluid and vibration analaircraft, any engine could benefit. It has potential for use
ysis, advanced process control and loop tuning software
in harsh manufacturing environments as well as transpormounted on any plant asset. It then triggers maintenance,
tation, distribution and warehouse fleet management.
operations or engineering actions based on rules, conditions
Self-powered sensors are battery-free: Battery mainand customer-defined algorithms and models.
tenance can be costly and difficult when condition-moniWeb Services technology allows InFusion Condition
toring sensors are installed in confined spaces or at remote
Manager to communicate with enterprise systems such
locations. Clarkson University researchers have developed a
as ERP, EAM and MES. Microsoft .NET technology is
sensor technology that generates its own power from vibraleveraged to provide the asset and business intelligence
tions. The hermetically-sealed wireless sensor eliminates the
information.
need for batteries and can conceivably remain in service for
decades maintenance-free.
New York State Route 11 Bridge was the test platform.
E-mail Contributing Editor Sheila Kennedy, managing director of
An electromagnetic generator on a girder harvests energy.
Additive Communications, at [email protected].
For more information, see:
www.purdue.edu
www.clarkson.edu
26
PS0801_26_TechTool.indd 26
www.kcftech.com
www.infusionecs.com
www.techbriefs.com
www.ewh.ieee.org/tc/sensors
January 2008
1/10/08 2:04:51 PM
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can kil
Counterfeits
Don’t risk lives, reliability and
profits just to save a buck
By Jim Montague, Executive Editor, ControlGlobal.com
and Paul Studebaker, CMRP, Editor in Chief
PS0801_28_33_CvrStry.indd 28
1/10/08 2:05:18 PM
W
e who live and work in societies with long,
strong histories of industrial responsibility and
regulatory compliance are accustomed to choosing freely among a variety of sources for components and
replacement parts. “Original” or “factory” parts come
from the company that built the machine and are understood to be the same as those used on the production line.
Original equipment manufacturer (OEM) components
are expected to be made by the company that supplies the
factory, and therefore equivalent to factory parts in every
way but the name. Aftermarket parts come from a variety
of sources and are trusted according to the brands under
which they are built or sold.
We’ve chosen our parts based on real or perceived quality, value, supplier reputation or support,
and suitability for intended purposes. Some prove better than others, but we’ve rarely been surprised
by nonfunctioning or dangerous parts. Maybe this is because it traditionally has taken a significant
investment in manufacturing equipment and the supply chain to establish a brand, make the parts
and bring them to market. That, plus the requirements of certification agencies such as Underwriters
Laboratories (UL), have largely kept low-quality and non-functional components out of our plants.
But not anymore.
A growing pain
ill
Moving beyond Rolex watches, low-quality bolts and brand-name auto parts, counterfeiters are
producing fake industrial equipment and components complete with bogus marks, packaging,
documentation and certifications. Also creeping into the supply chain are imitations or knockoffs that wear their own brands (or none) but deliberately mimic the appearance of famous-maker
products.
The International Chamber of Commerce (ICC, www.icc.cca.org) estimates that trademark counterfeiting accounts for about 6% of world trade. It’s worth an estimated $350 billion annually, according to the white paper, “The Threat of Counterfeit Product Approval Marks Warrants Aggressive Detection and Enforcement Action,” by a recent alliance between U.S. Occupational Safety and Health
Administration (OSHA, www.osha.gov) and the American Council of Independent Laboratories
(ACIL, www.acil.org). “In its mid-year 2005 report, the U.S. Department of Homeland Security’s
Customs and Border Protection division reported that customs seized more than $64 million dollars
worth of counterfeit products in 3,693 seizures. Electrical equipment, much of it intended for the U.S.
workplace, alone accounted for more than $6 million,” the paper says. “The International Anti-Counterfeiting Coalition (IACC, www.iacc.org) reports the majority of counterfeit products come from
Asia, primarily China, and that Eastern Europe also has become a significant source. The manufacture and distribution of counterfeit products has been linked to organized crime. Counterfeit approval
marks have been found on electrical products built with substandard materials and exhibiting compromised electrical spacing – both of which pose potential shock and fire hazards to U.S. employees.”
Jim Pauley, vice president, industrial and government relations for Schneider Electric (www.
us.schneider-electric.com), received a phone call from the U.S. customs office in San Francisco a couple of years ago. “They found a person trying to get through from China with a suitcase full of circuit
breakers with our Square D logo and UL labels on them,” Pauley says. “All of them were counterfeit.
This has led to several ongoing litigations, and six settled lawsuits, but we think the overall state of the
1/10/08 2:05:27 PM
MANAGEMENT
Reliability
problem is still much worse than people
realize or are willing to admit that it is.”
No one knows how many counterfeits go unreported, so it is difficult to
estimate how widespread the issue is.
“This is what we know, and there are
probably more,” Pauley says. “Customs
usually inspects about 2% of all cargo,
and the rest can’t all be crystal clean.”
The British Valve and Actuator Association’s (www.bvaa.org.uk) technical director reports there was very little
counterfeiting of mainstream valves
just five or 10 years ago, but now there’s
more anecdotal evidence than ever before about fake products and parts, coming mostly from Asia and specifically
China, says Rob Bartlett, director of the
organization. “Everyone has a story.”
Typically, a defective part will be
returned to the manufacturer, often
through an authorized distributor. “We
find out which contractor returned it,
find out where he got it, trace down
the source and refer it to the Consumer
Product Safety Commission,” says Bill
Snyder, vice president, channel development, Square D. “It gets traced back to
one or two factories in China, which get
raided and shut down. But they reopen a
few days later, a couple of miles away.”
The parts being copied were never
manufactured in China, Pauley points
out. “People think this is what happens
when you manufacture in China, but
these products are not made by us in
China,” he says. “They have counterfeit
‘Made in USA’ labels on them. This is
not a ‘manufactured in China’ problem,
it’s a different group. These are criminals
under U.S. law.”
Wild, wild Web
One contributor is Internet-based
businesses that routinely sell millions
of dollars worth of equipment and en-
able the smallest shop to market and
deliver items worldwide. These speedy,
global transactions can be helpful, but
participants reportedly don’t conduct
as much verification and certification
as traditional manufacturer-to-distributor channels.
“We haven’t personally identified
any counterfeit items, but our customers report seeing many items on eBay
for more than 30% off list prices,” says
David Stock, a system integrator at
Innovative Control Inc. (ICI, www.
innovativecontrolinc.com),
Crystal
Lake, Ill. “If someone else wants to
purchase equipment that way it’s fine
with me, but I think buying in an environment without distributors and
traceability is a serious risk.”
Some purchasers accept counterfeiting and knowingly buy fake devices.
“Some people actually choose to purchase counterfeit products, assuming
MORE THAN A NAME: THE CASE FOR FACTORY PARTS
Some vendors extend the definition of
counterfeit parts to include aftermarket
and other components, especially when
those are substituted for factory parts
without the knowledge and consent of the
equipment owner.
“It’s relatively easy to find counterfeit
parts. Generally, counterfeit (non-genuine)
parts look like the original parts, but don’t
have the same quality as genuine Atlas
Copco parts,” says Alessandro Fantacone,
aftermarket product manager, Atlas Copco
Airpower – Belgium (www.atlascopco.com).
“They’re cheaper, and as consequence they
have lower quality. Non-genuine parts
suppliers target high-volume consumables
– oil and air filters, and lubricants.”
Like many manufacturers of specialized,
heavy-duty industrial equipment, Atlas
Copco takes significant pains to ensure the
quality of consumables because they affect equipment durability, efficiency, and
performance. “When developing a new
machine we have a very strict procedure
where we qualify parts in several stages,
performing extensive tests to see how
they’re operating and performing,” says
Fantacone. “We work with high-quality
suppliers and collaborate in the design of
key components. If our replacement parts
aren’t used, we can’t assure that the machine will function as originally designed.”
Non-factory lubricants and air filters also
come with risks. “There’s a direct link from
oil quality to machine life. Non-standard oil
30
Sectioning a typical non-genuine and
a genuine Atlas Copco oil filter shows
where the wrong seal material or size can
cause oil leaks, a bypass valve with the
wrong setting can starve a compressor’s
airend of lubrication, and filter media
tensile strength, chemical compatibility,
micron (Beta) rating, and pleating affect
performance. In severe cases Atlas Copco
has seen non-genuine media disintegrate
because of chemical incompatibility or
restrict oil flow enough to cause airend
damage or failure.
can lead to higher water content and lower
bearing life,” Fantacone says. “We work to
minimize energy consumption. Most counterfeit air filters have higher pressure drops
than genuine Atlas Copco air filters. These
higher air filter pressure drops increase energy consumption and nearly always cost
more in electricity than saved by purchasing a non-genuine part.”
Non-factory parts may appear to be a
good purchase, but may lead to some hidden costs such as higher maintenance and
operating costs due to shorter lives and
higher energy consumption.
“If a service organization is offering you
a non-Atlas Copco part, it’s because the
service organization is interested in making higher profits,” Fantacone adds. “They
may sell it at 80% of the price of the Atlas
Copco part but they pay much less for it,
and the reason is simple: performance and
quality are much lower.”
Fantacone suggests you take these steps
to guard against inadvertently using nonoriginal parts:
1. Always ask for genuine parts.
2. Make sure your service provider is using factory parts. Look at the manufacturer’s Web site to see the part and
the box, and look at what is going into
your machine.
3. Check the billing or receiving paperwork against the manual to see that
the part numbers match.
4. If you see a big price difference or if
suddenly the part is half the price, it’s
probably not a factory part, and will
lead to higher lifecycle costs.
5. Remember that machine downtime is
a huge cost.
J 
1/10/08 2:05:40 PM
MANAGEMENT
Reliability
IDENTIFY AND AVOID
Clearly state the issues and risks of counterfeits to everyone within
your organization who has responsibilities for sourcing, handling,
using or maintaining MRO and supply parts. Give them these tips
to help avoid acquiring or using suspect parts, and encourage
them to question anything out of the ordinary with your suppliers. For mission-critical parts, develop a second, enhanced level of
ordering, receiving and managing inventory.
• Look for the mark – A system of standards exists for product testing and certification. Be wary of electrical, mechanical, plumbing, gas
or other standardized products if they don’t have a certification mark
from a nationally recognized testing laboratory (NRTL).
• Inspect the mark – Legitimate certification marks have distinctive graphics that often aren’t accurately reproduced by counterfeits. For a current list of NRTLs or their marks, visit OSHA’s Web site
at www.osha.gov/dts/otpca/nrtl/index.html.
• Poor spelling – Look for misspellings and unclear printing on
packaging, products, labels or instructions.
they’re paying less for products that are
equal in value to the legitimate products they mimic,” states the OSHAACIL report. “People who deliberately choose to buy counterfeit products
aren’t victims. Instead, they support
the criminally deceptive practices of
counterfeiters by creating a built-in
market for their goods. If consumers
stopped using counterfeit products,
counterfeiting wouldn’t disappear.
However, in many cases, counterfeiting would be less profitable and more
risky without these easy sales.”
Anthony Todarian of the Canadian
Standards Association (CSA, www.
csa.ca) adds that it and other agencies regularly issue product alerts and
recalls when it finds counterfeit products, and that eBay and other online
sellers have promised to remove them
when they’re notified.
It’s one thing to buy a contractor’s
leftover 10-pack of circuit breakers on
eBay, but greater numbers raise more
questions about where they’re coming
from. “When you see higher volumes
and a supplier saying it can deliver any
amount, you have to ask if this is a legitimate source,” says Pauley. “This is
why you can’t just run to the Internet
to buy circuit breakers. You have to
know your sources and start further
up the food chain. If you wait until a
product is delivered, it’s probably too
late.”
• Inferior packaging – Counterfeit packaging might show poor
quality such as blurred markings or partial illustrations. Red flags
include questionable or meaningless markings, or foreign newspapers used as packaging.
• Missing items – Check for missing product information or discrepancies between package contents and the item’s description
on the package. There also might be missing instructions, screws
or terminals.
• Cheap production – If a device looks and feels too light and flimsy,
it might be a fake. Check for signs of used appearance, evidence of
tampering/repairs, broken seals, scratches, obvious wear, corrosion,
pitting, and inconsistent material types, finishes and/or colors.
• Significantly lower pricing – Deals that are too good to be true
could mean a device is counterfeit, and so it should be checked
even more closely.
• Questionable source – Buy only from reputable, well-known
distributors or retailers.
Dangerous deceit
It would be one thing if counterfeiting only compromised patents, copyrights and sales revenues. But in the
case of industrial components, it’s also
a matter of functionality. “They put on
fake Square D and UL labels, and the
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parts don’t work. A counterfeit breaker subjected to a fault current that any
breaker would be expected to clear
just blows up,” says Snyder. “And this
isn’t limited to Schneider or Square D
– our competitors are seeing the same
thing with products from wiring de-
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MANAGEMENT
Reliability
vices to cords to allegedly explosionproof boxes and fittings.” Users might
not realize this until years later, when
those fake devices are called on to
work and fail instead.
We expect parts to fit, function and
endure. But counterfeits generally use
cheaper and less safe materials, such as
flammable plastics, less durable alloys,
loose tolerances and inadequate electroplating. Copiers cut production costs by
not respecting quality and safety standards, imitating external appearances
with no knowledge or understanding
of the technologies needed to produce
functional, durable parts.
In the case of gearboxes, “We’ve
seen direct knock-offs that look the
same from six feet away,” says Bill
Engle, plant manager, Dodge Gear,
Greenville, S.C. “You’ll save about
40%, but after 150 hours they catch
fi re.” Some of the knock-offs came
back from distributors as “warranty
returns.” Engle doesn’t know how the
end users get the knock-offs, but until
they get back to the factory, everybody
is under the impression they’re genuine Dodge gearboxes.
Poorly-made bearings contribute
to excess friction and wear that cause
overheating. “We’re seeing some counterfeit bearings from China,” says Bill
Bayliss, business manager-aftermarket
at FMC FoodTech (www.fmctechnologies.com/foodtech). “Some bearings
are very sophisticated and, as a result,
very expensive. But there’s a reason
they’re so expensive. Some customers
are finding out the hard way.”
Some fake bearings are obvious on
inspection. Visible clues can include
packaging differences, alternate countries of origin, oddball serial number
formats or differences in the look of
subcomponents. Names and logos
might be misspelled. Increasingly
however, the more sophisticated fakes
Covert identification
Figure 1. One of the simpler tools in
the battle for authentication is hidden
marking, such as this code visible only
under ultraviolet light. (Videojet)
are essentially identical under routine
inspection or testing. The hidden differences, determinable only by experts,
may have serious consequences.
These nonvisible differences can include nonhardened races, alloys without
adequate corrosion or wear resistance,
unserviceable seals or defective lubrication, suggests Shaeffler KG, maker of
INA and FAG bearings. In some cases,
the fakes can look “more real” than the
legitimate product, according to reports
from major bearing manufacturers. In
most cases, the final determination can
only be made by an authorized distributor or the manufacturer.
Falsification of bearing identity has
reached such proportions that manufacturers, major customers and testing
and certification organizations worldwide are discussing a “Global Bearing
Code of Conduct,” and the Japanese
Bearing Manufacturers Association
has published a poster showing a pair
of handcuffs whose one side is a large
ball bearing. The poster says, “Counterfeit bearings are illegal. They can cause
injury or death. Don’t produce them.
Don’t sell them. Don’t buy them.”
Can’t judge by appearance
While close visual inspection of devices
and documentation is supposed to help
find counterfeits, several sources say the
external appearance of many fakes is so
good that they’re almost indistinguishable from the genuine items. “You can’t
32
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1/10/08 2:05:59 PM
MANAGEMENT
Reliability
identify counterfeit products by physical
appearance,” says Snyder. “The counterfeits we are seeing today are indistinguishable – I cannot see the difference.
“We work with the government and
customs. We give them brochures that
show what to look for and the next
shipment has fi xed it. We say to look
for grease on the contactor jaws, they
put grease on the jaws.”
Even newer identification technologies, such as RFID chips and laser
etching, can be quickly adopted by
counterfeiters. “Many counterfeits look
pretty much like the real thing. They
might even have duplicate die marks
and moldings that serve no purpose.
We have seen situations where manufacturers have added holographic labels
to their products, and the counterfeiters
copied it nine months later,” says Pauley.
“Sometimes our engineers have to take
devices apart to compare the legit and
counterfeit version, and the fakes quickly fail if their performance is tested.”
Still, the battle for positive identification starts with the naked eye. “We
work with the OEMs for a way to authenticate a product,” says Jack Walsh,
director of sales, Videojet (www.video
jet.com). “The first way is by quality – a
high-quality product and packaging so
you can tell by looking. But counterfeiters are clever, and there isn’t always
packaging, so we do track and trace. At
the low level, it’s covert marking on the
product itself [Figure 1]. The high level
is using RFID or other markings as a
license plate that travels with the product.” Every product move in the supply
chain is recorded, and authorized distributors must be able to show traceability back to the source.
“An unauthorized supplier won’t
be able to provide the history,” Walsh
says. “This is going on in the automotive industry right now. It’s called
serialization, and it’s being used on
safety-critical and high-cost items.”
Registered part IDs can be accessed
through the Internet. “If a distributor
gets a suspect part, or Customs sees
a load of suspect parts or a warranty
claim is questionable, they can call the
J 
More resources at www.PlantServices.com/thismonth
“Statistics on the types, values and origins of gods seized by the U.S. Customs and Border Protection Agency”
Download the “No Trade in Fakes” supply chain tool kit from the Coalition Against Counterfeiting and Piracy (CACP), or see the Webinar
“Rotork copes with copies”
“Responsible repair and refurbishing”
Learn more about or report counterfeit circuit breakers
supplier and check it out,” he adds.
“We’re supplying end-to-end turnkey
systems for this.
“You can’t penalize the distributors
and shut them down when they say
they didn’t know the part was counterfeit. Now the manufacturers have a
way for them to know.”
Know your suppliers
Perhaps the best way to avoid counterfeit
devices is to buy from manufacturers and
distributors that are well known to your
own company and its engineers. It’s also
vital to maintain frequent personal contact with authorized suppliers because
counterfeiters can set up false representatives and corporations to support their
fake products and documentation.
“When you’re in a rush, you might not
check some certifications as closely as possible,” says Bartlett. “So, besides checking
that documents aren’t bitmapped images
and telephoning to confirm suppliers’
claims and identities, buyers also must be
responsible for their devices’ audit trails,
and make sure where, when and who
makes these products.”
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Knowing operating
characteristics and physical
limitations will help you
select the best machine
for your plant
By Niff Ambrosino
ost industrial air compressors are
supplied as self-contained packages
that include drive motor, inlet filter, mechanical and electrical controls, and various optional
accessories. Depending on the type and size of air
compressor, the package might be mounted on an air
receiver. Air compressors are classified either as positive-displacement or dynamic.
Positive-displacement compressors
Air is drawn into an enclosed chamber where the
volume is reduced by mechanical means, causing the
pressure within to rise and forcing the air into
the system. A simple example of a positive-displacement compressor
is the hand pump for inflating tires. The oper34
PS0801_34_38_Compressors.indd 34
ating principle for positive-displacement compressors
is either reciprocating or rotary.
Reciprocating type
A reciprocating compressor uses a moving piston in
an enclosed cylinder. In a single-acting design, compression takes place on just one side of the piston and
produces air on only one stroke per revolution. Double-acting compressors develop compression on both
sides of the piston and produce air on two strokes per
crankshaft revolution. This results in almost twice
the capacity of a single-acting design of identical bore
and stroke. In either case, the compressor might be
air or water-cooled, lubricated or non-lubricated.
January 2008
1/10/08 3:18:18 PM
EFFICIENCY
Compressors
Single-stage reciprocating compressors have one or more cylinders
connected in parallel to compress air
from atmospheric pressure to the final
discharge pressure in one step. Most
single-stage compressors are designed
for a maximum discharge pressure of
100 psig.
Multi-stage reciprocating compressors, on the other hand, have two or
more cylinders connected in series.
Each stage adds some degree of compression. For example, in a two-stage
unit, air is compressed from atmospheric pressure to an intermediate
pressure in the first stage, cooled by
an intercooler, and raised to the discharge pressure in the second cylinder.
Multi-stage reciprocating compressors
are more efficient, run cooler and have
longer life than single-stage compressors, all because the intercooler(s) remove the heat of compression. While
not typical for plant air, some specialapplication, two-stage compressors
can deliver 250 psig or more.
Single-acting reciprocating compressors are commonly air-cooled, have one
or two stages and are available to 150
hp. However, in most industrial applications, the maximum size is generally
30 hp. A measure of operating efficiency
is called specific power and is the kW
input to produce 100 cfm, or kW/100
cfm. For a single-stage, single-acting
compressor, the specific power is approximately 24 kW/100 cfm at 100 psig.
Typical specific power for a two-stage,
single-acting compressor at 100 psig is
19 kW/100 cfm to 21 kW/100 cfm.
Double-acting compressors are generally water-cooled and range in size
from 25 hp (single-stage) to 500 hp.
Common sizes for two-stage industrial applications range between 75 hp
and 250 hp. A two-stage double-acting
reciprocating compressor is the most
energy-efficient air compressor. Typical specific power at 100 psig is approximately 15 kW/100 cfm to 16 kW/100
cfm. Double-acting compressors have a
higher initial price, more expensive installation and higher maintenance costs
than other types of compressors.
January 2008
Rotary compressors
The lubricated rotary-screw air compressor is the most widely used design
for industrial applications. It’s characterized by low vibration, simple installation and minimal maintenance in
broad ranges of capacity and pressure.
A rotary-screw air end consists of two
air into the decreasing inter-lobe cavity
until it reaches the discharge port at the
opposite end of the rotor. Oil injected
into the rotor housing lubricates the
moving parts, removes heat and seals
the clearances to prevent back slippage
of the compressed air. The air/lubricant
mixture discharges into the lubricant
A two-stage double-acting
reciprocating compressor is the most energy
efficient air compressor.
close-clearance helical rotors turning
in synchronous mesh. The male rotor
has four helical lobes; the female has
five or six grooves. In a lubricated rotary-screw compressor, the male rotor
drives the female rotor.
Ambient air is drawn through a
suction port into a space between the
spinning rotors, which then force the
reservoir, which also serves as a separator that relies on directional and velocity changes. A coalescing-type filter
reduces the final lubricant-to-air concentration to 3 ppm to 5 ppm.
Operating at too low a system pressure (65 psig to 75 psig) increases the
velocity across the separator, which
leads to greater lubricant carryover. To
AMERICAN INGENUITY
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EFFICIENCY
Compressors
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prevent carryover at startup and when system pressure is too
low, a minimum-pressure device is used to maintain internal
compressor pressure above the manufacturer’s minimum.
The lubricant separated from the air stream circulates
through a cooler and fi lter before being injected back into
the air end. The temperature of the lubricant at the injection
port needs to be high enough to prevent condensation from
forming in the lubricant. Air-cooled units use a thermostatic valve to maintain an injection temperature of 150°F to
170°F. Water-cooled packages use a water-flow-regulating
valve or thermostatic valve, or both.
To remove condensate, rotary-screw packages use an aftercooler to reduce the discharge air temperature and a moisture
separator with an automatic drain. Most industrial applications
use air-cooled heat exchangers for the lubricant and compressed
air. Water-cooled models use shell-and-tube exchangers.
Single-stage lubricated rotary-screw compressors are
available in sizes from 5 hp to 600 hp and produce between
35 psig and 210 psig. Typical 100-psig specific power at full
load is approximately 18 kW/100 cfm to 19 kW/100 cfm.
Variable-displacement or variable-speed capacity control
can improve part-load efficiency.
Two-stage compressors are available for operation up to
500 psig. They generally achieve better energy efficiency when
used as base-load compressors. At 100 psig, specific power is
approximately 16 kW/100 cfm to 18 kW/100 cfm. Variable-speed
control can also make them suitable as trim compressors.
Non-lubricated rotary-screw air ends are similar to the
lubricated variety, except for the lack of lubricant injection.
Two types are available - dry and water-injected.
In the dry type, the male rotor doesn’t drive the female
rotor. Instead, timing gears, which are separated from the
compression chamber by lubricant seals and air seals, maintain proper rotor clearances. The operating temperatures are
around 350°F to 400°F because there’s no fluid injection to
help remove the heat of compression. Single-stage models
can reach 50 psig. Most manufacturers use a two-stage design
with an interstage cooler to produce pressures of 100 psig to
150 psig. Typical specific power at 100 psig is approximately
18 kW/100 cfm to 22 kW/100 cfm.
The water-injected, non-lubricated rotary-screw compressor
can produce 100 psig and more in a single stage because the
water injected into the compression chamber seals clearances
and removes the heat of compression. The water is removed by
conventional means, cooled and recirculated. Automatic controls maintain the water level and quality.
Other types
The sliding-vane rotary compressor uses a rotor with metallic
or non-metallic vanes that slide in and out of the rotor in an
offset housing. As the rotor spins, the vanes are forced outward
against the cylinder walls. During part of the revolution, the
contained volume between vanes decreases, and pressure rises
as it nears the discharge port.
J 
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EFFICIENCY
Compressors
Table 1: Comparison of Compressor Types (100 hp To 500 hp)
Category **
Two-stage double
acting reciprocating
Lubricant-injected
screw (single-stage)
Lubricant-injected
screw (two-stage)
Size and weight
3
1
2
2
2
System completeness
3
1
1
1-2
1-2
Can be located close
to points of use
4
2-3
2-3
2-3
3
Maintenance costs
3
1
1
1
1
Foundation
requirements
4
1
1
1
1-2
Reduced capacity
efficiency*
1-2
1-4
1-4
1-3
1-3
Lubricant-free air
(lube**/lube-free)
4/1
2
2
1
1
Lubricant carry-over
(lube/lube-free)
4/1
3
3
1
1
Lubricant changes
or make-up
(lube/lube-free)
4/1
3
3
1
1
Equipment cost
4
1
2
2
2
Installation cost
4
1
1
1
2
15-16
18-19
16-18
18-22
15-20
Full-load operating
kW/100 cfm ***
Lubricant-free screw
Centrifugal
Key: 1 = Very good; 2 = Good; 3 = Fair; 4 = Poor.
These evaluations are very general and might
not cover specific features of a given compressor type or manufacturer. They are intended
to provide a general guide in how to compare
compressors. It’s important to evaluate each
point in any comparison of quoted equipment. Other factors to be considered include
warranty and service requirements.
* It’s important to compare kW/100 cfm ratios at reduced capacity. Rotary compressors having variable displacement or variable-speed drive capacity controls might
provide substantial energy savings when
operating at reduced capacities.
** Any compressor requires appropriate
downstream air quality treatment.
*** Specific power kW/100 cfm based upon full
capacity at a discharge pressure of 100 psig
and a full-load motor efficiency of 92%.
Higher motor efficiencies are available.
Source: “Best Practices for Compressed Air
Systems,” a Compressed Air Challenge Publication (McCulloch and Scales 2007)
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The rotary-scroll compressor is a relatively new design in sizes from fractional
to 7.5 hp. Because of its small footprint,
multiple compressors and drives can be
mounted on a common base to provide
higher capacities. One of two identical
intermeshing spirals or scrolls is stationary and the other oscillates in relation
to the stationary scroll. (Editor’s note:
January 2008
D I S C O V E R
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EFFICIENCY
Compressors
go to www.PlantServices.com/scroll to
learn how the scrolls interact. Animation courtesy of Air Squared, Inc.) The
spirals are mounted with 180° phase
displacement to form air pockets with
variable volumes. As the moving scroll
orbits within the fixed scroll, the air
surge, where air flow reverses inside
the compressor. As the compressor
discharge pressure increases, flow
decreases. Eventually, the discharge
pressure can’t overcome the system
pressure and the air flow reverses,
going from discharge to inlet. Most
Variable-displacement or variable-speed capacity
control can improve part-load efficiency.
pockets diminish in size as they scroll
spirally towards the center. Most scroll
manufacturers limit maximum discharge pressure to 115 psig.
Dynamic compressors
A dynamic compressor uses highspeed impellers to impart velocity to
the air. A centrifugal compressor is
similar to a centrifugal pump, with
ambient air entering at the center of
a high-speed impeller that accelerates
the air radially. This velocity head is
translated to pressure head at the discharge volutes or diffusers.
The number of stages and impeller blade configuration determines the
operating pressure and flow rate. Most
industrial centrifugal air compressors
use a multi-stage design. Backwardleaning impeller blades can achieve
higher discharge pressures, but somewhat lower flow. Radial impeller blades
might achieve greater flow, but at lower
pressures. Your air demand and pressure
variation limitations determine the best
configuration.
Compressor manufacturers have
controls to avoid the phenomenon of
capacity controls automatically avoid
this condition at low demand. Typical
centrifugal compressor sizes start at
approximately 150 hp and the specific
power at 100 psig is approximately
15 kW/100 cfm to 20 kW/100 cfm.
Which do you need?
When comparing compressor types
for an application, it’s important to
consider the relevant factors and specific requirements (Table 1). For example, if the compressor is expected
to operate fully loaded, efficiency at
reduced capacity might be less important. However, if you anticipate wide
swings in air demand, then reducedcapacity efficiency might be a more
important factor.
Niff Ambrosino is general manager at
Scales Industrial Technologies, West Paterson, N.J. Contact him at [email protected]
and (973) 890-1010, ext. 230.
This article is based on information in the
Compressed Air Challenge publication, “Best
Practices for Compressed Air Systems” (2007,
David McCulloch and William Scales, P.E.).
Efficiency and loading – “Load ‘em up”
Air dryers 101 – “There’s more than one way to dry the air”
Unit cost of air – “How much is too much?”
Heat of compression calcs – “What does Mother Nature say about cooling hot air?”
Capacity control – “Finding the right match”
Speed-regulated drives – “Drive down the cost of compressed air”
Performance determinants – “Applying the pressure”
Dryer economics – “Don’t get hung out to dry”
Oil-free air – “Keep it clean”
For more, search www.PlantServices.com using the keywords cfm, compressor and
efficiency.
38
January 2008
1/10/08 3:19:03 PM
There is
science behind
preventing
slips and falls
By Ken Fisher
he axiom, “what is measured gets done,” applies to
preventing slips and falls if you measure the coefficient of friction (COF) of plant floors. Measuring
collects data and lays the basis for remedial and preventive
actions, which reduce injury, operational and other costs.
Data collection and follow-up entails:
• Measuring and recording the condition of your floors
• Improving, then maintaining, the floors to a desired benchmark level through effective treatments and proper care
• Auditing and documenting the state of floors to demonstrate due diligence, care and compliance with safety norms
Be wary of water.
A study of workers injured by slips and falls at U.S. Department of Energy facilities have showed that approximately
three-fourths of the indoor slip/fall events reported involved
water, according to the DOE.
Before doing anything else, benchmark the wet COF to record
Coefficient of friction definitions
Coefficient of friction (COF) is a number that indicates the
degree to which a floor is slip-resistant. The COF is determined
with an instrument that senses the slip resistance of a surface.
Both static and dynamic coefficient of friction measurements
are useful in determining floor safety.
Static coefficient of friction (SCOF) is the ratio of the horizontal force needed to start an object sliding to the force
pressing an object normal to the surface.
Dynamic coefficient of friction (DCOF) is the ratio of the
horizontal force needed to keep an object sliding to the force
pressing an object normal to the surface.
J 
PS0801_39_41_Flooring.indd 39
the slip resistance of the surface when it’s wet or contaminated.
This supports the rationale that if a floor is slip-resistant when
wet, it’ll be slip-resistant when dry. Quantify your results and
standardize your recordkeeping using a baseline COF, making
improvements and taking follow-up measurements.
Several organizations, including the insurance carrier CNA
and the National Floor Safety Institute, use or recommend a
device called the Binary Output Tribometer, or BOT-3000
(www.uwtlp.com). This is the only U.S. floor-testing device
that passes ASTM’s precision and bias standards, and can
measure both static and dynamic COF. The automated device
eliminates user variables that affect reading consistency. Digital
printouts and uplinks enable sharing, saving and storing data,
tracking trends and providing a legally-sound numerical trail
that documents improvements.
Raise traction
If a clean floor’s COF demonstrates that it’s slippery when
wet, apply a treatment or product to increase wet slip resistance. Two product categories have proven effective:
• Surface modifiers that increase traction on concrete, ceramic tile, quarry tile, stone, marble and similar surfaces
• Mop-on cleaners/treatments that raise traction on finished and other floors.
Surface modifiers improve the COF by chemically altering the mechanical properties of an unfinished mineral-based
floor. They produce micropores or imperceptible tread patterns
that render wet concrete, tile and stone floors safer to walk on.
Applying a penetrating sealer makes the surface more resistant
to soil. Slip resistance lasts several years with regular cleaning,
but reapplication should be handled by professionals. Surface
modifiers also are effective in showers.
39
1/11/08 10:34:18 AM
SAFETY
Flooring
Mop-on cleaners and treatments are
pH-neutral solutions with ingredients
that increase slip resistance. Though
dilution ratios are critical, unskilled labor can apply these water-based treatments for cleaning and slip resistance.
Once the floor achieves a COF safety
compliance benchmark of 0.5, 0.6 or
greater, (see sidebar: “COF standards”) it
needs regular, documented audits to prove
the floor is properly maintained and to initiate corrective adjustments as needed.
Implement polices and procedures
A written, enforced floor safety policy
and procedure guide can help improve
0OWERSWEEPINGREDElNED
safety, while demonstrating management’s commitment to prevention.
It should address common causes of
slips and falls, including poor worker
training, lack of weather contingency
planning, inconsistent hazard identification, inappropriate footwear and inadequate floor cleaning, among others.
It should detail how to perform and
document measurement, improvement
and maintenance of floor surfaces.
Teach and test new hires on these
documents; retrain employees annually. Document, fi le and send instruction and follow up to appropriate persons within the organization.
Learn from incidents
If people have already slipped or fallen,
examine the qualitative and quantitative loss data, where available, to help
identify how, where and under what
COF standards
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40
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To paraphrase OSHA, “A reasonable measure of slip resistance is static coefficient
of friction (COF). A COF of 0.5, which is
based upon studies by the University of
Michigan and reported in ‘Work Surface
Friction: Definitions, Laboratory and Field
Measurements, and a Comprehensive Bibliography,’ is recommended as a guide to
achieve proper slip resistance. A COF of 0.5
isn’t intended to be an absolute standard
value. A higher COF might be necessary
for certain work tasks, such as carrying objects, pushing or pulling objects, or walking up or down ramps [or on wet surfaces].
“Slip resistance can vary from surface to
surface, or even on the same surface, depending upon surface conditions and employee footwear. Slip-resistant flooring material such as textured, serrated or punched
surfaces and steel grating [or treatments]
might offer additional slip resistance. These
types of floor surfaces should be installed in
work areas that are generally slippery from
wet, oily or dirty operations. Slip-resistant
type footwear might also be useful in reducing slipping hazards.”
The American National Standards Institutes’ (ANSI) A 1264.2-2001 “Standard for
the Provision of Slip Resistance on Walking and Working Surfaces” recommends
a static COF (SCOF) of 0.5 for walking surfaces under dry conditions.
ANSI/NFSI B101.1 “Test Method for Measuring Wet SCOF of Common Hard-Surface
Floor Materials” recommends a SCOF of 0.6
on wet floors.
J 
1/9/08 11:46:28 AM
SAFETY
Flooring
Floor coating tests – “Using performance data to select floor coatings”
Anti-slip testing – “A look at portable slip meters”
Cleaning machines – “Planning a floor maintenance program”
Cleaning and restoration – “Clean up after yourself”
Catwalks and scaffolding – “High-minded safety is key to high-level work”
Non-slip flooring – “In search of slip-resistant flooring”
Textured flooring – “Selecting and maintaining textured floors”
For more, search www.PlantServices.com using the keywords flooring, friction and
slip resistance.
conditions the incidents occurred. Then,
appropriately plan and direct your remedial efforts. Performing physical inspections of incident areas might offer insight
about causes, enabling a more focused
and effective loss-control process.
Qualitative analysis examines conditions, frequency, severity and other
patterns. It determines what type of
footwear was being worn. It investigates whether there was a contami-
nant on the floor. It asks if “wet floor”
signs were in place. It checks to see if
there was a floor mat in place. It asks
whether this could have been a trip
fall, instead of a slip fall. It documents
the shift and time the event occurred.
Quantitative analysis, on the other
hand, determines the value or amount
of the losses, projects future losses based
on past losses, and estimates the overall
future cost of risk. This enables project-
ing a return on investment that compares
the cost of loss-control measures against
projected costs of business as usual. By
implementing a scientific, measurable,
audited and documented program that
identifies and prevents the causes of slips
and falls, you’ll reduce injuries, insurance
premium dollars and direct costs. Moreover, you will be protecting your employees, customers and future profits.
Kenneth Fisher is an advisor to the National
Floor Safety Institute (NFSI) and serves on
the NFSI/ANSI B-101 committee, which is
establishing a test method for measuring
wet static coefficient of friction of common
hard floor materials. He is chairman of a
sub-committee (NFSI/ANSI B-101-2), which
is developing a standard for chemicals
and treatments for hard tile surfaces. He
served on ASTM’s F-15 Committee dealing
with slip/fall issues. He can be reached at
[email protected] and (859) 493-0701.
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January 2008
41
1/9/08 11:47:12 AM
N T
BY JOHN CLARK
HOW TO
RUIN FAN
BEARINGS
Maintaining fan bearings to achieve long-term reliability
I
ndustrial fans play a critical role in a host of manufacturing activities, including the production of steel,
paper, cement and pharmaceuticals. Fan problems,
however, can reduce productivity and even bring production to a halt.
Bearing failure analysis demonstrates that most fan problems are preventable. Often, they can be traced to mistakes
associated with fan bearing installation or lubrication, such
as tightening locknuts while bearings are loaded or fi lling
bearing pillow blocks with excessive amounts of grease. The
following recommendations can help you avert common
bearing-related mistakes and keep the fans in your facility
running efficiently.
1. Get oriented
One cause of fan failure is confusing the fi xed and floating
bearing positions. A typical fan has two bearings supporting
the shaft. In most cases, the bearing exposed to the highest radial load should be fi xed, or axially held, within the
housing. Radial bearings generally perform better when the
axial-to-radial load ratio is low. Also, the axial force needed
42
PS0801_42_44_powertrans.indd 42
to float a bearing is lower when the radial load is lower (axial
force to move bearing = coefficient of sliding friction x radial
load, or Fa = µ x Fr).
The fan’s other bearing should be allowed to float internally or within the housing bore, thus accommodating shaft
expansion and contraction.
In most fan applications, the bearing closest to the motor or belt drive has the highest radial load and should be
the fi xed bearing. This is the case in most of the common
centrifugal fan arrangements – overhung belt-driven, center-hung belt-driven, and center-hung direct-driven fans.
Figure 1 shows the motor, bearing and rotor locations in
common centrifugal fan arrangements.
Overhung direct-driven fans are an exception to the rule.
Here, the bearing close to the motor is nearly unloaded and
should be allowed to float. The bearing farther away from
the drive handles the heavier radial load and should be fi xed
in the housing. Another case in which it might not be appropriate to fi x the most heavily loaded bearing is when the
fan rotor has a very tight clearance with surrounding structure (typically the inlet cone) in an overhung fan arrange-
J 
1/9/08 11:49:58 AM
EFFICIENCY
Power Transmission
ment. Here, it’s sometimes necessary to fi x the rotor-side
bearing so that thermal expansion and contraction of the
shaft doesn’t cause the rotor to rub.
Recently, at a steam-generation plant, roller bearings in
an overhung, direct-drive fan failed within two months of
installation. Production came to a halt while a replacement
fan was brought on-line. The cost of the shutdown was significant in diminished productivity and output.
The initial inspection revealed that the fi xed and floating
bearing positions had been reversed during installation. The
more heavily loaded bearing, which should have been axially
held, was allowed to float; the other bearing, which should
Avoid using tools made of softer
metals such as aluminum or brass
when installing fan bearings.
Basic fan types
Impeller attached
directly to motor
Held bearing
Direct-driven shaft with
cantilevered impeller
Free bearing
Held bearing
Direct-driven shaft with
straddle-mounted impeller
Free bearing
have been free, was fi xed within the housing. As a result,
roller skidding occurred during operation, leading to high
bearing operating temperatures, oxidation of the bearing’s
lubricant, and ultimate bearing failure.
Identifying the fi xed and floating positions and correctly
installing the replacement bearings solved the problem and
improved bearing life expectancy in the application.
2. Use the right tooling
You must use the right tools to avoid damaging the bearings.
Recommended installation tools include a set of feeler blades
to determine bearing clearance measurements, a steel hammer
and a hook spanner wrench. A fan bearing often is installed
inside a pillow block housing, on an adapter sleeve. The pillow block housing limits access to the bearing locknuts and
precludes using hydraulic mounting devices. Specialized hook
spanners, available from bearing manufacturers, provide better
access to the bearing within the pillow block base. These tools
allow installers to grip locknut notches securely and rotate the
locknut within the housing.
Avoid using tools made of softer metals such as aluminum
or brass when installing fan bearings. Pieces of the softer
metal can flake off during mounting and lodge in the bearing, causing premature failure.
3. Measure consistently
When measuring a bearing’s radial clearance, designate one
technician to perform all measurements. To obtain the correct
hoop stress on the inner ring, maintenance technicians should
take a series of radial clearance measurements when mounting
a tapered bore roller bearing. Failing to do so could result in the
bearing spinning on the shaft during operation.
No two workers have an identical touch with feeler blades.
To ensure consistency, the same person should perform the
J 
Held bearing
Belt-driven shaft with
cantilevered impeller
Free bearing
Held bearing
Belt-driven shaft with
straddle-mounted impeller
Free bearing
Figure 1. In these common bearing configuration for
centrifugal fans, the more heavily radially loaded bearing is
held or fixed in the housing while the other bearing is allowed
to float to accommodate shaft expansion.
clearance measurements on a bearing. A bench clearance
can be taken when the bearing is removed from its packaging. This verifies that the bearing was manufactured according to the correct specifications.
The starting radial clearance is measured with the bearing
loosely positioned on the shaft and under shaft load. Subsequent clearance measurements also are taken while the
bearing is under load. Using a moderate amount of force,
the technician inserts a feeler blade through the gap at the
12-o’clock position between the topmost bearing roller and
the bearing’s outer ring. The objective is to insert the thickest blade possible through the gap. The clearance should be
taken on one roller set at a time. This method establishes the
initial radial internal clearance.
This clearance reading serves as the baseline to measure
subsequent reductions in clearance during mounting. For
43
1/9/08 11:50:11 AM
EFFICIENCY
Power Transmission
example, if the starting radial clearance is 0.008 in. and
the recommended clearance reduction is 0.003 in., then the
clearance should be reduced until a feeler blade measuring
0.005 in. is the largest blade that can fit through the gap.
4. Don’t drag the rollers
After measuring the initial radial clearance with the bearing
under load, raise the shaft with a jack to unload the bearing.
Then the locknut can be tightened and the bearing driven
up the adapter sleeve. Inadvertently loading the bearing at
this point causes the bearing rollers to drag across the roller
paths, thus scoring the roller paths and damaging the bearing before it’s even operational. Verify that the bearing is
unloaded by rotating the bearing’s outer ring manually; it
should easily turn within the housing bore.
Once the bearing has been driven a certain distance up
the adapter sleeve, lower the shaft to take another bearing
clearance measurement. Repeat this process until you’ve
achieved the desired clearance reduction.
After installation, completely pack the bearing with
grease. Fill the base of the pillow block to a level equal with
the bottom of the shaft. Newer pillow block varieties sometimes have cast-in markings to indicate the correct grease
level. Don’t overfill the pillow blocks. Just as a person ex-
periences more drag when wading in waist-deep water than
in ankle-deep water, overlubrication causes more frictional
churning and drag inside the bearing, resulting in higher
internal friction and operating temperatures and a loss of
lubricant viscosity.
Relube software can estimate
the recommended relubrication
interval and grease quantity based
on factors including bearing type,
size and fan speed.
5. Add the lube
Fan bearings should be periodically relubricated. It’s best to
relubricate with smaller grease quantities at more frequent
intervals. Relube software can estimate the recommended
relubrication interval and grease quantity based on factors
including bearing type, size and fan speed. These programs
can reduce the risk of overfilling when relubricating. For example, if the relubrication program recommends adding 1
oz. of grease every month, the best approach would be to
inject 1/4 oz. weekly.
Once the fan bearings are back in operation, monitor them
for changes in vibration and operating temperature. Bearing lubricant can retain heat, causing operating temperatures
to rise. If you detect high temperatures, change out the old
grease, thoroughly clean the fan bearings and housings, and
refill with the initial grease filling. Even if operating temperatures remain normal, it’s a good idea to annually replace
old grease during planned maintenance shutdowns.
John Clark is an applications engineer at SKF USA Inc., based in
Kulpsville, Pa. Contact him for more information on fan bearing
installation, lubrication and maintenance at [email protected]
and (215) 513-4884.
Installing bearings – “Proper bearing removal and replacement”
Bearing designs – “Bearing misalignment”
Mothballing equipment – “Mothballing equipment when
demand falls”
Lubes & bearing failure – “Bearing lube basics”
Fan vibrations – “Don’t allow fan wheels to work with bad
vibes”
High-temp fan bearings – “Preventing fan failure at high temperatures”
For more, search www.PlantServices.com using the keywords
bearing, fan and grease.
44
January 2008
1/9/08 11:50:24 AM
WEB HUNTER
The power of element number six
Carbon dioxide is a common, but not the only, greenhouse gas
W
concept of carbon footprint at http://en.wikipedia.org/wiki/
e need to get past the debate about whether the
Carbon_footprint, a topic to which we’ll return shortly.
observed increase in the atmospheric concentration of carbon dioxide and other so-called
greenhouse gases can be attributed to anthropomorphic
Trees versus electrons
causes. Regardless of source, laboratories around the world
Getting this magazine to your desk requires the hewing
are measuring those increases with parts-per-trillion preand processing perfectly good trees, printing words and piccision. Then, we’ve got to get past jawing about the vatures, and burning hydrocarbons to get them to the nearest
lidity of any correlation between the increases in concenpost office. No doubt, that chain of events involves the retration and rising temperatures. There’s just
lease of lots of greenhouse gases. Maybe you
too much rhetoric surrounding these issues.
decide you’re going to get your news and inSometimes it all sounds like the crew arguformation via the good old Web. That’s more
A simple tally
ing about who poked the hole in the hull
eco-friendly. Says who? Certainly not Martin
of the statewhile the sinking boat takes everyone to pay
Stabe, a U.K.-based blogger. One of his essays
by-state totals
a visit to Davy Jones.
points out that the massive, worldwide comsays the country puter system needed to connect your screen
No argument matters nearly as much as the
way you’re going to cope with the hand you’ve
to some location out there in the void on the
is putting out
been dealt. OK, so what? Things are getting
world’s largest disk drive requires a surprising
5,799 million
warmer. Crank up the air conditioner, which
number of gigawatts. Several other amazing
tons of carbon
requires more electricity, which requires
large-scale tidbits of information await the cueach year.
burning more coal, which results in more
rious maintenance professional who ventures
atmospheric carbon dioxide, which might be
to www.martinstabe.com/blog/2006/12/09
jacking up the warming, which requires more
and scrolls down to “What is the media’s carair conditioning. And around and around we go. Maybe
bon footprint, in print and online?” If you go there, follow
that’s not the best way to cope.
some of the links in the story.
In the interest of broader intellectual horizons, we now
get our hands dirty searching for carbonaceous stuff in that
How much carbon is that?
morass we call the Web. Take advantage of the practical,
Last month, I mentioned the Virgin Earth Challenge
zero-cost, noncommercial, registration-free resources we’ve
and its $25 million prize for producing a worldwide net
uncovered. You’ll sound like an expert. Remember, we
removal of manmade atmospheric greenhouse gases
search the Web so you don’t have to.
each year for at least 10 years without any negative unintended consequences (you can read about it at www.
plantservices.com/articles/2007/227.html). Then, someThe public encyclopedia
where I read that the best answer to this global warming
The greenhouse gas situation might not be as bleak as some
issue is to stop taking carbon out of the ground and putpeople would have you believe. This good news comes from
ting it into the air. That image got me thinking about just
a generally reliable source. Did you know that the United
how much carbon is involved. So, I dropped in at www.
States ranked only 10th in the world based on per-capita
eredux.com/states/index.php, a site of unknown parentage
carbon dioxide emissions between 1990 and 2004? Also,
that purports to have an accurate tabulation of carbon footthe United States ranked 14th in per-capita greenhouse gas
prints for each of the 50 states. For example, the site ranks
emissions in 2000. So says Wikipedia, the online authorIllinois, with its 230 million tons of carbon output, as fifth
ity on so many obscure facts and figures. Where else would
in population, 30th in per-capita carbon output and 7th in
you learn that the size of your personal carbon footprint is a
total carbon output.
function of your age? Spend a few moments to research the
January 2008
PS0801_45_47_WebHunt.indd 45
45
1/9/08 11:50:52 AM
WEB HUNTER
A simple tally of the state-by-state totals says the country
is putting out 5.799 billion tons of carbon each year. The
site is ambiguous, however, about whether this refers to elemental carbon or carbon dioxide equivalents. Let’s assume
it refers to the elemental form. The bulk density of carbon
(as graphite) is 2.267 g/cm 2. Do the math and you’ll see that
1 million tons of elemental carbon is equivalent to nearly
524,000 cubic yards of the stuff. That’s a cube more than
240 ft. on a side. But, that represents only 1 million tons.
We’re talking nearly 5,800 times as much. Now, we have
a cube 4,344 ft. on a side. In one year, in one country. As
an aside, if the Web site meant CO2 equivalents, then the
4,344 figure drops to 1,186 ft. on a side. Anyway, it’s starting to seem like a lot of work for a measly $25 million.
Bigger bang for the buck
When it comes to having the power to destroy the world
as we know it, carbon dioxide actually is small potatoes.
It’s only one of a list of compounds that are lumped together as greenhouse gases. Some of those other chemicals persist in the atmosphere for eons, all the while
exerting a greenhouse effect thousands of times greater
than that of the puny ol’ CO2 molecule. For example,
tetrafluoromethane and sulfur hexafluoride are big baddies in the world of nasty gas, according to “Reducing
your carbon footprint? Think fluorine first,” an article by
Sébastien Raoux, Ph.D., president and CEO of Transcarbon International Corp., San Francisco. He argues
that, regardless of how important and useful fluorocarbons are, we’re better served by minimizing their use and
selecting only suppliers whose production processes use
as little of these as possible. Raoux also talks about the
potentially bizarre economics of the market for fluorocarbon emission trading. Take a read at www.cmsforum.org/
Fluorocarbon_Article_SRaoux_CSP.pdf for the details.
Bad water
Fully three-quarters of this third rock from the sun is
covered with water. Warmer water evaporates faster than
cooler water. The environment is getting warmer. The
confluence of those three tidbits bodes ill for this business of global warming. The reason is that water vapor, in
the absence of other nasty atmospheric chemicals, is itself
a kind of beneficial greenhouse gas. Unfortunately, those
beautiful clouds are now making things worse, according
to a story brought to you by National Public Radio. If you
want to read about the world’s original greenhouse gas,
pledge your mouse at www.npr.org and plug the number
15662891 into the search function at the top center. This
returns a link to the article in question. In fact, you don’t
46
even need to know how to read because you can listen to
the audio clip that was broadcast on October 29, 2007.
Space hogs
The world is an interactive place. Creature A makes a move,
creature B responds. It’s that free will thing we’ve all heard
about. So, we go about our lives engaging in our individual
lifestyles. As fun as your resulting standard of living might
be, it’s somewhat removed from the land and water resources that make it possible. Those resources are what constitute
your personal ecological footprint. It seems to me that the
world might even be a zero-sum game when it comes to the
When it comes to having the
power to destroy the world as we
know it, carbon dioxide actually
is small potatoes.
environment. If your standard of living requires no more
than your pro rata share of the total possible resources, you’re
a good world citizen. But, what with the world’s exponential
population growth, your fair share is actually appallingly
small. To get a sense of how small, drop in at www.eart
hday.net, click on “Ecological Footprint,” pick your country
and language, and answer 15 lifestyle questions. The Earth
Day Network, Seattle, then informs you of the implications
of having everyone on earth enjoy a lifestyle identical to
your own. It’s an eye-opener. Just for grins, take the test
again with the intent of minimizing your share. It’s harder
than you think.
The corporate tally
So, the equity markets will soon be asking how much
greenhouse gas can be attributed to your day-to-day plant
operations. Obviously, the answer isn’t going to come off
the top of your head, nor is it easy to formulate, nor is it as
low as you think. But the answer can be determined objectively if you’re diligent and kept appropriate records. For
guidance, I’d direct you to the Greenhouse Gas Protocol
for a pair of helpful standards. The one called “Corporate
Accounting and Reporting Standards” uses 148 pages to
show you how to quantify your plant emissions. The standard called “Project Accounting Protocol and Guidelines”
is a 116-page policy-neutral tool for quantifying the benefits to the climate that result from your capital projects
designed to reduce greenhouse gas output.
Both are published as a joint venture by two organiza-
January 2008
1/9/08 11:51:01 AM
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A bad trade
http://news.bbc.co.uk/2/hi/science/nature/7092989.stm
www.global-alliance-foundation.com/carbon.asp
E-mail Executive Editor Russ Kratowicz, P.E., CMRP, at [email protected].
Scrap disposal – “Spinning garbage into gold”
Energy mgmt services – “Energy management goes high-tech”
Solar energy – “Where the sun shines”
Energy conservation trends – “Don’t wait for dark”
Wind power – “From breeze to kilowatts”
Green overview – “Growing green plants”
Going green – “Does it pay to be green?”
Geothermal-based HVAC – “Better than a gold mine”
For more, search www.PlantServices.com using the keywords
atmospheric, carbon and greenhouse.
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47
1/10/08 3:05:11 PM
IN THE TRENCHES
The scenario presented here is based on a true story;
only the names have been changed to protect the innocent.
Removing the thorn
Acme learns a lesson about its strategy for paying off a leveraged buyout
A
cme Associates, a maintenance consulting firm, focuses on mega-malls, high-rise offices and other large
commercial facilities. The company realized there
were opportunities in the industrial market. Acme knew how
to consult and run an outsourced maintenance management
operation, but unfortunately it had no industrial experience.
Through some creative financing, Acme Associates bought
Nadir Consulting, an established, privately-held industrial
maintenance consulting firm. The owners, secure financially,
wanted to drop the daily grind. Acme needed Nadir’s loyal client base. The buyout gave Acme marketplace credibility.
Acme established a subsidiary, Acme Industrial, to serve
Nadir’s customers and other industrial clients it identified.
Acme began staffing the subsidiary with its own employees
who either wanted to do industrial work or had no realistic
promotion path within Acme Associates.
Then, Acme discussed employment opportunities with a
few Nadir consultants who possessed two critical skills: they
proved they could bring in new work and they could generate sufficient billable hours on existing contracts to justify
hiring them. One non-union Nadir employee Acme considered was Dawn Keyotey, a reliability consultant with years
of experience in the traditionally male-dominated field.
To make the deal work, Acme had to keep costs low. It
negotiated compensation packages with the Nadir employees that were generally less favorable than what Nadir paid.
For example, their Nadir rates were generally below what
Acme paid its own people. Nevertheless, Dawn accepted a
position at Acme Industrial even though her commission
schedule wasn’t finalized.
Despite that uncertainty, Dawn racked up billable hours
and found much new work. When she finally received a
copy of the commission schedule for new business she uncovered, she was shocked to find Acme would be paying a
seasoned consultant at such a low rate. She contacted the
other Nadir consultants and learned that they, too, were
given lower rates.
After giving this some thought, Dawn sent an e-mail to
the Acme executive team on her own behalf and that of her
Nadir colleagues to report their collective opinion that the
commission schedules are much too low for skilled, experienced industrial consultants. She also sent a copy of the
48
PS0801_48_50_Trenches.indd 48
e-mail to Al Geeblume, the Acme manager responsible for
the geographic region in which Dawn operated. On both of
these memos, Dawn signed off as “union president.”
Dawn then repeatedly asked Emma Rilldile, Acme’s HR
manager, to meet with her and the Nadir group to discuss
their concerns about the pay and other issues. When it
became clear that she wasn’t going to get a response, she
changed tactics. At each weekly field consultant meeting, Dawn raised compensation matters on behalf of her
Nadir colleagues. With that cat now out of the bag, the
other Nadirites became more emboldened to voice their
complaints about how Acme was treating them, the management structure, and the executives that constitute that
structure. When Dawn received her first commission check
under the new plan, the amount was incorrectly calculated.
This only gave her more complaint fodder. Nevertheless,
it didn’t dampen her motivation to continue searching out
even more new business. She needed the money.
Two months later, Al and Emma met with her in what
Dawn thought was going to be a reconciliation of financial
injustices and celebration of her success as a rainmaker. But
she was tragically wrong – in vicious retaliation for her endless carping, Al and Emma fired her without warning, then
danced a jig of victory with her confiscated Nadir company
laptop. Now the remaining former Nadir consultants could
complain about her termination that wasn’t done in accordance with the progressive disciplinary process outlined in
January 2008
1/9/08 11:52:13 AM
IN THE TRENCHES
Acme’s own employee handbook.
How could this situation have been avoided? Should employees
have any say in their own compensation package? Can Dawn’s
actions on behalf of the other Nadirites justify her claim to be
a “union president?” Does it make sense for Acme Industrial to
have different compensation packages for its own consultants and
those it cherry-picked from the Nadir lineup?
An attorney says:
Employers sometimes think they don’t have any concerns
under the National Labor Relations Act when they are dealing with non-union employees. Such isn’t the case.
The NLRA gives employees the right to engage in “concerted” activity for the purpose of collective bargaining,
mutual aid or protection. “Concerted” means a group of employees or even one employee, such as Dawn, who is speaking on behalf of colleagues. The NLRA further prohibits
employers from interfering with an employee’s right to engage in protected concerted activity. Put in simpler terms,
an employer can’t terminate an employee for speaking out
on behalf of a group of employees in an effort to better their
compensation or working conditions.
Was Dawn a union president? No. At the outset, there
was no union — Acme didn’t voluntary recognize a union
as the representative of its employees, and the NLRB didn’t
certify that a union represented Acme’s employees. If there
was no union, Dawn could not have been its president.
Apart from the termination of Dawn “in vicious retaliation for her endless carping,” Acme was free to offer any
commission scheme it wished, fair or unfair, higher or lower
than the commission scheme Nadir offered. If an employee
doesn’t wish to work for the compensation the employer offers, she is always free to decline the offer of employment.
That isn’t to say that employees don’t have a say in their
compensation. Applicants negotiate for more salary and
benefits all the time. But the best time to negotiate is when
the employee hasn’t yet accepted the offer of employment.
Dawn was either naive or precipitous in accepting a job
without knowing the commission arrangement. For the
protection of both employer and employee, commission arrangements should always be put in writing.
It doesn’t make any sense for Acme to pay its own employees working for Acme at a higher rate than it pays the
employees from Nadir. That unwise decision sparked the
chain of events that will no doubt result in Acme reinstating
Dawn to her position and paying her back pay.
Julie Badel, partner
Epstein Becker & Green, P.C.
(312) 499-1418
[email protected]
January 2008
A corporate consultant says:
Acme doesn’t understand the industrial consulting business. Creative financing is the first clue that due diligence
wasn’t done. Proven performers with strong client relationships should be embraced and cultivated. Also, the way to
build an engaged and productive merged team is through
communication excellence and building trust by acting with
integrity. Neither party did either.
Dawn’s nonproductive dialogue was off-target. The former Nadir group could have presented a logical, rational
business case for their position. Business would likely take a
major hit if they no longer serviced their customers. Presenting a plan for resolving the compensation issue would have
been a positive step. Most businesses provide some latitude
on various aspects of compensation. Had a productive dialog taken place, the Nadir employees might have accepted
greater risk in return for increased bonus potential.
Dawn continued to produce in the face of compensation
ambiguities. Seeing her squashed most likely caused the
other former Nadir employees to dust off resumes, backup
laptop data and begin a job search.
Dawn’s actions on behalf of the others can’t justify a
claim to be “union president.” Regardless of intention,
the phrase resulted in a defensive posture by management. This illustrates an important moral: professionalism builds rapport, over-familiarization can lead to
unintended consequences. Management’s posture didn’t
promote communication or trust and Dawn’s self-appointment signaled that Nadir employees might be disruptive. If communication and trust are low or known to
be poor, it’s best to act with integrity.
Dawn didn’t use good judgment by sending e-mails to
corporate executives instead of going through her “chain of
command.” Al might have been an ally had she not gone
over his head. That probably put him in the position of explaining why one of his people was so disruptive.
It makes no sense for Acme to have different compensation packages for its own consultants and those from Nadir. While it’s legitimate to have job classifications based
on experience and education, differences between legacy
and new employees won’t help build a team. Equal pay for
equal responsibility and capability should be the norm. It
makes no sense to start the relationship with conflict. This
is particularly true when legacy Acme employees lacked
the industrial consulting experience of the former Nadir
staff members.
Tom Moriarty, P.E., CMRP
Organizational Reliability Professional Services Consultant
(321) 773-3356
[email protected]
49
1/9/08 11:52:19 AM
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50
A major determinant of job satisfaction is fairness or equity.
People want to be treated fairly and get upset if they perceive
unfair treatment. In fact, fairness, or lack thereof, is a strong
predictor of absenteeism, quitting and work sabotage.
Fairness has a couple of important dimensions. The fi rst
is that employees want to know they’re being treated like
everyone else in their position. That is, if two do the same
work, then both should receive the same pay and benefits.
Employees want to receive fair pay given their training,
experience or work output. This is more subjective than the
point above, but employees usually compare themselves
with others inside or outside the organization who do similar work or have similar training and experience. The classic
case is of the female hospital nurses with extensive training
being paid less than the male building supervisors, many of
whom didn’t have a high school diploma.
By either of these criteria, Acme is off the mark in its payments to Nadir consultants. One could see problems arising
on this one. Sooner or later, the Nadir people would find out
that they’re now second class citizens. Acme should have integrated the two consulting groups, shared their knowledge
and resources, used the same pay and benefits structure, and
in that way reaped the benefits of the acquisition.
Acme should have paid its consultants the same rate at
the time of the acquisition. It didn’t, but had an opportunity
to correct the error with Dawn’s complaint. Again, it didn’t
correct the problem; rather it compounded the problem by
fi ring Dawn. Acme needs to hire a consultant to explain to
it how to run an effective consulting fi rm.
Professor Homer H. Johnson, Ph.D.
Loyola University Chicago
(312) 915-6682
[email protected]
Ever since late 1994, Francie Dalton has been offering her
practical wisdom and penetrating insights to the hapless characters at Acme. At the end of 2007, she told us this was a good time
to step out and present an opportunity for some fresh perspective
to tackle those “In the Trenches” HR issues. We appreciate every
word she’s written during her tenure as a contributor to one of the
most popular features in Plant Services. We wish her the best.
Our new correspondent, Tom Moriarty, P.E., CMRP, is
president of Alidade MER, Inc. and an organizational reliability professional specializing in industrial maintenance, reliability and leadership. During his more than 28 years of experience,
he’s been active in the Society of Maintenance and Reliability
Professionals, a Past Chair of the Canaveral, FL Section of the
American Society of Mechanical Engineers, and a member of the
Navy League and Military Officers Association of America.
J 
1/9/08 11:52:29 AM
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software for quick instrument setup and data downloads.
Fluke Corp.
(888) 308-5277
www.fluke.com
INSULATED TOOLS PREVENT
JOLTS FROM VOLTS
The 1,000-Volt Insulated Tool Line totals more
than 350 individual SKUs and includes screwdrivers, pliers,
cutting tools, wrenches, drive tools and keys, and insulated gloves. The
tools are easily identifiable by their thick layer of orange plastic insulation, which protects users from shock when working on live circuits to
1,000 VAC and 1,500 VDC. The tools come in two grades, each aimed at
different work environments. VE Series tools are designed for craftsmen
who install and maintain standard electrical equipment and wiring. VSE
Series tools are for use around the highest live voltages.
Stanley-Proto
(800) 800-TOOL
www.stanleyproto.com
GASKETING MATERIAL MINIMIZES VOC EMISSIONS
The Style 3575 Sage GYLON gasketing material for severe chemical service applications reportedly features superior load retention, reduced
permeability and improved sealability characteristics. The Sage
GYLON PFTE gasket is specifically designed to help plants minimize emissions from hazardous
solvents and chemicals, including volatile organic compounds
(VOCs). Withstanding high pressure and temperatures from -450°F to
+500°F, the gasket can be produced in any size in one-piece construction
to meet gasketing needs for large-diameter equipment.
MAKE A PULL BOX IN SECONDS
The EZ Form pull box features a flat design that consumes minimal
volume for easy storage in the warehouse and on service trucks,
where space is at a premium. The pull boxes can be hand-formed
in 15 seconds or less, making them a convenient solution for installations where an extra pull box is required to fill an unanticipated
need. Forming is quick and easy by bending along pre-scored
fold lines, and the sides of the box interlock and snap into place
without the use of tools. The pull boxes feature 16-gauge steel
construction and flat covers, which may be removed for easy wiring access.
Hoffman Enclosures
(763) 422-2211
www.hoffmanonline.com
PLASTIC PINCH VALVE YIELDS HIGH CYCLE LIFE
The Series HSA all-thermoplastic, air-operated pinch valve features a long-lasting sleeve element with variable thickness and
a tapered shape. The sleeve element is molded from EPDMh2, a
new formulation of ethylene-propylene-diene-monomer using a
proprietary curing process for
greater elasticity and durability. This elastomer, combined
with the new design, enables
the pinch element to achieve
more than 1 million cycles
under test conditions. The
pinch valve has ½-in. true
union connections, threaded
or socket. It uses compressed
air via a 1/8-in. NPT connection,
and requires a common threeway air solenoid to operate, with 45 psi over line pressure for full
closure. Valve body materials are offered in Geon PVC, Corzan CPVC,
natural polypropylene and Kynar PVDF.
Garlock
Plast-O-Matic Valves
(800) 448-6688
www.garlock.com
(973) 256-3000
www.plastomatic.com
January 2008
PS0801_51_Products.indd 51
51
1/10/08 2:06:27 PM
CLASSIFIEDS
Products and Services
Out
LED Stroboscope
cessing.com
Search Savvy™ for
the Food Industry
Partner with the leader of the
food recruitment industry.
www.people-capital.com
630.321.1599
Out
The brightest,
fully featured
LED strobe
NiMH battery life
up to 10 hours
● Pulse Width Modulation
for sharp images at high speed
● Up to 120,000 fpm/rpm
● Push button x2 and ÷2
● 359° Digital phase shift by 1°
● Store up to 19 flash rates in memory
● Rugged aluminum housing
●
866-527-4666
www.hoto-instruments.com
www.plantservices.com
REPRINTS
are available on a custom basis from
FosteReprints
Contact Claudia Stachowiak at 1-(866)-879-9144 ext.121 or at
[email protected]
52
PS0801_52_Classifieds.indd 52
1/11/08 11:23:58 AM
January 2008
1/11/08 11:29:40 AM
FAST FACTS
ADVERTISER
PAGE
ADVERTISER
Advance
40
Curtis-Toledo
AitkenProducts
24
DonaldsonCompany,
Inc.Ultrafilter
AmericanPowerConversion
11
AmericanTechnicalPublishers
36
PAGE
31,33,35,37
EmersonProcessMgmt.,
MicromotionDiv.
AppliedIndustrialTechnologies
MicrowestSoftware
32
QuincyCompressors
IBC
Ramsay
36
Rexnord
47
ShepardNiles
50
4
6
47
Fluke
PAGE
17
FlirSystems-Imaging
ApexEngineering
ADVERTISER
IFC,20
27
SPXDehydrationand
ProcessFiltration
18
GardnerDenver
12
BC
Sullair
3
8
Sulmac
44
ARCAdvisoryGroup/
AutomationResearch
25
Inpro/Seal
BaldorMotorsandDrives
19
KaeserCompressors
BentlySystems
41
MacroAirTechnologies
22
UESystems
50
ColumbusMcKinnon
14
MACTek
38
Vaisala
16
PLANT SERVICESSALES oFFICES
MIKE brEnnEr
Group puBLISHEr
Arkansas, Northern California,
Minnesota, oregon, Washington
Phone:(630)467-1300,ext.487
Fax:(630)467-1120
e-mail: [email protected]
MIKE balzano
DISTrICT MANAGEr
Alabama, Arizona, Southern California,
Colorado, Idaho, Illinois, Iowa, Kansas,
Kentucky, Louisiana, Michigan,
Mississippi, Missouri, Montana, Nebraska,
Nevada, New Mexico, North Dakota,
oklahoma, South Dakota, Texas, utah ,
Wisconsin, Wyoming, ontario/Canada
Phone:(630)467-1300,ext.425
Fax:(630)467-1120
JErrY bUrnS
DISTrICT MANAGEr
Connecticut, Delaware, Florida,
Georgia, Maine, Maryland,
Massachusetts, New Hampshire,
New Jersey, New York, North Carolina,
rhode Island, South Carolina, Vermont,
Virginia, Washington D.C., West Virginia
Phone:(630)467-1300,ext.427
Fax:(630)467-1120
SCoTT WalTErS
DISTrICT MANAGEr
Indiana, ohio, pennsylvania, Tennessee
Phone:(630)467-1300,ext.805
Fax:(630)467-1120
SUbSCrIPTIon InForMaTIon
(888)644-1803or
(847)559-7360
rEPrInTS
foster reprints, (866)879-9144
www.fostereprints.com
January 2008
PS0801_53_AdIndex.indd 53
MICHaEl ConnaUGHTon
ACCouNT EXECuTIVE
Alberta/Canada, British Columbia/Canada,
New Brunswick/Canada, Quebec/Canada,
postcards, Literature reviews
Phone:(630)467-1300,ext.804
Fax:(630)467-1120
PollY DICKSon
INSIDE SALES MANAGEr
Classifieds, product Spotlight
Phone:(630)467-1300,ext.396
Fax:(630)364-4175
FaITH DalTon
INSIDE SALES MANAGEr
Digital Sales
Phone:(630)467-1300,ext.485
Fax:(630)467-1120
PUTMan MEDIa, InC.
555W.PierceRd.,Ste.301,Itasca,IL60188
Phone:(630)467-1300,Fax:(630)467-1120
53
1/11/08 1:48:31 PM
energy eXPerT
2008: The year of energy integration?
Combining forces leads to breakthroughs in energy productivity
T
text of some year-end reflections was the visit we made on
he start of a new year is a time to reflect on the past
the third day to the Gersthofen Industrial Park near Augsand look into the future. This is a particularly interburg in Bavaria. An integrated past is ever-present at the inesting time for energy. In 2007, we’ve seen a growdustrial site, founded in 1900 by Hoechst to take advantage
ing awareness of the crucial and rising impact of energy seof integrating run-of-river hydroelectricity with canal transcurity, cost and pollution to the success of our companies,
portation. During the past century, it has evolved into an
our economy and our communities.
industrial park home to 12 companies and facilities. Rather
While this visibility is a welcome change, much of the curthan each of these facilities being an independent “energy
rent energy discussion is disjointed and has shades of “magic
island,” Gersthofen Park gives us a glimpse of benefits that
bullet” thinking. It focuses on isolated actions and technolocan be gained by energy integration.
gies, and rarely captures the benefits of integration discussed so many times in this
Energy services are provided by a dedicolumn. When companies, communities
cated company all the factories use. This
recommendations… company, an affiliate of MVV Energie, the
and even entire countries or regions conare rewarded with
sciously put together programs to educate
city utility in Mannheim, provides eleccash payments.
and reward people and implement end-use
tricity and gas, as well as process steam,
efficiency measures, heat recovery, efficient
heating, compressed air, oxygen, water
energy distribution and lower-carbon fuel
and wastewater along with security, site
choices, the results are breakthroughs in energy productivity.
rail transportation and other services. The high level of inThese breakthroughs fundamentally change the economic,
tegration results in lower costs, reduced pollution and greater
political and environmental playing field for energy.
reliability. It also is easier to adapt the service mix to accommodate changing end-user needs and available technologies.
In the industrial context, one of the most obvious areas
Duplication of equipment and staff is minimized.
is heat recovery. I never fail to be amazed by the frequent
Efficiency also is part of the offering, with tenants and the
assumption that the massive amounts of heat produced as
service company meeting regularly to review and implement
byproducts of industrial processes and generating electricity
recommendations from any of the 1,600 employees or 12
are nothing more than waste products to be eliminated with
companies. These are rewarded with cash equal to at least 10%
costly cooling towers using vast amounts of valuable water.
of the annual savings for the individuals or teams concerned.
One of my industrial clients has declared 2008 to be the
year when heat recovery will be a major strategic focus, recThis level of integration doesn’t happen by chance. It reognizing the value of the millions of dollars wasted on valuquires a slew of changes in management attitude, utility and
able fuel. A group of senior operational managers from the
municipal regulation, acceptance of new operating practices
United States and Europe recently gathered in Germany, a
and implementing unfamiliar technical approaches. This
country that has long recognized the value of heat recovery
100-year-old industrial site has evolved from a late 19th to a
in both industry and community. In a couple of days, they
21st century example of the clear benefits of energy integrawere updated on different heat-recovery strategies, technoltion, and remains globally competitive.
ogies and management approaches. By the end of the two
Industrial energy productivity strategies will increasingly
days, the group not only had gained some new knowledge,
demand the rational integration of efficiency, heat recovery, cobut developed a lengthy list of possible heat-recovery and
generation, renewable and traditional energy sources in a single
cogeneration actions that collectively will save a significant
seamless approach. Will 2008 be the year when you accelerate
amount of money. Heat recovery strategies generally also
the implementation of these approaches in your plants?
create over-proportional reductions of greenhouse gases, a
major factor in an increasingly carbon-conscious world.
Peter Garforth is principal of Garforth International LLC, Toledo,
What mainly caused me to think of this event in the conOhio. He can be reached at [email protected].
54
PS0801_54_EnergyEx.indd 54
January 2008
1/10/08 2:06:45 PM
John Wayne— the “Duke,” a legend onscreen and off. His stature,
tough-as-nails style and steadfast convictions conveyed enduring
strength. He represented true grit — and the epitome of what is best
about America. His friends and fans knew they could always count
on him — whether for honesty and reliability or for a stellar performance.
Like the Duke, our QR-25 heavy-duty compressor’s work ethic is legendary. Since it was introduced in 1937, the QR-25’s quality, durability and
dependability have been rock solid. How’s that for true grit?
For more information, visit
www.quincycompressor.com/truegrit
© 2007 Quincy Compressor an EnPro Industries company
John Wayne used with permission of Wayne Enterprises.
www.johnwayne.com
1/9/08 11:58:17 AM
WHAT’S PROTECTING YOUR
MOTOR BEARINGS? NOTHING.
Unless you specified the IEEE-841 for severe duty service, your motors are
unprotected from contamination entering the bearing environment. A fact of
life. According to maintenance professionals, the root cause of 75% of all motor
failures are traced to failed bearings. Protect the bearings, save the motor.
Inpro/Seal Bearing Isolators:
•
•
•
•
•
provide permanent bearing protection
are non-contacting
require no maintenance
consume zero energy
are guaranteed to double the lifetime of your motors
For in-depth information on motor isolator designs and how they operate, go
to www.inpro-seal.com. Same day shipments are available at no extra charge.
Custom designs can be made for your exact requirements. Visit www.inpro-seal.
com or phone 800-447-0524.
INPRO/SEAL
THE ORIGINAL BEARING ISOLATOR
NOTE: NEMA Premium motors and IEEE-841 motors, installed with Inpro/Seal Bearing
Isolators standard, have equal efficiencies.
1/9/08 11:58:31 AM

Don`t risk lives, reliability and profits just to save a

Transcription

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