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ensures
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PlantStruxure architecture provides you with a global view of the entire facility,
closing the gap between the field and enterprise and delivering real-time information
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With PlantStruxure architecture, you can finally meet your automation needs and
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input #3 at plantengineering.hotims.com
June 2011
D EPARTMENTS
7 Online
9 Forum
21 Best Practices
61 Product Mart
62 Internet Connection
63 Advertiser Contacts
64 Comment
13 Product Exclusive
PLANT ENGINEERING (ISSN 0032-082X,
Vol. 65, No. 5, GST #123397457) is published 10x per year, monthly except in
January and July, by CFE Media, LLC, 1111
W. 22nd Street, Suite #250, Oak Brook,
IL 60523. Jim Langhenry, Group Publisher /
Co-Founder; Steve Rourke CEO/COO/Co-Founder.
PLANT ENGINEERING copyright 2011 by CFE
Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC
used under license. Periodicals postage paid at
Oak Brook, IL 60523 and additional mailing offices.
Circulation records are maintained at CFE Media,
LLC, 1111 W. 22nd Street, Suite #250, Oak Brook,
IL 60523. Telephone: 630/571-4070. E-mail:
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send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak
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foreign. Please address all subscription mail to
PLANT ENGINEERING, 1111 W. 22nd Street, Suite
#250, Oak Brook, IL 60523. Printed in the USA.
CFE Media, LLC does not assume and hereby
disclaims any liability to any person for any loss or
damage caused by errors or omissions in the material contained herein, regardless of whether such
errors result from negligence, accident or any other
cause whatsoever.
Cover Story
29 What is your relay telling you?
Troubleshoot your motors by understanding your relays.
system upgrades
34 How not to install a high-efficiency motor
,WWDNHVPRUHWKDQMXVWWKHPRWRUWRGHOLYHUDQHIFLHQWRXWFRPH
Best Practices
June 2011 3
10HST2817
#1 IN TOUGH APPS
WORLD-CLASS SERVICE
PURPOSE-BUILT
RETURN ON INVESTMENT
PROVEN HERITAGE
input #4 at plantengineering.hotims.com
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Maintenance Solutions
PlantEngineering.com
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Ph 630-571-4070, Fax 630-214-4504
37 Treating corrosion as
a process variable
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9 Forum
Entries open for Leaders Under 40, Top Plant
Process variability pays big dividends
CSIA members find value in certification, audits
Product Exclusive: Battery-free wireless push button
Delivering a culture of safety for 1,000 days
PLANT ENGINEERING
June 2011 5
input #5 at plantengineering.hotims.com
ONLINE
www.PlantEngineering.com
Video tutorials
22%
14%
11%
4%
1%
June 2011 7
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2010 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
input #6 at plantengineering.hotims.com
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sales@flexicon.com
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FORUM
Who are manufacturings
Leaders Under 40?
Nominate someone today
Plant Engineering to honor outstanding young
manufacturing professionals in September issue.
The most significant issue facing
manufacturing is the lack of an emerging skilled workforce to help U.S. manufacturing reach its potential in the global
manufacturing economy. To call attention
to this issue, Plant Engineering will again
honor the outstanding young manufacturing personnel as part of a special issue
in September.
Entries are now being accepted at www.
PlantEngineering.com for the 2011 Leaders Under 40 recognition. To be eligible,
the nominee must be a working professional in manufacturing under the age of
40. Nominees will be evaluated based on
their background, recommendations from
their supervisors, and the completion of
June 2011 9
FORUM
Process availability pays big dividends
Does a making an investment in process improvement to increase system
integrity during an era of reduced operat-
Courtesy: Pepperl+Fuchs
an asset that will continue to provide savings to your facility over the lifecycle of
the plant. In process plants all over the
work are striving now more than ever to
reduce operational expenditures while
increasing productivity and efficiency.
Process engineers place a tremendous
amount of emphasis on system integrity
requirements. Why? Because its a variable that can be controlled when the right
equipment is in place.
The time value of money is also being
affected by the recession. Most investment institutions are paying half of 1%
for savings accounts, and maybe 3% for
the long term of a certificate of deposit.
Consider the cost associated with an
unplanned shutdown: The oil and gas
and petrochemical industry estimates
an unplanned process shutdown runs
on average of more than $100,000 per
day. What is the return on investments to
avoid an unplanned shutdown?
The decision to invest in process integrity typically follows a few logical steps:
Pricing comparison of components
available
Weighing the price difference
against benefits
Past performance
Estimated return on additional
investment.
Today modern industrial process
facilities rely tremendously on the bulk
power supplies that provide power not
only the control system architecture but
also to bus powered control and mea-
input #7 at plantengineering.hotims.com
10 June 2011
PLANT ENGINEERING
June 2011 11
input #8 at plantengineering.hotims.com
FORUM
CSIA members find value in
certification, audits
Organization charts new goals at CSIA Executive Conference.
By Bob Vavra, CFE Media
input #9 at plantengineering.hotims.com
12 June 2011
PLANT ENGINEERING
Better
K
Safer
K
More Productive
K
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"
#$
GANTRY
CRANES
CLEVELAND
TRAMRAIL
800.821.0086 www.gorbel.com
FORUM
CSIA seeks greater connection
with end user community
By Bob Vavra, CFE Media
Hazardous Duty
Enclosure Protection
800-441-7475 Vortec.com
14 June 2011
PLANT ENGINEERING
Rental Solutions
9 Power Generation
9 Heating and Cooling Sol
utions
9 100% Oil-free Comp
ressed Air
9 Dehumidification
9 Process Eng ineering
9 Cooling Towers
FORUM
OSHA asking for views on
health and safety
OSHA will conduct a wide-ranging survey of employer
CFE: What is OSHAs timeframe for reporting the results?
health and safety practices beginning this month. The
survey will be sent to about 19,000 health and safety
OSHA has not yet announced a deadline for the first reportprofessionals and culminates a nine-month process to ing of results. The survey itself will conclude in August.
get the survey and its funding approved.
CFE: What are the expected outcomes? How does OSHA
The Baseline Survey of Safety and Health Practices
will be sent to private sector employers of all sizes and intend to use the results to improve workplace health and
across all industries under OSHAs jurisdiction. Questions safety?
include whether respondents already have a safety
OSHA believes the survey will be useful in providing
management system, whether they perform annual
a better idea to everyone in the occupational safety
N
inspections, who manages safety at their establishand health community concerning how occupational
ments and what kinds of hazards they encounter
safety and health is managed and what hazards are
EPTH: perceived
at their facilities.
by employers across industries and sizes
Participants either can complete the online survey
of firms. OSHA will use the data to more accurately
or get a paper copy sent to them. The research group
estimate the costs and paperwork burdens of regulaconducting the survey will have results returned to OSHA tion and to better design and direct outreach and guidance
by August 2011, one year after the intent to conduct the efforts.
survey was first announced.
CFE: Have there been past surveys that would help
CFE Media asked OSHA officials about the study and
benchmark
this new data?
what the goals of this new outreach will be:
OSHA collected similar data in a 1993 survey in order
to develop a baseline of safety and health practices. About
Chemical
Food
Pharmaceutical
Plastics
Powders
Construction
Laboratory
Textiles
Metals
Ceramics
3,500 establishments were surveyed. OSHA will consider
this date to assess historical change. However, the 2011
survey was designed to collect data for what OSHAs needs
to know today and tomorrow rather than as an attempt to
estimate historical progress. OSHA may use similar surveys
in the future to assess regulatory and outreach efforts.
How could those people who want to let their views be
known on occupational health and safety do that if they
dont get the survey mailed to them?
Vibratory products from Cleveland Vibrator integrate with material
The survey is designed as a mechanism for collecting
handling operations to enable the reliable ow of bulk solids in demanding
facts about industries and firms in statistically valid wayit
applications. Items include:
Portable Vibrators for small bins, hoppers and more
is not intended for the collection of data on stakeholder
8 &1/0(!".!-1!*5
views or opinions. The participants were selected at random
8),0+.%.1/$%+*! 2!./%+*/3%0$ +.9,%/0+* %)!0!./%6!/
from a database of millions of establishments.
800$!/%(5* %*0!.$*#!(53%0$/(!!2!05,!.'!0/3!( ! %*
various locations
Rotary Electric Vibrators for screeners, conveyors and more
8.#!/0+'+"
)+0+./%*(1 %*#* ,+(!2!./%+*/
8 &1/0(!"+.!+10,10/".+)
0+
(/
Air Piston (Pneumatic) Vibrators for bins, hoppers and more
81,,+.0,%0%!/".+)
(/'#0+
0+*/
8!0((%%),0(%*!"!01.!/(%#$03!%#$0+*!,%!!)+ !(/3%0$0+1#$
10%(!$+1/%*#/* +0%*#+,0%+*/"+./,!%(%6! ,1.,+/!/
!00$!-1(%05/!.2%!* .!(%%(%055+1!4,!0".+)5!./+"
!*#%*!!.%*#* )*1"01.%*#!4,!.%!*!+*001/0+ 5
CFE: How could those people who want to let their views
be known on occupational health and safety do that if they
dont get the survey mailed to them?
OSHA: The survey is designed as a mechanism for
collecting facts about industries and firms in statistically valid wayit is not intended for the collection of
data on stakeholder views or opinions. The participants
were selected at random from a database of millions
of establishments.
Air Piston Vibrators Turbine Vibrators Rotary Electric Vibrators Ball Vibrators Electromagnetic Vibrators Vibratory Tables
Vibratory Feeders Vibratory Screeners Ultrasonic Screeners Vibratory Conveyors Tailored On Demand
16 June 2011
PLANT ENGINEERING
Competition
t t t t t
Competition
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ePower
t t t t t
t t t t t
t t t t t
A Nilsk-Advance Brand
2011 Nilsk-Advance
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PLANT ENGINEERING
June 2011 17
FORUM
18 June 2011
PLANT ENGINEERING
ANSI OR ASME.
MINE.
Hi, Im Michelle and I have been working with our customers across the United States for the
last 10 years. Products that optimize quality in your air supply are not just accessories we
offer; they are a way of life for us at Atlas Copco. Thats why we produce such a wide variety
of dryers, aftercoolers, filters and oil-mist eliminators just to name a few.
We all perform best when working within our optimum environment, right? And, manufacturing
environments are no different. Moisture in your air supply is something that should be avoided
at all costs. Water is a by-product of compressing air. But there are ways to ensure this
moisture doesnt get downstream and cause equipment malfunction. And more importantly,
moisture can lead to contamination of your end products, leading to costly product failures
and potentially harming your hard-earned reputation.
Our mission is to continue to bring sustainable productivity through safer, cleaner, more
energy-efficient, and cost-effective compressed air technology. Simply log onto
www.atlascopco.us/michelleusa or call 866-688-9611 to learn more about us, our products,
and how we have earned and will continue to earn our reputation.
BEST
PRACTICES
Propane-fueled forklifts
deliver savings, performance
June 2011 21
BEST
PRACTICES
22 June 2011
Backlit display
because blackouts kept
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Remote display
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Your reach
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Fluke 233 Remote
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PRACTICES
Courtesy: The Donaldson Company
BEST
into the airstream. It uses about 0.005
grain per cubic foot of air. This is 100
to 4,000 times less dust concentration
than in a typical industrial dust collector
airstream.
Another critical factor to consider is
that media face velocity differs greatly
between general ventilation and industrial
dust collection. A typical dust collector
will have a media face velocity in the
range of 0.5 to 12 feet per minute. By
contrast, ASHRAE 52.2 tests airflow
velocities in the 118 to 748 feet per minute range. That means the magnitudes
are 10 to 1,500 times higher in a MERV
test than in a dust collector. Since media
velocity can affect efficiency, the applicability of the MERV test for an industrial dust collection application should
be questioned.
24 June 2011
PLANT ENGINEERING
Pressure drop
Another issue is that ASHRAE 52.2s
notation of pressure drop does not
acknowledge the broader performance
To learn more about our complete compressed air services visit us online at:
www.ingersollrandproducts.com
input #17 at plantengineering.hotims.com
BEST
PRACTICES
Whats next?
Given all the reasons the MERV rating system is inappropriate for industrial
dust collectors, where does that leave
us? If there were a new standard, it
should consider many of the main performance characteristics that an end user
is concerned aboutprimarily those
discussed in this article. Other considerations end users have for choosing an
industrial dust collector may also need
to be considered. Size, cabinet integrity,
noise, and the ability of the filter system
to recover from an upset condition are
other characteristics that end users typically want to know about.
26 June 2011
PLANT ENGINEERING
Leaders in the industrial dust collection industry, ASHRAE, and ISO are currently working together to address this
issue. ASHRAEs technical committee
5.4 has recently completed a research
project (RP1284) to determine the best
way to develop a test specification for
Joe Beauvais of Cox Engineering monitors the climate-controlled Mobile Penguin Display Cart his firm created for the New England Aquarium using
a portable MovinCool PC7.
800-264-9573 | www.movincool.com
2011 DENSO Sales California, Inc. MovinCool, SpotCool and Office Pro are registered trademarks of DENSO Corporation. QR Code is a registered trademark of DENSO Wave Incorporated.
NOBODY
WILL SECOND GUESS
Torit PowerCore
is the new standard
in dust collection.
Learn more:
Donaldson.com/ToritPowerCore
800.365.1331
2011 Donaldson Company, Inc.
COVERSTORY
Thermal overload
When a relay displays this message
about high motor temperature and shuts off
the motor, look for changes that may have
increased the load, such as a torn conveyor
belt, stuck raw material, or failed bearing.
Thermal overloads detected by digital relays
are not really a result of high temperature.
The cause is the motor current exceeding the
normal motor current and service factor settings, which is then tracked by the thermal
model programmed into the relay.
This model estimates the motor temperature based on the current. Some sophisticated
relays use input from temperature sensors on
the windings, but often only to bump up the
thermal model if the calculated temperature is
less than what is being measured by the sensor.
Too-frequent starts are another cause of
overtemperature, and relays having dynamic
thermal-overload capability will protect the
motor. A motor built to NEMA standards is
designed to provide two starts from cold without damage. To relate this to a thermal model,
the motor uses approximately 50% of its available thermal capacity (I2t) with one start.
Therefore, if the motor is interrupted during a
start, it will soon be in danger of damage and the
relay should trip. Thermal capacity is based
on motor specifications entered into the relay by
the user and can be customized for fan-cooled
PLANT ENGINEERING
June 2011 29
COVERSTORY
motors that do not require the full 50% of the
thermal capacity to complete a start.
The advantages of the dynamic thermal
model are that it is more accurate than winding
temperature sensors alone, it is not confined
to discrete spots in motor windings, and it
reacts faster to sudden changes. Also, because
it tracks the motor temperature so accurately, it
can keep the operator from restarting the motor
when it is still too hot. In contrast, electrome-
Table 1: Troubleshooting
Alarm
Possible cause
Recommended action
Let motor cool down to safe level before restarting; check relay for time-to-reset to plan
restart time. After restarting, ensure motor is operating at or below rated current, reducing
the load if necessary. If this is a multiple-motor application (i.e., conveyor belt), ensure
motors are balanced and working together properly. (See Littelfuse Startco white paper:
Motor Selection for Belt-Conveyor Drives.) In relay data log, check thermal capacity
required to start motor and ensure relay is set to allow reset as soon as it is safe.
Overcurrent
Immediately de-energize the motor and look for evidence of short-circuit damage in the
cabling and motor. Test insulation and check for blown fuses prior to re-energizing.
Current
unbalance
Check motor terminals and other locations for bad connections, inspect and/or test motor
windings for faults, check supply power.
Phase loss,
current
Inspect fuses on the feeder and/or motor for the phase in question. Check cable for opencircuit. Check connection to motor terminals. Safely check to see if voltage is present on
the phase.
Safely check to see if voltage is present in the main feeder or supply panel for the phase in
question. Check upstream cabling and fuses for open-circuit.
Inspect the connections to the motor terminals. Confirm the phase sequence, and correct
wiring problem.
Phase-to-ground short.
Inspect cabling, terminal box connections, and motor windings for damage or evidence of
short to ground. Test insulation resistance for confirmation of fault.
Thermal
overload
Phase loss,
voltage
Phase reversal
Earth leakage
Overvoltage
Undervoltage
Check power quality monitors. Start motors one at a time. Review system design to
ensure transformer is sized properly and cable lengths are appropriate.
Overtemperature
Ensure motor cooling fins and any other cooling measures/channels are operating as
expected. Clean the motor of excess dust and debris. Check current and unbalance readings on relay. Fix room ventilation if required. Inspect the bearings; lube if necessary or
replace if damaged.
Jam
Load has increased beyond the motors capability or a mechanical jam has occurred.
Check the motor for mechanical jams, failed bearings, or other problem that would prevent the rotor from turning. Inspect the load to determine if it has changed.
Undercurrent
Check the motor for mechanical jams, failed bearings, or other problem that would prevent the rotor from turning. Inspect the load to determine if it has changed.
Motor
differential
Check if the motor protection relay is measuring a small ground-fault current. If so, check
the motor windings for a fault near the edge of the winding. Inspect the rest of the windings for any phase-to-phase faults.
Check motor relay frequency setting, and ensure the correct supply is connected to the
motor. To ensure metering and protection measurements are not distorted when using a
variable frequency drive (VFD), enable Frequency Tracking on the motor protection relay.
This allows the calculated values to be adjusted based on the output frequency of the VFD.
Check the motor relay for related events (overload or jam trips). Check the motor for
mechanical jams, failed bearings, or other problems that would prevent the rotor from
turning. Inspect the load to determine if it has changed.
Underfrequency/
overfrequency
Failure to
accelerate
Underspeed/
overspeed
30 June 2011
PLANT ENGINEERING
To resolve stubborn
system problems,
we dig deep.
ProActivity
REsolve
Efciency
Monitoring
Design
Repair
Learning
Inventory
COVERSTORY
in a resistance grounded system, newer digital
motor-protection relays have the option to accept
inputs from sensitive current transformers.
Another method of detecting a phase-toground fault is using an insulation monitoring
relay. Traditional ground-fault relays detect
a fault by measuring the current with a transformer, and some damage to the motor may
occur before the relay trips.
An insulation monitoring relay prevents the
motor from starting if it detects a ground fault,
avoiding that potential damage. However, on a
grounded system, the insulation monitor cannot be used while the motor is energized.
Courtesy: Littelfuse Startco
Jam
32 June 2011
PLANT ENGINEERING
Summary
Plant managers can save troubleshooting
time and better protect motors using digital
relays. As relay prices fall and plants remain
understaffed, managers have a decent argument for upgrading older thermal-style
overloads with modern devices.
PLANT ENGINEERING
June 2011 33
COVERSTORY
34 June 2011
PLANT ENGINEERING
stationary part of the motor, knows as the stator. As the alternating current flows into the
motors stator coils, a rotating magnetic field
is established.
The motors rotor consists of a shaft along
with three separate coils wound into the
motors rotor. The rotating magnetic field
developed by the alternating current flowing
through the stator creates an electric current in
the windings on the rotor. The current generated in the rotor windings creates a magnetic
field that follows the stator magnetic field,
resulting in a torque on the rotor that causes
it to rotate.
Since the current generated in the rotor
windings is created by the movement of the
stators magnetic field, there must be a difference between the rotational speed of the
stator, known as the synchronous speed, and
the rotational speed of the rotor. The difference
in rotational speed between the stator and rotor
is called slip, and the amount of slip depends
on the load on the motor. For example, a twopole motor connected to a 60 Hz power source
has a rotating magnetic field in the stator of
3,600 rpm. If the slip created by a load is 50
rpm, then the motor will rotate at 3,550 rpm.
Now how does this relate to EISA motors?
Higher efficiencies in electric motors are
accomplished by using more copper in the
windings of the rotor. The larger winding
in the rotor provides lower resistance to the
induced current in the rotor. This creates a
stronger magnetic field in the rotor, resulting
in less slip and a higher motor rotational speed.
For example, by reviewing the U.S. Dept. of
Energy MotorMaster Program, the average 75
hp standard efficiency motor has a rotational
speed of around 3,535 rpm with a full load
motor efficiency of 94%. A NEMA Premium
efficiency motor of the same size, meeting
the EISA requirements, has a rotational speed
of around 3,555 rpm with a full load motor
efficiency of 96%. Notice the NEMA Premium
efficiency motor has a 2% increase in full load
efficiency and rotates 20 rpm faster than the
older standard efficiency motor.
By replacing a standard efficiency motor
with an EISA motor of higher rotational speed
and higher efficiency on a centrifugal pumping
application, you do not see a 2% reduction in
pump operating cost that you would expect
with a more efficient motor.
The reason for this lack of energy savings
can be found in the system. This is what is
happening in the system:
The EISA motor has less slip than the
Conclusion
When you replace an electrical induction
motor with a higher efficiency motor, the
motor improvements made to increase the
motor efficiency typically will reduce the
slip in the motor, resulting in a higher motor
rotational speed. If the motor is driving a centrifugal pump, the increase in rotational speed
results in an increase in the pumps head. This
additional head developed by the pump at its
new higher speed requires additional power
from the motor. The only way to take advantage of the higher efficiency motor is to adjust
It is important to
evaluate the total
system and not focus
on a single item in
the system.
EISA 2007
General purpose motors (subtype I) manufactured after December 19,
2010, with a power rating of at least 1 horsepower but not greater than
200 horsepower, shall have a nominal full-load efficiency that is not less
than as defined in NEMA MG 1 (2006) Table 1212 (aka NEMA Premium efficiency levels).
General purpose motor (subtype II), with a power rating of at least
1 horsepower but no more than 200 horsepower, manufactured after
December 19, 2010, shall have a nominal full-load efficiency that is not
less than as defined in NEMA MG1 (2006) Table 1211. Subtype II
motors now include:
U-Frame motor
design C motor
close-coupled pump motor
footless motor
vertical solid-shaft normal thrust motor
- tested in a horizontal configuration
8-pole motor (900 rpm)
poly-phase motor with voltage of no more than 600 volts
(other than 230 or 460 volts).
Fire pump motors manufactured after December 19, 2010, shall have
nominal full-load efficiency no less than as defined in NEMA MG-1 (2006)
Table 12-11.
June 2011 35
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POWER TOOLS
MAINTENANCESOLUTIONS
INSIGHT
Treat corrosion as
a process variable
By Michael McElroy and Kristen Barbour
Pepperl+Fuchs, Inc.
Power monitoring
The PM3 power monitoring
and metering module monitors
the power of branch and main
circuit applications. The PM3
is a device that measures current and voltage, calculates
power and energy usage, and
provides breaker status. A ULlisted, add-on communications
device, the PM3 module monitors electrical system parameters and can be mounted to
the load side of all three-pole
Series G LG and all three-pole
Series C KD breaker frames.
Eaton Corporation
www.eaton.com
Input #200 at plantengineering.hotims.com
Actuator
Figure 1: The actual conditions present in a process can be drastically different than what
is shown in offline monitoring. This graphic illustrates why online variables are extremely
important to any process. Courtesy: Pepperl+Fuchs, Inc.
PLANT ENGINEERING
June 2011 37
MAINTENANCESOLUTIONS
Traditional corrosion
monitoring techniques
There are four traditional corrosion
monitoring techniques: mass loss measurements, ultrasonic examinations,
resistance measurements, and polarization resistance determination. Mass
loss, commonly referred to as coupons,
are sacrificial pieces of metal that are
inserted into the process. The coupons
are made of the same properties as the
pipe or vessel being monitored. Coupons are weighed prior to insertion and
38 June 2011
PLANT ENGINEERING
A deeper look
All of the techniques listed above
have been successfully used in real-life
applications. The question would then
become Why change what works?
Consider the scenario in Figure 1.
These data points were collected
on a periodic basis, potentially by
using mass loss coupons, ER probe,
or pigging. Typically what happens is
a decision is made on how much corrosion inhibitor is to be used based
on the current data point with respect
to the prior point. The goal is to find
the acceptable balance of the rate of
corrosion versus the amount of inhibitor used. Not only is this process time
consuming, potentially taking a year,
but what is happening in between the
data points?
Figure 2 could represent the reality of the process. The cause for these
swings could be virtually anything
INSIGHT
Encoder
The A3M encoder with
integrated Profibus output is
a rugged, absolute multiturn
encoder with 31-bit output
(14-bit singleturn and 17-bit
multiturn), where the absolute
positions are native to the
encoder, without an internal
power source. Applications
include packaging, cranes
and outdoor warehousing systems, robotics, motion control
applications, and general
manufacturing.
SICK, Inc.
www.sickusa.com
Input #202 at plantengineering.hotims.com
Walk-behind
scrubbers
The SC750
and SC800 walkbehind scrubbers
pair a low-maintenance design with
flexible performance to handle
everyday cleaning, tough
soils, and spills in industrial
environments. These mid-size
scrubbers are optimized for
productivity, with high-capacity solution/recovery tanks21
gal on SC750 models and 25
gal on SC800 models. These
scrubbers allow for 84 minutes of continuous scrubbing
to yield a fast ROI for owners.
The scrubbers also come
equipped with Advances SoftTouch paddle system, which
provides users with maximum
control while preventing finger pinching that may occur
between the machine and an
obstruction.
Advance
www.advance-us.com
Input #203 at plantengineering.hotims.com
PLANT ENGINEERING
June 2011 39
MAINTENANCESOLUTIONS
An example of
Conclusion
Corrosion moniperformance-based
toring is slowly
control application
undergoing a
was in a producchange from manual
tion unit of a large
methods to online
chemical complex
methods. This could
in the southeastern
be compared to the
U.S. Previously, the
changes that started
cooling system was
about 25 years ago
controlled with a
in pH monitoring,
traditional pH/conwhich went from
ductivity controller
manual to online
with separate chemwith the developical feed pumps
ment of new elecfeeding each of the
trode technology
treatment materiand new microproals. There was no
cessor-based transonline corrosion
mitters.
monitoring. Only
Traditional corcorrosion coupons
rosion monitoring
were used.
techniques provide
Due to the proproven ways to
duction process,
determine corrosion
there was signifirates. Determining
cant variability in
corrosion rates by
the heat load to be
only using these
rejected by the cooltechniques does
ing water system.
not allow processes
That variability
Online corrosion monitoring enables users
to be controlled as
affected the temto determine the effectiveness of their cora process variable.
perature of the cirrosion inhibitors, and to detect and correct
This information
culating water, the
corrosion issues through upkeep and preis static and canrate at which heat
ventative maintenance, before they become
not be correlated to
was rejected in the
a costly problem.
events occurring in
cooling tower, and
the process.
the corrosivity of the
General corrosion or localized corrowater. That in turn varied the demand for
each of the treatment materials. The control sion can be monitored online and in real
system was inadequate for the application. time without additional hardware and
In fact, the system suffered from excessive software. The addition of HART protocol
enhances the functionality of this standard
corrosion and fouling.
It was then replaced with a performance- 4-20 mA signal. As a result of this innobased system that utilized the monitoring vation, corrosion can be monitored and
of five variables: pH, conductivity, ORP, controlled like other process variables,
corrosion (LPR), and fouling. In addition, such as temperature, pressure, and flow.
the treatment program was changed by the For the first time, corrosion monitoring
new supplier. Following an initial cleanup can be achieved and can begin to conand repassivation period, corrosion rates set- trol the huge annual cost associated with
tled down well within the range of industry corrosion. Corrosion monitoring has now
entered the world of process control
norms.
General corrosion dropped to below 2 and automation.
MPY on carbon steel and localized corroMichael McElroy is the business develsion (pitting) decreased dramatically. Fouling
also decreased to well below heat exchanger opment manager for CorrTran. Kristen
design allowances. The control system auto- Barbour is product marketing manager
matically adjusted the treatment chemistry for Pepperl+Fuchs, Inc., Twinsburg, Ohio.
www.pepperl-fuchs.us.
to swings in heat loads
40 June 2011
PLANT ENGINEERING
INSIGHT
Solenoid valves
NITRA pneumatic BVS
series modular solenoid
valves are body ported, threeport, two-position poppet
valves available in normally
open or closed configurations.
Models are available with
removable flying leads or 8
mm micro DIN connectors,
are DIN rail mountable when
used with BVM series manifolds, and feature flow coefficients from 0.02 to 0.05. Units
are available with 12 or 24
Vdc, or 120 Vac solenoid coils
and a pushbutton manual
operator.
AutomationDirect
www.automationdirect.com
Input #204 at plantengineering.hotims.com
Retaining rings
The Ventus spiral retaining
rings are designed to withstand the rigors and functional
stresses of the wind power
industry. A machined lughole
makes field installation and
removal far easier than traditionally designed spiral rings.
Rotor Clip Company, Inc.
www.rotorclip.com
Input #205 at plantengineering.hotims.com
Flowmeters
The TVA Target Variable
Area flowmeter is designed
for use on saturated steam.
It available in DN50, DN80,
and DN100 sizes. With a wide
flow range turndown of 50:1,
it is ideal for applications with
large variations in flow rates.
Spirax Sarco, Inc.
www.spiraxsarco.com/us
Input #206 at plantengineering.hotims.com
CFE: When your customers have had success at changing, whats been the common element in that change?
Crump: It varies. Many customers make adjustments to
processes and systems in their plant to reduce energy usage.
Heating processes (like those taking place during curing or
autoclave or industrial furnaces operations) immediately
CFE: In what industries have you seen the greatest interest come to mind. If they can be made more efficient, theres a
in energy monitoring? Whats driving that interest?
huge potential for cost savings.
Crump: Several industries, including commercial buildFor example, there was a refrigeration system (at an old
ings, cold storage (such as for food and beverage), and meat packing plant) that had an automatic defrosting system
government. But interest is growing in all industries as
for its freezer coils. The way it was supposed to work was
facility owners and managers realize that energy use can
that periodically, hot refrigerant would blow through the
IN
be managed just the same as their other costs.
coils so ice buildup on the surface would melt and
DEPTH: cold
As for whats driving the interest in energy monitoring,
evaporate. The hot gas for this procedure came through
its the same thing that drives manufacturing plants and
piping, and old automatic valves at each coil regulated
other large facilities to deploy any technologyan oppor- the defrosting process.
tunity to improve efficiency and increase profitably, in this
This plant implemented Opto 22 energy monitoring hardcase, through cost cutting. As it stands now, energy represents ware and found that the cooling coils in the freezers werent
one of the single largest opportunities for businesses (in all working properly and the hot gas was continuously leaking
industries) to reduce costs.
to the coils in the freezers. So too much heat was being
introduced, and to counteract this, the refrigeration system
CFE: What should manufacturers reasonably expect in was running a lot more (using much of its capacity just to
terms of savings and ROI?
support itself) and costing literally thousands of dollars
Crump: Its a tricky question. Youre asking, How much per month. So in this case, changes involving maintenance
can I save if I purchase an energy monitoring system and issues produced ROI for the monitoring system.
start measuring? And the answer is, Youll never know
And sometimes change comes in the form of simple, comyour potential for energy savings until you actually begin mon sense business practices. There was a manufacturer in
monitoring and measuring. Ive seen it range from hun- the automation industry that began energy monitoring and
dreds, all the way up to hundreds of thousands of dollars.
quickly discovered that a lighting system in one area of its
One statistic I can share is that the recent study Efficiency factory areas was continuing to operate two hours past the
and Innovation in U.S. Manufacturing Energy Use (pre- time when all the employees that worked in that area had
pared in part by the U.S. Department of Energy) noted that punched out and gone home for the day. In this case, its
many manufacturing plants can easily reduce their energy easy to see the simple change that was made to cut costs.
consumption by 10% to 20%.
So my point is, there may be no common element in terms
of what the change is. The common element is that gaining
CFE: Its one thing to measure energy usage; its another access to energy data almost always reveals things that
to change manufacturing processes to reduce energy usage. were previously unknown. This, in turn, leads to a variety
Crump: True. But is it prudent to change any manufactur- of changes, both in corporate philosophy and policies, as
ing process without first understanding whats going on? well as to manufacturing processes and other business
The first step has to be information gathering. You need the operations.
data first because (as we are fond of saying around here)
CFE: Are these devices really just a means to an end of
you can only intelligently control what you can ably meahaving
a sound energy strategy?
sure. Once plant personnel, energy managers, and facility
operators begin aggregating the real-time data they need to
Crump: Yes. Energy monitoring devices are the means to
correlate their energy use with specific business operations, an end. They are what enable personnel in plants and other
its then that they can begin effectively identifying specific facilities to acquire the data they need to make competent
problems, designing energy management initiatives that decisions. Thats the keydecision making. The fresher and
reduce costs, and exercising control over their processes, more comprehensive the energy data youre gathering is,
machinery, systems, and equipment.
the better decisions youll be able to make.
PLANT ENGINEERING
June 2011 41
Subscribe today at
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MECHANICALSOLUTIONS
Proper lubrication
plays a role in
energy efficiency
Choosing the
correct lubricant
can improve
energy efficiency
and reduce costs.
By Hermann Siebert
Klber Lubrication
June 2011 43
MECHANICALSOLUTIONS
44 June 2011
PLANT ENGINEERING
INSIGHT
Piping products
Calculate true
savings when reducing
air system pressure
By Mark Krisa, Ingersoll Rand
PLANT ENGINEERING
June 2011 45
MECHANICALSOLUTIONS
Heat of compression dryers use the heat contained in the compressed air stream to
regenerate the dryer desiccant beds, utilizing what is often wasted energy. The dryer
requires no supplemental power to regenerate its dry beds.
Courtesy: Ingersoll Rand
46 June 2011
PLANT ENGINEERING
INSIGHT
106
P4 Pressure at far
end of Finished Goods
building 0.65 psid
Palletizing robots
102
PSI
New high-performance
palletizing robots, a powerful
programming software and
three palletizing grippers,
complement existing products to address the market
demands for easy, fast, and
efficient robotic palletizing
options. The compact IRB
460 is capable of up to 2,190
cycles per hour. The IRB 760
is designed for high-output
and full-layer palletizing with a
payload capacity of 450 kilograms and a reach of 3.2 m.
98
94
Artificial Demand is the increase in demand assosciated with operating at a pressure higher than required. The two slopes
tangent to the pressure curve are an example of the level of artifical demand observed at the West Hershey facility.
90
11:36:00
AM
11:37:00
AM
11:38:00
AM
11:39:00
AM
11:40:00
AM
11:41:00
AM
11:42:00
AM
11:43:00
AM
11:44:00
AM
11:45:00
AM
11:46:00
AM
11:47:00
AM
11:48:00
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11:49:00
AM
ABB
www.abb.com
Input #209 at plantengineering.hotims.com
Mini-drag machines
The R-SF line of mini-drag
machines provides repeatable processes suited for a
range of components from
propellers and
golf clubs to
artificial joints
and dental
implants. The
machines
provide 40
times the
grinding power
of rotary vibrators yet eliminate impingement between
delicate components. They
include hydraulically powered
carousel assemblies allowing vertical movement for
versatile processing and are
equipped with up to four rotating work stations with independent drives.
Rosler
www.rosler.us
Input #209 at plantengineering.hotims.com
PLANT ENGINEERING
June 2011 47
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630-571-4070
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ELECTRICALSOLUTIONS
INSIGHT
Energy meter
The OptoEMU
Sensor energy
monitoring appliance connects to
utility meters, plant
equipment, and
facility systems to
gather real-time
facility and equipment energy usage data.
The sensors communication
capabilities now include support for Modbus/TCP, a standard, Ethernet-based industrial communications protocol.
This enhancement allows the
Sensor to effectively perform
in any Ethernet-based Modbus architecture-without need
for translators, software development, or other middleware.
rc flashes happen when an electric current passes through the air between
two conducting metalsan arc fault.
Almost instantly, an arc can superheat
the air around it to a temperature up to 35,000
Fabout four times the suns surface temperature. This extreme heat ionizes all nearby
materials, including copper, insulation, and
metal enclosures, creating explosive gaseous
plasma as those materials expand to many
thousands of times their solid volumes.
Under these conditions, the copper changes
to plasma, with a volume about 67,000 times
that of its solid form. Or, stated differently,
each cubic inch of copper converts to almost
39 cu ft of copper vapor.
Arc faults are different from bolted faults on
the load terminals of standard, metal-enclosed
switchgear. Switchgear equipment is designed
Opto 22
www.opto22.com
Input #210 at plantengineering.hotims.com
CNC control
The iAdaptS adaptive
control solution into the CNC
system for increased machine
tool productivity. The iAdaptS
improves material removal
and minimizes cycle time by
automatically optimizing the
cutting feedrate based on the
actual spindle load. Additionally, integration of the iAdaptS
product within the CNC
now eliminates the need for
mounting space, simplifying
installation while improving
the capabilities of the original
iAdapt product.
FANUC FA America
www.fanucfa.com
Input #211 at plantengineering.hotims.com
PLANT ENGINEERING
June 2011 49
ELECTRICALSOLUTIONS
Evolving safety standards
Arc faults have numerous causes that
fall into two categories: One comprises
intrusive environmental factors such
as cabinet moisture, insulation
failures, overvoltage, corroded
terminals, dust, dirt, and animals, including rodents and
snakes; the second category is
human error such as improper
work procedures, misplaced
tools, loose connections, and
inadvertent contact with energized components.
Inadequate maintenance
practices are often contributors to both categories. As the
number of arc flash incidents
suggests, they are a paramount
electrical safety concern, for
which a range of industry
safety standards have evolved.
In North America, the main
safety standard for working
with electrical equipment is
NFPA 70E: Standard for Electrical Safety in the Workplace.
It addresses electrical safety
requirements for workplaces to safeguard employees during such activities
as the installation, operation, maintenance, and decommissioning of electric
conductors, electric equipment, signaling and communications conductors
and equipment, and raceways in public
and private facilities.
Under NPFA 70E, employees whose
work may potentially expose them to
arc flashes are required to wear arcrated protective clothing. This clothing
is made of fabric that provides thermal
insulation and is also self-extinguishing to minimize burns, as prescribed
by ASTM F 1506-08, Standard Performance Specification for Wearing
Apparel for Use by Electrical Workers
to Momentary Electric Arc and Related
Thermal Hazards.
OSHA has said that clothing conforming to ASTM 1506 complies with
the OSHA 29 CFR 1910.269 (Electrical Power Generation, Transmission
and Distribution) directive regarding
the wearing of protective clothing that
will not contribute to severity of burns.
Personal protective equipment (PPE)
is a primary part of an arc flash injury
50 June 2011
PLANT ENGINEERING
and sides of the equipment (Type 1 arc resis- mounting rack height (2 m) that do not cause
tant protection only applies to the front of ignition of the horizontally mounted indicathe cabinet.)
tors are ignored.
UL Listed, performance tested, and
Accessibility Type 1: That arcing does
classified as arc resistant per ANSI/IEEE not cause holes in the freely accessible front
C37.20.7
of the enclosure.
Reinforced enclosure to withstand pres Accessibility Type 2: That arcing does
sure from internal arcing faults
not cause holes in the freely accessible front,
Internal venting system with pressure sides, and rear of the enclosure.
dams and pressure vents to channel the flow
Criterion 4: That no indicators ignite as a
of arc fault gases and vent these gases out result of escaping gases. Indicators ignited
the top of the gear and away from personnel as a result of the burning of paint or labels,
Reinforced front
glowing particles, and
with gaskets plus doors Individuals should work
so on, are excluded from
with extra hinges and on MCCs or other electrithis assessment. Highstronger latching systems
speed movies or video
One-piece circuit cal equipment only after all
may be used to evaluate
b r e a k e r d o o r s w i t h power to the equipment has
the cause of indicator
insert panels for control been turned off.
ignition.
devices such as fuses,
Holes in horizontally
indicating lights, and circuit breaker control mounted indicators caused by particles that
switches when required
do not ignite the indicator are ignored. Sur Reinforced bolted rear covers
face discoloration or charring that does not
Insulated bus bar system
result in glowing or flaming of the indicator
Shutters in circuit breaker compartments cloth is allowed. Any indicator cloth with
Sill channel with integrated arc plenum surface discoloration or charring shall be
No configuration restrictions
replaced with new cloth before additional
Suitable for solidly grounded or resis- testing.
tance-grounded configurations.
Criterion 5: That all the grounding connections remain effective.
There are five criteria listed in ANSI/IEEE
Conclusion
Std C37.20.7-2007 as follows:
Arc flashes present a serious safety risk.
Criterion 1: That properly latched or
secured doors, covers, and so on, do not While the best protection is prevention by
open. Bowing or other distortion is permit- enforcing strict safety rules, mandating
ted provided no part comes as far as the proper maintenance, and supporting that
position of the indicator mounting racks or with regular safety training, advances in
walls (whichever is closest) on any assessed technology have enabled electrical equipment
manufacturers such as Siemens to design and
surface.
Criterion 2: No fragmentation of the enclo- engineer much more arc-resistant safety feasure occurs within the time specified for the tures into their products and systems such as
test. The ejection of small parts, up to a indi- switchgear and MCCs.
While standards continue to evolve, they
vidual mass of 60 g, from any assessed external surface above a height of two meters and inherently follow these kinds of innovations.
from any external surface not under assess- Nonetheless, the proper performance testing
ment, is accepted. No restriction is placed on of new and innovative arc-resistant safety
features cannot await standards. At the same
the number of parts allowed to eject.
Criterion 3: Assessment of burn-through: time, it is important that the application testIt is assumed that any openings in the switch- ing of new safety features be validated by a
gear caused by direct contact with an arc will qualified third-party like the UL to ensure that
also ignite an indicator mounted outside of the safety features work as intended and
the switchgear at that same point. Since it to prevent tragic accidents.
is not possible to cover the entire area under
Pablo Medina is product manager, Walt
assessment with indicators, any opening in
the area under assessment that results from Karstens is product engineer for tiastar MCC,
direct contact with an arc is considered cause and Keith Flowers is program manager for
for failure. Openings above the indicator WL breakers, all part of Siemens Industry Inc.
INSIGHT
Control modules
The CS series of process
control modules provides PID
loop control without using
a PLC. The modules allow
control of temperature, flow,
and pressure; the single- and
dual-loop modules also provide ramp-and-soak controls.
Up to 16 of these modules
can be attached to any CS
series master to provide up to
32 independent control loops.
Choosing an advanced CS
master also gives you features such as a virtual HMI,
data logging, and web server.
Omega Engineering, Inc.
www.omega.com
Input #212 at plantengineering.hotims.com
CMMS analyzer
Bigfoot CMMS manages,
analyzes, and reports on all
aspects of system maintenance, ensuring maximum
efficiency, safety, and longevity. Features include scheduling unlimited preventive maintenance tasks and procedures
with automatic reminders and
analyzing historical maintenance issues to help predict
future events. It has been
upgraded to a Web-based
version, compatible with any
Internet browser.
Smartware Group
www.bigfootcmms.com
Input #213 at plantengineering.hotims.com
PLANT ENGINEERING
June 2011 51
AUTOMATIONSOLUTIONS
June 2011 53
AUTOMATIONSOLUTIONS
The integrated MES allowed for both internal and external integration, allowing the pulp and paper manufacturer to better communicate with its main contractors.
54 June 2011
PLANT ENGINEERING
anteeing an accelerating pace of technology, to properly understand it and make wellthe reality is rapid changes to the technology informed decisions.
landscape. A well-designed MES strategy can
Start with disparate data. This is data from
help protect existing investments, better future many different places typically available in
proof, manage lifecycle costs, and ensure col- a plant: process equipment, field devices,
laborative access to data.
quality systems, control systems, data histoIt is important to select MES vendors with rians, inventory systems, business and ERP
strong relationships to major technology com- systems, asset management, and data from
panies so IT trends can be anticipated and outside the plant like energy costs, economic
leveraged. A benefit of new technologies is trends, geopolitical situations, and weather
improved capabilities of capturing details, conditions.
measurements, and other data points that
One goal for the business is to gather the
may not have been measurable before, and data together in meaningful context to prothe opportunity to turn the data into meaning- vide insight and information. From there,
ful representations.
users can make sound conclusions upon
The question then becomes: What do I which concrete actions can be taken. This
do with all of this data and how can I make is what delivers business results and creates
sense of it all? More data might seem like a value out of the data.
helpful way to improve processes, but when
While moving from data to value is not a
systems and personnel are inundated with simple task, options are available. An orgadata, operations can become stretched and nization can invest in copying data into data
personnel can become overworked. Employees warehouses, federating data (i.e., keeping
with too much data to digest can find their the data with the system that owns it), or a
efficiency dropping. The disruption in the combination of techniques.
business can fuel this inefficiency, and facIt takes experience and domain expertors such as an aging
tise to determine
workforce or loss of Employees with too much data
the best methods
domain expertise adds
for implementing a
to the problem.
comprehensive data
to digest can find their efficiency
Whats more, data
visualization and
is not always readily dropping. The disruption in the
acquisition stratavailable or inherently
and there is a
business can fuel this inefficiency, egy,
easy to access. Points
horizontal flow that
can be isolated, lost, and factors such as an aging work- must be accounted
inaccessible, incorfor when creating
rect, late, or under- force or loss of domain expertise
value out of data. For
productive. Combine
instance, information
these and the result adds to the problem.
must be extracted and
is a set of data that is
orchestrated from the
unreliable and makes a system that can con- initial sets of data, processed and concluded
sistently and comprehensively make sense of upon. Actions can be taken on the resultmeasured data essential, not a luxury.
ing conclusions based on the information,
which then translate into technical or ecoMaking sense of the data
nomic results.
That leads us to a second challenge that
A final challenge of inordinate amounts of
plants face with the stacks of information data is visualization and visibility, and getat their disposal: not only what to do with ting the right information to the right people
it all but how to make sense of it and cre- in way that doesnt tie up their bandwidth.
ate subsequent value. Data, of course, is Acquiring the right information goes a long
meaningless without context, and making way toward the overarching problem that
sense of vast amounts of data necessitates plants face of keeping costs under control.
the proper tools and technologies to analyze For instance, being able to understand what
the data. Plant personnel often complain of products to make at a given time based on
being data rich and information poor or changing energy costs helps keep producdrowning in data but starving for informa- tion expenses in check and sheds light on the
tion. Extracting information from that data most cost-effective methods of production.
must be proactively gleaned and analyzed Creating visibility out of information allows
INSIGHT
Remote SCADA
The FAST/TOOLS webbased SCADA system
enables remote engineering
and maintenance, and allows
the deployment and real-time
management of process applications via secure web-based
services, thereby increasing
overall equipment efficiency
and return on assets.
Yokogawa Corp. of America
www.yokogawa.com/us
Input #214 at plantengineering.hotims.com
Drive system
The VLT FlexConcept is a
unified and optimized drive
solution engineered for the
food and beverage, and packaging industries. It consists of
a highly efficient helical bevel
gear driven by a compact permanent magnet motor, and is
combined with efficient inverter drives. It is available for
centralized or decentralized
application in dry, wet and/or
aseptic-critical areas. It can
reduce the costs associated
with stocking, storing, and
maintaining spare parts. The
system provides up to 90%
energy-efficient operation.
Danfoss
www.danfossdrives.com
Input #215 at plantengineering.hotims.com
PLANT ENGINEERING
June 2011 55
AUTOMATIONSOLUTIONS
operations to be more agile and mitigates the
instances of lost opportunities.
56 June 2011
PLANT ENGINEERING
INSIGHT
Inverters
The 8400 Inverter series
features L-Force automation
technology for tailored motion
control solutions that deliver
stable and high dynamic performance in material handling
and logistics applications.
Identical installation, parameterization, and user operation
across the 8400 series enable
ease of installation and
operation of a single production line or full factory automation. The 8400 inverters
optimize automated industrial
processes, such as winding,
extruding, and filling.
Lenze
www.lenze.com
Input #216 at plantengineering.hotims.com
Relief valves
The PRV model
proportional relief
valves provide
proportional venting of overpressures for piping
systems up to 1 in.
in size. End connections include
NPT female, BSPP
female, and BSPP
male in sizes 1/4, 1/2, 3/4,
and 1 in. The valves open
gradually and reseat in proportion to the increase and
decrease in pressure over the
set opening pressure. The
valve design is unaffected by
system back pressure up to
50% of the valves set pressure. PRV proportional relief
valves feature 316L stainless
steel construction of the body,
trim, and spring housing.
Swagelok
www.swagelok.com.
Input #217 at plantengineering.hotims.com
Courtesy: Honeywell
Optimizing
your
HMI
June 2011 57
AUTOMATIONSOLUTIONS
cell or control a process isnt the same
data the line manager needs to do his job,
McPherson explained. Or even if it is
the same, it likely needs to be presented
in a different fashion, he said. Starting from scratch for each application or
function wastes time and productivity.
If the foundation for the system is laid
in the control layer or SCADA layer,
and then built upon, a lot can be accomplished quickly and easily without a lot
of reconfiguration and reintegration.
Plants need to leverage what they have
through better use of reporting and data
management tools, said McPherson,
adding that information-centric tools
that access the right data can enable
better decisions.
It doesnt require a new infrastructure to do that, he went on. Its a matter of connecting to the real-time data in
the controllers and the HMIs, of getting
historical data from the historians, maintenance management systems, or production schedulers. And only since the
recent economic downturn have plants
started actively looking for ways to do
these analyses.
Scott Miller, Rockwell Automation business manager, visualization
software, supports McPhersons view.
Investing in and developing a control
strategy that is reusable and flexible and
will pay dividends as the plants information needs evolve, he said. All plant
systems and operations are dynamic.
What a plant needs today is not what it
needed three months ago or will need
three months from now to operate opti-
Rugged electronic interfaces come in a variety of sizes, operator input methods, memory options, and configurations and are software programmable to allow information to be presented and viewed as efficiently as possible in all kinds of situations.
58 June 2011
PLANT ENGINEERING
Going green,
saving energy
facility at the point of changing out HMIs or OIs might
want to consider going
green by choosing energy-saving
components when possible. One
option is Siemens ProfiEnergy energy management system, which helps
facilities incorporate dynamic energy
management into their HMIs.
The technology, explained Alan
Cone, product manager at Siemens
Industry, lets operators easily shut
down loads that are not required
during nonproductive periods. Existing hardware and software can be
integrated simply using ProfiEnergy
power modules such as the Simatic
ET 200S PM-E RO power module
(shown) or function blocks in the
controller.
You can add function blocks at
the PLC to control equipment, said
Cone. If the production unit takes a
half-hour lunch break, an instruction
code can be programmed into the
system to shut down unused equipment for that time so it is not using
energy unnecessarily. It has the
capability within the HMI to be programmed so that it ramps back up 5
minutes before personnel return. It is
extremely flexible.
PLANT ENGINEERING
June 2011 59
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June 2011 61
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shell.com/lubes
The inventor and original patent holder of the Bearing Isolator, a compound labyrinth oil seal. Bearing Isolators are
proven to more than double the bearing life and overall
reliability of pumps, motors, gearboxes turbines, and other
rotating equipment.
Inpro/Seal
Shell Tellus Premium Oils are designed to prolong component life, prolong oil life, and promote better system
cleanliness.
Shell
apc.com
American Power Conversion makes UPS, rack, cable and
colling products for industrial; environments. Users enjoy
higher availability of sensitive electronic, network, communications and industrial equipment of all sizes
American Power Conversion Corp.
atlascopco.us
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment,
industrial tools, assembly systems, services and rentals.
The Atlas Copco Group includes such brands as Atlas
Copco, RS Equipment Rental and Chicago Pneumatic.
Atlas Copco
automationdirect.com
AutomationDirect offers 6,500+ industrial automation
products through their free catalog and online store. The
catalog features PLCs, operator interfaces, sensors,
switches, motors, drives, and more.
AutomationDirect
donaldson.com
Compressed air purifications solutions, compressed air
filters, dryers and process water chillers.
Donaldson Company, Inc.
dupont.com
Why invest in the proven quality, innovation and research
that go into DuPont KEVLAR, NOMEX, TYVEK and
TYHEM? Because life is worth protecting.
DuPont
us.fcurtis.com
Over 500 distributors world-wide. Products ranging from
1/3 HP to 300 HP reciprocating compressors, oil injected
screw compressors, water injected screw compressors.
FS-Curtis Air Compressors
gexpro.com
Gexpro, formerly GE Supply, now part of Rexel, is a fullline, international distributor of electrical parts, power generation products, voice and data equipment, fasteners and
security equipment.
Gexpro
kamandirect.com
Kaman distributes a wide variety of Power Transmission
and MRO products and components to industry, including: bearings, motors, drives, motion control, material handling, fluid power as well as related maintenance supplies
and accessories.
Kaman Industrial Technologies Corp.
lubriplate.com
Lubriplate, Division of Fiske Brothers Refining Company
manufactures more than 200 high quality lubricants for all
types of industry. High performance synthetic lubricants
and NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.
mobilindustrial.com
Mobil Industrial Lubricants offers premium quality synthetic and mineral grade oils and greases to the industrial
market. Additionally, we support our products with a full
slate of expertise services.
Mobil Industrial Lubricants
stanleyproto.com
Pros who work the demanding jobs demand Stanley
Proto. Our industrial hand tools are built to be precise,
durable and make work easier.
Stanley Proto
sullair.com
omega.com
Omega offers more than 100,000 state-of-the-art products for measurement and control of temperature, humidity, pressure, strain, force, flow, level, pH, conductivity,
data acquisition, electric heating, and custom-engineered
products.
Omega Engineering, Inc.
ustsubaki.com
phoenixcontact.com
woodhead.com
myresumelady.com
The Rsum Lady exists to assist Industrial Maintenance
and Reliability professionals to get their expertise,
talents and potential into a format that is appealing and
purposeful.
The Rsum Lady
gouldspumps.com
schneider-electric.com
Schneider Electric and its brands deliver innovative solutions for electrical distribution, machine and process control and automation, power and lighting management and
engineering services.
Schneider Electric
hitachi-america.us/airtech
seweurodrive.com
Hitachis innovation of Oil-Free Air Compression technology is now available in North America and includes
Oil-Free Rotary Screw, Oil-Free Scroll & Oil-Free Vortex
blower designs.
Hitachi Ameria, Ltd.
PLANT ENGINEERING
spiraxsarco.com/us
Spirax Sarco applies world class knowledge, service and
products to the efficient pressure and flow control of steam
an other industrial fluids.
Spirax-Sarco, Inc.
62 June 2011
sea.siemens.com
Siemens Energy & Automation, Inc. (SE&A) manufactures
and markets one of the broadest ranges of electrical and
electronic products, systems and services to industrial and
construction market customers.
Siemens Industry, Inc.
webb-stiles.com
Webb-Stiles Co. is a manufacturer of engineered conveyors and conveying systems. Complete engineering, manufacturing, controls and installation capabilities. Plants
located in Cleveland, OH. and Gadsden, AL.
Webb-Stiles Co.
Place next to your computer or go online to plantengineering.com for hot links to these companies.
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June
CONTACTS
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company directly, please let them know you read about them in Plant Engineering.
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Aggreko LLC
866-215-7966
15
12
www.aggreko.com
ITT
315-568-7659
31
20
www.ittpps.com
20
15
www.atlascopco.com
ITW Vortec
800-411-7475
14
11
www.Vortec.com
MOVINCOOL
800-264-9573
27
18
www.movincool.com
www.omega.com
www.parkerstore.com
www.RIDGID.com/tc40
AutomationDirect
800-633-0405
C-2
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www.automationdirect.com
Baldor
800-828-4920
C-4
23
48
16
www.baldor.com
www.cfemedia.com
13
www.clevelandvibrator.com
RIDGID
800-769-7743
36
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RIG-A-LITE
713-943-0340
10
www.rigalite.com
www.Sereply.com
Stanley Proto
860-225-5111
19
14
42
www.PlantEngineering.com
www.flexicon.com
Flexicon Corp
888-353-9426
Fluke Corp.
888-443-5853
23
16
GoatThroat Pumps
886-639-4628
12
Gorbel Inc
585-924-6733
13
10
Hyster
252-931-5679
Ideal
800-435-0705
11
Ingersoll-Rand
704-655-4000
25
17
www.ingersollrandproducts.com
www.fluke.com
www.GoatThroat.com
www.gorbel.com
www.hysterusa.com
9
www.idealheatseeker.com
Schneider Electric
847-397-2600
www.stanleyproto.com
60
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Virtual Manufacturing/
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Yaskawa Electric America, Inc
800-927-5292
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PLANT ENGINEERING
June 2011 63
COMMENT
Telling a true story about manufacturing
T
Bob Vavra
Content Manager
64 June 2011
PLANT ENGINEERING
SUMMER 2011
DISASTERS
PAGE 2
COMMISSIONING
MISSION CRITICAL
STANDBY POWER
SYSTEMS
PAGE 14
PV SYSTEM
INSTALLATION
AND MAINTENANCE
PAGE 20
PV REFLECTIVITY
SAFE FOR AIRPORTS
PAGE 25
Supplement to Periodicals Publication
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PV system installation
and maintenance
Engineers should know
the basics of photovoltaic
system selection,
specication, and testing in
order to provide clients with
the safest product.
PV reectivity safe for
airports
Consulting rm analyzes
reectivity issues of
proposed PV array.
New Products
8 ee
14 ee
20 ee
25 ee
27 ee
Cover image
courtesy of NOAA
www.csemag.com/purepower
FEATURES
cover story
ee
ff
Developing a strategy to ensure the availability of fuel for your generator system is a key element
of disaster planning.
Courtesy: NOAA
www.csemag.com/purepower
FUEL QUANTITY
Identifying the amount of fuel needed
to power your critical equipment during a reasonably predictable natural
catastrophe is the rst step. A rough
consumption calculation for diesel
generators is 7 gallons of fuel per
hour for each 100 kW of generator
rating; i.e., a 200 kW generator would
consume 14 gallons of diesel fuel per
hour. A typical goal for on-site storage is three days worth of fuel. A site
requiring a 2 MW generator installation should have approximately
10,000 gallons of available stored fuel
to provide a three-day supply. To
ensure the necessary amount is on
hand in the event of a disaster, you
should factor engine exercising into
your equation, and understand that
relling a partially depleted storage
tank may not be practical until sufcient fuel is depleted to justify a fuel
delivery. Purchase a storage system
that will accommodate your disasterthreshold fuel plus the amount you
will consume for engine testing as
part of regular maintenance.
When determining the amount of
fuel to store on-site, you must consider
the criticality of your location and the
nature of your operation at the site. If
your facility provides critical functions
required for your business that are not
duplicated in another location, a larger
ee
PURE POWER // SUMMER 2011
REFUELING AVAILABILITY
STORAGE AND
COMPARTMENTATION
ff
spill detection methods. Local and state codes may have additional requirements for outdoor storage solutions.
For outdoor generators, engineers often specify that the
fuel be stored in belly tanks under the generator. This can be
a convenient, space-saving option, though there is a practical
limit to the amount of fuel a belly tank can hold. If a tank
is too large, stairs, platforms, or ladders may be required
to gain access to service the generator. If a belly tank is too
small, your operating time will be limited if it is your only
method of storage. Discuss these considerations with your
operations and maintenance staff.
In-building storage may be the best solution for smaller
amounts of stored fuel (Figure 3). It also offers better protection from temperature uctuations, weather events, and
tampering. An example from Hurricane Katrina illustrates
this point. As noted in FAILURE OF INITIATIVE: Final
Report of the Select Bipartisan Committee to Investigate
the Preparation for and Response to Hurricane Katrina,
Many of the parish EOCs [Emergency Operations Centers]
and public safety facilities were wiped out or ooded. Jefferson Parishwas in better shape to respond because it
had protected its EOC. Jefferson Parish Emergency Manager
Dr. Walter Maestri explained the EOC was in a hardened
facilityan old incinerator with cement wallswith the
command center, living quarters, and emergency generator
www.csemag.com/purepower
FUEL QUALITY
If you store fuel on-site, consider installing a fuel ltering or
polishing system that will remove moisture and help prevent
www.mtu-online.com
kW - 600 kW
load acceptance
// Low lifecycle costs
// One-step
MTU Onsite Energy Corporation / 100 Power Drive / Mankato, Minnesota 56001 / USA / Phone +1 800 325 5450 / Fax +1 507 625 2968
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Figure 4: If you store diesel fuel on-site, standard fuel ltering should
be supplemented with a fuel polishing system that will help prevent
fuel degradation and remove moisture.
Courtesy: GHT Limited
PLANNING AHEAD
It is impossible to predict every disaster scenario that could
impact your fuel supply. But with early, careful planning, you
can determine the amount, availability, storage, protection,
and quality of a fuel supply that can support your operations
through many of the most common natural catastrophes that
occur in your region. A balanced strategy that considers costs
and risks will ensure the success of your plan.
%
T H E
E N E R C O N
C A P A B I L I T Y
POWER PACKAGES
FOR ANTARCTICA
SPECIFICATIONS:
HARSH ENVIRONMENTS.
TOUGH SPECIFICATIONS.
MUST BE RELIABLE,
RUGGED & SERVICEABLE.
<
<
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CUSTOM SWITCHGEAR < CONTROL SYSTEMS < PACKAGING <POWER MODULES < ENCLOSURES < CO-GENERATION
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selecting/sizing transformers
TRANSFORMERS FOR
While commercial building designs change,
their electrical loads remain fundamentally
unchanged. Properly sizing and selecting
transformers ensures that these loads are
accommodated.
CONSTRUCTION TYPES
There are different construction types for transformers used
in commercial buildings. Our understanding of their general
characteristics will allow the designer and end user to make
the proper selection for the electrical system application.
Following are some of the transformer types available in the
industry along with a few of their characteristics:
Ventilated dry-type transformers are ventilated by air,
use larger space for clearance, and use different insulating
materials to augment the dielectric strength of the air. They
contain an enclosure surrounding the windings for their mechanical protection and the safety of personnel. This type is
the most common to be used in the building indoor electrical
system distribution. See Table 1 for typical dry-type transformer ratings, dimensions, and weights.
Sealed dry-type transformers are similar to dry type in
most of their characteristics. The difference is they contain an
enclosed tank with nitrogen or other dielectric gas to protect
www.csemag.com/purepower
selecting/sizing transformers
COMMERCIAL BUILDINGS
Figure 1: Miami International Airport South Terminal expansion was designed with about 50 transformers that feed a diverse group of loads for
the 208 Y/120 V 3-phase, 4-wire electrical distribution system that serves the 936,880-sq-ft building. Types of loads include lighting, signage,
telecommunication, and security systems. Courtesy: Borrelli + Partners; photographer: Steven Brooke
APPLICATION TYPES
There are different ways in which transformers are installed
and used as part of a commercial building electrical system.
These application types include:
Indoor distribution transformers are used with panelboards and are separately mounted to supply the specic
electrical load requirements in a system-specic application
within the system distribution. Several transformer types
rated higher than 600 V for oil insulated type, higher than
35,000 V for dry type, and other transformers rated higher
than 600 V are required to be located in vault rooms, which
By Ralph Baeza, PE, LEED AP, TLC Engineering for Architecture, Miami
ee
ff
selecting/sizing transformers
10
SIZING
208Y/277V 3PH,
4W PANELBOARD
Primary
overcurrent
protection
device
Secondary
overcurrent
protection
device
75 kVA
transformer
Primary
feeder
Secondary
feeder not
exceeding
10 ft.
Floor
PRIMARY
SECONDARY
FLA = kVA (V x 3)
FLA = 75 kVA (480 V x 3) = 90 A
FLA = kVA (V x 3)
FLA = 75 kVA (208 V x 3) = 208 A
Transformer secondary
overcurrent protection device
Notes:
1. The above approach might vary per NEC Article 450 and others for specic
project requirements.
2. If the transformer is located within a room that can reach 104 F, the
conductor in the primary must be rated by a factor of 0.88 since NEC Table
310-16 is based on 86 F.
Figure 2: Good design and installation require the proper transformer
feeder and overcurrent protection device sizes to be based on the
National Electrical Code. The drawing shows an example of a 75 kVA
step-down transformer with associated primary, secondary, feeder,
and overcurrent protection device sizes. Courtesy: TLC Engineering for
Architecture
In addition, the size of the commercial facility will determine the appropriate approach for designing the electrical
distribution system for the specic application. In this electrical system design, the transformer can be used as part of a
substation, primary unit substation, secondary unit substation, or network conguration.
www.csemag.com/purepower
SELECTING
Transformer selection starts with the kVA rating required to
supply the loads connected in the electrical system. Another
consideration for indoor distribution transformers is the type
of load: linear or nonlinear. Linear loads include resistive
heating and induction motors; nonlinear loads are produced
by electronic equipment that contributes to the distortion of
the electrical power signals by generating harmonics. The
harmonics resulting from nonsinusoidal currents generate
additional losses and heating of the transformer coils, which
reduce the transformer life expectancy.
Indoor transformers for nonlinear loads can be selected
with a K rating, which allows the transformer to withstand
nonlinear conditions in the electrical system. K-rated
transformers do not mitigate or eliminate harmonics.
However, they do protect the transformer itself from damage
caused by harmonics. For harmonic mitigation, K-rated
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12
selecting/sizing transformers
TEMPERATURE
RISE
(DEGREES C)
APPROXIMATE
DIMENSIONS
(INCHES)
APPROXIMATE
WEIGHT
(POUNDS)
80
29 x 17 x 17
225
37.5
80
32 x 22 x 20
369
75
80
36 x 22 x 24
631
100
80
46 x 35 x 30
768
15
115
27 x 15 x 15
175
37.5
115
31 x 20 x 18
375
75
115
34 x 22 x 22
575
100
115
36 x 22 x 24
700
80
25 x 22 x 17
310
30
80
28 x 25 x 18.5
425
45
80
32 x 27 x 21
635
75
80
38 x 29 x 23
850
112.5
80
42 x 33 x 26
1,035
15
115
22 x 15 x 16
295
30
115
25 x 22 x 17
385
45
115
28 x 25 x 18.5
565
75
115
33 x 27 x 21
750
112.5
115
38 x 29 x 23
960
Note: The above information is for reference only since actual equipment dimensions
and weight will vary with equipment manufacturer.
PRACTICAL APPLICATIONS
In the past two years, two large projects in Miami Dade
County have been built: the Florida International University
football stadium and Miami International Airport South
Terminal. Both projects included dry-type 480 V, 3-phase
to 208 Y/120V V step-down transformers (in NEMA 2
enclosures), ranging from 15 kVA to 112.5 kVA in the
electrical system distribution design.
The 18,688-seat FIU football stadium was designed
with about 12 transformers as part of the electrical system
distribution in order to supply general-use receptacles,
small motors, and other loads in the stadium building
structure and the attached eld house building. The MIA
South Terminal expansion was designed with about 50
transformers with similar intent as the stadiums but a
more diverse group of loads for the 208 Y/120 V 3-phase,
4-wire system, which also included lighting loads, signage,
telecommunication, security systems, and other loads part
of this building project (Figure 1).
INSTALLATION
The installation of power transformers and transformer
vaults must comply with the requirements of National
Electrical Code (NFPA 70) article 450 and specic local
authority having jurisdiction requirements. Some principles
to consider for transformer installation include locating them
in isolated rooms with proper ventilation, clearances, and
accessibility. Otherwise, they can be installed on open walls
or steel columns or above suspended ceilings.
In addition, there are other specic requirements based
on the transformer type, such as weatherproof enclosures
for dry-type transformers installed outdoors or a transformer
vault room for oil-insulated transformers installed indoors.
In addition, a good design and installation require the
proper transformer feeder and overcurrent protection device
size based on NEC articles 240, 250, 450, and applicable
sections of Article 310 (Figure 2).
LOOKING AHEAD
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14
Commissioning
ensures that all
components of the
mission critical power
system function
according to design
specications and the
owners expectations.
By Wayne F. Beierman,
BSEE, Sebesta Blomberg Inc.,
Roseville, Minn.
www.csemag.com/purepower
Standby
power systems
LOAD TESTING
Generator load testing is the enjoyable part of the commissioning process (Figure 1). First, the generator/engine is
started to ensure that the engine starts and runs, air intake
and exhaust louvers open, and that there are no engine uid
or exhaust system leaks.
We perform two engine generator load tests: one for 2
hours and one for 4 to 8 hours. The 2-hour load test is the
shakedown cruise. This test is started with a cold engine,
which means that it has not been run for 24 hours prior to
the start of the test. The engine is started by removing the
normal power source to the ATS. The generator is immediately loaded to 100% capacity using external load banks.
These load banks are connected to the ATS in smaller systems, or the generator for large systems with multiple ATSs.
The engine/generator is timed from the start signal initiation to when the generator picks up the full load. For life
safety systems, the interval from initiation to the system
providing full load must be less than 10 seconds. Pertinent
engine and generator readings are taken at short intervals
during the engine test. The 2-hour test provides the opportunity to take the generator for a test drive to ensure that all
functions meet standards.
The 4- to 8-hour test is the long voyage. We start the
engine and load the generator in increments and observe all
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PURE POWER // SUMMER 2011
15
16
ff
ATS TESTING
Figure 2: Verifying the electrical grounding system integrity is part of
the initial safety inspection prior to testing. Courtesy: Hartseld-Jackson
Atlanta International Airport
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18
Properly functioning indicators let operations and maintenance personnel know that the ATS in this MCSP system
is operating correctly during both normal and emergency
situations.
The ATS operational transfer test becomes a systems integration test by incorporating the engine/generator into the
commissioning process. At this point, the applicable time delays have been programmed into the ATS and are conrmed
during this test. I prefer to initiate this test by interrupting
the normal power source. However, this test can also be initiated by using the ATS Test Switch. The ATS operation from
the loss of normal power to the generator picking up standby
power is timed with a stopwatch. In the Atlanta Airport
project, the Life Safety (S) ATSs switched to emergency in
less than 10 seconds. The Emergency (E) ATS switches were
programmed with a delay and transferred in less than 20
seconds. The Legally Required (R) ATSs transferred in about
30 seconds.
UPS TESTING
A UPS is often used in MCSP systems such as data centers
where computer power cannot be interrupted. UPS commissioning is usually performed in cooperation with the
UPS and battery systems manufacturers representatives. All
pre-alarm and alarm conditions and the specied communication to all applicable alarm panels and the BAS are tested.
All UPS switching operations are conrmed, including the
static switch, normal-to-battery operation, and emergency-tonormal operations. The nal UPS test is to remove all normal
and standby power, then load-test the UPS to 100% load
with a load bank terminated at the UPS output. This load
test is recorded and timed to conrm that the UPS meets the
owners requirements.
FINAL TESTING
The nal commissioning test is an integrated system or a
loss-of-power test. All MCSP components are tested during
the loss-of-power test. In the most comprehensive test, we
load the MCSP system to 100% using load banks. We initiate this test by having the local power company interrupt
normal power to the site. We test the generator start-up, ATS,
and UPS operations as a system. This is what would happen
during a normal power outage. We interrupt the engine/generator to ensure that the secondary backup equipment functions, i.e., the data center UPS systems. When all nuances
of the MCSP have been tested on generator power, normal
power is returned to the site.
With the resumption of normal power, the loss-of-power
test is still not completed. Now, we test to ensure that the
MCSP systems components transfer the load properly. We
ensure that the ATSs switched back, the UPSs maintained
power to the systems, the engine generators go into cool
down and shut off properly, and that the fuel day tanks are
at the proper level. In short, we ensure that the MCSP system
is prepared to pick up another real-world power outage.
If the equipment commissioning has been properly performed, the loss-of-power test is enjoyable. This test also
involves management, operations, and maintenance personnel. They get to experience the MCSP system functioning as
it is designed and specied. When executed correctly, the
loss-of-power test is a good training experience and a condence builder. It provides the reassurance in knowing how
the MCSP functions and what it can do. When that happens,
facility managers and facility engineers sleep better at night.
> Services
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Implementing Energ
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> Cooling
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2011 Schneider Electric. All Rights Reserved. Schneider Electric and Active Energy Management are trademarks owned by Schneider Electric Industries SAS or its affiliated companies.
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20
pv installation/maintenance
By Jack Smith, Contributing Editor
PV SYSTEM INSTALLATION
Engineers should know the basics of photovoltaic system selection, specication, and testing
in order to provide clients with the safest product.
ate on a Sunday afternoon, the Kern County Fire Department responded to a call it received about a commercial structure re at a store on Rosedale Highway in
Bakerseld, Calif. Crews found that a row of solar panels on the roof had caught re. Some of the panels were still
live when the crew arrived, so the re crew had to take extra
precautions until electrical power could be disconnected.
Fortunately, the crews quickly extinguished the re, which
didnt penetrate the roofs metal decking. Ofcials cleared the
store, which reopened about four hours after the call. The
lesson to be learned from this example is not that solar energy
is unsafe or dangerous; it is to raise safety awareness when
working with photovoltaic (PV) arrays and systems. While
reghters and rst responders need to know how to safely
disconnect electricity to ensure emergency personnels safety
and to allow egress, facility maintenance technicians need to
know how to keep the electricity owing safely and reliably.
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pv installation/maintenance
21
PV installation standards
and certication
In most cases, the applicable standard for photovoltaic (PV) systems
is the National Electrical Code (NEC). Article 690 of the NEC deals
specically with PV system installations, covering wiring methods,
overcurrent protection and disconnect provisions, grounding, and
other issues. Generally, PV system installations must be inspected
according to NEC requirements, and inspectors generally check that
listed equipment is used. Underwriters Laboratories (UL) is one of
a few organizations that provide safety listings for PV equipment.
The Institute of Electrical and Electronics Engineers (IEEE) has
published a number of standards, recommended practices, and
guidelines for PV systems and equipment, including IEEE 929, which
outlines the basic operational and safety requirements for gridconnected PV systems.
The North American Board of Certied Energy Practitioners (NABCEP) offers certications and certicate programs geared toward
renewable energy professionals throughout North America, including
a certication program for solar electric installers. The complete
listing of NABCEP-certied solar PV installers can be viewed on the
organizations website (www.nabcep.org).
AND MAINTENANCE
ee
ff
22
pv installation/maintenance
POTENTIAL PV PROBLEMS
PV array
Regulation and AC
conversion
Battery bank
Figure 1: A basic solar energy installation begins with PV panels collecting sunlight. The PV array supplies dc voltage to an inverter, which
converts the dc into ac.
Courtesy: U.S. Dept. of Energy, Energy Efciency & Renewable Energy (EERE)
Most PV systems that are installed by qualied and reputable professionals are installed safely and reliably. However,
having a PV electric power system installed by untrained
persons can lead to trouble. Some of the common problems
associated with the design, installation, and operation of PV
systems include:
N Extensive shading of the PV array
N Insecure structural attachment to rooftops
N Inadequate weather sealing for roof and other penetrations
N Unsafe wiring
N Unsafe battery installation or improper battery
maintenance or use
N Insufcient conductor ampacity and/or insulation type
N Using unlisted equipment
N Improperly applying listed or unlisted equipment
N Improper placement of overcurrent protection and
disconnect devices
N Improper system grounding
N Inadequate labeling on major system components and
disconnect devices
pv installation/maintenance
N Inadequate documentation on
system design and operating and
maintenance requirements.
23
TESTING AND
TROUBLESHOOTING
Any PV system design package must
include supporting documentation,
which shouldat a minimuminclude system specications, electrical
schematics, mechanical drawings,
parts lists, materials lists, and source
lists. Documentation should also
include installation and checkout procedures, user and operator training,
maintenance requirements, troubleshooting guides, and a list of the
specic tools and equipment required
to perform these tasks.
Maintenance requirements for PV
installations depend on the type of
system design and equipment used.
Some installations require very little
attention, perhaps just annual inspections. Othersespecially those with
batteriesmay require maintenance
intervals of four to six months, or
even component (usually battery) replacements over the systems lifetime.
Typical maintenance items that PV
installations may require include:
N Inspecting wiring connections and
terminations for looseness and
corrosion
N Inspecting wiring harnesses to
ensure they are neatly bundled
and protected
N Inspecting the PV array for
cleanliness, absence of damage,
and structural integrity
N Inspecting roof penetrations and
weather sealing
N Maintaining batteries, which
may include cleaning, adding
electrolyte, charge equalization,
and replacement.
Regardless of whether you are
installing or maintaining a PV system,
use the appropriate tools for the task.
Typically, you can test and maintain
the PV system with a high-quality
digital multimeter, a clamp meter, or
an oscilloscope.
Being aware of potential problems,
Smith is a technical writer and editor based in North Aurora, Ill. He is also a Pure
Power contributing editor.
! " #
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01
#
Input #408 at cse.hotims.com
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ee
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PURE POWER // SUMMER 2011
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W E B C A S T
Expert Guidance on Standby
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PURE POWER // SUMMER 2011
Battery cabinets
EnerSys has earned a special seismic certication
by the Ofce of Statewide Health Planning and Development (OSHPD) in California, for its DataSafe
16-V battery cabinets. The DataSafe 16-V battery
cabinets were certied in accordance with ASCE
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for the design of equipment and nonstructural components that help protect operations. The cabinets
were approved in the rst round of the OSHPD
testing process at the ISO/TEC 17025-accredited Environmental Testing Lab in Dallas. OSHPD
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structures to seismic shaking and ground motion.
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