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CONTENTS
FEATURES:
Setting the Stage for Smart Manufacturing.............................................................................................9 Take the Pain out of System Design and Startup with Drives Configuration Software...............................10 Innovative Robotic Palletizing System Highlights Manufacturing and Distribution Center .......................12 Recent Evolution in Industrial Manufacturing Leads to Improved Quality, Better Output .........................13 Protect Your Home and Family with Backup Power Supplied through a Transfer Switch ...........................14 Alternative Backups Sources on the Rise................................................................................................15 Three-Part Safety Portfolio Reduces Arc-Flash Risk................................................................................17 Optimize Maintenance and Energy Efficiency Monitoring Motor Operation Yields Significant Savings..........................................................................18 MIT Study Creates Electroindustry-based Method for Mapping Products to Energy Use and GHG Emission...........................................................................................................20 Applying the Law of Conservation of Energy..........................................................................................22 Fire Pump Motor ControllersAt the Heart of Life Safety .....................................................................24 1IS IEC Participation Grows...................................................................................................................25 Energy Efficiency Improvement with Permanent Magnet Motors and Variable-Frequency Drives..............26
ECO BOX
NEMA electroindustry text and cover pages are printed using SFI certified Anthem paper using soy ink. SFI certified products come from North American forests managed to rigorous environmental standards. SFI standards conserve biodiversity and protect soil and water quality, as well as wildlife habitats. SFI forests are audited by independent experts to ensure proper adherence to the SFI Standard. SFI participants also plant more than 650 million trees each year to keep these forests thriving.
Publisher | Joseph Higbee Managing Editor / Editor in Chief | Pat Walsh Contributing Editors | William E. Green III Chrissy L. S. George Economic Spotlight | Timothy Gill Standards | Vince Baclawski Government Relations Update | Kyle Pitsor Art Director | Jennifer Tillmann Media Sales Team Leader | Stephanie Bunsick
electroindustry
electroindustry (ISSN 1066-2464) is published monthly by NEMA, the Association of Electrical Equipment and Medical Imaging Manufacturers, 1300 N. 17th Street, Suite 1752, Rosslyn, VA 22209; 703.841.3200. FAX: 703.841.5900. Periodicals postage paid at Rosslyn, VA, and York, PA, and additional mailing offices. POSTMASTER: Send address changes to NEMA, 1300 N. 17th Street, Suite 1752, Rosslyn, VA 22209. The opinions or views expressed in electroindustry do not necessarily reflect the positions of NEMA or any of its subdivisions. Subscribe to electroindustry at www.nema.org/subscribe2ei Contact us at comm@nema.org Follow NEMA: www.nema.org/facebook, blog.nema.org, podcast.nema.org, twitter.com/NEMAupdates, www.youtube.com/NEMAvue, www.nema.org/linkedin
CONTENTS
NOTES:
NEMA Officers........................................................................................................................................................................................3 Comments from the C-Suite..................................................................................................................................................................3 View from the Top..................................................................................................................................................................................4 Learn More..........................................................................................................................................................................................IBC
27 29
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ELECT NERAL LAND GE / 2%) 9. PORT 2,223 (4% 82 RIC CO,
DEPARTMENTS:
Government Relations Update................................................................................................................6 IEEC Promoting Efficiency through Automation...................................................................................................................................6 Cyber Threat Looms Over 113th Congress..............................................................................................................................................6 President Signs Energy Efficiency Bill into Law.....................................................................................................................................7 NEMA Welcomes Vote to Normalize U.S.-Russia Trade Relations.........................................................................................................7 OSHA Revised Hazard Communication Standard Comes Online..........................................................................................................8 CPSC, Industry Prepare for 2013 Activities............................................................................................................................................8 Electroindustry News...........................................................................................................................27 2012 Motor Summit Convenes in Zurich............................................................................................................................................27 Medical Imaging Industrys Leadership to Protect Patients from Unnecessary Radiation................................................................28 ESFI Recognizes Electrical Safety Leaders...........................................................................................................................................29 Magnet Wire Section Elects David Reed Section Chair.......................................................................................................................29 NEMA Board Approves New Members:..............................................................................................................................................29 Innovation Incentive: How to Engage Suppliers and Drive Innovation..............................................................................................30 Code Actions/Standardization Trends....................................................................................................31 ANSI C12 Electricity Metering and Smart Meter Updates..................................................................................................................31 International Roundup........................................................................................................................32 NEMA Launches Latin America Initiative............................................................................................................................................32 Economic Spotlight.............................................................................................................................IBC
t as of August 2012; includes utilities ot receive American Recovery and 2009 (ARRA) funds.
31
Source: U.S. EIA, form EIA-861 Data, 2011 (file 8)
Contact us at zpryme.com and smartgridresearch.org to learn more about how Zpryme Smart Grids Practice can help you better understand and engage the Smart Grid ecosystem. 2012 Zpryme Smart Grid Insights: Intelligent Research for an Intelligent Market. All Rights Reserved.
Officers
Chairman John Selldorff President & CEO Legrand North America First Vice Chairman Christopher Curtis President & CEO Schneider Electric Second Vice Chairman Thomas S. Gross Vice Chairman & COO Eaton Corporation Treasurer Don Hendler President & CEO Leviton Manufacturing Co., Inc. Immediate Past Chairman David J. FitzGibbon Vice Chairman & CEO ILSCO Corporation President & CEO Evan R. Gaddis Secretary Clark R. Silcox
Looking ahead, energy storage technology has the potential to go a step further to unlock previously unavailable resources.
Looking ahead, energy storage technology has the potential to go a step further to unlock previously unavailable resources. One example of this is in regenerative braking, a concept now familiar to many thanks to hybrid cars. A pilot project at SEPTA, the Philadelphia-area rail system, captures energy from decelerating trains and stores it in batteries. The energy can then be used to reduce SEPTAs own energy consumption, but it also delivers highly responsive on-demand power to the local utilitya service for which SEPTA is paid. In all of these examples, its important to point out that efficiency has a business case. Drives offer a particularly compelling one, but there are many
The electrical sectors role in new cyber policy is complicated by the fact that the Federal Energy Regulatory Committee, through the North American Reliability Corporation, already regulates the bulk power system through Order 706, Mandatory Reliability Standards for Critical Infrastructure Protection.
Liability protection for entities that take positive action against the cyber threat is, in concept, a carrot with which all agree. However, major differences remain as to what precisely an entity must do to earn that protection, from sharing cybersecurity threat information with the federal government to getting third-party verification that the entity
is complying with federally-approved voluntary best practices. The cyber threat is only growing larger making the need for a consensus approach by industry and the U.S. government even more urgent. ei Jim Creevy, Director of Government Relations | jim.creevy@nema.org
Smart Manufacturing
Bruce M. Quinn, Vice President for Global Government Affairs, Rockwell Automation, and 1IS Government Affairs and Trade Committee Chair
n the near future, the global manufacturing sector will look nothing like it does today.
Advanced manufacturing technology is rapidly transforming the global competitive landscape. The companiesand nationsthat act now to seize its promise will thrive in the 21st century. Those who are devoted to incremental change and fail to engage in smart manufacturing will rapidly fall behind. The NEMA Industrial Automation Control Products and Systems Section (1IS) endorses an initiative to define a roadmap for the implementation of advanced process manufacturing technologyor smart manufacturingin the U.S. The section represents the relay and industrial control industry with its 32,873 full- and part-time employees of manufacturing establishments within the U.S. during 2010 with total shipments of $8 billion1. The sections primary objective is to maintain and improve national, regional, and global market access for the products and services of its members. Smart manufacturing marries information, automation technology, and human ingenuity to bring about a rapid revolution in the development and application of manufacturing intelligence to every aspect of business. It will fundamentally change how products are invented, manufactured, shipped, and sold. It will improve worker safety and protect the environment by making zero emissions, zero-incident manufacturing possible. It will help keep jobs in this country by keeping manufacturers competitive in the global marketplace despite the substantially higher cost of doing business in the U.S. In the 1980s and 90s, manufacturers took steps to address those higher costs by reducing waste and improving their operations through lean manufacturing practices. Those efforts, while ongoing, are producing diminishing incremental returns and businesses cannot cut their way to prosperityinnovation is the path to growth. It is time for a new, bold strategy for U.S. competitiveness that will capitalize on smart manufacturing as a strategic asset for growth.
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Investments in a smart manufacturing infrastructure are essential to securing Americas industrial future and economic well-being of its citizens. Smart manufacturing will increase the flexibility of our plants, reduce the use of energy, improve environmental sustainability, lower the cost of products, and enable us to develop innovative products using next-generation materials. We must act together to make that future a reality. Here are four crucial first steps: Industrial/Manufacturing Competitiveness. Investment in U.S. industry, its supply chain, and technologies will make it more efficient, sustainable, and globally competitive. Research and Development. R&D tax credits for innovative manufacturing processes and applied research on the factory floors go beyond basic science and new product research in corporate labs. Manufacturing Workforce Development. Provide the educational and training infrastructure American manufacturing needs to compete successfully in the global market. National Manufacturing Strategy. Prepare the country for the market-altering leaps in manufacturing productivity and efficiency that smart manufacturing will bring about. The section will be discussing specific policy positions and start crafting specific legislative language that might prove helpful. Our focus will be on the 113th Congress, working with the House and Senate manufacturing caucuses and others, as well as the administration to development meaningful policy in support of U.S. manufacturers. We invite your participation in our effort.
ei
As Rockwell Automations senior executive in Washington D.C., Mr. Quinn ( bmquinn@ra.rockwell.com) is responsible for government affairs, communication, and strategic business development at state, federal, and global levels.
Take the Pain out of System Design and Startup with Drives Configuration Software
Greg Mears, Product Manager, Drives Software, Rockwell Automation
nverters, drives, variable frequency drives, motor driveswhatever you call them, engineers understand and accept their performance-enhancing, energy-saving, and motor-protection benefits.
and can become a nuisance for programmers, typically during system start-up when time can be limited. In the past, the first phone call to tech support involved troubleshooting to remedy these communication gaps. With integrated drives configuration, users can now configure both sides of the network connection at the same time with one tool, reducing the potential for errors. This capability can be especially beneficial in applications involving a large number of drives, where managing the various configurations can consume an inordinate amount of engineering time and resources.
That acceptance has led to a proliferation of drives offerings, with much of the hardware based on similar technology resulting in excellent or enhanced quality across leading brands. Engineers considering drives options may want to focus on the ease-of-use tools and features provided by the configuration software as much as the actual hardware. By examining the whole drives package, especially the configuration software, engineers can make a more informed decision that saves them time and labor during configuration, commissioning, and startup. Like all software, drives configuration software is experiencing rapid evolution making it easier to use and more powerful. The most profound advancements involve integrating the controller and drive. For networked drives, integration capabilities help lower programming, installation, and overall ownership costs by minimizing the software tools required. This helps users gain faster startups, improved accuracy, and easier drive-system maintenance.
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Rockwell Software RSLogix 5000 v20 software from Rockwell Automation delivers the high performance of an integrated control system for manufacturers and machine builders requiring a smaller control system, integrating motion capabilities on the EtherNet/IP network with the Allen-Bradley CompactLogix controller family.
The PowerFlex 755 AC Drive Add-On Profile, opened in Rockwell Software RSLogix 5000 v20 software from Rockwell Automation, illustrates drive configuration integrated in the controllers programming environment. Images courtesy of Rockwell Automation
names. This minimizes the potential for errors when defining various network I/O. Tags can then be created in the control development environment and accessed via HMI (humanmachine interface), reducing set-up and configuration time. A copy-and-paste programming feature can quickly create additional duplicate drives.
reducing drive startup and commissioning time, wizards can improve set-up accuracy by significantly reducing manual configuration with the end device. Engineers also can enjoy the benefits that device configuration software can offer to simple, hardwired, or stand-alone applications. Drives are just one of many components in a system. For these applications, device configuration software can take what once required several different software configuration tools and wrap it into a single software package with a simple catalogue of devices available at the engineers fingertips. Combining a controller with a full suite of compatible components and application development toolsapplication profile, quick starts, wiring diagrams, and pre-developed HMI screenscan provide engineers with a simplified way to implement common control tasks as part of the machine design. This dramatically improves end user experience and reduces the risk of potential engineering programming, training, and maintenance nightmares. Clearly, its not just about hardware anymore. With simplified programming software, engineers can say goodbye to the complicated world of drive-controller integration and hours of grueling tagging and coding validation. Advancements in programming software capabilities are just the start of integration and interconnectivity capabilities to come. ei Mr. Mears serves as product manager for Low Voltage Drives, Control Products & Solutions, at Rockwell Automation, and is responsible for drive configuration software, embedded logic control, safety, and integration activities with other Rockwell Automation products.
NEMA electroindustry January 2013
Simplify Coding
A common problem in many drives installation projects is that multiple engineers are developing different versions of the same code. With numerous code variations, installation and startup become more tedious and complex. Thats because engineers must check and verify each versionand the specific set of errors used with each codeto confirm a smooth installation. Programming software capabilities, such as user-defined add-on instruction, encapsulate drive-specific operations into a reusable module of code. This reduces the development and validation effort, and promotes consistency among projects since theres no need to constantly reinvent commonly used control algorithms. Some software packages further simplify the programming of networked drives with tag generator tools. Users no longer have to worry about I/O mapping and correlating the I/O image with device user manuals. Tag generating tools help save users a significant amount of programming time per device, depending on the complexity of the device. Startup wizards for drive commissioning are another key advancement in drives configuration software. Instead of using a linear list editor to navigate through hundreds of parameters, startup wizards provide a simple step-by-step process. Graphs, images, and descriptive text assist the user through the remaining commissioning process. Besides dramatically
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A robotic arm can pick up four 55-pound buckets at one time. Photo courtesy of ABB
unn-Edwards, a leading manufacturer and supplier of paints and painting supplies, serves professionals and consumers throughout the Southwest. Established in 1925, the company sells most of its paint through its own 109-store network. It faced a challenge in 2010 when it consolidated all manufacturing and distribution operations into a new, fully automated facility in Phoenix.
on the right. If needed, the buckets from line A can be placed on pallet B, or from B to A. The vacuum gripper is strong enough to pick up the buckets but sensitive enough not to remove the tint plugs that are attached to the top of each pail. The system is unique for several reasons including its use of a single robot, its speed and flexibility, the weight of the load that is being palletized, and the dexterity of the gripper. The biggest consideration for us was the cycle time, said Clay Fenstermaker, director of engineering at Dunn-Edwards. We first considered an overheard gantry robot system, but Systems Automated came up with a simulation that showed that the fixed position, ABB robot could deliver the rate we needed. This could well be the most sophisticated five-gallon paint bucket packaging line in the world, said Mr. Fenstermaker. The system was launched in January 2011. The Phoenix plant has been designed to accommodate future growth of the company for years to come. ei Mr. Tallian has more than 20 years experience in the development of robotic material handling and packaging systems for a wide variety of industry segments, specializing in robotic assembly, picking, packing, and palletizing applications.
In designing the palletizing system, the requirement was to palletize the five-gallon buckets of paint at a rate up to 48 buckets per minute, building two pallets every 90 seconds (36 buckets/pallet). An integral part of the automation portfolio is an innovative, high-performing robotic palletizing system, which was designed and installed by Systems Automated of Sylmar, California. The system utilizes a single ABB IRB 660 articulated arm robot and a vacuum gripper that can pick up four 55-pound buckets at a time. The current speed of incoming lines requires a speed of 44 buckets per minute, with excess cycle time capacity available when necessary. Because the system is able to achieve such high speeds, DunnEdwards is able to serve two incoming conveyors and build two pallets at a time. The ABB IRB 660 robot sits between the two conveyors and picks buckets from the left conveyor and puts them on a left pallet or from the right conveyor for placement
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ndustrial manufacturing has been evolving over the last 20 years. Everyone knows about jobs that have moved offshore or the pressures to improve profits and productivity, but not everyone is aware of the new businesses and products that have developed as a result of the recent evolution in industrial manufacturing.
over an industrial communication network or even over the internet to remote locations results in minimal down time on the factory floor. New proximity and photo sensors keep track of products during the manufacturing, assembly, and packaging processes with higher scan rates for productivity improvements. They improve product quality with better output consistency. Even such basic control products as a start-stop pushbutton are available for wireless control operation or connection to an industrial communication network for simplified connection with less wiring than older conventional solutions. The programmable logic controller or PLC has also evolved in the last 20 years. Long known as the brains of an industrial automation system, they can now perform more sophisticated tasks, but with the simplicity of many of popular point and click computer systems. Products and services from the NEMA industrial automation companies have long been the backbone for the manufacturing floor, but now they are taking a lead position in the evolution of manufacturing in the world today. ei Mr. Fowler is a staff product specialist for low voltage power and control products at Schneider Electric. He has held several product management and marketing assignments during his 36-year career in the industrial control and automation industry and is past chairman of the NEMA 1IS Business Committee.
Competitive pressures have never been greater in manufacturing, and as a result a large number of companies either greatly scaled back or totally eliminated their industrial engineering and maintenance departments. While realizing short-term profit improvements, the need for this skill to keep factories running at peak efficiencies gave way to the birth of a thriving business in manufacturing plant services. A large number of manufacturing facilities now rely on outside service companies with special expertise to keep their electrical distribution, control, automation, and infrastructure running at peak efficiency levels. Industrial service companies are also providing their customers with new product solutions from NEMA member companies. Automation systems that increase productivity or products, such as NEMA Premium efficiency motors coupled with variable speed drives, reduce energy consumption, which will also help achieve LEED certification, reduce a manufacturers carbon footprint, and improve our environment. New products from NEMA industrial automation member companies are also contributing to productivity and profitability improvements on the factory floor. NEMA industrial automation products have long been known to provide the safe distribution and control of electrical power on the factory floor, but now they are adding intelligence to these basic electrical products. Products such as electrical circuit breakers and electric motor starters provide control and protection as well as provide predictive maintenance and self-diagnostic information when a problem occurs. The ability to communicate the information
The NEMA Premium program covers single-speed, polyphase, 1500 hp, 2, 4, 6, and 8 pole, squirrel cage induction motors. Learn more at www.nema.org/NEMA-Premium-Motors Contact NEMA for the current version of ANSI/NEMA MG 1.
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Protect Your Home and Family with Backup Power Supplied through a Transfer Switch
Neil A. Czarnecki, Vice President, Engineering, Reliance Controls Corporation Daniel G. Scheffer. PE, Vice President Engineering and TechnologyASCO Power Switching and Controls, Emerson Network Power
torms like the recent Hurricane Sandy left more than eight million customers without power. Many of the residential customers either
owned a standby generator or quickly acquired one to protect their homes and families. While such generators provide the opportunity to power essential appliances such as refrigerators, freezers, heating systems, pumps, water heaters and the like, the ability to do so safely requires the use of a transfer switch.
The proper application of transfer switches avoids dangerous practices such as backfeeding electrical panels or dryer outlets, which can inadvertently energize power lines and endanger electrical utility workers and neighbors; mitigates fire, shock, and appliance damage hazards in the home from makeshift wiring practices; and protects the occupants from exposure to toxic levels of carbon monoxide. Optional standby transfer switches are safety devices that are required by the National Electrical Code (NEC). Article 702.6 states, Transfer equipment shall be required for all standby systems subject to the provisions of this article and for which an electric-utility supply is either the normal or standby source. The use of transfer switches provides protection from inadvertent interconnection of the normal and alternate supplies, a condition that occurs when a standby generator is connected to residence wiring supplying power through the de-energized utility wiring to neighbors homes or to the utility transformer. Obviously, inadvertently electrifying circuits that other people believe to be dead pose significant safety hazards. Utility workers and neighbors have been electrocuted by making contact with these backward fed circuits.
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hen severe weather blows into town, theres a chance that you or your neighbors may lose power. Although we cant prevent
these outages, there are ways to prepare for them. Having a backup power source is a good place to start.
One alternative backup power is the battery. Batteries a form of energy storageare available in several applications that range from charging small appliances, like a cell phone or laptop computer, to larger products, like wheelchairs, electric vehicles, or energy systems (e.g., wind, solar, or emergency lighting). Several NEMA member companies are involved in these portable energy technologies and offer products for residential and commercial use. Duracell offers the Powerpack 600, a standalone form of portable power for ac, dc, and USB-powered electronics. With its 600W capacity, it could power a portable light, cell phone, laptop, portable cooler, or small TV. You could also connect it to jumper cables to give your vehicle a little juice. For batteries strong enough to power emergency lighting, wheelchairs, telecommunications networks, and uninterruptible power sources, Panasonic offers a valve-regulated lead-acid (VRLA) rechargeable battery. Its predecessor, the classic lead-acid battery or flooded battery, is open to the atmosphere so gases escape the battery rather than being recombined back into water. With these types of batteries, water must be added back. Virtually all the gases created inside a VRLA battery are recombined back into water, so no water addition is required. This feature is why they are called maintenance-free.
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Whole House vs. Partial A whole house transfer switch has the distinct advantage of being able to run any of the loads in the home. Partial transfer switches, whether automatic, non-automatic, or manual, power only those critical circuits predefined by the homeowner. Thus, they require less attention, but are more restrictive in that they cannot power any loads other than the predefined critical circuits. Whole house systems usually require professional installation, as their installation generally affects the incoming utility power. Where a whole house transfer system is installed ahead of the existing service disconnect, the transfer equipment must be verified as marked suitable for use as service equipment. Partial transfer systems can sometimes be do-ityourself installations. Subpanel vs. Load Side A subpanel style transfer installation generally uses a small loadcenter that is powered by either the main loadcenter or the generator through a single transfer switch. It is a simpler system, but requires that the circuit conductors be moved from the main loadcenter into the subpanel. This can be a daunting challenge in some installations. Load-side transfer equipment is more complicated, involving a transfer switch for each individual load. However, they install after the branch circuit breaker, making installation much easier and less expensive. Separately Derived vs. Non-Separately Derived A separately derived system requires that all current-carrying conductors be switched (including the neutral). This requires the use of a three-pole (line 1, line 2, neutral) transfer equipment solution. (Ground conductors are not switched.) A non-separately derived system requires that both neutrals be solidly connected, not switched. This allows for the use of two-pole (line 1, line 2) transfer equipment. NEC allows either configuration. For additional information, see NEMA ICS 10, Part 1, Annex B1.
Stay Safe
With safety maintained as a top consideration, standby generators can be an effective means of protecting home and family from the ravages of Mother Nature. Transfer switches provide the only safe interconnection method. Be safealways use a transfer switch.
ei
Mr. Czarnecki is a member of 1IS and 5LVDE committees on transfer equipment, the NEMA primary representative to NEC Code Making Panel 13, chair of the CANENA committee on transfer switch standards, and other bodies. Mr. Scheffer is a member of NEMA 1IS, SCAC, and C&S Committee.
Much of the information in this article was adapted from NEMA ICS 10 Part 3 Safety Bulletin: NEMA Safety Considerations for Residential Transfer Equipment and Residential Transfer Switches, which can be downloaded at www.nema.org/Transfer-Switches.
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Helping protect employees working on or near energized electrical equipment requires mitigating risks associated with high levels of incident energy, especially when the potential hazard is an uncontained arc flash of current that can reach 35,000 F. Extreme temperatures can cause clothes to ignite or even burn skin directly. Molten metal and shrapnel can explode into the air from a motor control center (MCC). Standards set forth by the National Fire Protection Association and other organizations have begun to address arcflash danger. Portions of OSHA and IEEE codes, as well as the National Electrical Code relate to standards for personal protective equipment and limits of approach focused on withstanding an arc flash. Other guidelines that take a proactive perspective include equipment design standards aimed at containing arc flash in the first place.
A robust arc-flash option provides: a pressure relief system that redirects gases through the top of the enclosure arc-containment door latches resistant to high internal blast pressures insulated power bus closing plates at the ends of each MCC lineup Using a lower horizontal bus rating (maximum 1,200 ampere bus) and smaller main disconnects reduces electrical hazard further by minimizing let-through energy within the MCC. Closed-door Technology Closed-door power removal technology allows an operator to disengage an MCC unit from the power source without opening the enclosure door. Removing the unit stabs from the power bus before opening the door to troubleshoot or perform maintenance minimizes personnel exposure to the main bus and hazardous voltage.
Improving arc resistance and adding closeddoor capabilities in Rockwell Automation CENTERLINE MCCs resulted from customer input and feedback critical to addressing the growing concern of electrical safety. Photo courtesy of Rockwell Automation
Three-Pronged Approach
The optimal approach to MCC arc-flash safety combines proactive, preventative methods with systems, designs, and features that protect employees from electrical hazards.
Remote Monitoring Extending IT infrastructure to control equipment and applications adds a risk management capability critical to avoiding arc-flash exposure. MCCs integrated with DeviceNet and EtherNet/IP (trademarks of the Open DeviceNet Vendor Association) networks enable personnel to monitor, troubleshoot, and diagnose the MCC remotely without exposure to dangerous conditions and power equipment. In addition, real-time remote data monitoring, without opening an MCC door, increases the ability to identify potential problems before a safety event occurs. Arc-Resistant Devices IEEE C37.20.7-compliant arc-resistant control devices and enclosures help protect personnel by minimizing arc initiation and increasing MCC structural containment properties.
After withdrawing and disconnecting the stabs from the power bus, an employee can open the door and remove the unit. Using a remote operation tool to disconnect and connect stabs places the operator safely outside the arc flash boundary. Premium closed-door technology uses a multipoint validation system to provide power removal confirmation, notifying the operator when the power stabs are entirely withdrawn from the vertical bus. Closeddoor power removal also helps companies put processes back online faster by reducing the need to obtain hot-work permits to service equipment.
Safety First
Rockwell Automation was the first NEMA MCC manufacturer to combine CENTERLINE ArcShield arc resistance and SecureConnect closed-door power removal technologies. Improved safetywith a focus on improved productivity and cost managementis an automatic, integral element in emerging MCC technology. ei Mr. Krause serves as engineering development manager for Low Voltage Motor Control Centers, Control Products & Solutions, at Rockwell Automation.
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small percentage of motors and motor loads in the U.S. are equipped with traditional condition-based monitoring systems, which are usually reserved for the most critical and expensive equipment. That leaves the majority of motors without monitoring systemsand a tremendous potential to save energy and reduce downtime due to unexpected conditions that are caused by a lack of data. Today, advanced relays provide a costeffective way to monitor parameters that can help organizations improve the energy efficiency of their systems.
Condition monitoring systems (CMSs) consist of hardwired vibration sensors, pressure transducers, and resistance temperature detectors connected to a data acquisition system. Qualified personnel then analyze the data from sensor outputs and take appropriate action. The lack of adoption stems from the costs, time, and complexity associated with conventional condition-based monitoring systems. Advanced motor overload and monitoring relays can help fill the gap. They monitor parameters to gain more precise and real-time perspective of performance. Although relays do not monitor the exact same parameters as a conditioning monitoring system, they provide critical information that can reduce costs, save energy, and improve maintenance.
Advanced relays help Sheboygan Regional Wastewater Facility identify and resolve situations before they lead to energy inefficiencies or downtime. Photos courtesy of Eaton Corporation
conventional wiring approach would not be cost-effective on these smaller motors, so the potential energy savings and optimized preventative maintenance would be negated. Yet, without critical power data, the resulting unscheduled downtime and inefficient operation of equipment translates into: reduced throughput environmental fines energy waste higher maintenance costs increased capital expenditure reduced profitability Today, solid-state motor overload and monitoring relays can provide real-time line, load and motor protection, and control. In addition to monitoring electric motor health, the technology provides line conditioning for improved motor reliability and reduced maintenance downtime. These electronic relays help reduce installation and infrastructure costs by up to 84 percent compared with conventionally wired systems. Further, all motors need a relay anyway. Users can configure the system locally or with a variety of standard industrial communication protocols, allowing for integration into supervisory control and data acquisition (SCADA), programmable logic control, and distributed control systems. Motor protection relays equipped with fieldbus protocols enable maintenance and operations teams to monitor key failure indicators on motors in real time. As
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Advanced relays provide a cost-effective way to monitor parameters that can help organizations improve the energy efficiency of their systems, while reducing downtime
Previously, the extra power draw would have gone on for an extended time without being detected, leading to large energy losses and extra mechanical and electrical stress on the pump and motor. Using the data from motor overload and monitoring relays, a service technician was immediately dispatched. He removed a foreign object that was wrapped around the impeller, which had resulted in a decrease in the power draw back to the normal level. Results The advanced relays provide added monitoring and are helping Sheboygan identify and resolve situations before they lead to energy inefficiencies or downtime. With the ability to monitor motors and pumps in hard-to-access areas, Sheboygan now can trend real-time motor and pump conditions that could have gone unnoticed for days or weeks when using traditional bi-metal protection and flow meters. Additionally, a full suite of protection is provided, including a low power feature that protects pumps against starved or dead-headed conditions. ei Mr. Trimmer is the product manager for advanced motor protection with Eaton Corporation. His experience includes sales, marketing, and application experience in the electrical industry.
Real-World Example
Sheybogyan Regional Wastewater Treatment Facility serves 68,000 people in Sheboygan, Wisconsin. Average daily flow is about 11 million gallons, and if there is a rain event or substantial snowmelt, peak flow can reach 64 million gallons. It is essential that all pumps operate effectively to ensure that increased flow levels can be managed properly and adverse sewer problems avoided. Problem At its Indiana lift station, Sheboygan had three 75 hp motors with a full load current of 96 amperes. It was using three bi-metallic overload relays to protect the motors and flow meters on the output of the pump to ensure proper flow from the pumps. Flow data was communicated to its headquarters and logged in a SCADA system. However, they had no means of monitoring anything else related to the motor or pump. After retrofitting advanced overload and monitoring relays in place of the bi-metallic overload relays, the maintenance supervisor later noticed one of the three motors was drawing more power (75kW), while the other two were drawing only 50kW. Yet, all three flow meters for each pump reported the same flow reading. This increase, if left undetected, is equivalent to an additional $10,900 in annual energy costs, assuming a 50-percent duty cycle.
An advanced overload relays user interface combines protection, operation and monitoring values into a single display.
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MIT Study Creates Electroindustry-based Method for Mapping Products to Energy Use and GHG Emission
Robert Boteler, Government Relations, Nidec Motor Corporation
EMAs Motor and Generator Section (1MG) recently participated in a Massachusetts Institute of
Use, 99.778%
Materials, 0.115%
Technology (MIT) research project designed to increase NEMA members understanding of and ability to influence the environmental impact of their products, specifically with regard to energy and greenhouse gas (GHG) emissions.
Manufacturing, 0.094%
Characterizing the carbon footprint of a product generally requires a comprehensive lifecycle analysis that considers the environmental impacts of a product from raw material extraction and transportation to manufacturing (or service provision), distribution, consumer use, and end-of-life disposal. MIT has developed a streamlined approach, which focuses on the identification of the principal drivers of carbon impact within a product and the characterization of the effect of changes in those factors. The project leveraged existing data and input from NEMA member firms to create an electroindustry-based method for mapping product characteristics to potential energy use and GHG emissions. One valuable benefit of this effort is insight into the risks and opportunities for carbon mitigation within the industry.
Figure 1. Overall lifecycle impact, expressed as global warming potential, of a typical 25 hp NEMA Premium electric motor, operated for 5,000 hours/year over 20-year lifetime powered by an average U.S. electricity grid mix. This is based on a general purpose, 6-pole, cast iron, premium efficiency, and total fan-cooled enclosure.
The study shows that, under typical use conditions for motors 1 hp and larger, the use phase dominates other lifecycle stages in terms of energy consumption, and the associated GHG emissions related to energy consumption are variable depending on dominant energy sources in the region in which the item is used (e.g., GHG emissions in a coal-dominated energy grid would be higher than in a hydroelectric-dominated energy grid). When a motor is fully employed during its entire service lifetime (5,000 hours/year for 20 years), the use stage makes up more than 99.8 percent of the impact in terms of lifecycle energy. If a motor is used at the same intensity for just one year, the use stage impact remains highly dominant, making up 98.6 percent of the lifecycle energy impact. However, there may be exceptions for motors that are not frequently in use. For motors that are used for 50 hours or less during their lifetime, the impact of materials and manufacturing stages is greater than that of the use stage. Under most use scenarios powered by the average U.S. electricity grid mix, the materials and manufacturing combined are responsible for less than 0.5 percent of total lifecycle carbon emissions, where the manufacturing burden is a bit lower than the materials burden. The MIT study evaluated three sample polyphase categories. NEMA members provided specific information detailing
Measuring Efficiency
The project also represents the initial phase of a broader exploration into this important issue. The methodology is scalable and expected to be applicable to a wide variety of NEMA products and divisions. Motors were selected as an initial test product because of their impactelectric motors are responsible for 40 percent of global electricity usage, most significantly from driving pumps, fans, compressors, and many other mechanical traction equipment. The International Energy Agency (IEA) estimates seven percent of global electricity demand could be saved through the use of higher energy efficiency motors (IEA, 2006). To date, limited research has been reported on the carbon footprint quantification and methodology development for these products specifically.
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Motor-Driven Solutions
The determination that greater than 1 hp electric motors likely have more than 99.8 percent of global warming potential (GWP) in the use stage confirms the need to improve and manage
Figure 2. There is a fixed relationship between horsepower and frame size. For an ac motor with given horsepower, frame size is variable, ranging from 2 poles, 4 poles, 6 poles, and 8 poles. Operated for 5,000 hours/year over a 20-year lifetime with an average US electricity grid mix.
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hen input and output current measurements are made on a modern variable frequency drive (VFD), the current at the output of the VFD may exceed the input current to the VFD. This seems to violate the law of conservation of energy. Are the measurements and/or the reporting actually correct? If so, how can this happen?
Voltage (V)
800 600 400 200 0 -200 -400 -600 -800
In order to understand what these measurements show, lets look at an example in detail and consider the way in which an ac induction motor draws current. Example The rms (root mean square) voltage and current below was reported on a start-up report for a VFD: input 22A at 476V; output 28A at 480V.
Voltage Boost
One question raised by this data dealt with the slight increase in rms output voltage compared to the applied input voltage. While this could be the result of a test meter that doesnt properly measure the voltage of pulse-width modulation (PWM), the meters measurement is most likely accurate. To understand this slight boost, it helps to know how a PWM VFD operates. The incoming ac voltage is rectified to produce a dc bus voltage, which is then inverted back to a controlled ac output voltage by the VFDs output stage. It is possible to provide a slight boost in the rms voltage supplied to the motor in each of these stages of the drive. On the other hand, the current drawn by the motor is significantly higher than the current drawn by the VFD. This is generally the greater cause of confusion. It appears that the VFD is making current from nothing. What is happening? First, the VFD does not really control the current drawn by the motor. It simply provides voltage to the motor and the motor draws the current that it needs. The amount of current that the motor draws depends on the load applied to the motor, the design of the motor, and the frequency and voltage of the ac that the motor receives. Example of Resistive Load To understand the relationship between voltage, current, and power, start with a simple example. Assume that 3-phase, 480Vrms ac voltage is applied to a 3-phase bank of resistors and the current drawn by each leg is 28Arms. The total power delivered to the bank of resistors can be calculated as: P=(3 ) V I where: V = 480V = 0.48kV; I = 28A; P = 23.3kW
Current (A)
50 40 30 20 10 0 -10 -20 -30 -40 -50 50
This is a resistive load; voltage and current are in phase with each other, i.e., voltage and current rise and fall at the same time and pass through zero at the same time. To calculate the power delivered to the bank of resistors, simply calculate the instantaneous 3-phase power at each point of the curves by using the same formula as above.
Power (kW)
50 45 40 35 30 25 20 15 10 5 0
When the voltage is positive the current is positive, and when the voltage is negative the current is negative; thus, the product of the two is always positive. The horizontal line shows the average power, which is the same 23.3kW that was calculated above.
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Voltage (V)
800
Voltage (V)
Voltage (V)
Many meters measure apparent and real power. They must measure voltage and current at the same time. It is possible to calculate real power if apparent power and power factor are known. Real Power=Power Factor Apparent Power
Current (A)
50 45 40 35 30 25 20 15 10 5 0
Power (kW)
50 40 30 20 10 0
Power (kW)
In the example above, the power factor of the lightly loaded motor was 0.707. The real power that the motor was drawing was: Real Power into the motor = 0.707 3 480 V 28 A = 16.5kW How does this compare to input power drawn by the VFD? The power factor of the input of a modern VFD is generally highin this case, around 0.955. A similar calculation for input power gives: Real Power into the drive = 0.955 3 476 V 22 A =17.3kW A comparison of apparent power drawn by the drive (18.1kVA) and apparent power drawn by the motor (23.3kVA) make it appear that the law of conservation of energy is being broken and the VFD is acting like a perpetual motion machine. The real power supplied to the drive was 17.3kW and the real power drawn by the motor was 16.5kW. Utilities often charge a power factor penalty to customers whose buildings have a low power factor because the extra current required to serve a building with a low power factor requires the utility to invest in larger distribution transformers and power lines. Because VFDs generally have a high power factor, they help buildings meet utility power factor requirements without the need to add power factor correction equipment. ei A teacher, Mr. Fonstad has also served as chair of the Engineering Committee of the Variable Frequency Drives Product Section of the Air Conditioning and Refrigeration Institute.
NEMA electroindustry January 2013
In each of the highlighted regions, the polarities of the voltage -10 -20 the current are opposite. The power in these regions is and -30 negative. Negative power means that this current isnt delivering -40 energy from the VFD to the motor. Instead, it is delivering -50 50 energy back to the VFD. This reactive or recirculating current is measured by the ammeter between the VFD and the motor. A power calculation using (kW) the ammeter reading will be Power too high.
50 45 40 35 30 25 20 15 10 5 0
50
45 Using the data above and (3 ) V I gives the following values: 40 input 22A at 476V and output 28A at 480V. 35
(3) V I= (3) 22 A 0.476kV=18.1kVA 25 (3) 15 V I= (3) 28 A 0.480kV=23.3kVA It looks like the drive is delivering more power than it is 5 drawing from the power line! 0
10 20
30
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hen it comes to Industrial Control Section products, perhaps none can be deemed more important or necessary to life safety than the fire pump motor controller. Forgotten or possibly relegated by some as the proverbial redheaded step child of motor controllers, not one building constructed higher than what municipal water pressure can provide whether it be for commercial, high rise residential, industrial, healthcare, or educational purposescan be legally occupied without one.
fire pump controls primarily based on technical data provided by NEMA 1IS SC10. Because the fire pump controller is required to be activated in emergencies when the usual power supply may become interrupted and or unavailable, transfer switcheswhether integral to the controller or provided upstreamare another 1IS product and component in the life safety system made up of the controller, motor, pump, and sprinkler arrangement. In fact, the inclusion and allowance of upstream transfer switches being located within the pump room in the 2013 edition of NFPA 20 are a result of a collaborative effort between the NEMA 1IS SC10 and 1IS SC 16 (transfer switch equipment) members.
Sprinkler systems in such buildings require these controllers to operate the motors that drive the pumps which in turn provide the required water pressure necessary to extinguish a fire in the event of an emergency. NEMAs 1IS Technical Subcommittee 10 (SC10), which comprises 99.9 percent of North American manufacturers of fire pump motor controllers, is charged with the responsibility for the technical oversight of these products, and is proactively engaged in UL, CSA, FM, CANENA, IEC, and most notably in NPFA 20 Standard for the Installation of Stationary Pumps for Fire Protection technical activities, where the heart and regulatory pulse of fire controller safety resides. This critical piece of equipment is typically isolated within its own protected environment in what is termed the pump room.
Harmonization Efforts
SC10 member companies were rewarded in 2006 for their technical harmonization efforts with the publication of the first tri-national fire pump controller standard (UL 218) developed under CANENA. Chairman Douglas Stephens, ASCO, is currently leading members in the development of the first revision of that standard, which will encompass the latest NFPA 20 edition changes. From an international perspective, SC10 members were instrumental in developing one of the few successful adoptions of a U.S.-based standard for international use, namely the IEC 62091, which when published in 2006, relied heavily on NFPA 20 philosophies. When the IEC 62091 re-surfaces for its maintenance cycle sometime during 2016, SC10 members and their expertise will again be central in its review and enhanced revision.
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A unique and additional component of fire pump controller discipline is its mandatory compliance to factory global (FM) requirements if installed in premises insured by an FM-affiliated insurance carrier. FM 1331/1323 certifies that a compliant
While NEMA has been well represented in relevant IEC SC17B Low Voltage Switchgear and Controlgear activities, more members are needed in IEC TC64 Electrical Installations of Buildings activities. Participation can affect installation requirements for member equipment. Members are urged to join USNC TAGs and review draft documents to ensure that U.S. concerns are addressed and U.S. products are not subjected to market access restrictions. There is continuing evidence that LVDC circuits will support an expanding number of applications, particularly the output of renewable energy resources and data centers, where there seems to be a focus on 390V dc systems. This seems to be an opportunity for new products, especially for control functions in dc circuits. Another significant activity for 1IS membership is the IEEE effort to create documents harmonized for North America to counter the European bias of IEC 61000-3-2 and 61000-3-12. ei Ken Gettman, Director of International Standards | ken.gettman@nema.org
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Energy Efficiency Improvement with Permanent Magnet Motors and Variable-Frequency Drives
Jun Kang, PhD, Manager of R&D and Applications Engineering, Yaskawa America Inc.
bout two-thirds of electricity is consumed by electric motors used in industrial facilities. According to the U.S. Department of Energy, motor systems are responsible for 63 percent of all electricity consumed by U.S. industry and the electric bill represents more than 97 percent of total motor operating costs.
In the induction motor, slip frequency (i.e., the frequency difference between stator rotating flux and mechanical rotating speed) induces current in the rotor windings. The interaction between rotating magnetic field and induced rotor current produces a driving force, but the rotor current causes copper loss (calculated as I2R) that decreases motor efficiency. Permanent magnet (PM) motors are more efficient than induction motors because there is no I2R loss in the rotor, and motor current is lower than in the induction motor. PM motors have many other advantages that include compact size, light weight, and high torque. A position feedback sensor has been one of the main obstacles that reduces the widespread use of PM motor for general-purpose applications. However, lowcost high-performance CPUs and establishment of the speedsensorless control theory in variable-frequency drives (VFDs) enables the introduction of reasonably-priced, highly efficient, variable frequency PM control drives. Figure 1 shows the energy saving effect of PM motors in HVAC application. One hundred VFDs are driving 3.7kW fan motors for ventilation for 24/7, 365 days a year at 75 percent speed. When induction motors are used, annual power consumption is about 1,810MWH while PM motors consume 1,670MWH.
Speed-sensorless control theory in variable-frequency drives has led to reasonably-priced, highly efficient, variable frequency PM control drives.
Permanent magnet motors are more efficient than induction motors. Photos courtesy of Yaskawa America Inc.
Saved energy is 140MWH and annual reduction in CO2 is approximately 58.8 tons. It corresponds to the CO2 absorption of 4,200 50-year-old cedar trees. Utility cost saving is about $16,800, assuming 12 cents per kWH. ei Dr. Kang is oversees technology innovation for power electronics and drive business at Yaskawa America Inc.
Figure 1. Efficiency of induction and PM motors controlled by VFD. Illustration courtesy of Yaskawa America
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Electroindustry News
2012 Motor Summit Convenes in Zurich
The 2012 Motor Summit was held in December in Zurich, Switzerland. It is held in alternating years that EEMODS (Energy Efficiency in Motor Driven Systems) is not scheduled. These are the two international conferences that bring together the motor industry. Organizer Conrad U. Brunner reported that 180 participants from 23 countries attended. is engaged with Motor Coalition partners and the U.S. Department of Energy. Mr. Hoyt wrote and presented another paper on the evolution of the NEMA Premium program for motors with a focus on the verification testing that was incorporated in 2010. Other topics at the Motor Summit included new motor systems efficiency policy for China, experiences with PM motors, Motor Policy Guide, and extended product approach for fan and pump systems. These are just a sample of U.S., Europe, Asia, and Australia. The meeting began with Mr. Delaney and Mr. de Ruvo outlining the basis of the proposed program. Two working groups were formalized, per previous meetings and discussions: MotorsStrategy MotorsTechnical Professor Martin Dopplebauer, KIT Germany, and Professor Bernd Ponick, University Hannover Germany, agreed to co-chair MotorsTechnical. Mr. Delaney and Mr. de Ruvo will continue with MotorsStrategy. Participants representing NEMA are Mr. Boteler and Mr. Hoyt (Strategy); and Bill Finley, Siemens; and Manny Gonzalez, GE (Technical). Provisional terms of reference for the project were discussed. These included determining the Conformity Assessment System (ISO/IEC) most appropriate for GMLP. The parties agreed that ISO Type 5 was the goal. The NEMA Premium motor testing and verification detailed in Appendix G and Appendix H of the NEMA Premium license will serve as the model for the planned testing and verification protocols. The meeting also included a review of existing IEC rules, additional requirements and operational procedures, label design, and business plan. The timeline for the GMLP is an aggressive 12 to 18 months, with an introduction planned for EEMODS 2013, which will be held October 28-30 in Rio de Janiero. ei William Hoyt, Industry Director | bill.hoyt@nema.org
Rob Boteler co-authored a paper on NEMA regulatory activity. Photos by Thomas Burla
The motor industry has become increasingly international, placing greater efforts at harmonizing and accepting test methods and performance standards. Three U.S. participants made important contributions to the summit: Rob Boteler, Nidec Motor Corporation and NEMA 1MG Energy Management Committee Chairman Dan Delaney, Regal-Beloit Corporation and NEMA/IECEE1 Global Motor Labeling Program (GMLP) Co-Chair William Hoyt, NEMA Industry Director Mr. Boteler and Mr. Hoyt co-authored and presented a paper on NEMA regulatory activity in which the industry
1
William Hoyt presented a paper he wrote on the evolution of the NEMA Premium program.
papers and presentations delivered by academia, policy experts, and motor manufacturers. Next Steps on Labeling After two organizational meetings prior to Zurich, NEMA and IECEE met on the last day of the summit for the first meeting of what is now the IECEE GMLP. It formalized the structure of the working groups and established building blocks for the program. Mr. Delaney is co-chair with IECEE Executive Secretary Pierre de Ruvo. The meeting was called to order with representatives present from the
IEC System for Conformity Testing and Certification of Electrotechnical Equipment and Components
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Electroindustry News
Medical Imaging Industrys Leadership to Protect Patients from Unnecessary Radiation
The medical imaging industry has revolutionized the ability to diagnose and treat patients with technologies that have enhanced the quality of healthcare and ushered in a new era of medical diagnostics. With some modalities, these images are generated using x-rays, and through the Medical Imaging & Technology Alliance (MITA), a division of the National Electrical Manufacturers Association (NEMA), manufacturers have collaborated to develop industrywide standards to reduce patient exposure to unnecessary radiation. This year, NEMA published two control standards to enhance the safety of medical imaging technologies without compromising their quality. XR 262012 Access Controls for Computed Tomography (CT): Identification, Interlocks, and Logs requires that specific permission is assigned for selected uses beyond those needed for daily routine scanning. By limiting access to alter protocols and permitting manual locking of the user interface, unauthorized users cannot access system controls. With these new safeguards in place, only authorized users can perform or change protocols, thereby minimizing the patients risk of exposure to undue radiation. Similarly, XR 27-2012 X-ray Equipment for Interventional Procedures User Quality Control Mode helps imaging facilities conduct quality testing and monitor x-ray equipment by providing an essential set of equipment controls and quality tools. Quality control user interfaces provide controlled access for x-ray dose-related constancy testing, access to and export of imaging data, electronic documentation of dose-related parameters in exam protocols, and direct access to radiation dose structured reports. These new standards build on MITAs longstanding commitment to ensure safe and effective patient care without compromising access to the most advanced, high-quality medical technologies available. For example, XR 25-2010 CT Dose Check, published in 2010, introduced two new features that assist medical practitioners in providing better care: dose notifications and dose alerts. The initiative allows manufacturers to reduce cumulative dose and medical errors by deploying additional notifications and dose alerts, and recording dose information. With these new safeguards and standards in place, physicians are better equipped to use medical imaging technologies to diagnose disease, monitor treatment, and save lives, as evidenced by recent peer-reviewed research studies. Case Studies For instance, research conducted at the Memorial Sloan-Kettering Cancer Center and published in the Journal of the American Medical Association ( JAMA) in May 2012 indicates that low-dose computed tomography (LDCT) screening of individuals at increased risk for lung cancer results in significantly fewer lung cancer deaths (356 vs. 443 deaths; lung cancerspecific mortality, 274 vs. 309 events per 100,000 person-years for LDCT and control groups, respectively). A study published in the April 2012 issue of JAMA affirmed that advanced screening methods beyond mammography are enhancing breast cancer diagnosis for women in higher risk groups. Specifically, the use of ultrasound or MRI as an adjunct to mammography to detect cancer in women with dense breasts and other risk factors. As demonstrated by these and other recent studies, medical imaging is an increasingly critical component to early disease detection. Despite the numerous benefits provided by medical imaging technologies, medical imaging manufacturers recognize the importance of mitigating the risks posed by ionizing radiation. The industry is committed to developing new products, system innovations, and patient care initiatives that optimize radiation dose while continually improving the ability of these technologies to aid physicians to diagnose disease and stage treatment. For example, in June 2012 MITA received the U.S. Food and Drug Administrations Leveraging/Collaboration Award for developing a cooperative network aimed at reducing unnecessary medical radiation exposure to pediatric patients. MITA has also partnered with the Alliance for Radiation Safety in Pediatric Imaging and its Image Gently campaign to educate medical professionals and parents about imaging protocols that can reduce imagingrelated dose for children. MITA companies also champion and implement ALARA, the as low as reasonably achievable principle, a universal guideline of radiation dose management and optimization that is incorporated into the development of all imaging procedures and technologies. Advancement of medical imaging technologies requires technological innovation to enhance image quality as well as minimize exposure to radiation. With the introduction of new standards and ongoing radiation safety initiatives, medical imaging manufacturers are undeniably leading the charge. ei Gail M. Rodriguez, PhD, Executive Director of MITA | grodriguez@medicalimaging.org
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electrical contractors since he began his career at NECA in 1976 as a field associate. Schneider Electric received the 2012 Safety Award for Excellence (SAFE) for outstanding efforts in fighting counterfeit electrical products. Chris Curtis, CEO, Schneider North American, accepted the honor on behalf of Schneider during NEMAs 2012 Illuminations Weekend dinner.
In December 2011, Schneider Electric launched the first report and reward program of its kind in the electrical industry. It conducts international investigations and raids, monitors the internet to identify counterfeiters and remove their listings, sponsors international anti-counterfeiting conferences, and works with federal authorities on criminal investigations.
ei
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Electroindustry News
Innovation Incentive: How to Engage Suppliers and Drive Innovation
Today, its not simply enough to say that you are an innovative company; you must be able to continuously demonstrate your capability and capacity to innovate. The challenge is that there is not much new under the sun, and unless you are blessed (or burdened) with a significant structure and budget to support continuous research and development, driving innovation can very quickly become an uphill battle. Fortunately, all hope is not lost. Innovation in its less than pure form can be invoked if we set aside the idea of continuously investing in and testing new ideas and concepts, and shift our focus to determining how we might better utilize existing resources to drive new and innovative change. The answer to this somewhat challenging question lies outside our very door, literally. Innovation can and should be driven through supplier engagement and incentives. Several years ago, I was asked to negotiate a contract resolution between an electronic component supplier and its customer. The customer had, over a period of 12 months, requested and purchased dozens of components in an attempt to complete a ballooning and fragmented project. The plight to develop an innovative solution to a longstanding problem had resulted in several misguided investments, none of which was able to resolve the problem. The customers unwillingness to engage their supplier in developing an innovative solution resulted in unnecessary material costs and significant delays, the results of which had tarnished the buyer-supplier relationship to the point that mediation was required. But who was at fault? It was apparent that the customer had failed to consider two very basic tenants of the circumstances at hand. First, what was the root cause of the problem? Second, who might be most qualified to address the root cause(s)? The electronic component supplier had never been engaged in the problem, only used as a resource to provide material. The component supplier in turn failed to ask its customer about the reasons behind the excessive and somewhat erratic purchases, thereby missing the opportunity to engage sub-tier suppliers to determine if more innovative and less costly solutions existed. To be innovative is to offer solutions to customers that resolve issues that either do not yet exist or have not escalated to the point that resolution is deemed to be necessary. This type of innovation requires engagement at all levels of the supply chain, including sub-tier suppliers. Casemore and Compay has identified several steps to creating such innovation. Here are the top three: 1. Convey intent. Today the buyersupplier relationship is still adversarial to a large extent. Customers identify problems, outline possible solutions, and then ask suppliers for products or services that will deliver intended solutions. There is very little dialoguejust one-way communication. Intentions between buyer and supplier must be clear. Using supplier portals (e.g., Graingers Gateway) or investing in supplier conferences (e.g., Kicker Audio) are great ways to initiate dialogue with suppliers to outline your intent to collect, analyze, test, or engage in developing new solutions. If you dont communicate your intent, dont expect results. 2. Collaborate. Beyond the everyday sales transactions are opportunities to identify new choices, test options, and develop robust solutions that are both unique and innovative. Proctor and Gamble (P&G) makes a concerted effort to reach out to its supply base and collaborate on solutions. As a result, P&G has made the claim that it expects more than half of its innovation to be generated outside of R&D in 2012, making collaboration a strategic component of its innovation formula. 3. Whats in it for me? Despite collecting revenue, what would engage a supplier to invest in new opportunities? The theory behind Pavlovs dog still applies today. Suppliers must have incentive to invest time and resources in innovation. Incentives can vary depending on the complexity of the innovation and the organization, but using supplier rewards and recognition, or sharing in the profits and progress of innovative ideas are great examples of how to encourage suppliers to participate. Innovation is not something that can be achieved alone, nor is it an elusive new concept that must be first proven in R&D. The most innovative ideas are often those that evolve as a collaborative concept. Engage your suppliers to provide incentives to drive innovation and watch your competitive advantage soar. ei Shawn Casemore, Founder and President, Casemore and Company, Inc. | shawn@casemoreandco.com
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ANSI C12.11-2006 (R2007) Instrument Transformers for Revenue Metering, 10 kV BIL through 350 kV BIL (0.6 kV NSV through 69 kV NSV) C12 SC15 also reviews and provides input to the development and maintenance of ANSI/UL 414 Standard for Meter Sockets. ANSI C12 SC17 C12 Subcommittee 17 and working groups 1, 2, 3, and 4 met in October to address development, revisions, and other technical issues regarding data communication electricity metering protocols. Standards under the purview of C12 SC17 are: ANSI C12.18 Protocol Specification for ANSI Type 2 Optical Port ANSI C12.19 Utility Industry End Device Data Tables
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International Roundup
NEMA Launches Latin America Initiative
Building on the very successful Promotion of U.S. Electrical Product Exports to Central America, Dominican Republic, and the Andean Region, a four-year program funded in part by the Department of Commerce Market Development Cooperator Program, NEMA launched a new initiative funded entirely by its sections. The new program focuses on the Latin American countries having free trade agreements with the U.S.Chile, Colombia, Costa Rica, Dominican Republic, El Salvador, Guatemala, Honduras, Nicaragua, Panama, and Peru. NEMA staff developed strong working relationships with the key organizations in each country responsible for codes and standards that impact members products. Moving beyond these successes, the program has the following objectives: formal adoption of electrical installation codes that are based on the National Electrical Code in all the target countries formal adoption of product standards harmonized with those used in North America by all the target countries formal adoption of energy codes and green building standards that are consistent with the latest versions available in the U.S. increased awareness and understanding by the governments and electrical communities in the target countries about the need for conformity assessment and inspection to ensure safe electrical installations heightened awareness about the proliferation of counterfeit products by the electrical community and local customs officials proactive encouragement of energy efficiency regulations that are consistent with North American requirements
A very specific list of activities has been defined for the program, including regular meetings between NEMA staff and key officials in each of the target countries, to discuss and advance all the subjects included in the list of objectives. Organizations slated for meetings include standards development organizations; conformity assessment authorities; government officials, particularly commerce and energy; customs officials to discuss intellectual property rights, counterfeit products, and action plans; leading electrical distributors; member company representatives in each country; and U.S. embassy officials. In addition to regular networking and intelligence-gathering meetings, NEMA will organize and conduct technical seminars/workshops on specific product systems to address electrical distribution and utilization issues such as overcurrent protection, bonding and grounding, etc. This differs from previous workshops conducted on more general topics electrical installation code; product standards; and testing, certification, and inspection. The new program will focus particularly on the products from the sections providing funding. Plans include three or four such workshops in different countries each year, resulting in at least one such workshop in all of the countries by the end of the three-year project. Latin America continues to be a region that attracts electrical product manufacturers from the European Union and more recently from China. These global competitors look upon the region as a growth market and strive to either displace U.S. technology or to eliminate any codes and standards, allowing for low-cost and unsafe products to proliferate in the market. ei Gene Eckhart, Senior Director for International Operations | gene.eckhart@nema.org
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Learn
More
The Medical Imaging & Technology Alliance (MITA), a division of NEMA, is the leading organization and collective voice of medical imaging equipment, radiation therapy and radiopharmaceutical manufacturers, innovators, and product developers. MITA standards enhance the safety of medical imaging without compromising quality. XR 25 allows manufacturers to reduce cumulative dose and medical errors by deploying notifications and dose alerts. XR 26 safeguards protocols and system controls. XR 27 helps imaging facilities conduct quality testing and monitor equipment. More at www.www.medicalimaging.org
February
Lights up on lighting systems. Energy savings from lighting can no longer be achieved simply by using an appliance/ component approach. It can be achieved, however, when lamps, ballasts, drivers, luminaires, and controls work together in a systems approach. Next months issue of ei explores lighting controls, LEDs, and other new technologies; updates from the Department of Energy and enlighten America; and the second annual members Product Showcase.
Coming in
NEMAs Industrial Automation Division includes Industrial Automation Control Products and Systems Section (1IS) as well as motors and generators, arc welding, carbon/manufactured graphite, and power electronics. For a list of 1IS standards, visit www.nema.org/ Industrial-Automation-Standards The NEMA Premium program covers single-speed, polyphase, 1500 hp, 2, 4, 6, and 8 pole, squirrel cage induction motors. Contact NEMA for the current version of ANSI/NEMA MG1. www.nema.org/ NEMA-Premium-Motors
13 iStockphoto.com/Kativ 13 iStockphoto.com/fotomy
13 iStockphoto.com/IPGalanternikD.U. 13 iStockphoto.com/Lenorlux
14 iStockphoto.com/geopaul 32 Maximus256/Shutterstock.com
Economic Spotlight
EBCI Gauges Business Confidence
The Electroindustry Business Confidence Index (EBCI) indices gauge the business confidence of the electroindustry in Asia, Europe, North America, and Latin America. The most recent EBCI for current North American conditions can be found at www.nema.org/Dec12-EBCI. Shipments of Industrial Control Equipment Weaken NEMAs Primary Industrial Controls Index decreased 1.6 percent on a quarterto-quarter basis during the third quarter of 2012. The index stands 1.2 percent below its year-ago level but 45 percent above the cyclical trough observed in mid-2009. More at www.nema.org/ ShipmentsOfIndustrialControl Motors Shipments Fall Sharply Demand for motors declined for first time this year during the 2012Q3. This backslide follows on the heels of a 5.4 percent gain posted in the second quarter and a 5.9 percent gain recorded in the first quarter of this year. More at www.nema.org/MotorShipmentsFall Lighting Equipment Demand Dwindles NEMAs Lighting Systems Index declined in the third quarter of 2012 after a positive performance in the first half of 2012, falling 3.3 percent on a quarterto-quarter basis. On a year-over-year (y/y) basis, the index decreased by 1.1 percent. Lighting equipment demand has struggled to gain traction since the recovery began and remains well below the levels observed during the previous economic expansion. More at www. nema.org/LightingEquipmentDwindles HID Lamp Shipment Indexes Continue to Decline Indexes for high intensity discharge (HID) lamp shipments declined for the second consecutive quarter in 2012Q3. More at www.nema.org/ LampShipmentsDecline T12 Fluorescent Lamp Index Tumbles The T12 lamp shipment index tumbled to 37.5 a decline of nearly 40 percent on a y/y basis during Q3the first quarter following the implementation of the new efficiency standards for general service fluorescent lamps. More at www.nema.org/ FluorescentLampTumbles ei
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