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Raise Hazard
Awareness
Electrical Safety
Is Everyone's Job
SEPTEMBER 2010
Read more, watch free videos, and download the software at:
www.productivity3000.com
features
28 / COVER STORY
Raise Hazard Awareness
Electrical safety is everyone’s job
22 / RELIABILITY
Best Practices Awards
Four companies exhibit the best in reliability
38 / POWER TRANSMISSION
Reliability Goes Green for Rotating Equipment
Four innovations can help you meet sustainability goals
45 / HVAC
A Discussion of HVAC Coil Coatings
The solution to leaking HVAC coil epidemic could be coatings
specialists
OSHA 10- and 30-hour training – Hard work that pays off
Training provides general awareness on primary safety and 17 / HuMAN CAPITAL
health matters. Owning Your Circumstances
www.plantservices.com/articles/2010/06osHatraining.html It’s the honorable thing to do
19 / ASSET MANAGER
ultrasound assisted lubrication
Adding ultrasound monitoring to standard lubrication best Fleet Asset Management
practices can lead to fewer failures, extend motor and bearing Your CMMS can be an active partner in minimizing mobile asset
life, and decrease the amount of lubricant used. operating cost
www.plantservices.com/articles/2010/07ultrasoundassisted
27 / TECHNOLOGY TOOLBOx
lubrication.html
Heat Exchanger Integrity
Multiple methods confirm the integrity of tubes and tube sheets
How VFDs save energy
Analysis and examples of power conversion by variable-frequency 58 / ENERGY ExPERT
drives. The Perfect Energy Storm
www.plantservices.com/articles/2010/06Vfdssaveenergy.html Reliability, cost, environmental factors can affect availability
Information at your fingertips in seconds! Whether you’re planning, procuring, installing and commissioning or operating
a plant, W@M – Life Cycle Management from Endress+Hauser keeps you up to date on the complete installed base of pro-
cess automation equipment, even for non-Endress+Hauser products. W@M is designed as an open and flexible information
platform with software applications and services that reduce equipment failure and plant downtime, and minimize repair
and maintenance costs, cutting total life cycle costs. Talk to us today. We’ll be glad to tell you more about how W@M can
help improve your business. www.us.endress.com/W@M
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143 Sales: 888-ENDRESS
inquiry@us.endress.com Service: 800-642-8737
www.us.endress.com Fax: 317-535-8498
mike brenner
Group publisher
editorial staff
paul studebaker, Cmrp
editor in chief
Coming to the end of a long, hot summer
pstudebaker@putman.net
russell l. kratoWiCz, p.e., Cmrp from the midwest to the eastern Sanitation immediately comes to
executive editor
russk@putman.net seaboard, the summer of 2010 has been mind, but sanity also is a major concern.
the hottest and most humid in 20 to 60 The Chicago Tribune reports that the
alexis GajeWski
associate editor, digital media years, depending on your location. Here men already have been trapped under-
agajewski@putman.net in Chicago, we had the longest string of ground longer than all but a few miners
stephen C. herner
80° F or above temperatures since 1955. I rescued in recent history. Survival after
V.p., creative services know that’s nothing compared to a regular 17 days is unusual, but because they’ve
sherner@putman.net southern summer, but crawling through made it this far, they should emerge
jennifer dakas the many road construction zones – with physically fine, Davitt McAteer, former
art director the windows open, because unlike me, assistant secretary for mine safety and
jdakas@putman.net
my A/C is taking a vacation – I have to health at the U.S. Labor Department,
david berGer, p.enG. sympathize with the workers getting it told the Tribune. But the stress of being
contributing editor
done under these conditions. And I can’t trapped underground for a long period
peter Garforth help but notice that, as a group, we’re not of time can be significant. “There’s a
contributing editor
getting any younger or thinner.
sheila kennedy But we do have more gizmos and gad- up here on the surfaCe,
contributing editor
gets. Manlifts and slings let us access diffi- the eConomy GroWs While
joel leonard cult locations with relative ease. Supports employment staGnates.
contributing editor
and braces allow us to work comfortably
bob sperber in odd positions. Sophisticated “zero
editor at large gravity” fixtures inspired by the movie psychological pattern there that we’ve
industry’s steady-camera technology can looked at,” said McAteer, but “there are
publiCation serviCes
hold heavy tools for precise work at arm’s people who can talk them through that.”
Carmela kappel reach (www.plantservices.com/zerogravity). Up here on the surface, the economy
assistant to the publisher
ckappel@putman.net Thanks to this summer’s Gulf of grows while employment stagnates.
Mexico oil spill, I’ve learned more than Factory and office staffs work harder and
jerry Clark
V.p., circulation I ever imagined I would about work- longer to increase production while skit-
jclark@putman.net ing at the bottom of the ocean. At the tish executives sit on their cash or use it
jaCk jones near-freezing temperatures and 2,400 psi for acquisitions, leading to another kind
circulation director water pressure a mile under the surface of survivors’ stress.
jjones@putman.net
of the Gulf of Mexico, remotely operated In the Middle East, combat troops are
rita fitzGerald vehicles (ROVs) serve as workers’ eyes now officially withdrawn from Iraq, or
production manager and hands. Operators can preprogram an renamed “advise and assist brigades.”
rfitzgerald@putman.net
ROV to park at a designated spot, anchor But it’s not clear how many will actually
jill kaletha itself by gripping framework, and reach come home, what opportunities they’ll
reprints marketing manager
Foster reprints out to adjust a set of valves designed to be have here, or how long before they’re
(866) 879-9144 ext.168 gripped by its high-torque, rotating claws. redeployed to Afghanistan. Or Iran.
jillk@fosterprinting.com
Meanwhile, about 2,300 ft. below the All in all, it’s not so bad to be stuck in
administrative staff surface of Copiapo, Chile, 33 workers traffic on a hot summer day, even with-
trapped for 17 days before they were out A/C.
john m. Cappelletti
president/ceO
located and found to be alive might
have to survive another four months on
julie Cappelletti-lanGe
Vice president
sustenance piped to them through a 6-in.
borehole while rescuers dig a shaft large paul studebaker, Cmrp, editor in Chief
keith larson enough to bring them up to the surface. pstudebaker@putman.net, (630) 467-1300 x433
V.p., content
rose southard
V.p., technology and Web development www.PLANTSERVICES.Com SEPTEmbER 2010 7
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Preventable Disasters
Getting more people to fight the Maintenance Crisis
During the iCoMs Conference in Adelaide, Australia, not a contributor to profitability. Perhaps more U.S. schools
the Asset Management Council (AMC, www.amcouncil. will implement similar programs.
com.au) asked me to kick off a “find our theme song” contest The frighteningly common situation at engineering con-
in hopes of fostering pride and passion for our profession. ferences is that only a few new engineers are in the audience
I’m not “American Idol” material, but I gave it my best shot. each year. Most attendees were either practicing or masters
I played “The Maintenance Crisis Song” video (www. with one foot into full-time retirement.
plantservices.com/maintenancecrisis) and then sang
“Find Me a Maintenance Woman.” Music is, after all, a When askeD if anYone haD a
powerful tool for influencing attitudes, perceptions, and
forMalizeD MentorshiP ProCess
decisions. Some songs started major societal movements
and changes. Though my tonal quality might not be ready or suCCession Plan, not a sinGle
for prime time, it inspired a quartet of engineers to write Person raiseD a hanD.
their own version.
This group loved it and helped fill a void in the normally
dry engineering conference by adding what John Hardwick, After witnessing the quality and depth of knowledge rep-
the chairman of the AMC, called “pizzazz.” I don’t portray resented, I hope more efforts are implemented to recruit new
myself as a singer, but the attendees whooped, hollered, and engineers to attend this dynamic event. I love the Australian
chuckled over the lyrics and video. I got a standing ovation. culture. As a smart aleck, I fit in and enjoyed some clever
Several approached me afterward to offer sage advice – “Hey repartee with the attendees.
mate, don’t give up your day job.” And even though Australians’ most popular expression
The next day, during my keynote address, they heard what is “No worries, mate, she’ll be alright,” some of the trends
I do on my day job – supporting the economic transforma- underway are cause for great concern if action isn’t taken
tion underway in an 11-county region surrounding Fort to replenish and develop current and future workers. The
Bragg, N.C. They agreed the interactive 3-D technology challenges are vast and deep, but if more of us confront the
used for technical skill development can serve as a bridge to issues head-on, we’ll make serious progress at mitigating
improve the skills and performance of a future workforce. more preventable problems.
In fact, several consulting and contract maintenance On the flight from Australia to Los Angeles, I met Juan
companies are helping me contact the leaders of P3I, the Ospina. He plays keyboard, and after hearing various versions
public-private partnership for innovation based in Fay- of “The Maintenance Crisis Song” via my laptop, he agreed to
etteville, N.C. I participated in a panel discussion titled join the fight. Most of his generation isn’t picking up skilled
“Strategic Asset Management – A Concept or Reality?” with trades, and he realized the Maintenance Crisis is a serious
Hardwick, Anne Howe, CEO of South Australia Water Au- problem. Upon his arrival home, he convinced Aguanilé Salsa,
thority (SAWA), and Penny Burns, principal director, AMQ a Latin-Grammy-Award-winning band, to produce a salsa ver-
International. We agreed that organizations might be on sion of “The Maintenance Crisis Song.” This version will have
varying levels in the journey to implementing this strategy. trombones, trumpets, bongos, and a Latin beat.
When asked if anyone had a formalized mentorship process The first half of song will be in Spanish, the second half in
or succession plans, not a single person raised a hand. English. That should help acquire more supporters to fix the
This conference had wonderful speakers. One explained crisis worldwide. It will be on SkillTV.net, so stay tuned.
that every second, across the world, we lose 1 ton of steel to Check the SkillTV blog if you’d like to join me during my
corrosion. Another said that Western Australia University fall conference schedule. I’ll be keynoting the Facilities De-
is adding engineering courses in its business curriculum. cisions conference in Las Vegas and plan to attend the SMRP
The objective is to give future executives a grounding in conference in Milwaukee.
engineering strategies to better manage assets instead of
believing the traditional fallacy that maintenance is a cost, e-mail Contributing editor Joel leonard at joel@skilltv.net.
when the floor finishing project came out for bid from
one of the local general contractors in charge of the ten-
ant improvement, there was no detailed specification for
the product type or criteria, only a small blurb in the finish
legend mentioning a white epoxy floor coating that would
meet USDA standards.
But long before work at the new Papa John’s Salad and
Produce facility in Tolleson, Ariz., began, Brian Whited,
key accounts manager, Techniquex (www.techniquex.com),
knew the correct flooring system to use for the large expan-
sion project. Three years earlier, Techniquex had worked
for Papa John’s Salad and Produce at its facility in Tempe to
solve a problem of concrete deterioration caused by exces-
sive water exposure. Knowing the exact conditions the new
flooring would face under excessive traffic, constant water
Installing 40,000 sq. ft. of Diamond-Crete RT plus an additional
immersion, and low temperatures, he was sure the best
100,000 sq. ft. of sealed and burnished concrete took a 10-man
solution would be Diamond-Crete RT by DiamondStone crew six weeks of 10-to-12-hr. days.
Products (www.diamondstoneproducts.com).
Whited, recalling the bid information was vague, con- cement with chemical, thermal shock, and thermal cy-
tacted the contractor directly to express his concern. “After cling resistance. A non-sacrificial antimicrobial additive is
I spoke with the contractor and realized the new build-out integrated throughout the system to inhibit the growth of
was for Kevin Jones at Papa John’s Salad and Produce, I im- microorganisms such as bacteria and its odors. The system
mediately told him of our past experience at their other fa- used at Papa John’s Salad and Produce also includes an
cility. We agreed that giving the client a few options, includ- optional quartz aggregate broadcast along with a finish coat
ing the Diamond-Crete RT, would be the best approach.” of DiamondStone Aromatic Urethane 100.
The estimating staff at Techniquex reviewed the plans Techniquex crews arrived on the job site in late June to
and construction schedule and quickly realized the project begin installing 40,000 sq. ft. of the Diamond-Crete system
needed to be fast-tracked. This was yet another indication to along with an additional 100,000 sq. ft. of sealed and bur-
use the Diamond-Crete RT system because of its short cure nished concrete.
and quick turnaround. The 10-man crew quickly sprang into action, prepping the
Once the contractor received the proposals for the proj- areas scheduled to receive the DiamondCrete RT. The prep
ect, it was time to begin negotiations. Techniquex provided work took a little more than one week to complete. Once the
several samples of the proposed systems and installed floors had been cleaned, the crew began installing the RT
mock-ups so Jones, the owner, could select colors and system. The crew worked 10–to-12-hour days for six weeks
texture. Techniquex recommended the Diamond-Crete to complete the project.
system, but the price was substantially higher than the The installation went flawlessly and Papa John’s Salad
other options. Whited explained the advantages, including and Produce now has a new facility with a beautiful floor
unlimited moisture tolerance, thermal expansion quali- system designed to keep production areas safe and clean for
ties, warranty duration, and installation timeframe. “Once many years to come. In a letter of recommendation written
Kevin and the contractor were educated on the products after project completion, Kevin Jones wrote: “I couldn’t be
and the differences between them, the extra cost wasn’t an more pleased. You’ve been responsive and have delivered a
issue,” says Whited. finished product perfectly suited to my needs. Your recom-
The owner and contractor both agreed to use the system, a mendations were spot-on, and you accomplished the job
three-component, rake-and-trowel, polyurethane-modified with little disruption to my operation.”
© 2010 Copyright Hyster Company. Hyster and are registered trademarks of Hyster Company. WWW.HYSTER.COM
2857_10HST2561_ER_PS.indd
PS1009_FPA.indd 14 1 8/10/10
8/25/101:36:29 PM
9:41 PM
your space
close your eyes for a second and think about your ride to type of progress board to indicate visually how close you are
work this morning. If you’re driving right now, don’t really to that goal. We routinely place our simulated thermometer
close your eyes. You probably remember seeing the same things visuals in the lunch room and the lobby when we are in the
that I saw on my way to work: cell phone users who had the middle of Red Cross campaigns or United Way fund-raisers,
phone in one hand and making hand gestures with the other,
women putting on makeup while looking in the vanity mirror
and steering with their knees, people reading papers or books anythIng you can do to MaKe
with the book propped on the steering wheel, and people the project More VIsIBle wIll
texting while driving – sorry, nobody is that good, just lucky so further Increase your chances
far. A crazy sight, no doubt, but a sign of the times. The people of sustaInaBle change.
who surround us every day really aren’t concentrating on the
primary goal, which is to arrive at their destinations alive and
in one piece, while putting no one else’s life in danger.
I remember my first opportunity to be coached by my dad showing everyone the increase in “temperature” as we gain
in Little League baseball. His most important bit of advice in donations for the year. Why not use something similar
was “keep your eye on the ball.” Good advice, as it turns out. for an improvement project to show the cumulative savings
It works for any sport involving a ball. It also is pretty useful it generated? Anything you can do to make the project more
when you are trying to plow that first straight furrow in a visible will further increase your chances of sustainable
field using a distant tree or fence post as a target. It works change and improvement.
pretty well for Navy pilots landing on an aircraft carrier – in Communication and feedback to everyone is critical to
fact, pilots “call the ball” to ensure the correct landing ap- success. You don’t want to hear little sound bites around the
proach. And it works very well in business when you have an lunch room like “I wonder what’s going on with Project X.
important initiative underway and need to maintain focus They never tell us anything.” Unless your project or initia-
on the ultimate goal. tive is going to result in a global disaster, there should be
Sometimes it’s difficult to visualize what the ball is going no reason to withhold information or otherwise keep your
to look like until we finally see it. In a new initiative, no mat- people in the dark. Information is power, and information in
ter how well we plan and execute, it’s hard to imagine what the hands of employees provides the power to move a project
the finished product is going to be without some type of forward much more quickly and efficiently than any small
visual reference. In an operating facility, there are an endless group or team could manage.
number of distractions each day that can easily take our eyes When you set a goal or establish a vision for the future,
off the ball and pull us into another, seemingly more impor- you have to keep your eye on the ball. More importantly, you
tant issue that will deprive the primary initiative of critical want everyone’s eyes to be on the same ball. It can’t be just
focus and effort toward completion. your personal goal or vision. If you want real change and
As project or initiative leaders and managers, it’s our job improvement, it must be shared with everyone around you
to make sure that everyone involved in the project has the to leverage the best possibility for success.
same vision of what the completed project will look like. So, go out and put the ball on the project wall and then
How will we know whether we’ve succeeded? Do we have challenge all to look at the ball on the wall and help as they
some measure by which we will know success, or will it just can, so you don’t fall and miss the ball. And when you reach
be a guess on the part of the project team? the end, take the ball down from the wall and reinstall it on
One of the best methods I’ve seen is to place the vision or the Victory Wall. My apologies to Dr. Seuss.
ball in a prominent and public place in the facility, where
everyone who walks in can see clearly what the goal is. Of Bob call is a principal consultant with life cycle engineering, Inc.
course, if you’re going to do this, you also must publish some e-mail him at bcall@lce.com.
S:10”
1-888-777-2700 www.hertzequip.com
® U.S. Pat. Off. © Hertz System, Inc. All rights reserved. All other trademarks are the property of their respective owners.
“It’s not my fault. That’s not my job. Don’t blame me. actions of someone or something else to keep them below
It wasn’t my decision. I forgot. I’m too busy to get to that. the line. Instead, the accountable person accepts whatever
I thought I told you about that. I told someone else they ways in which his or her own behavior contributed to the
needed to do that.” situation and sets about overcoming the circumstances, no
Whether it’s your teenage kids who never seem to find the matter how difficult.”
dishwasher with their dirty glasses, an automobile accident To be accountable, you must accept what is. That’s reality.
at an intersection, or an upset at the plant, people seem to Reality doesn’t care if we’re aware of it or not. Reality exists
have a set of conditioned responses. Their responses are like
reflex actions.
THe beNefIT Of OwNINg reALITy Is THAT
I’ve always valued working with people who have the
ability to recognize their roles in disheartening situations. yOU geT PAsT bLAMe ANd exCUses.
For the parent who is annoyed by the teenager’s inability to
find the dishwasher, the parent’s role was in not being more
insistent in communicating the importance of cleanliness independently of our judgment and opinions. When we
and respecting others. For the person who was involved in don’t recognize reality or become aware of reality and try to
an accident, that person’s role might have been not being live by what we want the reality to be, we will most often be
a defensive driver, or even the consequence of leaving the discouraged or disappointed. People who don’t recognize re-
house 30 seconds later than planned. ality are easily identifiable; they are the ones who complain,
In a plant upset situation, the operations manager who blame, judge, resent, worry, regret, control, or procrastinate.
doesn’t own the circumstances might believe an operator They are below the line.
was too slow to notice a flow rate or pressure change in a When you don’t accept reality, it’s like not knowing about
process. In this case, the operations managers who own a kick-me sign on your back. You can’t understand why
their circumstances consider the fact that they allowed people keep kicking you in the butt. When you get clued
shortcuts to the new employee orientation program, or that in to reality, you have choices about what to do with that
the maintenance manager asked for time to fix a flow rate or knowledge. If you know the kick-me sign is on your back,
pressure sensor alarm last month. you can, of course, leave it there (not smart) or you can
I value working with people who own their roles in remove the sign and stop getting booted in the butt. When
situations because at their core they are realists. They see you own your circumstances, you can move beyond negative
various sides of issues and usually recognize opportunities feelings and defensive actions.
to improve as a result. Accountable people recognize that What if you recognize and accept reality, but other
they and others might have had a role in the problem; they persons around you don’t? Aren’t you still going to have
might be the direct cause of the problem, they might have people blaming and playing the victim? My answer is
contributed to the problem, or they might have passively “probably.” But your insight will be the path toward at
allowed it to occur. least minimizing the problem. You will be in a better po-
The benefit of owning reality is that you get past blame sition to influence others and the overall situation. As a
and excuses. When you get past blame and excuses, you can result, whether you’re a craftsman, foreman, or manager,
focus on solutions. you will be seen as more professional and capable than
In their book, “The Oz Principle,” Roger Connors, Tom those who don’t embrace reality.
Smith, and Craig Hickman use the terms “above the line” Help others to embrace reality. When problems arise,
and “below the line” to define when someone acts with ac- don’t join in the blame game. Take the high road. Look for
countability (above the line) and when that person is stuck solutions that lead to higher value outcomes.
in what the authors refer to as the “victim cycle” (below the
line). One quote from the book I particularly agree with: “A Tom Moriarty, P.e., CMrP, is president of Alidade Mer Inc.
person who owns his or her circumstances never allows the Contact him at tjmpe@alidade-mer.com and (321) 773-3356.
Read our white paper on how to take your organization to the Next
Generation of Maximum Overall Equipment Efficiency! Call 1.888.437.4968
today to get your copy.
I F S – T H E G L O B A L E N T E R P R I S E A P P L I C AT I O N S C O M PA N Y
w w w. I F S W O R L D . c o m
most companies have a range of asset types such as equip- as use of similar technologies for brakes, transmissions, and
ment, buildings, infrastructure, computers, and fleet or mobile exhaust systems, and specialized tools and facilities such as lube
assets to maintain. Although these asset classes have much pits, vehicle paint facilities, and wash bays. Standard operating
in common, there are some key differences in the processes, procedures and job plans often are based on the manufacturer’s
systems, and resources used to manage them. many hours of experience across multiple industries. Job plans
provide guidance as to when and how to do various inspec-
Defining fleet/mobile assets tions and preventive maintenance procedures, once a certain
For our purposes, mobile assets are any motorized equip-
ment on wheels. This includes fork lift trucks, automobiles, historical Data can be comPileD
trucks, and tractors. The vast majority of these assets con- to Determine the oPtimal interval
sume fuel or electricity to power their movement.
Many wheeled assets aren’t powered, for example, carts,
between insPections.
lift trucks, wagons, and trailers. These can be used for
transport, material-handling or people-moving applications. milestone is reached in terms of time passed since purchase,
Without a power source and drive system, these assets are time driven, or distance traveled.
far less complex and not all that unique in terms of mainte- With many similar assets in the field, historical data can
nance management requirements. be compiled to determine the optimal interval between
The term “fleet” implies multiple mobile assets. Sometimes inspections or when it is best to perform maintenance tasks
fleet assets are identical, but not necessarily. For example, such as changing the oil, replacing the timing belt, and
a plant can have 20 or more different types of automobiles, rebuilding the engine. The bigger the fleet and the more
trucks, and transportation assets, with different specifications, similar the mobile assets maintained, the easier it should be
model years, attachments, and accessories. to achieve economies of scale. At least that is the theory.
However, in practice, there’s no lack of inefficiencies in
Processes to suPPort fleet assets a typical fleet maintenance shop. In my experience, this is
As with any asset requiring maintenance, key high-level in part because of the usual bureaucracy of big companies,
processes include work order management, preventive but it’s the attitude of management and workers that largely
maintenance, condition-based maintenance, spare parts prevents fleet maintenance shops from achieving their po-
inventory management, asset lifecycle management, and tential, especially in the public sector. Although contracted
managing equipment history. But there are some interest- service garages are far more efficient because of their fleet
ing characteristics that apply to a fleet of mobile assets. One maintenance focus and profit motivation, they have a repu-
of the most important differentiators of fleet maintenance tation for sacrificing quality for price.
over maintenance of other asset classes is the relatively high
percentage of use-based or condition-based maintenance, as cmms requirements for fleet maintenance
opposed to unexpected failure-based maintenance. A CMMS is certainly relevant to any fleet maintenance shop;
Although numbers vary by fleet and application, the relative however, there are some specialized features and functions
percentage is typically greater than 80% maintenance triggered that are highly desirable.
by condition or usage – time, meter, or event. This might be VMRS codes: The American Trucking Association estab-
explained by a number of possible factors, but perhaps the most lished the Vehicle Maintenance Reporting Standards codes to
significant is the high consequences of unplanned failure in standardize on the hierarchy of vehicle assets in terms of sys-
terms of health, safety, the environment, regulatory penalties, tems, subsystems, and components. As well, progress has been
or loss of revenue. This is especially true when failure occurs in made in building a hierarchy of essentially problem / cause /
locations that are difficult to access. action codes related to the asset hierarchy. Some of the CMMS
Another factor is the relatively high number of similar vendors ship their systems with VMRS codes loaded and allow
mobile assets making it easier to establish industry norms, such users to edit the coded fields to better match their specific fleet
specifications or to provide greater detail. fleet assets are typically more acute and complex. Vehicles
Fuel management: One of the largest ongoing costs asso- can have different warranties for the overall vehicle, as well
ciated with maintaining a fleet is fuel, as well as costs related as systems, subsystems, components, and even parts. Many
to fuel consumption such as maintenance of tires, fuel CMMS vendors recognized the value of a comprehensive
systems, and engine. Modern CMMS packages that accom- warranty management system. Their software has advanced
modate the needs of fleet maintenance can track odometer features such as tracking multiple warranty types per asset,
readings and fuel consumption on work orders and then use handling parent/child and master warranty relationships,
condition-based maintenance and asset history to adjust the favoring parts closer to warranty expirations for stock issu-
maintenance plan for better fuel management. ance, and preparing a warranty claim.
Campaigns and product recalls: Sometimes a vehicle Facilities scheduling: Most CMMS packages can sched-
manufacturer has a product recall to address a safety- ule work orders – matching work backlog to available labor,
related issue. Some CMMS vendors have features to help parts, and tools. However, few CMMS vendors also will
manage the recall, such as ensuring that all of the vehicles help users to book an appropriate garage bay as part of the
are brought in for service at the appropriate time and the scheduling complexity. Fleet maintenance planners need to
work is completed by a designated date. A campaign is the ensure an asset brought in for service will have the appropri-
internal version of a product recall – for example, a decision ate facilities, such as a bay with an inspection pit, heavy duty
by the engineering department to replace a given part with a lift, or paint booth.
superior-quality, third-party brand.
Warranty claims and tracking: Although there’s a need e-mail Contributing editor David Berger, P.eng., partner, Western
for warranty
CRC claims and
Capabilities tracking2/15/10
7x4.875 for any asset,
10:42the AM
needsPage
of 1 management Consultants, at david@wmc.on.ca.
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Use our online product selector guide to easily find the perfect solution for your individual application needs.
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Technology waits for no man. That’s why at Robinson Fans, our expert engineers are constantly advancing the
air movement industry with innovative products and services. But as we move forward, it’s important to know
we haven’t forgotten our past. With over one hundred years of experience, we’re still leading the way with
high-performance equipment and proven solutions that make your operations and processes more productive.
Robinson Fans. The name behind what’s ahead.
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ElEcTrical audiT cuTS coSTS for nearby workers. The chain had to be lubricated and
Competitive necessities prompted the Crown Candy Corp. carefully cleaned twice each week. Replacing the chain
plant in Macon, Ga., to have Arrow Hart, a unit of Cooper drive with a synchronous belt drive solved both problems.
Wiring Devices, audit its electrical infrastructure. Arrow Hart’s The conversion produced two immediate benefits – noise
recommendations included watertight receptacles, plugs, and reduction and no contamination risk from the twice weekly
connectors for areas regularly exposed to hosedown or spray need to lubricate and clean the chain – and one longer-
with cleaning agents and corrosion-resistant receptacles, plugs, term benefit – eliminating mechanical stress on startup.
and connectors for areas exposed to incidental water spray, www.papajohns.com
humidity, and airborne contaminants. Many of the receptacles
and switches needed flip covers as additional protection. Wire aquaTic EnvironmEnTal ProTEcTion
mesh grips were recommended where cable and conductors The Trenton Wastewater Treatment Plant in Trenton, Mich.,
are subjected to strain. Arrow Hart recommended an industrial which processes an average of 4 million gallons of wastewa-
motor control for areas regularly exposed to sugars and syrups. ter per day, faced a budget shortfall. Like most government-
After the upgrade, downtime caused by electrical problems run operations, wastewater plants must accept the lowest
and failing equipment should be reduced, and Crown Candy bid for any project. This means the most affordable combi-
should see as much as 25% improvement in productivity. nation of process automation hardware and software wins.
www.crowncandy.com Trenton upgraded its main process control system and
power distribution system. Redundant servers running HMI
chain drivE To bElT drivE convErSion software monitors the plant’s SCADA system wirelessly
PJ Food Service, the Papa John’s Quality Control Center, to four remote pumping stations, and now management
in Des Moines, Iowa, produces pizza dough for roughly can troubleshoot problems immediately and remotely.
230 stores in a nine-state region. The plant uses a chain- A Rockwell Automation services and support contract gives
driven dough bowl elevator to lift 600 lb. loads 360 the plant monthly on-site visits and software upgrades.
starts a day. While the drive operated reliably with proper When a main server meltdown blinded the plant, within five
maintenance, it posed two problems. Each start delivered hours the service technician transferred plant operation to a
a shock load to the entire system. It was tough on the redundant system.
equipment and produced an uncomfortable 85-dB noise www.trentonmi.org
Headline
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If your company is like most, it’s reduced capital breakers, we can revitalize aging equipment
and operating budgets butHeadline
still expects things to without the need for prolonged shutdowns—
run like they always have. Square D™ Services saving you time and money.
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Electric, or its affiliated companies in the United States and other countries. 998-2014b
Valero’s Paulsboro Refinery in New Jersey has a capac- a balance must be found in the quest to move farther to the left
ity of 195,000 barrels per day and employs nearly 550 indi- on the P-F curve. One way to achieve this is by relying not only
viduals. Condition-based maintenance is used extensively on level-type alarms, but also on technologies that automate
and employs a mix of permanent and portable technologies, the data analysis and anomaly detection processes that human
depending on asset criticality. Low-criticality assets are experts would use if manually reviewing data. Paulsboro has
addressed by a portable data collection system. High- and used the System 1 software’s decision-support capabilities to
mid-criticality assets are addressed by online systems. For embed subject-matter expertise for a particular asset or class
its most critical assets, Paulsboro uses GE’s Bently Nevada of assets and detect asset problems automatically. While many
continuous machinery protection systems in conjunction users employ the decision-support module to detect anomalies
with System 1 software. These assets include gas turbines, with the rotating machinery monitored by System 1 software,
steam-driven and motor-driven centrifugal compressors, what has set the Paulsboro facility apart is its use of the system
hydrogen reciprocating compressors, utility air compres- on non-rotating assets, as well. By bringing process data from
sors, and liquid ring compressors for flare gas recovery. Mid- the plant’s distributed control system (DCS), turbine control
criticality assets in the refinery’s coker unit are addressed systems, and process historian into the System 1 database,
by the Trendmaster system, a permanently wired “sensor Paulsboro is able to apply the decision-support engine in ana-
bus” architecture that monitors conditions several times lyzing and detecting anomalies on assets for which only process
per hour. Both the continuous monitoring systems and the measurements are available, addressing applications outside of
Trendmaster architecture are tied into System 1 software for conventional condition monitoring, and detecting problems in
a unified online condition-monitoring environment. non-rotating portions of turbomachinery.
One of the keys to Paulsboro’s success with condition- To address this mix of conventional rotating machinery,
based maintenance is its practice of managing machinery fixed equipment, and process-related applications, Paulsboro
“below the alert level.” Alarms set to notify machinery uses both GE’s machinery expertise in the form of pre-con-
specialists of impending problems allow uninterrupted op- figured RulePaks, and its own expertise in the form of custom
eration while appropriate actions, such as scheduling main- rules written by the resident subject-matter experts.
tenance, planning an outage, or recommending changes to “These rules are what allows us to automate the diagnostic
operating or process conditions, are taken. process,” says Jayesh Patel, reliability engineer at the Paulsboro
Managing too many alarm levels can become onerous, and facility. “We’re able to test our rules on historical data to make
sure that they fire when, and only when, we want them to.”
Point where impending
For example, the feed filter for the naptha hydrotreater has a
failure is detected is Vibration
Oil Analysis
direct effect on product quality and operational problems,
Potenial Failure (P) 1–9 months
1–6 months Thermography and as such it is critical to production. Before imple-
3–12 weeks
Quantitative PM
mentation of the decision-support system, the filters
P0 P1 5–8 weeks were replaced every 45 days to 90 days, but more
P2
P3 Audible Noise than a third (35%) were replaced under an
1–4 weeks
P4 emergency work order. In the past two
Heat by Touch years, the filters have been replaced 10
P5
1–5 days times, and not one was under emer-
gency conditions.
P6
Smoke
It’s also important to Valero
0 days that the stack emmissions ana-
P7
lyzer results agree with those
Point where asset obtained when the emissions
stops doing what its
are analyzed by a lab. The
P–F Interval users want it to do is
Failure (F) System 1 software rules are
used to make sure these re-
The P-F curve shows qualitative time relationship between potential failure (P) and functional failure (F).
The further to the left (closer to P0) one can operate for any given asset, the easier it is to plan maintenance ports are in agreement, thus
and lower the likelihood of surprise functional failures. avoiding penalties.
TM
Always air. Sullair: a concern for the future. Our logo says it all.
“Always air” expresses Sullair’s Underlying Sullair’s leadership is a For more than four decades, the
commitment to customers by dedication to reduce the amount Sullair logo has generated a deep
offering new ideas and technologies. of natural resources consumed to impression of our customer-driven
From mines in Peru to ski slopes create electrical energy and to philosophy. It creates an emotional
in the USA, we help our minimize environmental impact, connection and trust in the benefits
customers lower maintenance both in the manufacture and use our products and services offered
costs, improve productivity, and of our products. you through our worldwide
extend equipment life. distribution partners.
Sullair Corporation, 3700 East Michigan Boulevard, Michigan City, IN 46360 • Telephone 1-219-879-5451 • www.sullair.com
TM
heat exchanger flaws and fouling increase fuel and is faster and more efficient than nondestructive ultrasonic
maintenance costs and put production at risk. New choices testing, the internal rotating inspection system (IRIS). This
in heat exchanger testing, design, and materials are alleviat- measures thinning and pitting in small-bore pipes using a
ing these concerns. probe in a flooded tube, and data is displayed and recorded
Acoustic testing: Acoustic pulse reflectometry (APR), used as it’s removed.
in seismic studies, duct investigation, and musical instru-
ment research, is the basis for AcousticEye’s non-invasive The depTh of coRRosion WiThin
heat exchanger testing systems. APR measures one-dimen-
a Tube is an indicaToR of The heaT
sional acoustic-wave propagation and records and analyzes
the reflections produced by changes in the cross-sectional exchangeR’s ReMaining life.
area of the tubular system to detect flaws. AcousticEye’s
Dolphin 2000’s technology detects leaks, wall loss, full
or partial blockages, corrosion, and fouling. The Dolphin Corrosion avoidance: An all-aluminum evaporator
system’s patented software identifies defect type, location, eliminates the problem of formicary corrosion in traditional
and severity. The user can assign thresholds for each flaw copper-tube evaporators. Delphi’s MCHX evaporator for
type so that only measurements exceeding the threshold are indoor settings performs in condensing and evaporating
categorized as flaws. Before accepting or rejecting flagged modes, while consuming 40% less mass than a competitive
items, the technician might drill down for further measure- product. It has a brazed aluminum construction and micro-
ment information, including the signal graph. channel condenser technology that requires less refriger-
Because the analysis is automated, tubes can be tested in ant. Delphi also announced a new condenser for outdoor
less than 9 sec. without the aid of experts. The Dolphin’s applications having an optimized corrosion-resistant alloy.
speed and suitability for any tube configuration, size, or ma- The MCHX condenser, launched in 2003, was updated to
terial makes 100% inspection coverage possible. By compari- improve robustness and simplify installation.
son, traditional sampling methods, such as standard eddy Anti-corrosive materials: A team of scientists at MIT’s
current or ultrasound testing, are more time-consuming Pappalardo Micro and Nano Engineering Laboratories
and require skilled professionals to interpret test results. recently discovered a way to transform polyethylene into a
Helium testing: Another non-destructive approach detects material that conducts heat as well as most metals, while re-
leaks in heat exchanger tubes and tube-to-tube sheet con- maining an electrical insulator. The material’s high thermal
nections using helium. The leak testing process from SGS, conductivity could someday be applied to heat-dissipating
once limited to LNG carriers, has been extended to heat applications such as heat exchangers. In large quantities,
exchangers by SGS Korea. The gas is introduced into the the fibers could be potentially cheaper than metals for heat
exchanger’s internal space and overpressurized, the gas exchanger fins. So far the researchers produced individual
passes through welding flaws, cracks, and pinholes before fibers in a laboratory setting, and they hope to produce
entering a sniper attached to a helium mass spectrometer. whole sheets of material with the same properties and inte-
An ion chamber ionizes the gas, and the ion collector sends grate them into real-world applications.
its signal to the indicator.
Ultrasonic testing: Corrosion depth in a tube is an indica- e-mail contributing editor sheila Kennedy, managing director of
tor of the exchanger’s remaining life. The heat exchanger life additive communications, at sheila@addcomm.com.
assessment system (HELAS) from SGS Group measures the
ultrasonic immersion length, which is converted into the RefeRence Web siTes:
corrosion depth inside cooling water or air-fin type tubes.
www.acousticeye.com www.mit.edu
It estimates the remaining life using two extreme-value www.sgs.com www.heatexchanger-fouling.com
analysis methods: minimum variance linear unbiased esti- www.delphi.com www.netl.doe.gov
mate (MVLUE) and maximum likelihood (MLH). HELAS
non-electrical employees can not only safety awareness, can help prevent equipment, a useful training curriculum
ensure their compliance with OSHA serious injury or worse, and sends a could include a variety of elements.
safety standards but, more importantly, strong message that the employer is • General electrical awareness
reduce the risk of electrical accidents serious about establishing and adher- • Consequences of electrical hazards
and enhance the level of protection for ing to safe work practices. Keep that in • The safety model
all their workers. mind if you have non-electrical work- • Major hazards and prevention
ers that don’t have electrical hazards strategies
OrientatiOn, training, awareness training and will be work- • Lockout/tagout (LOTO) awareness
and awareness ing in and around hazards. • Basic personal protective equip-
Because many companies provide a An effective electrical safety and ment (PPE) awareness
general orientation program as part of hazard awareness program provides an • Reporting hazards to a supervisor
the new hire process, including electri- overview of potential electrical hazards, • Follow-up training.
cal hazard awareness training along strategies for protection and avoidance, Because electricity is such a familiar
with general workplace safety instruc- and instruction on company policies part of everyday life, this powerful en-
tion is the best way to guarantee that and procedures that support safe work ergy source often is used with minimal
new employees are alerted to potential practices. While the specific elements of caution and little thought regarding its
electrical hazards. A well-designed an awareness program vary depending potential hazards. Workers are espe-
initial orientation enhances worker on the industry, facility, machinery, and cially vulnerable to electrical hazards
because they’re often operating in
fast-paced situations involving intricate
machinery, power tools, crowded work
areas, and exposure to variable weather
and other environmental factors.
Because the average worker often lacks
basic electrical knowledge, a general over-
view of how electricity works is a good
place to start electrical safety awareness
training. Just as the fire triangle provides
the three elements that produce a fire –
oxygen, heat, and a fuel source – there
are three basic elements that comprise a
complete electrical circuit – a source of
energy, a load, and a complete path. The
primary goal of awareness training is to
keep workers from becoming part of this
electrical circuit.
Topics that can be used in electrical
awareness training include:
• Electrical hazard awareness (see
Safety Model):
–What is the hazard?
–What are the risks and dangers?
–How can it be controlled?
• Basic electrical terms:
–Voltage and current
–Insulators and conductors
psv –Alternating and direct current
–How a transformer works
3782055A_PE_PS.indd
PS1009_FPA.indd 31 1 4/15/10
8/25/10 12:56 PM
9:46 PM
safety / electrical
with insulation, training workers as spot- modified increase the risk of contacting
ters, using a service to locate the under- electrical current. Also, improper use of
ground power lines, requiring employees extension cords, such as anchoring them
to maintain a distance of at least 10 ft. from with nails or staples, can pose a serious
power lines, and providing non-conductive risk. To avoid these common problems,
wood or fiberglass ladders when working workers should be trained to inspect cords
near power lines. continually and remove from service or
ITT.
equipment can cause wear and tear that for hard or extra-hard use. Employees also
results in insulation breaks, short circuits, can extend the life of cords by removing
and exposed wires. Without protection, a them from receptacles by pulling on the
We’ll assess your system, perform upgrades, and cut your energy costs while improving reliability—
ground fault can send current through a plugs, not the cords.
worker’s body, causing serious injury and Lack of appropriate barriers and
possibly death. Employees who regularly warning/caution signs: Since many
To straighten out unnecessarily complex pump systems, call Energy Performance Services from ITT.
use power tools and other electrical equip- employees who aren’t qualified electri-
ment should receive awareness training cal workers face exposure to electrical
about ground-fault circuit interrupters and hazards every day, they should be trained
the assured grounding program. They also and encouraged to recognize risks and
should be trained to inspect all electri- respond appropriately to protect not only
cal equipment visually before use and to themselves but also their coworkers. One
remove from service any equipment with of the most obvious safety precautions
frayed cords, missing ground prongs, or employers can take is setting up barri-
cracked tool casings. ers or warning signs to alert employees
Equipment not used according to to potential danger. Unfortunately, they
manufacturer’s requirements: If electrical are sometimes overlooked. While non-
Inefficient pump system?
equipment is used in ways for which it’s electrical workers don’t have the technical
not designed, employers can no longer de- training to correct many electrical hazard
pend on the manufacturer’s built-in safety situations, they should be trained not
features. Common examples of misuse only to heed barriers and warning signs
include attaching ungrounded, two-prong but also to alert management of the need
adapter plugs to three-prong cords and for barriers or signs when they recognize
tools; using modified cords or tools, such potential danger.
as removed ground prongs, face plates, or
insulation; and using tools with worn insu- LOtO and PPe
lation or exposed wires. Employees should Lockout/tagout (LOTO) refers to a specific
be strongly advised in electrical safety process to safeguard employees from the
orientation to use equipment according unexpected energization or startup of
to the manufacturer’s instructions and machinery and equipment, or the release
to refrain from modifying cords or using of hazardous energy during service or
them incorrectly. maintenance activities. An authorized
Improper use of extension and flex- qualified electrical employee turns off and
ible cords: The normal wear and tear on disconnects the machinery or equipment
extension and flexible cords can loosen or from its energy sources, locks and/or tags
expose wires, producing hazardous condi- the energy-isolating devices to prevent
tions. Cords that aren’t three-wire type, the release of hazardous energy, and takes
not designed for hard-service, or have been steps to verify that the energy has been
Optek
Optical Switches
Allied Stock Number
387-0042
Phoenix Contact
QUINT Power Supplies
Allied Stock Number
209-0045
THINK ALLIED
SM
© Allied Electronics, Inc 2010. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
Our 5 and 10-kV insulation testers meet the requirements for use in CATIV 600 V
applications, in line with IEC61010-1. Some of the features of the units include:
prevent grease from entering the waste stream. getting it straigHt tHe first time
In one case, a company in the northwestern United States
replaced cast-iron pillow blocks with lubed-for-life bearing
units on its multi-lane sorting machinery used for apple pro-
cessing. The conventional pillow blocks had sustained rusting
and lubricant washout and had a life expectancy of only three
months. The new bearings featured corrosion-resistant com-
posite housings.
After the test period proved successful, the company spec-
ified the lubed-for-life composite units as drop-in replace-
ments for the conventional cast-iron units. The composite
units feature specially coated insert bearings and stainless
steel sealing components. They withstand high-pressure
washdowns without purging grease and are lubricated with
USDA-approved food-grade grease.
Equipped with these bearing units, the upgraded apple
sorters have operated for a full year without requiring any figure 1. a handheld laser shaft alignment tool can provide real-
bearing-related service. time alignment values.
Studies estimate that, in a typical application, these lubed-for-
life units save more than 100 oz. of grease per unit annually. De- ter can hold 250 ml of either grease or oil. When activated,
pending on the number of units, in a single year a plant can keep the motor drives a piston that dispenses the lubricant at the
many thousands of ounces of grease out of the environment. preset user-selected rate. This single-point lubricator can be
mounted remotely to lubricate bearings in areas with high
Waste-reducing lube dispensers temperatures or excessive vibration.
Most bearings require periodic relubrication. For reasons Higher-capacity, multi-point lubricators are intended for
of productivity and sustainability, it’s important to follow heavy-duty applications such as hot gas fans and calendar
correct lubrication practices and avoid underlubricating or rolls in paper mills. These systems distribute grease or oil
overlubricating. from a central canister through as many as eight feed lines.
Underlubrication can cause metal-to-metal contact between Manual relubing is still the norm in many applications. It
bearing components and eventual bearing failure. Overlu- can be difficult, however, to measure the amount of grease
brication causes churning, which results in higher operating injected using manual methods. Grease meters can provide
temperatures and lubricant degradation. On the macro level, a sustainable solution. They can measure grease quantities
excessive lubrication throughout a plant increases lubricant by volume or weight accurately and display the amounts on
consumption and waste. built-in screens. They’re usually compatible with a variety of
Automatic dispensing systems can keep lubricant usage grease guns and pumps.
under control. They deliver a steady flow of lubricant di-
rectly to machine points, supplying just the right amount of green lubricants
lubricant needed. Lubricant formulation represents another sustainability issue. A
One popular type of single-point lubricator is a self- growing number of biodegradable “green” greases are available
contained, electromechanically driven unit consisting of a for applications if environmental contamination is a concern.
battery-operated motor and a lubricant canister. The canis- One such lubricant, a low-toxicity, synthetic ester oil-based
grease, is designed for water treatment, irrigation, agricultural,
more resources at www.plantservices.com forestry, construction, mining, and other such applications.
tOpic searcH The grease, intended for use in ball and roller bearings
selection algorithm “selecting the right bearing” and spherical plain bearings, complies with government
Wooden bearings “pick bearings off a tree” regulations on toxicity and biodegradability. It exhibits good
graphite-metal bearings “five bearing killers” performance in low-temperature startups and has superior
powertrain pdm “avoid the rolling thunder” corrosion-inhibiting properties.
bearings “How to not ruin fan bearings”
HigH-accuracy alignment instruments
for more, search www.plantservices.com using the The shafts on rotating machinery must be aligned properly
keywords alignment, bearing, and lubricant. to maximize mechanical efficiency. Shaft misalignment and
related problems impair productivity and consume additional
Visit www.flir.com or call 800.464.6372 to schedule your free demo and find out
why FLIR has been the most trusted name in thermal imaging for 45 years.
PS1009_FPA.indd 41
TSeries_PlantServicesAd.indd 1 8/26/10 9:45
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PM
Discover smart, safe, sustainable manufacturing
at the Automation Fair® 2010 event
Automation Fair is the premier automation industry event uniquely designed to help
you leverage your automation investments to achieve your goals. Attend in-depth tech
sessions and hands-on labs. Visit more than 100 exhibits and displays. Learn best practices
at specialized industry forums. As always, there’s no charge to attend Automation Fair — it’s all free!
November 3– 4, 2010
Orange County Convention Center
Orlando, Florida USA
Automation Fair is a trademark of Rockwell Automation, Inc. Copyright © 2010 Rockwell Automation, Inc. All Rights Reserved.
resources. Advanced alignment tech- lbs., consuming only 20 kVA of electric- nents are demagnetized automatically
nologies can improve and simplify the ity – a 50% reduction compared with after the heating cycle is complete.
alignment process. conventional induction heaters. Modern
A laser-equipped shaft alignment heaters have ergonomically designed Paul Michalicka is a sales manager for
tool, for example, displays live alignment yokes with a sliding arm, which allows SKF USA, Inc., in Lansdale, Pa. He can be
values, simplifies making instant adjust- users to load components without lifting reached at Paul.Michalicka@skf.com and
ments and corrections (Figure 1). This and removing the yokes. The compo- (416) 299-2894.
allows alignment to be completed more
quickly than with traditional methods.
The tool’s “soft foot” function verifies
that machine mountings are stable and
secure. The alignment values and set- The NeW
tings in these units can be stored easily
and uploaded via USB cable to a PC. INDUSTRIAL REVOLUTION:
A major food and beverage manu- it’s about MaXiMiZiNG PRoDuCtiVitY & saFEtY
facturer found that vibration analysis
revealed that alignment problems were
tHRouGH 5s VisuaL MaNaGEMENt
harming machine performance. The
plant used laser alignment instruments sPRaYoN® sYstEM MaGNEtiC CaN HoLDERs
to cut energy consumption by 8% in a Available for single or multiple cans, Sprayon®
large group of its pumps and motors. System Magnetic Can Holders can be located on
or near your equipment ensuring the right product
After the pumps and motors were is always used and improving productivity.
aligned correctly, energy usage dropped
for more info, visit sprayonsystem.com
by 30 kW per day, netting an annual
savings of more than $28,000, as well
as a reduction in unplanned downtime
and a decrease in the consumption of
spare parts.
Misalignment also affects V-belt
drives, synchronous belt drives, and
timing belts. It increases pulley and
belt wear and consumes excessive more of the sprayon® system elements
LU 202
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LU 700
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Covered by one or more of the following U.S. Patents: 6,244,821; 6,589,016; 6,817,835;
6,939,108; 7,252,478; 7,284,960; D587,799; D607,988 and other patents pending.
©2010 Delta T Corporation dba The Big Ass Fan Company. All rights reserved.
BAF_PlantServices_Pivot180.indd
PS1009_FPA.indd 44 1 8/17/10 9:49
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PM
HVAC/R refrigeration coils are leaking at an alarming rate IT’S THE WATER
in industrial, commercial, and residential applications. While
the reasons are many, chemicals ranging from household clean-
ers to industrial process compounds are the main culprits that
produce leaks and pitting corrosion on all types of coils.
Many HVAC manufacturers, distributors, and contrac-
tors might not realize that corrosion caused hundreds of
thousands of coil failures during the past decade. The source
is environmental pollutants, household cleaning agents,
pesticides, formaldehydes, building materials, and even off-
gassing of food. Each contamination source can corrode coil
tubing in a year or less, if the conditions are right (Figure 1).
For example, refrigeration coils in a South American fruit
processing plant’s banana room were continually failing.
Figure 1. Continuous contact with contaminated condensate
The chamber used ethylene gas to ripen the fruit. Byprod- caused this corrosion.
ucts from the gas generator combined with moisture in the
ripening area to form a weak acid that produced pinhole SEA TO SHINING SEA
leaks in the coil tubing after a year or less.
Also, most coastal area HVAC equipment is bombarded
with corrosion caused by ocean salt (Figure 2).
Fluorides are used in municipal water treatment. Pitting Choosing the Right Coating
usually is visible to the naked eye on the exterior of a copper When confronting coil corrosion, first determine if it will
tube. It’s caused by chloride/fluoride ions that condensate recur after replacement. It’s difficult to know if corrosion is a
carries to the metal surface. The cations attack the oxide one-time phenomenon or a continuing problem in that loca-
film the metal uses to protect itself, essentially forming a tion. In the case of the banana processing plant or a coastal
corrosion-driven battery that consumes the copper. Once area unit, coils most likely will corrode continually, and
pits form, they progress through the tube wall forming a their replacement units should have a protective coating.
pinhole that leaks refrigerant. In less corrosive environments, you can attempt to pre-
Formicary corrosion (Figure 4), on the other hand, is vent corrosive materials from entering the return air stream.
caused by organic acids. Acetic acid is abundant in numer- You can store these materials in areas far from a return duct.
ous household products such as adhesives, paneling, particle This might eliminate the need to coat a replacement unit.
board, silicone caulking, cleaning solvents, vinegar, foam Choosing the most appropriate coating could save thou-
insulation, and dozens of other products. Formic acid can sands of dollars and eliminate repeat treatments. The wrong
be found in cosmetics, disinfectants, tobacco, wood smoke, coil coating could degrade heat transfer and lead to higher
latex paints, plywood, and dozens of other materials. The energy bills. Heat transfer is a major concern when coating a
corrosion these substances cause usually isn’t visible to the coil, especially in a retrofit, because the coil might no longer
naked eye, although black or blue-gray deposits sometimes perform at its design specification. The thinner the coating,
appear. Formicary corrosion produces a network of micro- the better the heat transfer. Another concern is the coating’s
scopic tunnels within the tubing wall. It resembles ant nest- hydrophobicity, or how well it sheds condensate. Ideally, water
type structures that are substantially larger than the surface would drain off of the coil quickly. Surface water accumulation
pinholes. Eventually, one or more progresses to the surface is detrimental because it can lead to mold and mildew. Most
and forms a pinhole, which quickly results in coil leakage. coatings don’t resist biological growth, but high hydrophobicity
can passively deter such growth.
the ChoiCes
The four most prominent HVAC coatings are polyurethanes,
epoxies, fluoropolymers, and silanes. Each offers differing
corrosion resistance, scratch resistance, flexibility, weight,
thickness, hydrophobicity, and heat transfer.
Polyurethane (PU), invented in the 1940s, can be manu-
factured as hard as fiberglass, bouncy as rubber, sticky as
glue, and soft as upholstery foam. Many off-the-shelf PU-
based coil coatings can be field-applied. PU formulations are
fairly inexpensive, less viscous, more flexible, and thinner
– typically 25 microns to 50 microns – than most coatings.
But, they aren’t as resilient or long-lasting as other coatings.
Epoxy, or phenolic-based, coatings generally are the
cheapest. Developed in the late 1920s, they’re known for
excellent chemical and heat resistance and often are used
for coating floors and other surfaces. The high viscosity of
epoxy-based systems leads to thicker coatings – approxi-
toPiC seaRCh
hePa filters “Waging the battle against dirty air”
Chiller tips “10 tips for improving chiller efficiency”
Finance “selling your hVaC project”
Refrigeration “10 cooler ideas”
Reheat coils “Watch those hVaC reheat systems”
Figure 3. This cross-section shows the results of pitting corrosion. Figure 4. This cross-section shows how deep-seated formicary
corrosion can penetrate a copper tube.
mately 50 microns to 100 microns – with poor flexibility and are accounted for in the system design specifications.
adherence. Epoxy is difficult to apply in the field. Typically, Fluoropolymers, first developed in 1938 by DuPont, are
the coil is disconnected and shipped to a contractor or OEM available in many forms under a variety of trade names.
for treatment. Because they’re thicker, epoxy coatings reduce They’re known for their high resistance to acids, solvents,
heat transfer, system efficiency, and capacity. Epoxy coatings and bases. They’re most effectively applied to metal
might best suit new installations where heat transfer losses through electrostatic powder coating or by a thermal sin-
tering, as is done for cookware and fluoropolymer-based field-use coatings haven’t gained traction in the industry
other non-stick products. typically is less than the more ad- because of the expense and the inabil-
Additionally, many field-applied vanced epoxy- and PU-based coatings, ity to apply those coatings in the field.
fluoropolymer sprays are available. but the lifetime and effectiveness are Silanes are excellent coupling agents
These sprays generally have poor ad- limited. Fluoropolymer coatings ap- that can bond dissimilar materials such
hesion, and their effectiveness quickly plied in the correct manner, through as paint (an organic material) and glass
diminishes significantly. The cost of thermal sintering or electrocoating, (an inorganic material). A variety of
silanes are available, many of which are
tailored for particular characteristics such
as flexibility, hydrophobicity, and scratch-
resistance. Thus, a properly formulated
FREE Hotel Nights and Spouse Pass for Early Bird silane coating can provide a flexible,
Registration resilient glass-like coating with good cor-
rosion resistance and water-draining ca-
pability that bonds well to aluminum and
copper (an inorganic material). Silanes
form an extremely thin coating – less
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fer. Silanes are resilient to cracking and
Nov 8-12, 2010, Bally’s Hotel on the Las Vegas Strip, corrosion, are hydrophobic, and reduce
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to apply properly in the field if you’re not
a trained applicator. The coil surfaces
Our Keynote Speaker is Special guest apperance by must be cleaned thoroughly and prepared
America’s most trusted Sig Hansen, Capt. F/V NorthWestern properly for a successful application, and
contractor, Mike
Holmes, host of Bally’s Hotel, Las Vegas, therefore it’s best if the coating is applied
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off-site. Although silane coatings typi-
cally are somewhat more expensive than
the other coatings, they also exhibit the
best heat transfer properties and typically
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five years or more.
Each coating technology carries
different levels of toxicity. A service
technician who is planning to apply
Register online now at www.inframation.org any of these coatings in the field
or call us at 866.872.4647 should be outfitted with proper OSHA
equipment and the appropriate breath-
ing apparatus.
Driven to Drink
Acme learns what happens when an employee overindulges
standards in place concerning conduct. If Bo didn’t want to if not most, companies. If Bo were operating a powered
abide by those standards, he should have left when they were industrial lift and had an accident, he’d have been tested for
put in place. Does a company not have the right to expect drugs and alcohol. If the test were positive, he would have
a certain standard of behavior for its executives? Bo drives been let go. The same standard should apply to those driving
a company vehicle with the company identity on the side. company vehicles. Bo must go.
That carries a greater level of responsibility than most others Jeffrey L. strasser, Bacova Guild
who work for the company but drive their own vehicles. Bo’s (540) 863-2656, strasser.jeff@bacova.com
auto-darkening helmets
Use these Miller Electric Digital
Elite Series auto-darkening weld-
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and grinding. The Digital Elite
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Plant Connection
THE CAREER RESOURCE FOR PLANT ENGINEERING PROFESSIONALS
Food Connection
THE CAREER RESOURCE FOR FOOD PROCESSING PROFESSIONALS
reading recent headlines, it’s impossible not to ask windows and integrated controls. It was clad with solar pan-
whether we’re in a perfect storm in which fears around els and connected to district heating and cooling, energized
energy-supply reliability, cost, and environmental effects by a combination of renewable, waste, and fossil energy
are coming together. If we’re in that perfect energy storm, supplies. It was within two minutes of light and heavy rail,
deep and effective productivity improvement are needed in located in a business park that included hundreds of homes
energy management and innovation. If the fears are ground- and offices. It even had a current energy-performance cer-
less, those that achieve the highest productivity and innova- tificate displayed in the lobby. This approach to building and
tion levels are likely to gain a substantial edge over their neighborhood design reduces electricity and other energy
rivals. This column was written on a transatlantic flight that consumption.
prompted thoughts about energy innovation, management, Some countries are reducing parasitic electricity demand
and competition. with deep-standby requirements. Some are developing net-
worked cooling systems fed by waste-heat from industry and
WITh a bILLIon chIneSe cITIzenS power plants. Helsinki, Finland, is considering using waste-
heat from a nuclear plant to heat and cool the city. Industry
geTTIng on The road, hoW much
is reacting to grid vulnerabilities with greater electrical
Longer can our oIL-uSe PaTTernS efficiency, improved management and control, and on-site
be SuSTaIned? clean and renewable generation.
Globally, the past decade was the warmest in recorded
history, with June temperatures hitting an all-time record. A
The oil spill in the gulf was the largest in history, with heat storm caused fires across Russia, with record tempera-
the full effects still unknown, and draws attention to our tures and smoke causing 350 deaths a day in Moscow. The
oil dependence. About 70% of our oil is imported and Russian and the Ukrainian grain fields that feed millions
mostly used in vehicles that, on average, use more than are damaged and exports are restricted. Floods of unprec-
twice as much fuel per passenger mile as in Germany. With edented levels destroyed the livelihood and infrastructure of
a billion Chinese citizens getting on the road, how much more than 20 million Pakistanis. China had the worst floods
longer can our oil-use patterns be sustained? Countries in its history, stretching national rescue efforts and killing
are attacking this in many innovative ways. In the process, hundreds in mudslides. The United States had record heat
they’re building new industries, including high-speed storms, air-conditioning being one of the major contribu-
rail, electric cars, super-efficient clean diesel hybrids, and tions to increased blackouts.
completely new ideas such as the Chinese “people mover” Are these signs of human-induced climate change
concept that will straddle freeways with cars driving un- through energy use? As a pattern, they’re consistent with the
derneath. Some ideas will go the way of the steam-powered climate scientist’s predictions, though any single event can’t
airship. Some will be the multi-billion-dollar corporations be linked definitively to energy use. If the patterns continue,
of the future. this will accelerate the imperative to fuel and energy ef-
Electricity supply in the United States has grown vulner- ficiency, even faster innovation, and disaster mitigation.
able. The number of blackouts is increasing. In the least The headlines tell us we’re in a perfect storm around
reliable regions, they total more than 200 minutes a year, energy. Whether we are or we aren’t, management that fails
and in the most reliable regions they last more than 90 to consider this possibility might very well end up on the
minutes annually. These exclude those caused by hurricanes wrong side of history. Assessing both the opportunities and
or ice storms. The imperative to slow or reverse demand is risks is no longer optional and clearly warrants CEO and
triggering all kinds of innovation – from smart grids to new board-level accountability.
approaches for building efficiency and management, distrib-
uted cogeneration, and renewable generation. Peter garforth is principal of garforth International LLc, Toledo,
My hotel in Copenhagen, Denmark, had triple-glazed ohio. he can be reached at peter@garforthint.com.
The Yaskawa V1000-4X is specially coated to protect against harmful elements penetrating
its enclosure. So, it is ready to provide dependable performance in tough washdown and dust-
tight environments common in food and beverage, processing, packaging, metal machining,
woodworking, pumping, refrigeration, and printing.
Get the fool-proof protection and performance you need in your drives. Call Yaskawa today.
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