Plant Engineering Octubre 2015

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Products | Rubber Track
37 Maintenance data
dard
PA 70E 27
49 Fit bearings properly
37 Maintenance data
dard
PA 70E 27
21 A global view of manufacturing
37 Maintenance d
Raising
the standard
Whats new with NFPA 70E 27
Performability
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Accountability
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Maintenance data
rd
70E 27
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KAESER SUCCESS STORY
COMPRESSORS
Keep It Under Control!
Kaeser puts automotive supplier in the drivers seat of compressed

air efficiency
PROBLEM:
A Tier 1 automotive seating and electrical supplier was interested in
taking advantage of local utility rebate incentives. For their compressed
air needs, they had been relying on four compressors manufactured
in the 1980s, inherited from a sister plant. Each unit operated in
modulation control and was manually switched on and off, leaving
the units continually fighting each other, resulting in wasted energy,
fluctuating pressure, and increased maintenance costs.
SOLUTION:
Kaeser performed a complete Air Demand Analysis (ADA) to identify
the plants current compressed air needs and to develop a plan for
implementing the most energy efficient solution possible. Additionally,
Kaeser recommended a Sigma Air Manager (SAM) master controller
to properly control the system and ensure the most energy efficient
combination of units would be selected to meet current plant demand.
RESULT:
Thanks to better controls and adding an energy efficient variable
frequency drive compressor, the customer was able to reduce their
annual maximum power consumption by 865,440 kWhthe equivalent
of removing 100 homes from the power grid for one yearall without
compromising stable system pressure. With the older compressors
relegated to back-up, annual maintenance costs have been reduced
from $37,000 to $18,000. Less maintenance also means less downtime,
for increased productivity.
Specific Power of Previous System:
28.93 kW/100 cfm
Specific Power of New System:
17.66 kW/100 cfm
Annual Energy Costs of Previous System:
$252,988 per year
Annual Energy Cost Savings:
$114,720 per year
Additional Savings in Maintenance Costs:
$19,000 per year
TOTAL ANNUAL SAVINGS:
$133,720
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TOTAL SAVINGS:
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2015 Kaeser Compressors, Inc.
customer.us@kaeser.com
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October 2015
Volume 69, No.8
Cover image courtesy: Emerson
27 Raising the standard

The latest updates to NFPA 70E require plant managers to re-examine their
electrical safety programs.
32 Ten essential steps to support arc flash

incident energy analysis
An arc-flash-incident energy analysis is the first step in this process that will quantify
the incident energy that will be released during an arc flash event at each location in the
electrical system.
33 Top seven arc flash safety measures

Here are seven ways to limit the exposure of workers to the risk of arc flash incidents.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 69, No. 8, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
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PLANT ENGINEERING
October 2015 3
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21 The Road to Hannover Messe 2016

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Hannover Messe 2016 will showcase the global strength of U.S. manufacturing. A significant part of that strength is the small and midsized manufacturers that make up more than 85% of all manufacturing plants. Officials from Hannover Messe
and the U.S. Department of Commerce,
along with some of the worlds top industrial manufacturers, opened the doors to
that segment of manufacturing at a kickoff
press conference Sept. 30 in Chicago.
Maintenance Solutions
37 Predictive maintenance:
Analyze data properly
Replacing everything in a plant instead of maintaining it is an absurd

idea. While new equipment can make a good first impression, what
builds long-term charm is smart maintenance of all that equipment.
41 Standardizing for
success
Standardization facilitates a lean,
efficient, and functional workplace.
It enables quick transitions between
personnel who perform the same
task, increases production speed, and
improves product quality through a
consistent application of tools.
43 Five steps to applying predictive

maintenance
Ensuring the right work is performed at the right time to minimize

downtime on production assets is crucial to productivity, but avoiding
costly unplanned maintenance is paramount as well. It can be expensive to remove a piece of equipment from production to perform routine preventive maintenance, only to find a function dictated by the
Preventive Maintenance (PM) task was not necessary.
Mechanical Solutions
49 The quest to find the perfect

bearing fit
While tight and loose are relative terms that

must be defined in the quest for the perfect fit,
any fit thats too loose or too tight can lead to
early bearing failure and costly downtime.
52 Using medium-voltage VFDs

for better pump process control
Many plant operators dont realize they need a more intuitive medium
voltage controller until it is too late. If there is a potential problem
with a high-energy pumping system, it is critical to know as much as
possible about that pump, motor, and system before the alarms go off.
PLANT ENGINEERING
October 2015 5
OCTOBER
Trending
New Products
Maintenance
Electrical
Mechanical
Energy Management
ONLINE: Manufacturing Day recap:

Your photos online
The 2015 Manufacturing Day on
October 2 was the largest event ever,
with more than 2,000 events across
the country. Many manufacturers took
our invitation to share their pictures
with us of their local recognition of
Manufacturing Day. A review of the
days activities can be found at www.
plantengineering.com, KEYWORD:
Manufacturing Day 2015.
Your most-read stories at www.plantengineering.com
Here are Septembers 10 most often referenced articles at www.plantengineering.com. In

September, readers in 175 countries on six continents reviewed more than 11,000 unique
articles. At www.plantengineering.com, our online community can search our entire database
for reference materials, best practices and review this months digital edition, all from their own
computer.
1. Engineering Leaders Under 40
2. The truth about five common VFD myths
3. Maintenance a prime benefit for IIoT
4. 10 steps to achieve world-class maintenance practices
5. A return to apprenticeships delivers skilled workers to Pratt & Whitney
6. Seven steps in predicting equipment lifecycle using obsolescence management
7. Take a total system approach to compressed air reliability
8. Six serious safety hazards to avoid in manufacturing jobs
9. Optimizing electrical systems through IIoT
10. Successful plant relocation; a checklist for success
Webcasts: 1 hour to knowledge
Plant Engineerings Webcast series offers a wide selection of on-demand knowledge

everything from the latest innovations concerning the Industrial Internet of Things (IIoT) to
reports on motors, air quality and safety. All Webcasts can be completed in just an hour, and
many of them offer continuing education credits.
Among the current topics at www.plantengineering.com/webcasts:
Motor and Drive System Considerations to Ensure Maximum Performance, Increase Reliability
and Extend Product Life
Considerations for Buying or Upgrading Dust Collection Equipment
5 Ways to Improve Your Plants Training Strategy
Portable Spot Air Conditioners in Industrial Applications: Increase Revenue and Create a Safe
Working Environment
3D Laser Scanning: Revolutionizing Facility Management
6 October 2015
PLANT ENGINEERING
Plant Automation
Safety
People and Training
Engineering eNewsletters
Stay in touch with
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industry, including
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product updates.
eNewsletters include:
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Connection, PlantMail,
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Showcase, and Whitepaper Connection.
Subscribe to one or more eNewsletters at:
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Read this on your tablet

The tablet and digital
editions of this
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enhanced and have
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subscribers. They also
Raising
include interactive tools the standard
such as videos, Web
links, and other items.
Update your subscription,
and receive the digital
edition in your e-mail in-box:
21 A global view of manufacturing
37 Maintenance Data
Whats new with NFPA 70E 27
www.plantengineering.com/subscribe
Upcoming webcasts
Register for educational webcasts at
www.plantengineering.com/webcasts:
November 3: IIoT Webcast Series
Part 3: Integration considerations
Join the discussion

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no added cost. You cant afford a factory shutdown, but you can afford the Keysight TrueIR Thermal Imager.
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IN FOCUS
Data-driven manufacturing challenges
the emergence of mass customization
By Greg Conary
Schneider Electric
The Internet of Things (IoT) is here,

with Internet-connected devices across
the enterprise and consumer devices
generating data that is constantly being
captured, analyzed, and acted upon all
around us. The insights gained from this
data are allowing for many industries to
be more efficient and productive, putting more pressure on operations staff
to ensure they are staying ahead of the
curve. However, the industry that is
being asked to store the most data is
often overlooked. Surprisingly, its not
health care, retail, or governmentits
manufacturing.
The first Industrial Revolution was
characterized by the mechanization of
production using water and steam, the
second by the introduction of mass production using electrical power, and the
third by using information technology
(IT) to automate production. However,
most recently weve entered into the
Fourth Industrial Revolution (also known
as Industrial Internet of
Things, or IIoT), which
is characterized by Internet-connected devices that
enable a new level of Big
Data and analytics.
By 2020, Gartner predicts that the IoT will
consist of 26 billion
devices and will generate
more than $300 billion in
incremental revenue, the
majority of which will be generated by

services. We already know that the industrial manufacturing process creates a ton
of data, and that more devices are becoming connected and networked.
As a result, were seeing a massive
explosion of data that has enabled new
business models and practices to be put
into place that are transforming the global
manufacturing playing field and allowing
organizations to compete on smarts, not
costs. Because manufacturing is one of
the largest economic drivers, this massive
shift brought on by IIoT creates tremendous benefits even beyond the plant floor.
The emerging mass-customization

model
For manufacturers, one of the biggest

capabilities emerging from the rise of
the IIoT is the mass customization of
products and services. The appeal of
mass customization is the potential to
help manufacturers reduce costs and gain
a competitive advantage in the market.
In the past, organizations that tried
to accomplish this mass-customization
model failed because the technology

wasnt able to keep up. Instead, manufacturers focused on mass-production
because it was most profitable to produce
a large quantity of the same product.
However, todays technology is allowing manufacturers to slowly step away
from the mass-production business model
and move into the mass-customization
one. Many of todays manufacturing
systems are able to produce make-toorder products that are inexpensive and
personalized, which is giving them a leg
up over competitors.
In the manufacturing industry, it is not
enough to be able to create branded or
personalized items. For organizations to
produce a wide range of unique products,
they need to also create flexible automation processes, machines, and manufacturing systems integrated with business
systems and consumers.
Essentially, manufacturers need to
move beyond a process control system
that has a central brain and understands
everything about the assets in the factory, to a model where each asset knows
Technology is allowing
manufacturers to slowly
step away from the
mass-production business model and move
into the mass-customization one. CFE Media
file photo.
PLANT ENGINEERING
October 2015 9
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everything about itselfand knows how, when, and why to
communicate directly with other components of the manufacturing process not necessarily going through a central
computer. By combining this business model shift with the
data and insights gained from the machines, manufacturers
are now able to empower a factorys assets to optimize their
own productivity and efficiency within the broader context of
the process control system. To put it simply, the plant assets
need to become smart.
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Internet-enabled connectivity of devices and analytical capabilities have pushed forward new models of manufacturing.
The development of self-organizing and -reporting systems
that have moved away from centrally orchestrated processes
to a more distrusted one is key. With the machines and other
assets of a plant communicating independently of one another
to make decisions, there is more room for flexibilityor
customization of products and services. To achieve this new
model of manufacturing, organizations need to think about
what makes their assets smart.
For example, adding smart objects to your plant allows
facility managers or engineers to create a digital model of
physical assets within the virtual environment. These smart
objects will now have the ability to attach to different data
sources and access the information that is available on a particular asset. This data, combined with different dimensions
and parameters in the context of one another, gives new and
deeper insights into the performance of an asset.
Additionally, it is vital to have connectivity and accessibility with smart objects. Without a level of connectivity, smart
objects are not able to be fully tapped into the framework of
a factory, therefore they are not able to provide insights to
those in the field or at the enterprise level of the organization. Building a fully connected network from the field to the
enterprise that pulls insights from power, process, building
management, and IT is essential to contextualizing data and
making it both visible and accessible.
Finally, to actually be considered a Smart Factory, a facility needs to generate intelligence from its smart assets. This
will allow for plants to move past the traditionally passive
automation process to a more intelligent, semi-autonomous
decision-making system. By adding intelligence to a control
system, assets are better able to leverage their available data
sources. Plant intelligence is helping to evolve the plant from
managing production targets and quotas to managing profit
performance.
Many manufacturers are being pressured to decrease their
time-to-customer delivery, as well as offer more unique products with an unpredictable demand. The rise of IIoT and its
impact on the creation of the Smart Factory is a huge win for
this shift, allowing for the flexibility, automation, and data
sharing needed to make the mass-customization business
model a reality, in a cost-effective and efficient way. PE
Greg Conary is senior vice president of strategy for
Schneider Electric.
12 October 2015
plant engineering
Control
Allied has the relay you need to keep it.
N a t i o n a l C o n t r o l s C o r p.
Take control at thinkallied.com/relays
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Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
IN fOCUS
IIoT offers many benefits for maintenance

The emergence of Industrial Internet of
Things (IIoT) as a plant strategy has focused
on productivity and operational issues. A
recent study by global consultancy Frost
& Sullivan talked about the relationship
between IIoT and maintenance. The study
found that service strategies will shift from
corrective to preventive and predictive maintenance services over the next five years.
Report author Srikanth Shivaswamy,
senior research analyst for industrial automation and process control for Frost & Sullivan, discussed the ways IIoT will impact
the maintenance area.
CFE Media: One of the hottest topics
around IIoT is the potential for better maintenance within plants. Has maintenance
been overlooked by most plant managers?
How will IIoT potentially change that?
Shivaswamy: Conventional maintenance
systems followed pre-set approaches for
maintenance and repairs; service activities
were performed according to pre-design
standard operating procedure. Maintenance

and repair operations were initiated based
on equipment or process flow breakdown.
Internet of Industrial Things would see
the emergence of scheduled and automatic
maintenance and repairs activities generated by pre-programmed algorithms.
Dynamic maintenance schedules can
be generated based on real-time data
by sensors.
Ability to migrate to a completely different service model to adjust to a new
process/ product /solution and improve
the overall performance of the end-user.
Flexibility to scale up and down the
services capabilities.
CFE: Will this increase in data also
change the training and skill set needed
for maintenance workers? What are the
challenges and opportunities here?
Shivaswamy: The skill set of the maintenance workers need to be tuned to understand the dynamic service models. In most
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trained to understand and operate the IIoT
based platform.
Challenges and opportunities:
Development of smart and user-friendly
platforms for data management.
Asset and resource management modules
Standard service and maintenance
models
Use of off the shelf mobile devices
Development of integrated cloud platforms to execute design, maintenance,
and business services.
CFE: What is the first thing plant managers should do to prepare for IIoT in their
facilities?
Shivaswamy: Information technology
and communication infrastructure in the
most of the plants needs to be improved
for complete implementation of IIoT modules. PE
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IN FOCUS
OSHA safety violations increase in 2015
Fall protection, lockout/tagout lead the way as overall violations increase by 4%
The preliminary OSHA top 10 violations for 2015 showed
little overall movement as fall protection was once again
the number one violation. Patrick Kapust, deputy director
of OSHAs Directorate of Enforcement Programs, presented
the Top 10 at the 2015 National Safety Council (NSC)
Congress & Expo, the worlds largest gathering of safety
professionals.
In injury prevention, we go where the data tell us to go,
said NSC president and CEO Deborah A.P. Hersman. The
OSHA Top 10 list is a roadmap that identifies the hazards
you want to avoid on the journey to safety excellence.
The top 10 ranking varied little from 2014, and in fact
vary only slightly from year to year. The only movement
came from the categories of ladders and electricalwiring methods, which swapped the seventh and eight spots.
There were 34,436 violations overall in 2015, a 4%
increase from 2014. Fall protection violations, which
dropped by a third in 2014, were up 10% in 2015, and
lockout/tagout violations were up 11% in 2015. The only
violations that showed any decrease were in the category
of electricalwiring methods and electricalgeneral
requirements.
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The Top 10 for FY 2015, their OSHA hazard standard

citation, and the 2014 total and ranking for each category are:
1. Fall Protection (1926.501) 6,721 (6,143, 1st)

2. Hazard Communication (1910.1200) 5,192 (5,161, 2nd)
3. Scaffolding (1926.451) 4,295 (4,029, 3rd)
4. Respiratory Protection (1910.134) 3,305 (3,223, 4th)
5. Lockout/Tagout (1910.147) 3,002 (2,704, 5th)
6. Powered Industrial Trucks (1910.178) 2,760 (2,662, 6th)
7. Ladders (1926.1053) 2,489 (2,448, 8th)
8. Electrical Wiring Methods (1910.305) 2,404 (2,490, 7th)
9. Machine Guarding (1910.212) 2,295 (2,200, 9th)
10. Electrical General Requirements (1910.303) 1,973
(2,056, 10th) PE
Chris Vavra is production editor, CFE Media,

cvavra@cfemedia.com.
See additional stories about plant safety and
security below.
Workplace fatalities rise,

while rate remains flat
Preliminary results from the Bureau of Labor Statistics
Census of Fatal Occupational Injuries released in September show the rate of fatal work injuries in 2014 was 3.3 per
100,000 full-time workers, the same as the final rate for 2013.
While the preliminary total of 4,679 fatal work injuries was
an increase of 2% over the revised count of 4,585 in 2013,
there was also an increase in hours worked in 2014.
Far too many people are still killed on the job 13 workers every day taken from their families tragically and unnecessarily, said U.S. Secretary of Labor Thomas E. Perez in a
statement. These numbers underscore the urgent need for
employers to provide a safe workplace for their employees
as the law requires.
Perez also cited slight improvements in some areas, and
declines in others, as evidence that the work OSHA and
other regulatory agendas do still is needed. Preliminary
results tell us 789 Hispanic workers died on the job in 2014,
compared with 817 in 2013, Perez stated. While we were
gratified by that drop, the number is still unacceptably high,
and it is clear that there is still much more hard work to do.
BLS data shows fatalities rising in the construction sector (along with an overall increase in construction employment). Dangerous workplaces also are taking the lives of
a growing number of people in oil and gas extraction, he
added. That is why OSHA continues extensive outreach
and strong enforcement campaigns in these industries. PE
16 October 2015
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IN fOCUS
Manufacturing revenues, hiring on
the rise, and spending will follow
Prime Advantage Survey finds strength in the sector, despite headwinds.
Manufacturing revenues are
on the rise, and manufacturing
hiring remains strong despite a
struggle to find skilled workers.
Those are among the findings
from Chicago-based manufacturers buying group Prime
Advantage in its 14th Purchasing and Manufacturing Survey.
The benchmarked survey
polls more 750 small and midsized U.S. industrial manufacturing companies. Prime Advantage is a buying consortium for
manufacturers with more than
750 member companies and
more than 125 endorsed suppliers.
Among the highlights of this latest
survey:
80% of respondents expect to be at
or above previous years revenues,
and 83 percent anticipate maintaining
or increasing revenue performance
in 2016.
Hiring is strong, as 61% of members planned to hire new employees
in 2015.
A lack of qualified workers remains
the top threat to manufacturing
growth among members for the second consecutive year, with 46% voicing this concern, down from 53% in
2014.
Mike McDonald, vice president of new
business relationships for Prime Advantage, discussed the survey findings with
Plant Engineering:
Plant Engineering: Your data indicates
widespread strength across the manufacturing sector. Are you seeing more
strength in the U.S. market vs. international, or is the sector growing across
the board?
Mike McDonald: While we didnt delineate between domestic and international
sales in this survey, we know through conversations with some of our members that
international business for some of them
The Prime Advantage Purchasing and Manufacturing Survey

found that manufacturers plan
to continue aggressive hiring
over the next year. Image courtesy: Prime Advantage
any further in this area with

our question structure, but
with business continuing to be
steady and growing for most
manufacturers, this number
didnt completely surprise us.
has slowed a bit, and the stronger dollar

has come into play as well. Prime Advantage members indicated in the survey that
the biggest drivers for a lift in revenues
were new products and new customers.
We believe these are the same members in
previous surveys that indicated increased
investment in (research and development), which looks to be bearing fruit.
PE: Investment in both people and processes are high. What is different in 2015
and 2016 than in past years that is fueling
this growth?
McDonald: The employment numbers
havent changed significantly over the last
few years; theyve been trending nicely
(to maintain or grow the workforce) since
2012, with virtually nobody reducing
headcount this year. So, employment
has been a consistent message, and we
see that continuing. There is still a speed
bump of finding enough skilled workers,
but we know that some of our members
have been addressing that through training programs and partnerships with local
community colleges to train students in
a skilled trade.
The capital spending numbers look
good with 73% of respondents indicating theyd either increase or hold their
planned investments steady, compared
to 57% last year. We didnt drill down
PE: Even with global political and economic issues, there

seem to be very few headwinds in the
U.S. manufacturing sector. Has the caution of the past few years finally given
way to sustainable growth?
McDonald: I think the feeling is that
domestic markets are solid and for many
of our members, thats enough. We certainly have members that conduct business globally and theres a slower pace
in certain international markets. Its been
interesting to see our members over the
last several years invest in new product
development, which is fueling some of
their current growth, which is great. I
agree that there dont appear to be any
major headwinds; but we also know
thats a fluid situation.
The two areas most companies are
keeping an eye on are healthcare costs,
and availability of trained workers. As
far as healthcare, the focus is how to
respond and comply with the (Affordable Care Act), while trying to control
the rising cost of healthcare for their
organization and provide the best coverage options to their employees.
And as far as trained workers, this
issue hasnt gone away, its just not as
pressing. Our most forward-looking and
innovative members have partnered with
local schools to offer training for trade
skills or broader exposure to the world
of manufacturing, which is great. PE
plant engineering
October 2015 17
IN fOCUS
Bring managers together to avoid security threats

By Greg Hale, ISSSource
Middle managers may or may not be

aware of the increased need for security, but they can be an obstacle when it
comes to implementing and promoting
security within their realm. While the

thought may seem to not make sense
at first, it makes perfect sense where a
middle managers compensation and
performance objectiveswhether it is
a process line, an entire plant or anything
in betweenfocus on performance.
With pure performance objectives
strictly in mind, security will often go
by the wayside.
One case in point is one chief information security officer (CISO) at an
oil and gas major who told a group of
about 50 ICS cyber security experts at
an invitation only meeting to discuss
cyber security in oil and gas that one
of his objectives handed down from his
chief executive is to go around and get
middle managers to adopt and follow
the security process, said John Cusimano, director of industrial cybersecurity
at aeSolutions. The CISOs mission is to
make security part of the culture.
The CISO said his biggest problem
is middle managers. Not the workers
in the trenches, but middle managers.
I have seen this with other clients
where even higher-ups (e.g. VPs) in
Engineering, Operations or even IT
may not be onboard with an OT cyber
security program, Cusimano said.
For such a program to be successful
it requires support from all three. Not
surprisingly, the battles are more about
company politics than anything else.
One of my clients, a global chemical company, operates a very successful
OT cyber security program, Cusimano
said. However, they really struggled in
the initial formation of the program due
to internal politics. The program was
chaired by someone from operations
who started his career in engineering.
He was able to easily get engineering
onboard but really struggled with getting IT, and thus the whole team, rowing
in the same direction.
He brought my company in to help
educate and establish a strategy for the
team. Initially, you could see and feel
the tension in the room as different
groups literally faced-off on opposite
sides of the table. This is where having
a neutral third-party who understands
both automation and IT and has experience working with complex organizations can really help.
Understanding the risks
We were able to help them understand

the risks to the company (not just their
18 October 2015
plant engineering
department) and identify areas of weakness (vulnerabilities) without pointing

fingers. After a couple of months the
team had developed a strategy and a
plan to conduct several site vulnerability assessments on sample facilities in order to gather more detailed
information.
The most brilliant part of the plan
was that the chairman of the committee
brought the IT people into the field for
a week long tour of several facilities.
It was the first time that most of them
had ever been in a plant. It was very eye
opening for them to see a real chemical
plant and to see the day-to-day challenges that operations faces and to see, firsthand, how their IT infrastructure interacted with the plant infrastructure. They
loved it. After a couple of days the
IT and OT people were working handin-hand to gather the information we
needed and conversations every night
at dinner were lively and constructive.
Most notably, when we got back and
had the next committee meeting everything had changed. Instead of tension
there was camaraderie and the groups
sat co-mingled around the table. This
was one of the most rewarding projects
I have worked on because I was able to
witness and be a part of bringing IT and
OT groups together to solve a common
problem, Cusimano said.
The idea of middle managers bottlenecking the security culture and program is a huge obstacle to overcome.
As executives in the corner office and
boards of directors are very aware of
the issue as are those working on the
day-to-day issues in the trenches. But
those middle managers remain a problem, said Martin Smith MBE, chairman
and founder of The Security Company,
and of the Security Awareness Special
Interest Group at the CBI Cyber Security Conference 2015 in London.
In a world where middle managers end up measured, and rewarded,
by performance, security will end as
ITs problem. (They only want to) be
measured by business performance
and not cyber-security performance,
Smith said. Smith said they have yet
to accept the idea cyber security is no
longer just a technology issue, but a
business issue.
plant engineering
October 2015 19
Often people will say awareness

is not necessary because people are
aware. That actually is not true as
true awareness and understanding
occurs because the point continuously
ends up hammered home to where it
becomes second nature. PE
Gregory Hale is the editor and

founder of Industrial Safety and
Security Source (ISSSource.com), a
news and information website covering safety and security issues in the
manufacturing automation sector.
This content originally appeared on
ISSSource.
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THE ROAD TO
HANNOVER MESSE2016
Hannover Messe: A great venue

for small manufacturers
Commerce, industry leaders tout U.S. Partner Country status for 2016.
annover Messe 2016 will showcase

the global strength of U.S. manufacturing. A significant part of that
strength is the small and mid-sized
manufacturers that make up more than 85%
of all manufacturing plants. Officials from
Hannover Messe and the U.S. Department of
Commerce, along with some of the worlds
top industrial manufacturers, opened the
doors to that segment of manufacturing at a
kickoff press conference Sept. 30 in Chicago.
For the first time, the United States will be
the partner country at Hannover Messe, the
worlds largest industrial trade show. Under
the theme Integrated IndustryDiscover
Solutions, Hannover Messe 2016 will take
place April 25-29 in Hannover, Germany. The
fair is expected to attract more than 220,000
attendees from more than 100 countries and
more than 5,000 exhibitors, including the largest contingent of U.S. manufacturers ever at Hannover. CFE Media
is the Official Media Partner for the U.S. Partner Country
at Hannover Messe 2016.
This show is going to be a great platform for small
to medium-size manufacturers to exhibit, said Antwaun
Griffin, deputy assistant secretary for U.S. operations for
the Department of Commerces International Trade Administration. Were working to make sure U.S. companies
have a prime location to leverage their opportunities.
All of this is to help the U.S. to not just stay ahead of
the curve, but also to help create the curve, Griffin added.
The Hannover fair is an excellent opportunity to promote American manufacturing and the interconnectedness of advanced manufacturing in a global arena, said
Dr. Caralynn Collens, CEO of UI LABS, which manages
the Digital Manufacturing and Design Innovation Institute (DMDII) in Chicago where the press conference was
held. Hannover Messes themes of the Internet of Things
and Industrie 4.0 are closely aligned with the strategic
direction of our institute, bringing together world-class
companies and innovators to transform manufacturing for
the digital age.
Bringing U.S. manufacturers to Hannover
With 96% of potential customers living outside the U.S.,

global trade and manufacturing has long been an important
component of manufacturing success. Combined with the
strength of the U.S. manufacturing economy coming out of
Dr. Caralynn Collens, CEO of UI LABS, which manages the

Digital Manufacturing and Design Innovation Institute (DMDII)
in Chicago, welcomed attendees to the press conference
Sept. 30 to discuss the U.S. Partner Country status at Hannover Messe 2016. Image courtesy: Hannover Fairs USA.
the global recession, Hannover officials have been looking to bring the worlds largest industrial manufacturing
economy to the worlds largest industrial trade show.
In light of Americas resurgence as a manufacturing
power, Hannover Messe, together with the United States
Department of Commerce and the German Federal Ministry
for Economic Affairs and Energy, decided it was time for
the U.S. to take center stage at the worlds leading trade
fair for industrial technology, Hannover officials said in
a press release.
To further that effort, both the Department of Commerce
and Hannover Messe officials are working to encourage
American manufacturers to attend and exhibit. The U.S.
Investment Pavilion in Hall 3 will allow state and local
economic-development agencies to discuss direct foreigninvestment opportunities with global partners. The U.S.
Commercial Service and SelectUSA will facilitate meetings
with buyers and trade delegations around the world.
Hannover Messe also attracts world leaders to the event,
and the 2016 fair should be no exception. President Obama
is expected to join German Chancellor Angela Merkel in
officially opening the fair on April 24 with a gala event of
entertainment. Past Partner Nations Country have seen their
plant engineering
October 2015 21
THE ROAD TO
HANNOVER MESSE2016
CFE Media named Official Media Partner

Two trade events in 2016 to highlight U.S. role in manufacturing.
Hannover Fairs USA has selected CFE Media as the Official
Media Partner for Partner Country USA at Hannover Messe
2016 in Hannover, Germany, in April 2016. CFE Media also
will be the Official Media Partner for the
2016 Industrial Automation North America
event at the IMTS Show in Chicago in September 2016.
The United States will be the Partner
Country at Hannover Messe in 2016, the
worlds largest industrial trade event, with
more than 220,000 attendees each year. The
Industrial Automation North America trade
event will be part of the biannual IMTS
Show in Chicago, the largest industrial trade
show in North America, with more than 100,000 attendees.
Our long partnership with CFE Media has been valuable, and we are pleased to partner with them on both major
heads of state appear, including Indian

Prime Minister Narendra Modi in 2015
and Russian Prime Minister Vladimir
The strength of small,

and mid-sized manufacturers
According to the latest census from the
North American Industrial Classification
System (NAICS), there are nearly 300,000
manufacturing plants in the United States.
Of those plants, almost 85% have fewer than
50 employees.
SIZE
PLANTS %
0 to 4 employees
130,203
43.8%
5 to 9 employees
40,231
13.5%
10 to 19 employees
38,898
13.1%
20 to 49 employees
42,379
14.2%
50 to 99 employees
21,289
7.1%
100 to 249 employees
16,217
5.5%
5,218
1.8%
1,940
0.6%
1,000 to 2,499 employees
664
0.2%
2,500 employees or more
152
>0.1%
All plants
297,191
Source: NAICS 2012 Census
22 October 2015
PLANT ENGINEERING
industrial trade shows in 2016, said Larry Turner, CEO of

Hannover Fairs USA. The U.S. has been a global leader in
manufacturing over the last decade, and next year will be
one of the most exciting years ever for the
industry. We appreciate having a partner
such as CFE Media to highlight the importance of these important manufacturing
trade events.
We know the value of Hannover Messe
as the finest industrial trade show in the
world, and it is even more valuable with
the United States as the Partner Country,
said Jim Langhenry, publisher for CFE
Media. We are honored to be selected as
Hannover Fairs USAs partner on these two important events,
and we look forward to working with them to deliver value
to everyone involved with these events. PE
Putin in 2013. Obama and Merkel are

expected to tour the U.S. Investment
Pavilion on April 25, which also is the
day of the German-America Business
Summit.
For European-owned companies
already firmly landed in the U.S., Hannover Messe represents a chance to show
off their global strength as well as the
value of their American investments.
This is important on the worldwide
stage. The show brings two strong countries together, said Greg Scheu, president of the Americas region of ABB.
More than 20,000 visitors came through
the booth at Hannover last year. The fairgrounds at Hannover are more than 50
football fields of technology, and for an
engineer like me, its a playground. We
couldnt be more delighted that were
partnering with Hannover Messe.
Manufacturing matters again, said
Dr. Helmut Ludwig, chief manufacturing officer for Siemens PLM Software.
Siemens is the largest single exhibitor at
Hannover Messe. Were optimizing the
digital enterprise. Were clearly focusing on adding value in manufacturing.
Its not the screwdriver any more in our
plants; its the iPad. You need to be in
Hannover, where you will see this in
action. PE
Source: Hannover Fairs USA
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research
2015 SAFETY STUDY:
Six findings on workplace safety
espondents to the Plant

Engineering 2015 Safety
Study identified six high-level
findings impacting the manufacturing industries today:
1. Commitment to safety: Three-
quarters of operations and senior

management personnel are very committed to safety in their facilities,
followed by line supervisors (64%)
and line workers (52%). An overall
increase in commitment to safety was
observed between 2014 and 2015.
2. Work group safety: The work

groups that feel the safest in their
daily tasks are plant management/
corporate executives (81%), safety
executives/managers (77%), and engineering (66%).
3. Safety programs: Ninety-five
percent of respondents believe their
employees feel safe on the job, and
82% have observed an increase in
productivity over time due to the
implementation of a safety program.
The costs of injuries and insurance
claims have also decreased since following a safety program.
4. Enforcement: Four out of five
facilities hold regular safety meetings, perform safety audits, and

have established a safety committee
in order to enforce safety methods.
Another 43% have implemented
incentive-based programs.
5. Safety meetings: The major-
ity of safety meetings are held

on a monthly basis, and the most
active contributors are line workers
(65%), plant management/corporate
executives (65%), safety executives/
managers (63%), and maintenance
personnel (63%).
6. Measuring success: Eighty-four
percent of facilities measure their

safety success by the number of accident reports and near-miss events,
while 74% compare their OSHA
recordables/time-lost accidents, and
46% observe lower workers compensation costs.
View more information at
www.plantengineering.com/2015Safety.
Amanda Pelliccione is research
director at CFE Media.
51%
of facilities with peak

load sharing programs reported
success, while 45% experienced
some difficulties they were able
to overcome. Source: Plant Engineering 2015 Energy Management Study
5.4%: The average per-
centage of jobs in manufacturing facilities currently unfilled.

Source: Plant Engineering 2015
Workforce Development Study
3 in 10 facilities are challenged with their employees not

recognizing safety as a priority.
Source: Plant Engineering 2015
Safety Study
MORE RESEARCH
Plant Engineering surveys its
audience on five topics each
year: salary survey, maintenance, energy management,
safety, and workforce development. All reports are available at
www.plantengineering.com/research.
All graphics courtesy: Plant Engineering, CFE Media
24 October 2015
PLANT ENGINEERING
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Eaton.com/
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Follow us on social media to get the

latest product and support information.
COVERSTORY
Providing workers with
the right personal protective equipment for the job
and information on how to
select the right equipment
can go a long way toward
keeping workers safe and
productive. Image courtesy:
Emerson
Raising the standard

The latest updates to NFPA 70E require plant managers
to re-examine their electrical safety programs.
By Wally Vahlstrom
Emerson Network Power
very three years, the National Fire

Protection Association updates
NFPA 70E: Standard for Electrical Safety in the Workplace.
The intent of the standard is to
reduce exposure to the hazards of
shock, electrocution, arc flash, and arc blast
while working on or near exposed electrical conductors or circuit parts that are or
can become energized. With greater overall
energy usage, higher system voltages, and
higher available fault current, the risk of
such exposure is on the rise, forcing plant
managers to make significant changes and
updates to their electrical safety policies
to comply.
Failing to make the necessary changes
can, and does, have dire consequences for
employees and businesses. In addition to
claiming one life every workday, arc flash
incidents can also lead to business disruption, equipment damage, legal liability,
increased insurance premiums, and regulatory fines.
For example, a recent arc flash incident
in Buffalo, N.Y., caused an electric technician to suffer third-degree burns on her
hand and first-degree burns on her face
because her employer failed to provide
proper face and hand protection. That
employer faces a proposed fine of $147,000
from OSHA. In another recent incident in
Florida, lax enforcement of safety policies
led to the electrocution of an electricians
apprentice by more than 10,000 V. The
utility company faces proposed penalties
totaling $90,000. OSHA fines following arc
flash incidents are just the beginning of the
costs for employers, as many subsequently
face expensive litigation, possible increases
PLANT ENGINEERING
October 2015 27
CoverStory
Once an arc flash risk assessment has been completed,
its up to the plant manager to share the results
with workers so they can use the information to properly
protect themselves on the job.

in insurance premiums, and likely, some
equipment repair.
Clearly, failure to properly protect
workers from arc flash hazards can exact
a cost no plant wants to pay. The key to
saving lives, preventing serious injuries,
and avoiding costly business disruptions
begins with understanding the latest changes and updates to NFPA 70E along with
what your plant needs to do to comply. This
article will review the standards newest
guidelines for identifying and assessing
arc flash risks, communicating those risks,
and training workers. It will also introduce
best practices for creating a safe electrical
work environment that is up to code.
Identifying and assessing arc flash risks
OSHA has always made it the employers

responsibility to identify and share onthe-job risks and hazards with employees,
including arc flash risks. To help accomplish this, NFPA requires plant managers to
perform an arc flash risk assessment prior
to allowing workers to perform tasks on or
near energized equipment.
In the 2012 version of NFPA 70E, a major
revision stated that the arc flash boundary
distance must be determined for all locations where the voltage is greater than 50
V and there is a possibility of performing
energized work such as maintenance, diagnostics, and testing. This requirement significantly expanded the scope of arc flash
risk assessments.
Furthermore, the 2015 version of the standard limited the use of the Arc Flash PPE
(personal protection equipment) Categories
Methodor table methodfor determining
the arc flash boundary distance. Specifically,
the tables supplied in the standard may only
be used in situations where 1) the specific
task to be performed appears in the tables,
and 2) the system meets the listed criteria for
short-circuit current magnitude and speed
of response of circuit protection. In many
28 October 2015
plant engineering
cases, facility managers do not have access

to the data and information needed to use
the tables correctly.
As a result, most plant managers will
need to use the more rigorous engineering
analysis method to complete the arc flash
risk assessment and calculate the arc flash
boundary distance. This method involves
reviewing technical data and using software
to perform calculations, which is obviously
more work than consulting the standards
tables.
However, while engineering analysis is
more costly and likely more time-consuming
to implement, it does generate site-specific
results that can better protect facilities and
workers, especially when considering that
tables are often misused in the field. The
extra effort of engineering analysis could
even save a life.
Communicating arc flash risks
Once an arc flash risk assessment has been

completed, its up to the plant manager to
share the results with workers so they can
use the information to properly protect themselves on the job. To facilitate communication, both NFPA and OSHA require employers to meet with contract employees to share
information about known hazards. Those
meetings must now be documented to ensure
compliance.
Additionally, owners of ac and dc electrical
equipment are responsible for properly field
labeling the equipment with arc-flash-hazard
warning labels that include the results of the
arc flash risk assessment. Arc flash equipment labeling first became an NFPA 70E
requirement in 2002, and the requirements
have been updated in 2004, 2009, 2012, and
2015. The standard now spells out the types
of equipment that need to be labeled, including switchboards, switchgear, panel boards,
industrial control panels, meter socket
enclosures, and motor control panelsany
equipment likely to require examination,
adjustment, servicing, or maintenance while

energized.
The new standard also makes it clear what
information needs to be on field labels,
including nominal system voltage and arc
flash boundary, along with information
employees can use to select the appropriate PPE:
If the engineering analysis method is
used to calculate the arc flash boundary, labels must include the calculated
incident energy (in calories per square
centimeter at working distance). Workers can then select PPE with an arc rating that meets or exceeds the incident
energy value posted on the arc-flashhazard label.
If the table method is used to determine
PPE requirements (which requires knowing the short-circuit magnitude and clearing time), then the equipment label needs
to include the PPE category indicated by
the tables. Workers must then consult a
different table to select the right PPE.
Beyond properly labeling electrical

equipment, owners of the equipment are
also responsible for keeping the labels up
to date. Its important to remember that even
small changes to the electrical distribution
systemlike replacing a fuse or circuit
breakerhave the potential to impact the
accuracy of arc flash labels, and thus, the
risk to electrical workers. To ensure compliance and keep workers safe, arc flash
assessments and label reviews should be
completed when any changes are made, or
at least once every 5 yr.
Training to identify and mitigate hazards
Properly labeling electrical equipment with

hazard information and providing workers
with the right PPE for the job can go a long way
toward keeping workers safe, but only if those
workers know how to read the labels and use
the PPE. NFPA 70E includes specific guideInfrared testing is a useful, practical tool for identifying defective components
and other conditions that could result in a fire or electrical breakdown. Image
courtesy: Emerson
plant engineering
October 2015 29
CoverStory
In the 2012 version of NFPA 70E, a
major revision stated that the
arc flash boundary distance
must be determined for all locations
where the voltage is greater
than 50 V and there is a
possibility of performing energized
work such as maintenance,
diagnostics, and testing.
ensure compliance, all training activities and

audits must be documented.
The 2012 version of NFPA 70E introduced
the requirement for annual worker audits.
These audits are intended to ensure that each
employee is complying with safety-related
work practices. The audits provide plant owners with the opportunity to observe and document each workers ability to identify a risk,
quantify the magnitude of the hazard, and
properly use PPE in a real work environment.
The audits can give invaluable insight into
whether or not workers have the qualifications needed to stay safe on the job.
Work with a partner to achieve compliance
With the equipment in a deenergized state, reviewing

your electrical equipment
using NFPA 70E standards
can be a helpful way to
understand the standards
provisions. CFE Media file
photo.
30 October 2015
lines for properly training workers to identify

and assess electrical and arc flash hazards and
to select and use the right PPE.
The most recent versions of the standard
include updates on when and how training
should be conducted, as well as requirements
for ensuring workers have the skills they need
to stay safe. Since arc flash can create a blast
strong enough to injure someone standing
more than 10 ft from the fault source, training must be provided for employees who
work aroundand not just onenergized
equipment. Preferably, the training should
be provided via an instructor-led course as
opposed to Web-based training. Workers must
be retrained (not just refreshed) at least every
3 yr, and the safety policies and training program must be audited at least every 3 yr. To
plant engineering
Clearly, to comply with the latest versions of

NFPA 70E, plant managers have their work cut
out for them. Many will need to conduct complex engineering analyses in multiple locations, overhaul their equipment-labeling programs, update training policies, and develop
worker-audit programs.
While there is no legal requirement for a
registered professional engineer to perform arc
flash hazard analysis, such a partner can be
instrumental in ensuring the accuracy of the
results, interpreting the analysis, and using the
information to develop more effective safety
programs for your plant. With the assistance
of a well-qualified engineering or testing company, you will be well on your way to ensuring
regulatory compliance and creating a safer work
environment. PE
Wally Vahlstrom is director of technical services for Emerson Network Powers Electrical
Reliability Services division. He is responsible
for failure-investigation work, conformityassessment services, power-system studies,
and reliability analysis.
CoverStory
Ten essential steps to support

arc flash incident energy analysis
By Scott Brady, P.E., Garrett
Hamilton-Smith, P.Eng, Nick Jackson, P.E., and Adam Reeves
Eaton
ncreasingly, facilities across the country are engaging engineering firms to

perform an Arc arc-flash-incident energy analysis for their electrical system,
as outlined in the 2015 version of NFPA
70E, Standard for Electrical Safety in
the Workplace. Per NFPA-70E-2015, an
arc flash risk assessment is a process that
identifies hazards, estimates the potential
severity of injury or damage to health,
estimates the likelihood of occurrence of
injury or damage to health, and determines
if protective measures are required.
An arc-flash-incident energy analysis is
the first step in this process that will quantify the incident energy that will be released
during an arc flash event at each location
in the electrical system. The results of the
incident energy analysis are printed on an
arc flash label for use by the qualified electrical worker to determine the appropriate
personal protective equipment (PPE) to be
worn while performing energized electrical work.
Establishing a culture that actively supports electrical safety involves more than
an incident energy analysis. Avoiding the
dangers associated with arc flash and shock
hazards require conscious decisions and
commitments by everyone, from the maintenance electricians and operators all the
way up to environmental health and safety
(EHS) and facility managers. Following
these 10 essential steps after receipt of an
arc-flash-incident energy analysis will help
enhance personnel and equipment protection, and help support compliance with
NFPA and OSHA standards.
Step 1: Read the report. The executive

summary will describe the major action
items associated with the analysis. In addition to recommendations pertaining to arc
flash, the executive summary also will
have details regarding over-dutied equipment and recommendations for protective
device settings.
32 October 2015
plant engineering
Step 2: Evaluate safe work practices.

Energized work should be the last choice
when it is not feasible to de-energize the
work location due to equipment design
or operation limitations. When energized
work is necessary, there should be a specific safe work procedure in accordance
with OSHA CFR 1910 Subpart R or Subpart S and NFPA-70E-2015.
Step 3: Determine qualified employees.
Per OSHA regulations, it is the employers
responsibility to determine not only who
is qualified to work on energized electrical equipment, but also to outline the
qualifications.
Step 4: Determine acceptable hazard
levels. The arc-flash-incident energy
analysis report may identify locations
with a high arc-flash-incident energy
level. In some cases, it is not feasible to
mitigate the arc flash hazard at all equipment locations in the facility. Prioritize
by reviewing operational goals and identifying locations where interactions with
the equipment are frequent and prolonged.
Step 5: Implement recommendations.
Work with your power-system engineer
to develop a plan to mitigate the hazards
identified in Step 4. Also, implement
recommendations for over-dutied equipment and protective device settings that
may have been identified in the report.
Step 6: Train personnel. Invest in appropriate training for electricians, maintenance personnel, site safety teams, and
facilities management teams. All of the
results and recommendations in the report
could be wasted if no one understands
how to use PPE correctly or read an arc
flash label. The training should assist site
personnel with answering the following
questions:
Who is qualified to work on electrical

equipment?
Is my day-to-day operation going to be
affected by our renewed focus on electrical safety?
What do I need to do to ensure my team
is working safely?
Step 7: Apply arc-flash-hazard warning

labels. Per NFPA-70E, electrical equipment
that is likely to require examination, adjustment, servicing, or maintenance while energized shall be field-marked with a label
containing: (1) the nominal system voltage, (2) the calculated arc flash boundary,
and (3) the available incident energy and
working distance as calculated by the arcflash-incident energy analysis.
Step 8: Order PPE. In the 2015 edition
of NFPA-70E, there are no standard PPE
categories based on calculated incident
energy. In development of the electrical
safety policy, a PPE system needs to be
implemented based on the incident energies calculated. Table H.3(b) in NFPA-70E
offers guidelines for selection of arc-rated
clothing and other PPE when incident energy exposure is determined.
Step 9: Verify electrical equipment is

properly maintained. NFPA 70E-2015 sections 205.3 and 205.4 require that electrical
equipment is properly maintained and documented in accordance with the manufacturers instructions and applicable codes and
standards. The electrical equipment owner,
or their designated representative, is responsible for maintenance and documentation
(205.3). NFPA 70E-2015 130.5(3) states
that condition of maintenance must be
considered for the overcurrent-protection
device used in the arc flash risk assessment. Improper or lack of maintenance of an
overcurrent-protection device can lead to an
increased operating time, which could result
in higher arc-flash-incident energy than the
values determined by an arc-flash-incident
energy analysis. If the incident energy for
an actual arc flash event is higher than
the incident energy calculated by the arcflash-incident energy analysis, the electrical
worker may not be wearing sufficient PPE.
Step 10: Manage the performance of
equipment and safety policies. A culture of
continuous improvement focuses on removing stagnation and implementing evolving
processes and procedures. Use this opportunity to ensure that equipment continuously
operates at peak performances, and to ensure
Remote racking mechanisms enhance safety

by providing a means to
remotely insert or remove
circuit breakers and auxiliary drawers. The technology
helps increase the distance
between the operator and
live components to reduce
the impacts of arc flash
exposure. All images courtesy: Eaton.
plant engineering
October 2015 33
COVERSTORY
Top seven arc flash safety measures
Here are seven ways to limit the exposure of workers
to the risk of arc flash incidents:
1. Train on safe work practices

2. De-energize equipment before accessing
3. Perform regular preventive maintenance
4. Wear arc-rated personal protective equipment (PPE)
5. Select tools rated for the environment
6. Use remote display or wireless test tools
7. Install an infrared window for switchgear.
NFPA70E: Standards for Electrical Safety in the Workplace provides the most comprehensive guidance for
protecting workers from electric shock and arc flash hazards. The 2015 edition added several new provisions,
including strengthening electrical safety programs, new test instruments and PPE requirements, expanded
training requirements, and a redefinition of what constitutes a qualified person permitted to work in areas
where there are exposed energized conductors and circuit components of greater than 50 V.
Courtesy: Fluke
safety policies and procedures are updated

and reviewed on a regular basis.
An incident energy analysis is a critical part of an overall risk assessment.
Although the analysis provides important
A sample arc flash label.
information for personnel and helps comply

with the NFPA 70E standard, it does not
estimate the risk associated with the work
being performed. The risk associated with
performing energized electrical work will
vary based on the work being performed,
condition of the equipment, and many
other factors that are best determined by
a qualified worker. Facility managers and qualified
personnel need to take the
next steps and determine
the protective measures
that are required and support a workplace culture
that actively supports electrical safety. PE
S c o t t B r a d y, P E , i s
Eatons Western region
manager for the technical
application support team.
Garrett Hamilton-Smith,
PEng, is a power-systems
engineer at Eaton. Nick
Jackson, PE, is district
operations manager at
Eaton. Adam Reeves is a
power-systems engineer at
Eaton.
34 October 2015
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MAINTENANCESOLUTIONS
Neatly cabled control panels, dust-free HMI
screens, and smoothly operating mechanical
parts dont last forever. While new equipment
can make a good first impression, what builds
long-term charm is smart maintenance of all that
equipment. CFE Media file photo.
Preventative maintenace:
Analyze data properly
Smart maintenance keeps that new machine feeling intact.
By Salman Aftab Sheikh
Intech Process Automation
nyone who has owned a new car

or bike will remember the thrill
and excitement of those first
few years with their vehicles:
shining parts, flawless performance, and maintenance-free
running. As is the natural course of things,
a few years later the shining parts begin to
rust and the roaring engine starts to sputter
while the suspension creaks and squeaks.
Though some may be motivated to discard their vehicles and get a new one, most
people either cannot afford that luxury or
see prudence in doing so, particularly when
all thats needed is good maintenance to
keep things running smoothly for many
years ahead.
The same dilemma is faced by plant owners; neatly cabled control panels, dust-free
HMI screens, and smoothly operating
mechanical parts dont last forever. And

unlike a vehicle, replacing everything in a
plant instead of maintaining it is an absurd
idea. While new equipment can make a
good first impression, what builds longterm charm is smart maintenance of all that
equipment.
Reactive vs. preventive
The term maintenance broadly covers any

continuous activity undertaken to improve
the faltering health of equipment and assets,
ensuring that both short-term and long-term
performance are not adversely affected.
There are two main types of maintenance
activities, defined by the state of assets
being maintained: reactive maintenance
and preventive maintenance.
Reactive maintenance is, as the name suggests, maintenance carried out to remedy a
PLANT ENGINEERING
October 2015 37
mAINTENANCESOLUTIONS
The term main-
tenance broadly
covers any continuous activity
undertaken to
improve the
faltering health
of equipment and
assets, ensuring
that both shortterm and longterm performance
are not adversely
affected.
failure or incident. Replacing broken tool

parts on a machine, restarting a conveyor
that stopped due to overloading, repairing
damaged pipelines, and run time debugging
of a software error all fall under reactive
maintenance.
Preventive maintenance, by comparison,
focuses on preventing failures or incidents
by promptly replacing or repairing equipment during routine shutdowns/inspections before they fail and cause trouble
during operation. Replacing filters every
two months, changing generator oil every
50 hr, and adjusting low inlet pressure on
compressors are typical examples of preventive maintenance.
Choosing between which method to use
depends a lot on the process, application,
and budget in question. Reactive maintenance is relatively low-cost in itself, but
depending on the criticality of processes in
question, the shutdown/failure cost could
be very significant. Similarly, preventive
maintenance incurs much higher costs, but
the potential shutdown and damage averted
can save a significant amount of operating
expense (OPEX).
The key here is for end users to evaluate
which processes are critical and which processes dont affect productivity as much. A
water-filtration system failure for residents
of a plant facility with clean tap water is
hardly the type of failure that requires monitoring. A similar system providing treated
water to an ammonia plant for production
becomes very critical, by comparison, and
requires frequent monitoring.
Since the ultimate goal of any plant
owner is to maximize productivity and
minimize expenditures, a very general
approach to choosing a maintenance strategy is to evaluate average failure cost
against average maintenance cost and
choose the lower cost.
Preventive maintenance: going deeper
Preventive maintenance is further divided

into three categories with varying degrees
of system uptime/reliability and operating
costs:
Periodic maintenance: Perhaps the
most typical form of maintenance, periodic maintenance is based on following
original equipment manufacturer (OEM)
and learned-from-experience timelines for
expected failures. These potential issues
are addressed by replacing components as
38 October 2015
plant engineering
scheduled to ensure smooth operation. This

maintenance incurs medium to high costs
and marginally high uptime.
Preventive maintenance: Going a step
over periodic maintenance, preventive
maintenance also includes reliability tests
and health checks to ensure asset availability. Results are compared with past data to
predict when failures may occur. Issues are
addressed before expected failures happen.
This maintenance incurs high costs and high
uptime.
Condition-based maintenance/monitoring
(CBM): This advanced form of preventive
maintenance relies on sophisticated software
algorithms and continuous monitoring of
data from field sensors and instruments to
accurately predict the state of each component. CBM presents a holistic view of
plant reliability and can help maintain a
plant with practically no downtime at all.
This maintenance incurs very high costs and
very high uptime.
Why predictive maintenance?
Choosing the right maintenance method

is critical. Just as reactive maintenance
of heat-exchanger failures is catastrophic,
CBM for auxiliary waste-treatment plants
is a major OPEX sink.
For oil and gas applications (and many
similar high-risk industries), the default
form of maintenance is shifting from periodic to predictive. While CBM provides
the highest level of reliability and control,
the degree of sophistication required for
implementation and costs incurred make it
a luxury that is not prudent in most typical
applications. Predictive maintenance then
becomes the best tool for ensuring sustained
productivity, and it can be improved with
smart planning and careful analyses.
The key to good predictive maintenance
is analyzing data from sensors, data from
probes, physical appearance, device-state on
visual displays, etc. A good plan to analyze
data and key insights on what to check helps
take maintenance a long way in ensuring a
great return on investment.
Know what to check
At the heart of it all, predictive maintenance

requires a thorough understanding of how
everything works both internally and with
its environment. This knowledge is often
found through original equipment manufacturers (OEM) documentation and expewww.plantengineering.com
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Another important aspect
of predictive
maintenance is
to ensure contingency in the
face of unforeseen issues.
40 October 2015
riences of maintenance teams who have

worked on similar systems long enough to
know their nitty-gritty details.
A starting point for any performance measurement is benchmarkingfinding out how
a system is performing becomes easier when
it can be compared to how it performed at
its peak. Benchmark results help point out
the key performance issues. The next step
is to have a good idea of root-cause analyses and trace these issues to their sources.
These sources are usually physical parts like
proportional-integral-derivative controllers,
valves, transmitters, and sensors, and can
indicate potential issues in equipment and
assets.
Automation systems have made tracking
changes in these parts much simpler with
the option to include alarms and metrics
reporting instantaneously within a control
system. A flow transmitter that checks outlet
pressure can be programmed to generate
alarms whenever the pressure goes over or
under a certain limit; similarly, a control
valve can be set with feedback (via a positioner) to indicate valve position in response
to the control signal. An alarm generated in
these situations calls for an inspection of
all associated equipment.
Many times, the alarm generates due to
failing voltages, aging sensors, or ungrounded wires, but it can also point to serious
issues like process parameter constraints
or aging equipment. Early indicators help
address potential threats and are among the
most common methods used in predictive
maintenance.
Good examples of early indicators are
the probes on compressors; a low-pressure
compressor typically has around 10 probes
monitoring all aspects of it. When inlet pressure goes below a certain limit, anti-surge
control gets active to maintain outlet pressure. Prolonged anti-surge can cause serious
damage to the compressor and is usually
detected through displacement sensors.
Typical compressor vibrations are
between 0.6 mils and 0.8 mils, alarms are
generated at 1.2 mils to 1.6 mils, and vibrations over 2 mils require an emergency shutdown since 10 mils will cause catastrophic
failure. Detecting increased vibrations early
on can help address issues in time and prevent shutdowns or worse.
In many cases, alarms and alerts cannot be
configured, and the concerned assets require
manual inspection to ensure reliability. In
plant engineering
situations like that, a well-defined checklist helps ensure long-term maintenance and
uptime. These checklists can be designed
based on OEM documentation and best
practices for maintenance. For example, a
checklist for a redundant-configuration control-system cabinet would include aspects of
physical inspection, wiring/junction inspection, and humidity/moisture inspection. A
detailed list of possible configurations of
LEDs on the controllers themselves would
be compared against a list of possible causes
and spontaneous remedies, if available.
These checklists can then be filled out
by periodic inspection staff members who
are able to pick out problems early on and
communicate them to the maintenance team.
The more thorough and analytical a checklist
is, the better it can reflect on equipment and
asset health.
Contingency plans
Another important aspect of predictive

maintenance is to ensure contingency in
the face of unforeseen issues. For very critical applications, a fail-safe system or fallback mechanism can help ensure minimal
damage and loss of productivity. Backup
generators, redundant controllers, spare
input/output modules, auxiliary plants, and
work-in-progress storage buffers are some
of the typical contingency methods used
in the industry to prevent damage and loss
from failures.
While it may seem a daunting task for
someone new to predictive maintenance,
the actual task is not as intimidating with
the proper homework and the right professionals to help plan things out. In the
absence of experience, a good third-party
operations-and-maintenance team can help
create operator and inspection checklists, set
up alarms, and optimize process parameters.
They also help with training to ensure that
in-house staff can perform these tests reliably and efficiently.
Knowing what degree of control is needed
and understanding all aspects of the facility
requiring maintenance are keys to building
a good maintenance plan. After that, it is
just a matter of having the right tools for
analyzing data and training the right people
to actively participate in these activities. PE
Salman Aftab Sheikh is a lead engineer at
Intech Process Automation. Intech Process
Automation is a CFE Media Content Partner.
Standardizing for success

Implement a systematic way to perform tasks and maintain equipment.
By David Welsh
SCA Hygiene Products
tandardization facilitates a lean,

efficient, and functional workplace. It enables quick transitions
between personnel who perform
the same task, increases production
speed, and improves product quality
through a consistent application of tools. In fact,
standardization often results in improved workplace culture, as managers and employees find
that their jobs are simplified and their everyday
tasks streamlined.
As one of the elements of the 5S process, Standardization (along with Sort, Set in Order, Shine,
and Sustain) helps businesses eliminate waste and
improve workplace efficiency, customer service,
and product consistency.
To standardize, plant management must engage
with their teams to set up machines in a consistent
way and use tools in a uniform manner. Although
these changes may require employees to sacrifice
their individual approach to performing tasks,
uniform practices and procedures create a more
productive workplace.
Less waste, greater productivity
working. The process of changing ingrained

approaches and behaviors can be complicated,
so management needs to be disciplined and committed to working with employees throughout
the transition period. Lets face it: Its never easy
to change even one persons habits, let alone a
group of people with various preferences and
routines.
Plant management must understand and clearly
communicate the benefits of the new system for
all employees, and employees must understand
whats in it for them. Standardization cannot be
pushed down from the top; it must be embraced
among the employees who are carrying out tasks.
New standards
While implementation challenges exist, there are

several ways plant managers can successfully support a standardized plant.
When implementing a new model with new
standards, plant managers are asking their engineers to compromise on personal preferences for
the greater good. Therefore, its critical that plant
managers involve employees in making standard-
Standardization improves productivity and

employee morale by eliminating inefficient
and frustrating practices. When machines and
tools are used in the same way and stored in
the same place, employees are more productive. When a machine remains on a uniform
setting, time is not lost to adjusting it to individual preferences.
When a tool is always stored in the same
place, there is no need to search for a wayward
item. Furthermore, when equipment is operated, maintained, or cleaned in a consistent
manner, the resulting products are more uniform, predictable, and of a consistent quality.
Breaking old habits
To reap the benefits of standardization,

plant management needs to overcome the
challenges of implementing a new way of
Its critical to the mission of standardization that all employees be engaged in
making decisions when implementing the
processes. Image courtesy: SCA Hygiene
Products
plant engineering
October 2015 41
MAINTENANCESOLUTIONS
K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD:
PREVENTIVE MAINTENANCE that further discuss this topic:
PREVENTIVE MAINTENANCE THE KEY TO MOTOR CONTROL CENTER RELIABILITY

The low-voltage motor control center is a key element in electrical control
systems because of the vital operating role they play in controlling motors and
production processes. Over the years, MCCs have evolved from cabinets that
housed basic electro-mechanical devices such as circuit breakers, contactors
and overload relays to centers of automation that may include variable frequency drives, soft starters and programmable controllers.
FINE TUNING YOUR PREVENTIVE MAINTENANCE SCHEDULE
A good CMMS system can deliver the information users need to better finetune their PM schedules. If a less-rigorous PM schedule gets the maintenance
team slapped with a corrective work order, its time to adjust.
OIL ANALYSIS AND PREVENTIVE MAINTENANCE
Imagine the implications of neglecting to check the lubrication systems of
plant equipment. Failure here would be both catastrophic and expensive.
Not only because of the cost of repairing the physical damage, but also the
time it takes to fix the problem and the revenue lost from the equipment not
being in use.
ization decisions. It is best to bring together all
stakeholderspeople who use a machine as well as
clean itto create a dialogue that will ensure that
the new methods work best for everyone. Managers should also visit sites that have benefited from
standardization, to see and experience how it functions over time. In this case, seeing is believing.
Stocking for standardization
When introducing standardization at a plant, there

are additional factors for managers to consider
that can affect purchasing decisions. These factors
are products, packaging, and storage, all three of
which are also essential to the production process.
Plant managers can increase efficiency and
decrease costs by thinking critically about the
tools bought and used for production. Be selective: choose products that are task-specific, purpose-made, and of consistent quality. By using
a task-based-designed product like an industrialgrade disposable wiper, employees expend less
time and energy to complete tough tasks when
compared to using less uniform alternatives, like
rental-shop towels and rags. Using high-quality,
task-based tools helps to ensure a high-quality
end product, because consistent tools yield consistent outputs.
The two other factors to consider are packaging
and storage. Ineffective product packaging creates
unnecessary mess, while non-standardized product placement causes wasted motion and energy
for employees. In a standardized workplace that
operates with high-performance tools, employees
42 October 2015
PLANT ENGINEERING
should be able to access needed products from

a space-efficient dispenser instead of searching
through piles for a suitable solution. Standardized,
convenient storage locations for specific tools and
productsas well as the use of product dispensers
that take up less spaceallow managers to create
a more organized plant floor with more efficient
storage solutions.
Simplifying jobs
By creating standard practices, managers increase

worker efficiency and productivity and improve
product quality through a consistent application
of tools. Managers and employees will find that
their jobs are simplified, which improves workplace culture. Its important to communicate benefits to all employees, work with employees to
develop the new standards, and stay committed
to making the change stick when implementing
the standardization process.
And dont just stop at process. Upgrade products, packaging, and storage to make the most of
the newly standardized workplace. The implementation process is the ideal time to make changes to these important features of any workplace. PE
David Welsh is the manufacturing excellence manager at SCA Hygiene Products in
North America. Welch has a bachelors degree
in mechanical engineering from the University of Delaware and an MBA from Widener
University.
THE BOTTOM LINE:

Standardization often results in improved
workplace culture, as managers and
employees find that their jobs are simplified and their everyday tasks streamlined.
To reap the benefits of standardization,
plant management needs to overcome
the challenges of implementing a new
way of working. The process of changing
ingrained approaches and behaviors can
be complicated, so management needs to
be disciplined
By creating standard practices, managers
increase worker efficiency and productivity and improve product quality through a
consistent application of tools. Managers
and employees will find that their jobs
are simplified, which improves workplace
culture.
Five steps to applying

predictive maintenance
By Mike Johnston, CMRP
T. A. Cook
nsuring the right work is performed at the right time to minimize downtime on production
assets is crucial to productivity,
but avoiding costly unplanned
maintenance is paramount as
well. It can be expensive to remove a piece
of equipment from production to perform
routine preventive maintenance, only to
find a function dictated by the Preventive
Maintenance (PM) task was not necessary.
Predictive Maintenance (PdM) is based on
the operating conditions of the asset and
the set parameters of its function, rather
than time- or calendar-based PMs.
The following steps are predicated on
the assumption that all assets in a facility
have been identified within a functioning PM program that uses a computerized
maintenance management system (CMMS),
which includes all planned and unplanned
maintenance activities, labor and material
costs accurately.
1. Follow the dollars
First, you need to determine where financial and human resources are expended
and itemize the assets that are vital to
your process. Concentrate first on assets
lacking a spare. Aircraft manufacturing is
one of the few industries where multiple
redundancies are engineered into a product. Chances are, you have a few backups
such as supplementary pumps for critical
processes. But no one can afford an idle
production line just in case it is needed
if something breaks down on the primary
line.
Using data extracted from the CMMS,

identify the high-cost and/or frequent
incidents that are consuming the maintenance budget and generating lost production. Examine 2 to 3yr of data to ensure all
potential issues are addressed. Include the
cost of lost product, whether its pieces,
cases, gallons, or tons. Many times these
costs are neglected in the calculations, and
an important piece of the cost picture is
lost. Occasionally, the cost of lost product exceeds that of the repair itself. Just
because an incident has a low occurrence
rate doesnt mean it should be discounted
from a PdM program.
2. Perform analysis
Once you have identified the bad actors

by cost/frequency, conduct an analysis
to examine the mean time between failure/rate (MTBF/R), and identify whether
the mean time is increasing or decreasing. Perhaps, youve already undertaken
some remedial actions and improved the
MTBF/R on a particular unit. However,
dont dismiss these incidents even if the
number of incidents is decreasing. The
time and costs consumed can still be significant and warrant investigation
3. Determine where to use PdM
Some assets are, and will generally be

expendable and can be run to failure. A
-hp motor on a conveyor segment comes
to mind. These motors are likely in stock
or can be obtained quickly and easily.
However, a 200-hp dc motor on a reversing rougher in a steel mill would be a
Acquisition of data is meaningless unless there is trained

staff to analyze and interpret the results, and actions are
taken to correct the potential failures identified.
plant engineering
October 2015 43
Ensuring the right
work is performed at
the right time to
minimize downtime
on production
assets is crucial
to productivity, but
avoiding costly
unplanned
maintenance is
paramount as well.
prime candidate for PdM, as well as

its gearbox.
The intent is to identify the assets
that would cause a catastrophic
impact should they unexpectedly fail.
While some assets will immediately
come to mind, others may come as a
surprise as to their difficulty to detect
an impending failure.
To better understand where PdM
should be deployed, a failure mode
effects analysis (FMEA) exercise
should be conducted, with the equipment ranked by their susceptibility of
failure based on severity, occurrence,
and detection criteria. This will generate the risk priority number on which
to prioritize the assets. This requires
accurate data from a CMMS to trace
past breakdowns.
4. Define the technologies to be used
Not all machines need be included

in PdM strategies. However, rotating
equipment, gearboxes, and electrical
distribution components are prime
targets for PdM. Vibration monitoring, oil/wear particle analysis, and

thermography are the most prevalent
PdM strategies deployed, regardless
of the industry. Bearing temperature analysis is also a common tool.
The failure that the site is attempting to detect drives the technology
employed.
Obviously, there is an initial investment to acquire the needed technology
and tools to implement PdM. Prudent
research and common sense need to be
applied. For example, only one infrared thermography camera needs to be
purchased, as it can be used sitewide.
The same would be true for vibration monitoring, since a portable unit
can be used throughout the facility.
Generally, oil analysis is conducted
offsite by a firm specializing in tribology, sometimes by the actual oil
vendor.
Another factor to remember is
training staff in using data collection
tools and data analysis. Acquisition
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of data is meaningless unless there is

trained staff to analyze and interpret
the results, and actions are taken to
correct the potential failures identified. If a site is not going to train
staff or use the information obtained,
it is better off outsourcing the PdM
function.
5. Deploy tools
After the tools have been purchased

and the staff trained in their use, you
can acquire the initial baseline data
and capture the results in the tracking program to plot it against performance standards developed by the
site or manufacturer. These results
should be continually plotted on an
asset deterioration curve. Many software packages are available that will
perform this function. Bear in mind,
the validity of a deterioration model
is based on the accuracy and reliability of the data employed.
When the impending failure has
been detected, planning should begin
to address the problem at the appropriate time, based on production,

business conditions, and the amount
of deterioration revealed.
A technological strategy for todays
high-tech equipment is a sound
approach to maintaining assets with
minimal production loss. A PdM program can reduce costs and downtime
to undertake inspections, as it uses
noninvasive tools and procedures
without interrupting production.
Assets that are properly monitored
and maintained via PdM rarely fail
and generate unplanned downtime.
PdM has the potential to generate
savings of about 30% in maintenance expenditures. Too little or too
much maintenance is avoided, freeing
staff to pursue other activities such as
reducing the backlog or performing
capital projects.
Whats not to like about that? PE
When the
impending failure
has been detected,
planning should
begin to address the
problem at the
appropriate time,
based on
production, business
conditions, and the
amount of deterioration
revealed.
Mike Johnston, CMRP, is a senior

consultant for T. A. Cook.
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The Industrial Internet of Things (IIoT), is about connecting machinesto each

other, to expert systems, and to management execution systems. This revolutionary
strategy delivers actionable information to intelligent devices and systems at all
levels of the manufacturing enterprise--from the plant floor to the corner office.
Control Engineering, Oil & Gas Engineering and Plant Engineering are joining
forces to launch a webcast series covering critical IIoT topics.
*This series is RCEP-certified and attendees qualify for Certified Professional Development Hour(s).
THE 2015 INDUSTRIAL INTERNET OF

THINGS (IIoT) WEBCAST SERIES:
WEBCAST ONE: Design considerations
Now available for on-demand viewing
Industrial Internet of Things (IIoT) concepts include
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WEBCAST TWO: Operations

Now available for on-demand viewing
Industrial Internet of Things (IIoT) can help manufacturers make
their right decisions with the right information at the right time.
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Tuesday, November 3, 2015
REGISTER NOW
Industrial Internet of Things (IIoT) promotes intelligent devices
and systems, sharing information and awareness among
all systems and the humans that use them.
For more information and to register visit:
www.plantengineering.com/IIoTWebcastSeries
MECHANICALSOLUTIONS
The quest to find the perfect bearing fit
Measuring is critical to the reliability of rotating equipment.
By Jim Bryan
EASA
uch has been said and done to produce the perfect fit for rolling
element bearings in motors and
other rotating equipment. Assembly of these machines requires that either
the inner fit to the shaft (journal) or the
outer fit to the housing (bore) is able to
slide; so if one fit is tight, the other must
be loose. While tight and loose are
relative terms that must be defined in the
quest for the perfect fit, any fit thats too
loose or too tight can lead to early bearing
failure and costly downtime.
A tight (interference) fit is usually recommended for motor bearing journals.
Standard fits for radial ball bearing journals
range from j5 to m5; the standard housing
fit is H6 (see Table 1). These are the standard fits and may be different depending
on the machine designers understanding
of the application.
Table 1 also shows that the tolerance
band generally widens as bearings get larger, and that the journal fit is always interference (shaft journal is larger than bearing
ID), while the bore fit is always line-toline (housing bore is the same dimension
as bearing OD) to loose (housing bore is
larger than bearing OD).
Extreme care when measuring
Interference fits and loose fits are

expressed in tenths (a unit equal to
0.0001 in. or 2.54 microns; m), a level
of precision that requires extreme care
to measure accurately. A recent study

involving 16 machinists in nine service
centers found that experienced machinists
with calibrated, well-maintained micrometers should have no problem measuring
journals within 2 or 3 tenths (5.1 m to
7.6 m). The same study, however, found
that 25% of the measurements of certified
master rings of known dimensions were
off by 10 tenths to 20 tenths [0.0010 in.
to 0.0020 in. (25 m to 51 m)], in most
cases due to lapsed calibration intervals
and improper use of machinists standards.
A note: Typical calibration intervals are
1 year; determine what is appropriate for
your facility or the service center you use.
There should also be written calibration
procedures to follow. The best machinists
compare each tool to the standard gauge
each time they use a different one. Good
practice indicates checking each tool at
least once each day it is used. Proper technique is the other part of the equation. This
method verifies both the tool and the user.
Bearing journals
Figure 2 (on page 51) illustrates the importance of precise measurement for the journal fit of a 6210 bearing for which the
acceptable limits are 1.9686 in. to 1.9690
in. (50.002 mm to 50.013 mm). For example, if a machinist measures 1.9687 in.
(50.004 mm), the measurement appears to
be acceptable. However, if the machinist is
Table 1: Measurement tolerance (red lines indicate

potential measurement
error). All images courtesy:
EASA
PLANT ENGINEERING
October 2015 49
MECHANICALSOLUTIONS
K
EY WORDS:
Here are some of the articles at www.plantengineering.com, KEYWORD: BEARINGS that further discuss this topic:
PROCEDURES FOR PROTECTING ELECTRIC MOTOR BEARINGS

Contamination can dramatically shorten bearing life and lead to costly downtime. Maintenance professionals should be knowledgeable about the effects of
contamination and well-trained in the procedures to prevent it. There are five
basic ways to maintain bearings and reduce the number of failures caused by
contamination.
DEBUNKING THE MYTHS AROUND BEARINGS
The wheels of industry turn on bearings, so why do the wheels often vibrate,
clatter, squeak, drag, and overheat? Bearings can fail for lots of reasons. Most
failures are related to lubrication and contamination, but myths and misconceptions handed from one generation of maintenance engineers to the next
help perpetuate many easily avoidable problems. These myths fall into three
general areas of bearing use: installation, misapplication, and lubrication.
SOLUTIONS TO FAN AND BLOWER BEARING PROBLEMS
Fans and blowers are simple pieces of equipment, yet require a lot of maintenance, particularly for bearings. The higher the speed, the more problematic
they become. This article details how to avoid common problems caused by
the improper selection of pillow block housings, seals, bearings, lubricant and
lubrication systems.
only able to measure to within 2 tenths
( 5.1 m), the confidence factor that the
measurement is in tolerance decreases to
75% of the capability, because only 3 of
4 tenths will fall within tolerancei.e.,
everything from -1 tenths to +2 tenths will
be in tolerance while -1 to - 2 will not. For
example, 1.9687 in. to 0.0002 in. = 1.9685
in. and would be out of tolerance.
A journal fit that is too tight will preload the bearing (reduce its internal clearance), which will increase the friction and
temperature and lead to premature bearing
failure. It is also important not to exceed
the tolerance in the other direction. If the
fit is too loose, it will allow movement
Figure 1: Fretting can be

seen in the bearing housing
and on the outer race.
50 October 2015
PLANT ENGINEERING
ranging from micromotion to the bearing

spinning on the shaft. The latter usually
results from the combination of a loose fit
and an increase in the internal friction of
the bearing.
Increased internal friction may have
several causes including poor or degraded lubrication, bearing race damage, and
excessive preload. If this type of damage
occurs, the bearing eventually will spin
even if the fit was originally in tolerance.
Bearing housing bores
The same principles apply to bearing

housing bores. If the fit is too tight, the
bearing can be damaged during an aggressive assembly attempt (i.e., a large mallet). If it is too loose, there may not be
enough friction between the outer race
and the bearing housing bore to prevent
movement ranging from micromotion to
the bearing spinning in the housing. It is
also possible for the fit to be within tolerance at ambient temperature but expand at
operating temperature, allowing the bearing outer race to move, especially with
aluminum housings.
Effects of small motions
Micromotion occurs when a variable load is

applied and there is room to move. Though
limited to an extent by the fit tolerance
band, it can still happen under the right conditions because the housing bore is loose
by design.
Radial load tends to inhibit micromotion, and a strong, consistent radial force
can pin the bearing race to the bore. But
the weaker the force, the greater the likelihood that the micromotion will occur (e.g.,
a perfectly aligned, direct-coupled application theoretically would have no
radial load).
Micromotion causes fretting
(mechanical wear at the surface),
which will appear as small rusty
patches on the bearing inner or
outer race, or on the housing or
shaft (see Figure 2). Because the
oxidized areas are usually harder
than the bearing surfaces, fretting
can accelerate mechanical wear.
Under the right circumstances,
fretting can occur on either fit.
Bearing fits are critical to the
reliability of rotating equipment.
Application conditions including
Journal
Bore (6200 series only)
Bearing #
d = ID
Fit
Min
Max
d = OD
6203
0.6693
j5
0.6695
0.6692
Fit
Min
Max
-1
1.5748
H6
1.5748
1.5754
6204
0.7874
k5
0.7878
0.7875
6205
0.9843
k5
0.9847
0.9844
1.8504
H6
1.8504
1.8510
2.0472
H6
2.0472
2.0479
6206
1.1811
k5
1.1815
1.1812
2.4409
H6
2.4409
2.4416
6207
1.3780
k5
6208
1.5748
k5
1.3785
1.3781
2.8346
H6
2.8346
2.8353
1.5753
1.5749
3.1496
H6
3.1496
3.1503
6209
1.7717
k5
1.7722
1.7718
3.3465
H6
3.3465
3.3474
6210
1.9685
k5
1.9690
1.9686
3.5433
H6
3.5433
3.5442
6211
2.1654
k5
2.1660
2.1655
3.9370
H6
3.9370
3.9379
6212
2.3622
k5
2.3628
2.3623
4.3307
H6
4.3307
4.3316
6213
2.5591
k5
2.5597
2.5592
4.7244
H6
4.7244
4.7253
6214
2.7559
k5
2.7565
2.7560
4.9213
H6
4.9213
4.9223
10
6215
2.9528
k5
2.9534
2.9529
5.1181
H6
5.1181
5.1191
10
6216
3.1496
k5
3.1502
3.1497
5.5118
H6
5.5118
5.5128
10
6217
3.3465
k5
3.3472
3.3466
5.9055
H6
5.9055
5.9065
10
6218
3.5433
k5
3.5440
3.5434
6.2992
H6
6.2992
6.3002
10
6219
3.7402
k5
3.7409
3.7403
6.6929
H6
6.6929
6.6939
10
6220
3.9370
k5
3.9377
3.9371
7.0866
H6
7.0866
7.0876
10
6221
4.1339
m5
4.1350
4.1344
11
7.4803
H6
7.4803
7.4814
11
6222
4.3307
m5
4.3318
4.3312
11
7.8740
H6
7.8740
7.8751
11
6224
4.7244
m5
4.7257
4.7250
13
8.4646
H6
8.4646
8.4657
11
6226
5.1181
m5
5.1194
5.1187
13
9.0551
H6
9.0551
9.0562
11
6228
5.5118
m5
5.5131
5.5124
13
9.8425
H6
9.8425
9.8436
11
the type of driven load, the connection to

that load (direct coupled or belted), and
the proper bearing for the application are
all factors to be considered in achieving
the correct fit.
It is of utmost importance, however, that
machinists use properly calibrated measuring tools and the correct techniques to
ensure accurate measurement of these precision tolerances. Not only must the gage
be calibrated according to the appropriate
schedule, but also it should be compared
to the standard regularlyat least daily.
If these measures are taken and fretting
still is a problem, several anti-fretting compounds are available on the market. Talk
to your bearing vendor. PE
Jim Bryan is a technical support specialist at the Electrical Apparatus Service
Association (EASA), St. Louis. A CFE
Media content partner, EASA is an international trade association of more than
1,900 firms in 62 countries that sell and
service electrical, electronic, and mechanical apparatus. For more information, visit
www.easa.com.
Interference fit
The BoTTom Line:
Loose fit
Figure 1: Bearing fit tolerances (shaft fits are lowercase, housing uppercase).
While tight and loose are relative

terms that must be defined in the quest
for the perfect bearing fit, any fit thats
too loose or too tight can lead to early
bearing failure and costly downtime.
There should also be written calibration
procedures to follow. The best machinists
compare each tool to the standard gauge
each time they use a different one. Good
practice indicates checking each tool at
least once each day it is used. Proper
technique is the other part of the equation. This method verifies both the tool
and the user.
Bearing fits are critical to the reliability
of rotating equipment. Application conditions including the type of driven load,
the connection to that load (direct coupled or belted), and the proper bearing
for the application are all factors to be
considered in achieving the correct fit.
plant engineering
October 2015 51
mechanicalSOLUTIONS
Using medium-voltage VFDs

for better pump process control
Product innovations revolutionize pump monitoring, process control management.
s rotating machines, especially pumps,

have grown in power and size, the
natural progression is to find more
efficient and effective ways to monitor
and control these critical process machines.
Since medium- voltage (MV) variable frequency drives (VFD) have come a long way
in just a few years, they have evolved into a
more intuitive and powerful part of the process
industry. With process pumps now working
in high-energy applications, it takes a more
robust design for the heavy lifting found in
typical industrial processes.
Todays MV drive for the process industries is an integrated process pump monitoring
and control management system consisting
of a modern, more efficient VFD, patented
logic control, and advanced pump display.
This innovation provides operational feedback about peak pump efficiency and overall
system energy usage. Advances in MV pump
controllers enable improved process control
and increased visibility of pump operations.
MV control and monitoring technology
is a key component in a pumps operation
and prolongs its lifecycle. Many plant operators dont realize they need a more intuitive
MV controller until it is too late. If there is a
potential problem with a high-energy pumping system, it is critical to know as much as
possible about that pump, motor, and system
before the alarms go off.
By Rob Lax
ITT
Improve pump system performance
By using VFD controls, plant operators

have the ability to more accurately control the pump and impeller speed at a
varied rate, allowing the pump/motor output to match the system requirement for
improved pump performance based on
varying load demands. These MV controls
also allow the integration of logic and
respond, when valves are opening or closing to bring on multiple system pumps to
handle a variety of process demands.
Ensuring your process pump is evenly
balanced during minimum and maximum
loads and keeping the pump close to Best
Efficiency Point (BEP) will lead to the optimal pump performance. With the innovative capabilities of the MV pump process
drive, pump operating systems are no longer inhibited by differing viscosities and
pump pressures in the work environment.
MV VFD controls are best used for heavy
industry applications, including crude oil,
metals, power generation, and medium- to
large-size municipalities.
Monitor pump operation
MV drives offer expanded monitoring

capabilities for industrial pump operations. Many vehicles are now able to selfmonitor and alert the driver when there is
an issue. Pump MVs now can streamline
the process using instrumentation, VFD
data, and patented algorithms to calculate and monitor critical pump operating
parameters.
Solutions are available that detail the
amps and speed of the process pump and
provide real-time pump operation information such as flow, Net Positive Suction
Head (NPSH) margin, BEP percentage, and
Todays MV drive for the process industries is an integrated
process pump monitoring and control management system

consisting of a modern, more efficient VFD, patented logic control, and
advanced pump display.
52 October 2015
plant engineering
By using VFD controls, plant operators have

the ability to more accurately control the
pump and impeller speed at a varied rate,
allowing the pump/motor output to match
the system requirement for improved pump
performance based on varying load demands.
Image courtesy: ITT
actual operating point on the curve.

Typical inputs used by MV drives to
model pump performance are pressure,
temperature, torque, power, and speed.
In the standard sensorless version, energy
levels and the status of your pump can be
calculated. Using suction and discharge
pressure, advanced versions can calculate flow, total dynamic head (TDH), and
NPSH. The MV technology is a necessary
maintenance function, as many pump failures are process related.
Provide greater visibility
MV drives provide the ability to see what

a pump is doing and its impact in a larger
pump system operation. Its important to
find an MV that offers visibility above
and beyond a standard VFD. Look especially for products that have large memory
and data capacity. Its wise to document
as much data as possible to become better acquainted with your machinery and
ensure its productivity. To view this data,
seek units with large displays. Some models are as wide as 12 in. and provide realtime feedback on BEP percentage calculation, flow/power ratio, and energy savings
calculations.
When searching for an MV solution, partner with a company that focuses strictly
on pumps and pumping systems, including centrifugal pumps and twin screw-type
pumps. This early choice will ensure that
future maintenance work on your product is
performed by a company who specializes in
your machinery. Some manufacturers apply
VFDs to other machines while others focus
strictly on pumps and pumping systems.
Consider this: A large gas plant in northern Russia is currently using an MV VFD
to better control and protect its pumps. The
plant chose a globally recognized solutions
provider to propose and install the new
monitoring technology. Plant managers had
recognized that their pumps were critical
to plant operations and safetyany downwww.plantengineering.com
time in their systems would be costly to

operations.
In these high-risk industries, a failure
in the pump operations can cause a catastrophic failure for the whole plant. Pump
operators need continual visibility so they
can make decisions that are critical to maintaining operations. The solution proposed,
and ultimately installed, for the gas plant
was a 6,900 V, 800-kW MV drive with four
BB5-type API multistage pumps. This controller provides pump operators with better
visibility of their pumps, increasing their
ability to monitor pump performance.
The increased visibility means pump
operators can make better, more informed
decisions about the critical operations
of their systems. Today, the gas plant is
operating successfully thanks to their new
technology.
Considering safety
Workplace safety is a major concern and

top priority for any plant and its employees. MV drives are equipped with multiple
plant engineering
October 2015 53
mechanicalSOLUTIONS
A large gas plant in northern Russia

is currently using an MV VFD to
better control and protect its pumps.
Summit
Ultima
Series
Extended Life
Rotary Screw
Compressor Oil
high-voltage components and require

specific sizing and insulation. More
components require a higher precaution for safety.
In North America, regulations from
OSHA and NFPA must be met with
this type of machinery. In other parts
of the world, similar agencies monitor and regulate this type of equipment safety. It is important to find
MVs that come with safety manuals
and companies that provide handson training so that plant workers can
become familiar with the technology.
Please note that special safety considerations are necessary for people
in close proximity to an MV VFD. To
ensure the safety of all plant employees, these types of products require
installation and training by specialized
professionals.
Price vs. value of product
Up to
12,000 hours of
Dependable Service
Summit Ultima is a high performance lubricant formulated
to outperform other synthetic compressor lubricants on
todays market. Ultimas unique formulation allows for better
compressor performance, and it is compatible with existing
O.E.M. lubricants. Summit Ultima Series synthetic rotary
sscrew
underair compressor lubricant benefits include: ur
Better thermal conductivity for lower operating temps
Superior protection against mechanical stress
Reduces power consumption through reduced friction
Eliminates varnish, sludge and carbon deposits
Protects against shear & viscosity loss under heavy loads
Product consolidation by application
Summit
Industrial Products
800.749.5823
www.klsummit.com
As with any large capital machinery

purchase, there are multiple considerations to take into account while
weighing the best decision for your
plant process operation. What comes
to mind first for many plant managers is cost and return on investment
(ROI). Depending on what features
the MV VFD offers, there may be an
opportunity to save on energy costs
when purchasing an MV drive, leading to increased ROI.
If energy savings is not high on
the list, it is important to make sure
to include the cost of extended warranties and process guarantees when
evaluating. Look for companies that
offer extended warranties in cases
when a pump and the MV are purchased together.
Companies can also offer increased
pump protection, global site support, and aftermarket support with
the purchase of an entire MV pumping system. Be sure to consider all
options to make sure the product
youre purchasing comes with the
additions needed to maximize pump
life and efficiency.
Before making any investment in
vibration and temperature controls,
keep in mind that a majority of pump
problems occur on the process side.
Consider allocating plant funds
54 October 2015
plant engineering
toward an MV VFD guarantee and

warranty so the pump can maintain
itself with VFD technology, ensuring
less downtime and avoiding unexpected aftermarket costs and costly
repairs.
The price of an MV and its value
are two different aspects, and each
should be considered. Price and
value of the MV are two different
aspects the buyer should be aware
of, as they are distinctly different.
The lowest price is not always the
best choice when providing this type
of important equipment.
It often is a significant investment
to purchase a plants most important pump machinery, but in the long
run, including a more intelligent
MV drive can usually optimize the
pumps performance and lifecycle.
Pump monitoring and control management is no longer a guessing game
with the introduction of the advanced
pump display on MV VFDs. Giants
in the natural gas industry, and many
others, are already relying on this
technology to help them control and
monitor their pumps safely and effectively. As control innovation moves
forward, a natural progression is to
provide monitoring displays that
share all aspects of the pumps performance and energy use.
It often is a significant
investment to
Investing in this type of equipment

requires multiple cons iderations
regarding initial capital cost, ROI,
support, equipment warranty, and
process guarantees. Choosing the
right MV VFD for a higher-energy pumping system can enhance a
plants overall operational efficien-
cy rates, increase pump lifecycles,

decrease unplanned repairs, enhance
overall plant safety, and decrease
plant downtime. PE
Rob Lax is global product manager
for PumpSmart control technologies
for ITT.
The Model 1020 is not only incredibly powerfulrecovering up to

5 tons of even the heaviest materials per hourits also uniquely
portable, so it goes almost anywhere. With a 99% efficiency rating,
noise levels below OSHA standards, and a performance guarantee,
its more than a cleaning system; its a business asset.
VAC-U-MAX 1020MFS 10 & 15 HP Continuous Duty Vacuum

50% more vacuum power than other industrial vacuums
Move mountains of material through hundreds of feet of hose
Vacuum rates up to 10,000 lbs per hour
One-man portable, fits through a 34 doorway
Versatile: Portable Vac or Breakaway Central Vac
XP electrics and HEPA filtration available
Let us solve your industrial vacuum cleaning

challenges. Visit vac-u-max.com/vacuum
or call 800-VAC-U-MAX.
purchase a plants
most important pump
machinery, but in the
long run, including a
more intelligent MV drive
can usually optimize
the pumps performance
and lifecycle.
plant engineering
October 2015 55
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Input #100 at plantengineering.hotims.com
stay
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Stay current
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56 October 2015
PLANT ENGINEERING
2/24/2014 10:19:58 AM
MEDIA SHOWCASE FOR ENGINEERS

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Wallmounts
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ple2014_digitlEditn_6th.indd 1
2/24/2014 11:52:49 AM
PLANT ENGINEERING
October 2015 57
On-demand Webcasts
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IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
Straddle stacker
Alarm horns
The D1x range of alarm horns, loudspeakers
and integrated alarm horn/Xenon strobe warning units employs the latest electronic technology and acoustic engineering, in robust, marine
grade, LM6 aluminum enclosures. Designed to
create the most effective warning signals available for use in Class I/II Division 1, Zone 1 &
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provide a choice of 64 alarm tones, including
many conforming to national and international
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E2S Warning Signals
www.e2s.com
The Model 6210 walkie straddle stacker truck features AC technology and navigates easily in tight areas with smooth, precise
control from dock to stock for applications ranging from retail
backrooms to manufacturing work in process. The versatile
Model 6210 walkie straddle stacker improves product storage in crowded
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providing better
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storing pallets
up to three levels
high in aisles as
narrow as 78 in.
wide and with
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move pallets from
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The Raymond Corporation
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Input #201 at www.plantengineering.com/information
Lab coat
The Kimtech Pure A7 Cleanroom Lab Coat provides enhanced chemical and biological
protection and superior contamination control for cleanroom environments. Available in
bulk packaging, the lab coats are easy to don and doff. Features include an advanced
barrier fabric, low lint to reduce contamination risk, an elastic wrist and thumb loops for
full wrist coverage and extra-long sleeves to help keep gloves in place.
Kimberly-Clark Professional
www.kimtech.com.
PLANT ENGINEERING
October 2015 59
IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
TIG and stick welders

The Dynasty 210 and Maxstar 210 welders
deliver up to 210 amps of output power, and
exceptional TIG and stick performance in easyto-use, versatile and portable packages that
also allow for upgrade flexibility. The Dynasty
210 power source is AC/DC TIG/stick-capable
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210 welds up to 1/4-in. steel in a single pass.
Offering class-leading portability, each standalone power source weighs 50 pounds or less
and features dual carry handles and a carrying
strap for easy transport. Base models of the new
power sources provide operator-friendly, menu-driven features and improve
performance on low-amperage applications.
Miller
MillerWelds.com.
Statement of Ownership, Management and Circulation

1. Publication Title: PLANT ENGINEERING
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AODD pumps
The Saniflo Hygienic Series
Original Metal AODD (air-operated
double-diaphragm) pump models
utilize the energy-efficient ProFlo SHIFT Air Distribution System.
The new Pro-Flo SHIFT Saniflo HS
pumps are available in 316 stainless steel and nickel-plated aluminum in 38 mm (1-1/2), 51 mm
(2) and 76 mm (3) sizes and feature maximum discharge pressures
to 8.6 bar (125 psig), maximum
flows to 844 lpm (223 gpm) and
maximum solid-handling size to
60.3 mm (2-3/8). The pumps are
available with maximum suction
lifts to 5.4 m (17.6) dry and 9.0 m
(29.5) wet.
Wilden Pumps
wildenpump.com
16. Electronic Copy Circulation

a. Requested and Paid Electronic Copies
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62,084
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62,659
62,874
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d. Percent Paid and/or Requested Circulation (Both Print & Electronic Copies)
99.10%
98.74%
(16b divided by 16c x 100)
17. Publication of Statement of Ownership: Publication Required. Will be printed in the October 2015 issue of this publication.
18. I certify that all information furnished on this form is true and complete. I understand that anoyone who furnishes false or misleading information on this form or who
omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil
penalities). Jim Langhenry (signed), Publisher
60 October 2015
PLANT ENGINEERING
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STAY INFORMED
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PLANT ENGINEERING
October 2015 61
For more information on how to advertise in Plant EnginEErings

Internet Connection, call Jim Langhenry at 630-571-4070 x2203
alliedelec.com
eaton.com
oeo.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical
products with over 50 sales offices across the United
States and Canada.
Allied Electronics
Diversified power management company and global technology leader in electrical systems for power quality, distribution and control, and more.
Eaton Corp.
OEOs mission is to deliver cost effective energy solutions

to businesses and institutions.
OEO Energy Solutions
americantrainco.com
electroind.com
Electro Industries specializes in power meters and smart
grid solutions that excel at revenue grade energy measurement, power quality and advanced telemetry.
Electro Industries/Gauge Tech
Orival is a leading manufacturer of self-cleaning water

filters, automatic water filters and strainers, for use as
industrial water filters, irrigation filters, cooling tower filters, and more.
Orival Inc.
American Trainco has provided live maintenance training

seminars over 10 years with over 60 experienced facility
maintenance instructors.
American Trainco
atlascopco.us
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment,
industrial tools, assembly systems, services and rentals.
Atlas Copco
orival.com
erectastep.com
parker.com
Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal
steps bolts together with no fabrication required and are
easily repurposeable.
ErectaStep
Parker Hannifin is the worlds leading diversified manufacturer of motion and control technologies and systems,
providing precision-engineered solutions for a wide variety
of commercial, mobile, industrial and aerospace markets.
Parker Hannifin Corp.
automationdirect.com
flexicon.com
rittal-corp.com
AutomationDirect offers over 16,000+ industrial automation products through their free catalog and online superstore including PLCs, operator interfaces, drives, enclosures, sensors and more.
AutomationDirect
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide
systems.
Flexicon Corp.
Rittal manufactures the worlds leading industrial and IT

enclosures, racks and accessories, including high-efficiency, high-density climate control and power management
systems.
Rittal Corp.
azimadli.com
FLIR Systems designed, develops, manufactures, markets, and distributes thermal imaging infrared cameras.
FLIR Systems Inc.
Azima DLI is the leader and premier provider of predictive

maintenance analytical services and products that align
with customers high standards for reliability, availability
and uptime.
Azima DLI
baldor.com
Baldor Electric designs, manufacturers, and markets a
broad line of industrial energy-efficient electric motors,
mechanical power transmission products, and more.
Baldor Electric Co.
bimba.com
Bimba Manufacturing provides pneumatic, hydraulic and
electric solutions, including a variety of stainless steel
body air cylinders that are easy-to-use and reliable.
Bimba Manufacturing Co.
camfilapc.com
Camfil Air Pollution Control (APC) is a leading global
manufacturer of industrial dust, fume and mist collection
equipment and is part of Camfil, the worlds largest air filtration company.
Camfil APC
distanceissafety.com
CBS ArcSafe remote racking systems increase safety.
Rack low- and medium-voltage draw-out circuit breakers while standing outside the arc-flash hazard protection
boundary.
CBS ArcSafe Inc.
claytonindustries.com
Clayton Industries is a leading manufacturer of equipment
for industrial process steam generationboth fired boilers
and unfired waste heat boilers.
Clayton Industries
62 October 2015
plant engineering
flir.com
greenheck.com
Greenheck is a leading supplier of air movement and control equipment, including fans, dampers, louvers, kitchen
ventilation hoods, and energy recovery and make-up air
units.
Greenheck Fan Corp.
us.kaeser.com
Manufacturer of air system products, including rotary
screw compressors, portable compressors, rotary lobe
blowers, vacuum packages, refrigerated and desiccant
dryers, filters, and condensate management systems.
Kaeser Compressors Inc.
seweurodrive.com
One of the largest global suppliers of drive technology,
SEW-EURODRIVE specializes in gear reducers, motors
and electronic motor controls.
SEW-EURODRIVE USA
sullair.com
Sullair is a designer and manufacturer of stationary and
portable rotary screw air compressors, air treatment
equipment, and pneumatic tools.
Sullair Corp.
klsummit.com
Industry leader in synthetic lubricant technology with a line
of over 200 products that can service almost any industrial
application.
Summit Industrial Products
keysight.com
vac-u-max.com
Keysight Technologies is an electronic measurement company that offers wireless, modular, and software solutions.
Keysight Technologies Inc.
VAC-U-MAX specializes in design and manufacture of

pneumatic systems and support equipment for conveying,
weighing and batching of dry materials.
VAC-U-MAX
lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and
NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.
newellrubbermaid.com
Newell Rubbermaid is a global marketer of consumer
and commercial products with a strong portfolio of leading brands.
Newell Rubbermaid
veyance.com
ContiTech Products are backed by a best-in-class distributor network, delivering innovative market-driven products
to maximize potential profit.
Veyance Technologies
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation
systems.
Yaskawa America Inc.
Place next to your computer or go online to www.plantengineering.com for hot links to these companies.
Remove at
Line
5
er 201
b
o
t
c
O
CONTACTS
Advertiser Contacts for plant engineers
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
Page
Number
Advertiser
Allied Electronics
800-433-5700
13
Atlas Copco Compressors

866-688-9611
15
AutomationDirect
800-633-0405
C-2, 16A-16D
RSC
Number
Send
Info
10
Kaeser Compressors, Inc

866-516-6888
Keysight Technologies, Inc

800-829-4444
www.atlascopco.us
12
1
44
23
C-4
28
Bimba Manufacturing Company

800-442-4622
23
Camfil APC
800-479-6801
CBSArcSafe
877-4-SAFETY
14
45
24
www.baldor.com
Orival, Inc
800-567-9767
Parker
480-830-7764
20
www.bimba.com/mead
Plant Engineering Electronic Newsletters

630-571-4070
46
17
4
11
14
ContiTech
888-899-6354
Gate C-1
29
DYMO - XTL
877-289-3966
35
Eaton Corp
412-893-4052
26
30
www.eaton.com/circuitprotection
Electro Industies/GaugeTech
877-EIMETER
12
www.AddMoreAbility.com
http://dymo.com/en-US/xtl-US
www.electroind.com
C-1, 10, 11
Flexicon Corp
888-353-9426
FLIR
800-GO-INFRA
19
Greenheck Fan Corp

715-359-6171
16
5
www.keysight.com/find/TrueIRimager
12
www.claytonindustries.com
ErectAStep
888-878-1839
www.kaeser.com/PE
OEO Energy Solutions

800-553-2112
47
www.plantengineering.com/global-si-database
18
21
www.CBSArcSafe.com
Clayton Industries
800-423-4585
Send
Info
36
www.camfilapc.com
CFE Medias
Global System Integrator Database
630-571-4070
RSC
Number
Lubriplate Lubricants Co
800-733-4755
www.AzimaDLI.com
Baldor Electric Company

800-828-4920
Page
Number
www.alliedelec.com
www.automationdirect.com
Azima DLI
800-654-2844
Advertiser
www.lubriplate.com
www.oeo.com
www.orival.com
16
www.parkertransair.com
Plant Engineering On-demand Webcasts

58
630-571-4070
www.plantengineering.com/ondemandwebcasts
Rittal Corporation
800-477-4000
3
www.RittalEnclosures.com
Rubbermaid Commercial Products/Brute

25
800-347-9800
www.rubbermaidcommercial.com/rcp/brute
SEW-EURODRIVE, Inc.
864-439-7537
39
22
Sullair Industrial Products

219-879-5451
31
19
Summit Industrial Products

800-749-5823
54
25
Vac-U-Max
973-759-4600
55
Yaskawa America, Inc

800-927-5292
www.seweurodrive.com
www.sullair.com
www.klsummit.com
26
www.vac-u-max.com
C-3
27
www.yaskawa.com
www.ErectAStep.com
6
www.flexicon.com
15
www.flir.com
13
www.greenheck.com
Industrial Internet of Things (IIoT) Webcast Series

48
630-571-4070
www.plantengineering.com/IIoTWebcastSeries
Need More Info? FAX this page to: 630-214-4504
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
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Title
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e-mail
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PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.
PLANT ENGINEERING
October 2015 63
INCONCLUSION
Who sets your plants safety standards?
S
Bob Vavra
Content Manager
The standard
for safety
begins not with
OSHA nor with
NFPA, but at
the front door
of your plant.
You and your
employees set
the standard
for safety.
64 October 2015
afety, as has been noted in this

space many times, is not a point
of negotiation in manufacturing.
It is a fundamental and inviolable
human right. It isnt something
workers should ever have to demand. It
is something management must provide
at every moment of every day.
As I tour manufacturing plants, safety is
the first thing I look for, and the first thing
with which Im usually confronted. From
something as simple as safety glasses to
as comprehensive as a 5-minute safety
video for visitors before they can enter
the facility, safety is the benchmark for
almost all great and good manufacturers.
So when encountering a situation
such as chicken-processor Case Farms
in Winesburg, Ohio, I have to remind
myself that this really is an exception to
the rules of safety. Still, the quote from
OSHA Administrator Dr. David Michaels
does give one pause, because government
officials usually arent this blunt.
In announcing 55 violations against
Case Farms on Aug. 13, Michaels left little
doubt as to his agencys disdain for Case
Farms safety practices. Case Farms is an
outrageously dangerous place to work,
Michaels said in a press release announcing $861,500 in fines against the company. In the past 25 years, Case Farms
has been cited for more than 350 safety
and health violations. Despite committing
to OSHA that it would eliminate serious
hazards, Case Farms continues to endanger
the safety and health of its workers. This
simply must stop.
Case was accused of violating standards on fall protection, personal protective equipment (PPE), improperly stored
oxygen cylinders, amputation hazards,
and what the OSHA press release called
numerous violations of electrical safety
standards. The company also has been
added to OSHAs Severe Violator Enforcement Program.
In deciding to contest the latest round
of fines and violations, Case Farms officials said in a statement published by Farm
and Dairy on Sept. 1, We do not agree
with the negative characterizations that
PLANT ENGINEERING
have been made about our company and

our employees The citations are being
reviewed and we will work with OSHA,
as we have in the past, to address the concerns outlined in the citations.
Theres a long distance between the
statement from Michaels and the one from
Case Farms, except for the part that says,
we will work with OSHA, as we have
in the past. Everyone agrees this is not
the first time OSHA and Case Farms have
discussed safety practices. It probably also
is worth noting the irony of the first line
on the Case Farms corporate website home
page, which reads: A core component
to Case Farms quality commitment is
to ensure the welfare and health of our
chickens.
In September of this year, OSHA reported that there was an increase in the number of workplace fatalities in 2014, the
last year for which statistics are available. There were 4,679 workers killed on
the job in 2014, compared with 4,585 in
2013. The fatality rate dropped 3.3% in
2014 because of increased hours worked,
but thats probably little consolation to
the 4,679 families who lost loved ones at
work in 2014.
Stories such as Case Farms and numbers such as the latest workplace fatality
figures are why we have safety standards.
OSHA and the NFPA are just two of the
groups studying the key issues around
workplace safety. The standards around
this issue continue to evolve. No one is
satisfied with workplace safety because
not everyone is safe. The efforts these
agencies and others make to improve
workplace safety must continue, and must
be adopted and enforced.
But the standard for safety begins not
with OSHA nor with NFPA, but at the
front door of your plant. You and your
employees set the standard for safety. No
one should be able to impose upon you
a safety standard greater than one that
you should insist on for yourself, and no
nasty words or huge fines will be able to
abate the damage if you fail to meet that
standard. PE
ENTER THE MATRIX
Using complicated systems for low harmonics or power regeneration?

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Our greenest drive ever, the U1000 goes beyond the performance of conventional
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12/18-PULSE
SYSTEM
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U1000 INDUSTRIAL
MATRIX DRIVE
Standard
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SYSTEM
U1000
Input Fuses
LC Filter
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Drive
Get personal with Yaskawa.

Call Steve Perreault today.
1-847-887-7147
YA S K A W A A M E R I C A , I N C .
D R I V E S & M OT I O N D I V I S I O N
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
2015 Yaskawa America Inc.
For more info:

http://Ez.com/yai828
The New Standard

in Large Motors
Whether you pump it, compress it, blow it or

convey it, Baldor Large AC GPM motors are the
perfect choice for your application. Available in low
voltage or medium voltage configurations, Baldor
Large AC GPM motors are inverter ready and in
stock for fast delivery.
Low & Medium Voltage

Modifications Available
And, if you need a general purpose motor

modified with optional features to fit your exact
specifications, you can count on Baldor Large
AC GPM motors to set the new standard in
performance with the fastest turnaround in the
industry.
In Stock & Ready to Ship
baldor.com
Designed for Safe Operation
479-646-4711
Download a QR reader app

and scan this code for
more information.
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2015 Baldor Electric Company

Plant Engineering Octubre 2015

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At ContiTech, were taking efficiency next level with

exclusive technologies, innovations and services

More ability is here with ContiTech.

input #29 at www.plantengineering.com/information

Products | Rubber Track

49 Fit bearings properly

49 Fit bearings properly

21 A global view of manufacturing

Conveyor Belt | Hydraulic Hose | Industrial Hose | Power Transmission

49 Fit bearings properly

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2015 Kaeser Compressors, Inc.

Join the Rittal Fan Club.

Hot spots are definitely not cool for protecting sensitive

Rittal electronics from failure or plant shutdowns. So rely on

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Up to 40 percent energy savings with diagonal fan technology

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Cover image courtesy: Emerson

27 Raising the standard

32 Ten essential steps to support arc flash

33 Top seven arc flash safety measures

LASER & PLASMA CUTTING

Farr Gold Series

Industrial Dust Collector

Chop Saw Dust

Laser Cutting Smoke

Thermal Spray Dust

LOOKS LIKE A SAFE BECAUSE ITS

AIR POLLUTION CONTROL

21 The Road to Hannover Messe 2016

Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com

Jerry Preston, West Coast

Stuart Smith, International

Replacing everything in a plant instead of maintaining it is an absurd

43 Five steps to applying predictive

Ensuring the right work is performed at the right time to minimize

49 The quest to find the perfect

While tight and loose are relative terms that

52 Using medium-voltage VFDs

ONLINE: Manufacturing Day recap:

Your most-read stories at www.plantengineering.com

Here are Septembers 10 most often referenced articles at www.plantengineering.com. In