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SPECIAL REPORT: Air quality from the top down 41
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Whats INside
6 Interactive 9 In Focus 21 In Practice 61 Product Mart 62 Internet Connection 63 Advertiser Contacts 64 In Conclusion
May 2013
Volume 67, No. 4
58 Innovations
PLANT ENGINEERING (ISSN 0032-082X, Vol. 67, No. 4, 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 2013 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 x2220. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@ cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/ yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 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
23
Find the fake!

Counterfeiting has a negative impact on not only companies bottom lines and reputations but also public safety. Counterfeit electrical products can overheat or cause short circuits, leading to fires, shocks, or explosions that can cost workers their lives and produce considerable property damage. It is important that facility managers understand the dire consequences of using unsafe counterfeit products and know how to avoid them.
Special Report
41 Indoor air quality

We normally dont give air a second thought. This month, we did. Weve collected five different perspectives on air quality. In each article, the goal is to make you think a little about the air you and your co-workers breathe within a plant each day, and how that air affects your operational success.
42 45 49 52 55 Manufacturing comfort: Air movement needed in supply chain facilities Pressurizing with dust collectors: Making the right decisions Active filter cleaning technologies extend filter life, improve efficiency Decoding efficiency for mechanical draft fans HVLS fans deliver energy savings from the top down
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9 In Focus
The 14 elements of OSHA inspections: How they affect maintenance processes Step-by-step on energy management software Equipment condition, not calendar, should drive maintenance
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Because all plants and facilities are unique in their own way, energy management opportunities are plant or facility dependent. This dependency makes the paying it forward approach extremely flexible. The flexibility begins with an initial current state analysis, which would identify future threats to profit ability and ways to reduce costs.
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A SCADA system should clearly show appropriate alarms indicating possible problems, but it shouldnt cry wolf for every routine change in plant operations. Plant personnel need to use this tool correctly by selecting and implementing systems that avoid alarm overload while making sure critical events are addressed in a timely fashion.
PLANT ENGINEERING
May 2013 5
MAY 2013
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Media library
Marshall on Maintenance: NEP and chemical safety

John L. Ross of the Marshall Institute discusses the Re nery National Emphasis Program (NEP) in this months Marshall on Maintenance blog. He notes, By all standards the program was successful. There were certainly still incidents in the re nery industry, but the nature and the resulting damage were greatly decreased. Gain more insight into safety and maintenance each month in Plant Engineerings exclusive blog series at www.plantengineering.com/blogs.
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Lubrication strategy and energy management
Plant Engineering content manager Bob Vavra discusses lubrication maintenance strategy and its impact on energy ef ciency with Geoffrey Polanek, industrial advisor for Mobil Industrial Lubricants. View this video and other informative and instructional videos at www.plantengineering.com/videos.
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6 May 2013
PLANT ENGINEERING
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IN FOCUS
The 14 elements of OSHA inspections: How they affect maintenance processes
By John Ross, Marshall Institute
their safety. Your employee participation program must be In the first part of our series written and all meetings well looking at OSHAs Process documented. of three parts Safety Management (PSM), Here is a question from the and specifically the National 100 static questions list that Emphasis Program (NEP), in the March was developed for the refinery NEP: issue of Plant Engineering, we learned Does the employers written employee the history and purpose of both PSM participation plan-of-action (see docuand NEP. ment request XLE.3.e) include informaHorrific and catastrophic incidents tion on how employees will be consulted were occurring around the world as a on the development of ALL PSM stanresult of unintended releases of highly dard elements? hazardous chemicals (HHCs). To stem As mentioned in part 1, the situation the nature and effect of these accidents, isnt that facilities dont have written prothe Department of Labor, through its cesses; in fact, many of the companies OSHA agency, initiated PSM in 1992 dealing with HHCs have these written and NEP for refineries in 2007. A few programs but just fail to execute them short years after that, riding on the suc- as written. Employee participation is a cess of the refinery NEP, OSHA initi- process that has to be thought out, and ated a CHEMNEP (Chemical National followed as written, to ensure that the Emphasis Program) to lay a level of workers have a clear and documented oversight on the other HHC facilities, path of communication for these imporin line with what was accomplished in tant PSM discussions. the petroleum industry. Maintenance has a significant impact To review from part 1, OSHAs NEP under this element because it has such a inspectors will review your programs significant impact on the success of the and processes around 14 major elements. PSM effort. Maintenance technicians are Here in part 2, we are going to discuss all involved in the complex task of testing 14 elements in detail and examine how and repairing the production equipment, maintenance is affected. and their well-being is on the line with every turn of the wrench. When any 1. Employee participation aspect of the system involving HHCs is The employee participation element is involved, maintenance must be involved perhaps the one with the shortest number in the discussion. This process of includof mandates, but with one of the larg- ing maintenance (and operators) must be est impacts. Right from CFR 1910.119, documented and followed, with an extenEmployers shall develop a written plan sively objective, evidence-laden path. of action regarding the implementation of the employee participation. The stated 2. Process safety information This element contains one of the most intent of this element is for employees, production, maintenance, and staff to highly concentrated, maintenance-spebe involved in all aspects of the PSM cific listings of all the elements. CFR program at your site, and to have repre- 1910.119 states our obligation as maintesentation in the development, discussion, nance leaders very clearly: the employer and eventual solution to issues around the shall complete a compilation of written process safety information before conprocess hazard analysis. Simply put, your employees need to ducting any process safety hazard analyknow whats going on that might affect sis required by the standard.
Second
Elements of NEP
The 14 major elements of OSHAs National Emphasis Program (NEP) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Employee participation Process safety information Process hazard analysis Operating procedures Training Contractors Pre-startup safety review Mechanical integrity Hot work permit Management of change Incident investigation Emergency planning and response 13. Compliance audits 14. Trade secrets
The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process. In this text, operators includes maintenance insomuch as maintenance works on and around the HHCs. The CFR text above indicates that your MSDS (material safety data sheets) information needs to be accessible and current, as do your P&IDs, component information listing, electrical classification, ventilation systems, and safe operating limits, and much, much more. This is a very intense element.
PLANT ENGINEERING
May 2013 9
IN fOCUS
It should be obvious what the impact on maintenance is in regard to the PSI element. Our maintenance technicians have to have access to and understand all the technical data around our production systems, including the component particulars and information on the hazards of the HHC involved.
5. Training
This element does specifically address the needs for those operating a process. To be sure, though, maintenance technicians need to be fully trained for all the functions they are performing, and that training needs to have been accomplished through a competent source and very well documented.
3. Process hazard analysis

This element is extremely technical in nature and includes a comprehensive what-if evaluation. The CFR reads, The process hazard analysis shall be appropriate to the complexity of the process and shall identify, evaluate,
6. Contractors
There are a lot of opportunities in this element to trip up an otherwise healthy and well-executed maintenance strategy. Contractors are perhaps unfairly known to do what they can get away with to get a job done. Under the auspices of PSM-NEP, there are some very unforgiving rules: The employer, when electing a contractor, shall obtain and evaluate information regarding the contract employers safety performance and programs. The employer shall inform contract employers of the known potential fire, explosion, or toxic release hazards related to the contractors work and the process.
Maintenance technicians are involved in the complex task of testing and repairing the production equipment, and their well-being is on the line with every turn of the wrench.
and control the hazards involved in the process. In this element engineers and maintenance leaders hone their Failure Mode and Effects Analysis (FMEA) skills, as well as exploring the consequence of failure. This process analysis will be conducted as a team and includes a review of the facility siting for possible hazards. After an initial PHA is conducted, the process hazard analysis is required to be updated and revalidated by a team no less than every five years.
7. Pre-startup safety review

This element and the element on management of change are closely tied together as the safe and effective management of this process lies squarely with plant maintenance and engineering. The standard requires that The employer shall perform a pre-startup safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information. The phrase change in the process safety information could literally mean a change in a single component. This is a very detailed requirement and one that cannot, and most certainly should not be taken lightly.
4. Operating procedures
At first blush it might not seem that there would be a maintenance impact under the heading of Operating Procedures, but this element has a few items of interest. Startups following a turnaround, and after an emergency shutdown is included in this element has a control measure to be taken if physical contact or airborne exposure occurs. If youve ever been at a plant during an emergency shutdown or a release, then you can attest to the fact that maintenance is heavily involved in addressing the situation.
8. Mechanical integrity
Along with the process hazard analysis, MI, or mechanical integrity inspections are required on a periodic time frame and must be well documented. Systems requiring this periodic inspection are: pressure vessels and storage tanks, piping systems, relief and vent systems and devices, pumps, controls, etc.
10 May 2013
plant engineering
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IN fOCUS
A very important concept comes into play in this element. Not only do the people doing the inspections have to be properly and officially trained in what to look for and how to conduct the inspections, but inspections and testing procedures need to follow recognized and generally accepted good engineering practices, The laypersons question would be, who told your guy to do it like that? This is a seriously simple question, but one that has to be answered in a very deliberate way.
9. Hot work permit

This is such a simple element, but it is so easy to violate if maintenance supervision and technicians become complacent. Aside from the inclusion of work completed by contractors that requires hot work permits, there is a great chance that the plant assigned resources could get this wrong. The employer The phrase change in shall issue a hot work the process safety inforpermit for hot work operations conducted mation could literally on or near a covered mean a change in a single p r o c e s s . S i m p l e enough? What does component. This is a very or near a covered process mean? How detailed requirement and near is near? one that cannot, and most A lso , th e p er mit h a s to document certainly should not, be that the fire preventaken lightly. tion and protection requirements in 29 CFR 1910.252(a) have been implemented. This has to be documented, but prior to all that, we have to train our personnel on the requirement and how to verify the aspects they are responsible for, as well has how to post and file these permits.
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10. Management of change

The employer shall establish and implement written procedures to manage changes (except for replacements in kind) to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process. The following considerations are addressed prior to any change: n The technical basis for the proposed change n Impact of change on safety and health n Modifications to operating procedures n Necessary time period for the change n Authorization requirements for the proposed change. Many organizations choose to issue an MOC for every change, regardless of whether or not it is a replacement in kind, just to get around any potential errors in this element. There are many details, and questions that maintenance and engineering have to answer satisfactorily to make this a safe process.
12 May 2013
plant engineering
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11. Incident investigation
This is another element where the language could be a potential tripping point for maintenance as well as operators. The standard calls for an investigation into all incidents that result in, or could reasonably have resulted in, a catastrophic release of HHCs. The ambiguity of the phrasing makes it almost necessary to include all incidents around HHCs to be classified as at least meeting the lesser criteria. Maintenance and engineering leaders must shore up their what-if scenarios in the PHAs to guard against even the slightest incident.
12. Emergency planning and response

Like most emergency situations at plants all across the country, any emergency planning and response actions will include maintenance resources. This particular element requires employers to establish and implement an emergency action plan, including a plan to handle small releases.
13. Compliance audits

This element is redundant of the actions required by other elements in the PSM-NEP. Once again, the standard requires that Employers shall certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed. This element continues to state the requirement that the audits will be conducted by at least one person knowledgeable in the process. Also noted in the standard is a requirement to retain the last two most recent audit reports. Maintenance personnel will quite often be called into service to be on the audit teams.
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14. Trade secrets

This element was a late add-in element published to acknowledge that until now, some companies kept process information secret from their own employees under the guise of proprietary information, in essence protecting their trade secrets. Maintenance personnel are typically involved in all aspects of the process but might be lacking in the knowledge of the details of production. Operations and maintenance employees have the expressed right, under this element, to be made aware of those secretive processes that might affect the health and safety of the employees. Of course, there is more information available on these elements and each organization has to be prepared to successfully question its own abilities and those of federal or state auditors. The intent of this program is to ensure that we perform our processes in a manner that is consistent with safety in all operations, engineering, and maintenance tasks that are E conducted involving HHCs. P
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Check out the Marshall on Maintenance blog for additional articles, videos, and updates from the Marshall Institute.
14 May 2013
PLANT ENGINEERING
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IN FOCUS
Step-by-step on energy management software
By Matthew Little eld LNS Research
To effectively manage the flow of energy through an organization, it takes a robust operational excellence program with the right combination of leadership, business process, and technology. Taken a step further, aligning these resources with operational, financial, and environmental objectives, executives can take a measured approach to realizing energy management improvements. When it comes to industrial energy and its relationship to the operational excellence model, energy directors and line of business leaders are constantly challenged with the management of energy procurement, use, and reporting. These three areas can be considered the sub-categories of industrial energy management software, each with its own respective functionalities and best practices. In comparing and selecting an IEM vendor, there are a few areas on which executives should focus. This article will examine the role of procurement in the LNS Research Industrial Energy Management software framework. In the area of procurement, there are six key areas of functionality that any industrial company should focus on when selecting an IEM software provider:
market data from third parties, internal data of energy needs, and demand forecasts. It should also be noted that the use of these tools is often coupled with analysts or consultants from the software company to augment internal resources at the industrial company itself.
theres insight into how contract terms may impact risk or a companys ability to shed peak load before commitments are made.
3. Billing management
With contract complexity, multiple sources of energy supplying a large industrial facility, and many large industrial facilities selling energy back to the grid, ensuring the accuracy of utility bills and minimizing the internal costs associated with managing billing processes is another major challenge for industrial companies. Billing management solutions leverage a combination of business process outsourcing to replace or augment existing resources. These solutions contribute to efficiency gains with the use of software that automates the collection of meter data and compares it to billing data, which often exists in disparate financial or ERP systems. The analytics provided as part of this functionality can highlight errors or other irregularities in either billing or consumption. This software is generally integrated with the contract management system and can also contribute insights into the use and efficiency of energy in operations.
2. Contract management
With the deregulation of energy markets, the emergence of peak load pricing and incentive programs for coordinating the consumption of energy with the needs of the grid are a focal point in energy management strategy. As a consequence, the complexity of energy contracts has become a challenge for many industrial companies. Its important for companies to have expertise and software that can assist in evaluating different contract structures. The utilization of incentive programs like demand response or peak load pricing can seem like an instant benefit for an industrial program. However, these contract decisions are often not fully evaluated and better terms could have been negotiated. IEM software can facilitate the integration of contract management functionalities and expertise with other areas of procurement, so, for example,
1. Risk management
The energy and manufacturing industries are inherently risky. Prices are clearly subject to volatility, as demonstrated by recent price changes in oil and natural gas. Similarly, the amount of energy an industrial company requires varies as the demand for the goods manufactured varies. Both of these market forces can put energy procurement professionals in a precarious position. They need effective tools for managing the uncertainty of energy prices and energy requirements. Risk management functionality provides capabilities to model and visualize the risks associated with energy prices and requirements, enabling energy professional to make optimal decisions. Inputs to these models include energy
Figure 1: Picking the right energy management software should be a step-by-step evaluation process that takes your unique plant situation into consideration. Courtesy: LNS Research
16 May 2013
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IN fOCUS
4. Peak load management
Many industrial companies today have moved to an environment where the price of energy depends on the demand of the grid. In these situations, there can be substantial savings in strategically shifting production to periods that have lower energy costs. Of course, there are also challenges to managing this process. Most energy programs today do not include energy on the bill Market forces can put of materials, and planning systems such as MRP do energy procurement not account for changes in professionals in a energy costs. precarious position. They IEM software provides functionalities for optineed effective tools for mizing consumption as it managing the uncertainty relates to peak loads. Data of energy prices and visualization, forecasting, and automation functionalenergy requirements. ities allow energy professionals to understand where energy is being used, when its being used, and how consumption can be altered to avoid premiums associated with peak loads. These functionalities can provide direct impacts to the bottom line.
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5. Demand response
Today, most energy professionals have an asset they dont even realize is available: the ability to curb energy consumption during periods of intense stress on the grid. By participating in demand response programs, large industrial companies can provide capacity (in the form of unused energy) to aggregators that can then be sold back to grid operators at a cost that is substantially less than bringing additional generation capabilities on-line. There are, however, challenges in dealing with a demand response event. It often requires quick response time and the ability to curb energy use for both critical and noncritical production processes. For the most part, this is still a manual process that requires engineers and supervisors quickly traversing the plant and communicating plans to operators and maintenance personnel. In the future, more and more companies will be using software for automating energy curbing programs. Building management and automation systems will be able to sense and react to demand response events, eliminating the need to manually alter energy consumption.
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6. Taking a suite approach

Within IEM software, procurement is an important part of the overall process, and a suite approach is critical to ensuring that all stakeholders are aligned with energy management objectives. Its not out of the ordinary for many of the areas mentioned above to be managed in silos rather than holistically throughout the organization. In fact, this is one of the energy management challenges faced by many manufacturing E and industrial organizations.P For more information on IEM, read LNS Researchs Industrial Energy Management Best Practices Guide.
18 May 2013
plant engineering
Equipment condition, not calendar, should drive maintenance

By Paul Lachance, Smartware Group
CMMS conventional wisdom tells us to schedule our machine preventive maintenance (PM) items on a calendar just like we do for our car tune-ups. Its been 90 days, so it must be time to recalibrate the auger in the extruder, or replace the impeller on a centrifugal pump. But what if its too early to check and replace a part? While being reactive and waiting to make repairs only after equipment fails hurts productivity, changing parts before the end of their run is also a waste of time and money. If youre doing too many PMs based on a calendar and youre wasting precious maintenance resources to do the work, you may want to consider more efficient options. To preserve equipment and ensure plant floor machines are fully operational and reliable, safe, and long-lasting, consider more proactive PMs. Lets say a piece of equipment has fallen below the acceptable performance threshold, slowing down production and reducing output. Meter trending may show that widget output falls after 600 hours of continued use, which may exceed the manufacturers recommendation for replacing components. Meter readings to periodically check production volumes and perform the necessary maintenance tasks trump calendar-based PMs, which remain static as production volumes change over time. Another useful PM, condition-based maintenance (CBM), is based on the health of your asset. CBM incorporates real-time data about machine health so that maintenance work can be done when it is actually necessaryand not according to a rigid calendar schedule. Monitoring machine health by controlling oil corrosion with a PM to change filters prevents failures. Checking oil levels, contaminants, temperatures, and vibration levels (among others) all fall under CBMs. A civil engineering company that manages wastewater treatment plants has to regularly test conditions of its centrifugal blowers for alignment, temperatures, vibrations, etc. Each blower
plant engineering
has a gearbox with an oil capacity of 27 gal. CBM tests allowed the maintenance team to analyze lab results for detecting metal in the oil, resulting in less frequent oil changesand lower maintenance costs.
This way the condition of the equipment E drives the schedule, not the calendar. P Paul Lachance is president and chief technology officer for Smartware Group, producer of Bigfoot CMMS. Read his blog, Lachance on CMMS, at www.plantengineering.com/blogs.
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May 2013 19
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IN PRACTICE
Using Lean to add value, achieve operational excellence
By Vince Campisi, CIO, GE Intelligent Platforms
here are three common ways to measure the impact of Lean on operational excellence. The first is whether or not manufacturing sites are operating at world-class levels, which is often measured by attributes such as on-time delivery against published lead times. The second is to measure against cost efficiency metrics, such as productivity or the cost of scrap. Last, but most important, is engagement. This includes things such as how involved employees are in helping drive continuous improvement ideas and participating in Kaizen events and action workouts. Many times in the Lean journey, teams move through a methodology on projects, deliver improvements, and move on to the next project. Six Sigma gives us the control phase to maintain changes for improvements, but even with that, it can be difficult to keep delivering benefits because the control phase itself can break down. Once momentum gets lost on the project, people can revert to their former processes that include wasteor teams may need to make necessary changes and inadvertently add waste back into processes. By maintaining automated control over a process with computerized systems, manufacturers have a much better chance of reducing their waste in the long term.
Enabling Lean and Lean Six-Sigma

One of the key steps in Lean is the identification of which steps add value and which do not. By classifying all the process activities into these two categories, it is then possible to start preserving value with less wok. Waste reduction is an effective way to increase profitability by reducing costs. It is hard to discuss Lean and waste reduction without calling out the seven types of waste, easily remembered by the acronym TIMWOOD. Transport: moving products that are not actually required to perform the processing Inventory: all components, work in process, and finished product not being processed Motion: people or equipment moving or walking more than is required to perform the processing Waiting: waiting for the next production step Overproduction: production ahead of demand Over processing: resulting from poor tool or product design creating activity Defects: the effort involved in inspecting for and fixing defects. Many Lean initiatives start by looking at manual processes and defining them. Often, this exercise is the first time that
a process is defined, documented, and analyzed. Right away, teams can see benefits from this exercise as obvious areas of waste can be immediately eliminated. The exercise takes time, as it is a manual process, but can be worthwhile because it drives good benefit. As teams continue along the Lean journey, they start to roll out processes more broadly and develop spreadsheets to help execute processes and report on them. However, process modifications start to peak, and eventually teams see erosion begin to take place. People can go back to their old way of performing tasks without new processes being enforced. The value realized starts to decline, and leadership may move on to another type of improvement initiative. However, the lifecycle of Lean projects and initiatives can continue to deliver value for the long term through manufacturing execution systems (MES) or computerized systems used in manufacturing that work in real time to enable the control of multiple elements of the production process (e.g., inputs, personnel, machines, and support services). MES helps create efficient and high-quality manufacturing processes by providing real-time operational insight into a plants performance and information at a single source. These digital capabilities support Lean and Lean Six Sigma efforts in the following ways: Graphically define and document work processes, making it much easier to start the Lean journey Find and eliminate the non-value-add activities more quickly and easily Execute work processes through a controlled, electronic systemensuring that processes are followed Improve processes in real time, not after the fact Automatically capture, store, and analyze production data, closing the loop for continuous improvement Digitize the control plan and its execution Keep process improvements consistent, so projects keep adding value. To ensure we dont let waste and inefficiencies creep back, IT technologies and digitization are important components to ensure we achieve sustained and scalable change. Standard work processes become embedded into the plant system, which can take Lean initiatives to the next level. With true standard work and an electronic environment for Kaizen, momentum remains high, waste is eliminated, and work processes are E monitoredand the gains grow year after year. P Vince Campisi is CIO of GE Intelligent Platforms
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May 2013 21
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COVERSTORY
Images courtesy of Eaton
Which one is counterfeit?

Identifying phony electrical products can save lives and profits
By Tom Grace Eaton
he counterfeiting of well-known brands and products is a growing problem, estimated to be 5% to 7% of world trade, or about $600 billion each year. Counterfeit health and safety products such as electrical and electronic products now occupy second place after pharmaceuticals on the list of those most frequently seized by U.S. Customs. Counterfeiting has a negative impact on not only companies bottom lines and reputations but also public safety. Counterfeit electrical products can overheat or cause short circuits, leading to fires, shocks, or explosions that can cost workers their lives and produce considerable property damage. These illegal products dont need to comply with performance and safety specifications and they are not tested or approved. It is important that facility managers understand the dire consequences of using unsafe counterfeit products and know how to avoid them. By definition, a counterfeit is a product, service, or package for a product that uses, without authorization, the trademark, service mark, or copyright of another intended to
deceive prospective customers into believing that the product or service is genuine. This makes detecting the difference between a counterfeit and authentic product difficult. In fact, Eaton has shown industry professionals, from plant and facility managers to independent electrical resellers, two seeming identical breakers and asked each professional to pick out the counterfeit breaker. After inspecting the breakers for everything from recognizable certifications and brand stickers to noticeable defects or missing parts, each professional leads to a common realization, I never would have thought it to be counterfeitI didnt know. You can do the test yourself by looking at the circuit breakers at the top of this page. Can you tell which one is counterfeit? The answer is at the end of this article. While identifying a counterfeit product is difficult at first glance, there are many ways to detect and avoid them prior to making an actual purchase. The best way to avoid counterfeit electrical products is to purchase products from the manufacturers authorized distributors or resellers. There is a higher risk of counPLANT ENGINEERING
May 2013 23
CoverStory
Counterfeiters do an excellent job of disguising their products to look like the real thing. The bar code (upper right), date code (lower left) and style number (lower right) on this circuit breaker are authentic.
terfeits if one cannot trace the path of commerce to the original manufacturer. Some manufacturers and certification organizations also provide tools to verify that electrical products are authentic. This can be an easy way to detect if a product is not certified and therefore should be avoided. For example, Eatons new Circuit Breaker Authentication (CBA) tool is designed to allow customers to detect if Eaton circuit breakers are counterfeit. By entering the bar code, part number, and date code found on the circuit breaker, the CBA tool is intended to immediately
In this counterfeit version of the breaker, you can see there is no date code. The style number and bar code are similar, but if there is a question, many companies have ways to verify the legitimate electrical equipment.
verify authentication. You will use this online tool, at www.eaton.com/counterfeit, to learn if you correctly guessed which circuit breaker is counterfeit. When shopping for electrical products, managers can look for key red flags that signify an item, or distributor, should be avoided. The first red flag is bargains that seem
too good to be true. Compare the price of that product to a similar product at a different retailer. If it seems too good to be true, the odds are it is. Scrutinizing labels and packaging can also help identify a counterfeit product, but is just one part of the detection process. As counterfeiters become more sophisticated, a higher level of scrutiny becomes necessary. Check for certification labels from organization such as UL, the National Electrical Manufacturers Association (NEMA), or other organizations that certify the quality and performance of electrical products. Avoid products that lack any identifying branding label or affiliation and be leery of additional markings or labeling not applied by the original manufacturers and of missing or poor-quality labels, out-of-date product codes, and non-genuine packaging. Pay close attention to products purchased. Quality control is often lacking in counterfeiting operations, so you may be able to spot a counterfeit simply based on its workmanship. Be wary of products that seem flimsy or that have any noticeable flaws. Always be on the lookout for materials that come with a product. Counterfeit products often dont include supplementary materials such as an owners manual or product registration card. Sometimes counterfeiters do not include all the parts that should come with the product, or some parts will be from a different manufacturer. Finally, if a product is suspected to be counterfeit, it is recommended to contact the original manufacturer. This will allow authentication of the suspect product and ensure that the potentially unsafe product is removed from the marketplace. Remember the circuit breaker photos? While the physical differences between the two breakers are nearly undetectable, the circuit breaker on the right is counterfeit. Try it out yourself by entering the highlighted information into the authentication tool at E www.eaton.com/counterfeit. P As brand protection manager for Eatons Electrical Sector, Tom Grace oversees counterfeit awareness, training, and prevention. This involves building awareness of the risks that counterfeit electrical products present to personal safety and the economy with end customers, contractors, inspectors, and electrical resellers. For more information, go to www.eaton.com/counterfeit.
Images courtesy of Eaton
24 May 2013
plant engineering
Seven tips to help combat counterfeits:

1. Buy authentic: The best way to avoid counterfeit electrical products is to purchase products from the manufactures authorized distributors or resellers. There is a higher risk of counterfeits if one cannot trace the path of commerce to the original manufacturer. 2. Verify authentication: When possible, use tools provided by the original manufacturer or certification organizations to verify electrical products are authentic. Eatons new Circuit Breaker Authentication (CBA) tool is designed to allow customers to detect if Eaton molded circuit breakers (MCCBs), up to 400 amperes, are counterfeit. By entering the bar code, part number and date code found on the circuit breaker, the CBA tool is intended to immediately verify authentication. To learn more, or download the CBA tool, visit www.eaton.com/counterfeit. 3. Scrutinize labels and packaging: When purchasing an electronic product, check for certification marks from organizations that certify the quality and performance of electrical products. Avoid products that lack any identifying branding label or affiliation. Be leery of additional markings or labeling not applied by the original manufactures with missing or poorquality labels, out-of-date product codes and nongenuine packaging. As counterfeiters become more sophisticated, counterfeit products become even more difficult to detect this way, creating an increasing need for additional scrutiny. 4. Avoid bargains: When shopping for electrical products, avoid prices that seem too good to be true. Compare the price of that product to a similar product at a different retailer. If it seems too good to be true, the odds are it is. 5. Pay close attention to products purchased: Quality control is often lacking in counterfeiting operations, so you may be able to spot a counterfeit simply based on its workmanship. If it is a product that is purchased habitually, compare the quality and the price of that product at a different retailer. Be cautious of products that seem flimsy or are noticeably poorly made. 6. Make sure everything is there: Counterfeit products often dont include supplementary materials such as the owners manual or product registration card. Sometimes counterfeiters do not include all the parts that should come with the product, or some parts will be from a different manufacturer. 7. Report suspected counterfeits: If a product is suspected to be counterfeit, contact the brand owner. This will either authenticate the product or ensure that it is removed from the marketplace.
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ELECTRICALSOLUTIONS
Go-to strategies for energy management
Condition-based maintenance will allow you to assess your building envelope and plug your leaks
By Chris Colson Allied Reliability Inc.
nergy management is a term that has a number of meanings, but Im sure most folks are mainly concerned with the one that relates to saving energy in businesses, industrial environments, and public-sector or government organizations. When it comes to energy savings, energy management is the process of monitoring, controlling, and conserving energy in a building or organization. Typically, this involves the following steps: Metering your energy consumption and collecting related energy data. Finding opportunities to save energy and estimating how much energy each opportunity could save. You would typically analyze your meter data to find and quantify routine energy waste, and you might also investigate the energy savings that you could make by replacing equipment (e.g., low efficiency motors replaced with high efficiency, lighting, upgrade or replace piping insulation). Taking action to target the opportunities to save energy (i.e., tackling the routine waste and replacing, upgrading, or repairing the inefficient equipment). Typically, you would start with the best opportunities, as defined by ROI.
Tracking your progress by analyzing your quantifiable meter data to see how well your energy-saving efforts have worked. When you look around, there are a large number of companies that provide energy management services offering a vast array of products and services that are intended to help the end user not only understand its inefficiencies but the actions it can take to become more energy efficient and responsible. I have personally had the experience of working with multiple clients in differing industry verticals and have seen how equipment reliability and energy efficiency go hand-in-hand. The ability to understand how and why equipment fails is essential in understanding and developing energy-efficient strategies for the operation and maintenance of industrial equipment. This will come as no surprise. Energy costs are rising and becoming a larger percentage of costs for industrial plants and facilities alike. Plant and facilities managers are looking for savings but are wary of full-scale, costly energy savings programs. However, most I have spoken with are interested in low or no cost opportunities if prioritized and executed in a way that funds future activities. I often refer to this as a paying it forward approach.
SMALLER, LONG-TERM SAVINGS

Building Envelope IT Equipment & Electronics
Analyzing savings and opportunities

Because all plants and facilities are unique in their own way, opportunities are plant or facility dependent. This dependency makes the paying it forward approach extremely flexible. The flexibility begins with an initial current state analysis, which would identify future threats to profitability and ways to reduce costs. The identified opportunities should, therefore, become an integral part of the corporate strategy to counter such threats and improve profit margins through energy
PLANT ENGINEERING
LOW COST / NO COST QUICK SAVINGS

HVAC Lighting Steam System Compressed Air Electrical Distribution
Figure 1: Follow-up system level audits. All graphics courtesy of Allied Reliability Inc.
May 2013 27
eLeCTRICALSOLUTIONS
Structural Control isture s Moisture & Humidity Hu Control C
4 Basic Functions of the Building Envelope
Generally speaking, the types of follow-up system level audits are illustrated in Figure 1. While each of the items listed above is important and savings are significant, each has a different ROI valuation. Some represent large savings and relatively quick ROIs, while others are steady savings over a longer duration. In the remainder of this article, Id like to draw your attention to the auditing of the building envelope, which can help (plants and facilities equally) identify where conditioned air is leaking or outside air and other matters are entering, causing systems to work harder (HVAC, steam, etc.) and be less efficient.
rP Press Pres su s Air Pressure C to ol Control
Temperature mperat Regulations gulatio ula
What is the building envelope?

To begin our discussion about building envelope, let me start by defining it as all of the components that make up the shell or skin of a building. These components are designed and utilized to separate the exterior of a building from the interior. The building envelope may also be defined as the components that separate conditioned areas from unconditioned space. Building envelopes are designed by project architects and engineers to meet the needs of each individual application (i.e., distribution warehouse, food processing facility, automotive manufacturer, commercial facility, etc.). The building envelope must be carefully designed with regard to climate, ventilation, and energy consumption within the structure. By serving the four basic functions of a building envelope, as shown in Figure 2, the envelope affects ventilation and energy use within the building. This is a key point to understand when identifying and quantifying related energy cost savings opportunities. Building envelopes are often characterized as tight or loose. A tight envelope is designed and built to allow relatively few air leaks. This often requires significant quantities of insulation, caulk, sealants, and energyefficient windows to create a tight shell for the building. A loose envelope is designed and built to allow air to flow more freely from the exterior to interior spaces. I should add that a loose envelope may be created by design or may be the result of poor construction. Debates are ongoing as to the benefits of tight versus loose building envelopes. Some advantages and disadvantages are shown in Figure 3. Regardless of the type of building envelope you might have, it is critical that it perform as it was designed and intended. To ensure proper
Figure 2: Building envelope functions
Tight Envelope
Advantages
High level control of: - Indoor air quality control - Energy consumption - Temperature - Humidity Reduced likelihood of mold or mildew caused by moisture infiltration Limited natural ventilation leading to more extensive mechanical ventilation requirements
Loose Envelope
Advantages
Allow natural air transfer Improved indoor air quality Often eliminates needs for mechanical ventilation Tend to be more drafty and uncomfortable Difficult to regulate temperature levels Increased chance of moisture-related mold Higher qualities of heated or cooled air able to escape Could lead to increased energy bills & negatively impact your environment by increasing greenhouse gas levels
Disadvantages
Disadvantages
Figure 3: Advantages and disadvantages of tight and loose building envelopes
savings. Applying good energy management practices is just as important to achieving these savings as the appropriate process technology. It should be remembered that any operational savings translate directly to bottom-line improvement, dollar for dollar. During a current state analysis, the plant or facility systems will be identified and evaluated for follow-up paying it forward energy opportunities. While most facilities and plants have common systems, such as HVAC, electrical distribution, and lighting, others are building specific, such as compressed air or steam.
28 May 2013
plant engineering
Safety? Naturally Integrated!
2013 Siemens Industry, Inc.
eLeCTRICALSOLUTIONS
immediate attention. Depending on the building design and size, you may be able to inspect the whole building envelope for insulation problems and air leakage. The two CBM technologies are great tools for identifying such issues due to the natural airflow with different velocities and temperatures. Doors, window frames, and seals should be checked for air infiltration/exfiltration. Penetrations of the envelope, such as water pipes, conduits, and exhaust pipes, should be inspected for proper insulation and sealant. Another reason I call these two technologies my go-to methods is the simplicity of combining the information with other small pieces of data (i.e., electrical load, air velocity, temperature difference) to quantify the size of the opportunity. These calculations can be done not only in financial terms, but also in terms that environmentalists will appreciate. Remember, we are identifying energy savings. All forms of energy can be represented in million metric British thermal units (MMBtu), which can then be converted to kilowatthours (kWh), then translated to CO2 (the EPA equates 1 kWh as being worth 1.37 lbs of CO2). So, lets say you identify $18,000.00 worth of savings yielding 353,843 kWh, you can also represent this as 509 barrels of oil, or 24,916 gal of gas, not consumed in a year.
Figure 4: Defective door and window seal
Figure 5: Building insulation and equipment efficiency opportunities
By using these technologies, you will be able to not only inspect large areas quickly, but also pinpoint exact problematic areas in need of immediate attention.
construction and performance, adequate testing and maintenance is required. While there are numerous technologies, tools, and methods that are used to test the performance of the building envelope, I have found two particular condition based maintenance (CBM) technologies as my go-to preferred method: infrared thermography and airborne ultrasonics. Having been exposed to CBM technologies being utilized as a predictive maintenance strategy to help identify and correct equipment and component defects, I became aware of the added energy management aspects that these technologies place in the hands of experienced users. The power of linking equipment defects and failures with energy management efforts and savings opportunities brings direct, bottomline value from maintenance. When a defect is present, not only does it put equipment at risk of operational failure, but it also begins performing less efficiently, costing you quality, increased energy usage, and in some instances, increased greenhouse gas emissions. A building envelope audit should include the use of both infrared thermography and airborne ultrasonics to inspect temperature differences, infiltration, and exfiltration (air, water, gas, and other applicable mediums). By using these technologies, you will be able to not only inspect large areas quickly, but also to pinpoint exact problematic areas in need of
Moving forward
As great as it is to identify savings and make the adjustments to obtain those savings, you are still left with being able to implement a sustainable strategy so that such inefficiencies do not creep back into your facility. To sustain the savings obtained through a building envelope audit, you will need to deploy a maintenance strategy that includes regularly scheduled maintenance activities that provide an indication to the condition of the item in question so that the appropriate corrective action can be scheduled as it is needed. Im going to close with one last point that may seem obvious, but for some unknown reason too often ends the same. While auditing and identifying defects is the first step, it is not and should not be the last step. An audit never adds value without execution. Prioritize the opportunities and begin executing in a way that funds the next item on the prioritized list. When you practice this philosophy, you E understand the value of paying it forward. P Chris Colson is director of operations with Allied Reliability Inc., and is the co-author of the book Clean, Green, & Reliable .
30 May 2013
plant engineering
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2013, RIDGID, Inc.
eLeCTRICALSOLUTIONS
All graphics courtesy of Integrated Power Services.
Motor repair/replace by the numbers

Calculating your efficiency will point the way to the right decision
By Walt Dryburg Integrated Power Services
Figure 1 (above): Making the choice to either repair or replace a motor comes down to efficiencies and costs.
generation ago, when a large industrial motor neared the end of its service life, the debate about repairing or replacing it was usually pegged to the magic number of 57. This was a number derived by purchasing agents, based on the residual value of a run-out motor plus repair cost, versus the cost of a new motor and the delay in getting it into service. If the motor could be repaired for less than 57% of the price of a new one, it was repaired; if the internal damage was extensive and repair cost was going to exceed 57%, the agent ordered a new motor. That was then.
This is now: Energy costs are greater, motor efficiency can be greater, and repair technology is much improved, resulting in little or no loss of motor efficiency after a rewind. (In fact, when rewinding an older pre-EPACT stator, a service center can actually improve efficiency on larger horsepower units.) For ac motors particularly, the repair/replace choice has become complicatedespecially for medium and large motors that run for an intermediate or high number of hours per year. Complicating the issue is the fact that there are three categories of induction motors: standard, first-generation energy efficient (EE), and current EE motors. In the real world, they are often used interchangeably.
32 May 2013
plant engineering
Motor circuit evaluation (MCE) testing provides a heads-up when a motor is nearing the end of its useful life. If the megohm (commonly called megger) part of the test shows resistance to ground is less than 100 ohms, the motor is nearing the end. Surge testing tends to back up results of the megger test if surge patterns are uneven. Hi-pot testing is a go/no-go test in that it is destructive to windings; a motor that fails a hi-pot test is no longer serviceable. Its easy to show that, for motors that operate nearly continuously, in choosing between repairing a standard unit and buying an EE motor, the new motor wins hands down because it will pay for itself in a few years. What is less clear is choosing between the repair of an existing EE motor or replacing it with a new oneor making the same choice between two standard motors that operate for fewer hours. Only at the lower end of horsepower range, below 40 hp, and low operational time does the old 57% rule still apply.
Annual energy savings ($)

4,000
Savings for EE mtr vs Std mtr U.S. dollars ($)

3,000
2,000
1,000
Savings for EE mtr vs Rewound EE mtr
0 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000
Hours
Figure 2: Comparison of annual energy savings for a 100-hp EE motor versus a standard efficiency motor and an EE motor that has been rewound. (Energy cost is based on the national average, approximately $0.10/kWh.)
Advanced repair technology

In simplest terms, EE motors are made more efficient by tightening manufacturing tolerances and packing more conductor into the motor to reduce internal losses. Likewise, repair technology has become more precise, too, and the degradation of efficiency that was common in a motor rewind has been cut drastically. Now, repair shops can rewind a motor to its original nameplate efficiency and, in certain circumstances, improve efficiency. This applies to both standard and EE motors. Obviously, the cost of a rewind can vary with the degree of internal damage, but a typical price for a 100-hp induction motor that we will use as an example is between $2,500 and $2,700or $2,600 average per IPS Washington Service Center price guidelines.
The hours threshold

n High hours: When a motor operates more than 4,000 hours per year, the cost of energy becomes the overriding factor in the repair/replace decision. Like a high-mileage vehicle, the cost of fuel quickly outweighs the cost of vehicle, and a repair/replace decision becomes a matter of choosing the solution with the greatest efficiency (see Figure 2). Typical applications are those devices that operate almost continuously, including large compressors, petrochemical pumping stations, crushers, feedwater pumps, paper
machines, some metal extruders, plastic film lines, saw mills, rolling millsor just about anything that operates for three shifts. The example of the 8,000-hr, 100-hp motor in the figure illustrates the logical choice: According to NEMA projections, a 1% increase in efficiency will save $695/year at a power cost of $0.10/kWh, the rough national average in both the US and Canada. The difference between standard and EE motors of this horsepower is about 4%, so the savings would be $2,780/year. A new EE motor costs around $8,800. Cost of a typical rewind is $2,600. So, projected over a 10-year life span, the savings in energy alone dictate the choice to buy a new EE machine. n Intermediate: In the mid-time region those motors that operate up to 3000 hours per yearthe decision to repair or replace may be determined by your location. That is because the cost of power varies around the country, from a little over $0.05/kWh to over $0.13/kWh. The examples cited here are based on national average, but power costs that are 30% higher than average call for different thinking. In cases where power costs are high, a motor operating in the intermediate-hours region may have annual power costs similar to one in the high-time region and should be considered a high-hours motor. Conversely, if power costs are low, annual power costs
350 325 300 275 250 225
Replace
Decision coef cient
200 175 150 125 100 75 50 25 0 Br Breakpoint
Repair
Figure 3: The Replace/ Repair Calculator is an empirical index to enable motor users to estimate whether to replace or repair an existing motor that has failed or is about to fail.
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eLeCTRICALSOLUTIONS
local utility. Also, conservatively estimate that if the motor is rewound, it will lose 1% efficiency, from 95.5% for the new one to 94.5%. Cost of rewinding is $2,600, and a new replacement costs $8,800. Should it be rewound or replaced? Decision coefficient = 3,000 hrs x $0.09/kWh x (95.5% 94.5%) x $2,600 / $8,800 = 79.77 On the calculator, this figure falls well within the repair region. On the other hand, had the motor run another 1,500 hours and been located in an area where energy costs are $0.13, then the answer would have been right at the breakpoint. This equation shows the overriding importance of efficiency. By simply changing the efficiency shift from 1 to 2, the coefficient doubles. Also, the equation is conservative in that it does not include an escalator factor for increases in power costswhich, like death and taxes, are a certainty. Thus, if the calculator indicates that the repair/replace decision is near the breakpoint, the wise choice would be to replace the motor to take advantage of the new motors greater efficiency as power costs increase.
Figure 4: Not every motor gets this bad, but monitoring the condition of a motor on a continuing basis will indicate when repairs are needed or if replacement is the more cost-effective option.
could push the motor into the low-hours category. n Low-time: For low-time motorsthose with annual operating hours of less than 1500the choice is much the same as it was in the past. If a rewind is going to cost more than 57% of the price of a new unit, opt for the new machine. Examples include most motors that are used for one shift per day or less. Unless they are unique or part of unique equipment, nobody repairs ac motors under 15 hp. The math and reasoning are simple: The minimum repair cost will exceed the 57% threshold.
Decisions on dc motors
The dc machine is, as the saying goes, a different animal. Except for bearings, its wear points are different than those of ac machines and its much more expensive to buildby a factor of 2 to 4, depending on its design. Likewise, dc machines are somewhat more expensive to repair than ac units, but not by a factor of 4 unless the commutator and armature are completely destroyed. Large dc machines cling to those specialized applications where extremely precise control of speed is paramount, or where it is possible to use a regenerative drive to recapture a portion of the energy already invested in the rotating mechanism. Other than that, dc technology has been shouldered aside by ac, and large dc motors have become relegated to those applications where nothing else can be controlled as precisely. Repair/replace decisions for dc are usually simpler than those for ac because there is no premium efficiency line manufactured. Also, because the motors are more expensive to manufacture, users tend to hold onto them longer. For dc machines, the repair/replace breakpoint tends to be higher than that for ac, E about 65% the price of a new unit. P
If the calculator indicates that the repair/replace decision is near the breakpoint, the wise choice would be to replace the motor to take advantage of the new motors greater efficiency as power costs increase.
The calculator
The simplest way to make a preliminary repair/replace decision is to use the calculator shown in Figure 3. Here is how it works. First determine the following: n Annual running hours for the motor application (HA) n Local energy cost, in $/kWh (E) n Efficiency change, in % (FNEW FREPAIR) n Cost of repair, in $ (CR) n Cost of a new motor, in $ (CN) and insert the values in the following equation: Decision coefficient = HA x E x (FNEW FREPAIR) x CR/CN For example, assume that a 100-hp, 3000hr energy-efficient motor is showing signs of failure. Energy cost is $0.09 from the
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plant engineering
AUTOMATIONSOLUTIONS
Figure 1: Avoid alarm flooding by using an alarm management system to prioritize alarms.
All images courtesy of InduSoft.
Managing alarms effectively

Many SCADA systems have built-in features that can be used to improve alarm handling, operator response times, and root cause analysis.
By Fabio Terezinho InduSoft
H
PLANT ENGINEERING
as managing alarms at your facility become a problem? Are operators missing critical alarms that could lead to unscheduled downtime or incidents because theyre inundated with too many low-priority alarms? Once alarms are acknowledged, does it take too long to find the root cause? Conditions change continually in a manufacturing or process plant. Some changes are routine, such as when a motor stops or starts in response to normal operations. Others can be mission critical, such as a temperature rising above maximum limit. Operators are
constantly monitoring conditions to prevent problems and achieve maximum efficiency and productivity. The introduction of computer-based SCADA systems and the great technological leaps that followed have significantly reduced the cost of alarming, making it almost free to add an alarm point. Most plants are controlled by one or more automation systems, and these systems provide a wealth of data to the SCADA system, data that can be used to monitor nearly every aspect of a plants operation. With modern automation and SCADA systems, alarms can be added to a screen without incurring the expense of adding a hardwired alarm point and a panel-mounted indicating device. While nearly free alarms can provide great benefits, care must be taken in SCADA system design each time an alarm point is added. For example, adding too many alarms can create alarm fatigue for operators who may be diswww.plantengineering.com
36 May 2013
tracted by low-priority items at the expense of identifying the root cause problem. A SCADA system should clearly show appropriate alarms indicating possible problems, but it shouldnt cry wolf for every routine change in plant operations. Its easy to blame the SCADA system for alarm overload and other alarm-related issues, but its only a tool. Plant personnel need to use this tool correctly by selecting and implementing systems that avoid alarm overload while making sure critical events are addressed in a timely fashion.
Creating an alarm management system

The key to preventing alarm flooding from distracting operators is a proper design of the SCADA system, specifically its alarm handling features. A well-designed system will prioritize alarms to prevent serious alarms from being overlooked as a result of an alarm overload involving a large number of low-priority alarms. It will also offer other advantages, such as the ability to more easily diagnose the root cause of a problem. The first step in designing a SCADA alarm system is developing a comprehensive plan that determines alarm criteria. This design step should be accomplished with a team consisting of plant operators, plant engineers, and others who have a deep understanding of how the plant actually works. This team will determine and document: n How alarms should be prioritized n What type of operator intervention is required for each alarm n How much time should be allowed for an operator to respond to an alarm n Operator alarm handling and escalation procedures n How to structure the system to handle various routine alarms. The importance of alarm limits in configuration Most modern SCADA systems are PCbased, and the selected system should include built-in features to allow low-cost and straightforward implementation of an effective alarm management regime. A properly designed SCADA-based alarm management system should help operators distinguish between high-priority and low-priority alarms, respond properly to each alarm, and quickly determine alarm root cause. The alarm management system should contain tools to implement these
featuresincluding, but not limited to, configurable alarm limits, alarm displays, and most importantly, filters. When selecting a new SCADA system its important to look for features that will make it possible to prioritize alarms and messages by setting limits and providing sorting capabilities. Creating worksheets with alarm limits is one of the best ways to begin the alarm management process. Alarm limits define high and low values along with deviation set points, creating betting alarm management by helping operators to quickly determine the alarm priority with a glance at the screen. These alarm limits can be properties of tags, and shouldnt count against the total number of tags in the SCADA system. This is important as SCADA software is often priced based on total tags. For example, a tag can be created called Temperature that has a setpoint value of 100 degrees. The HiLimit tag property might be set
Figure 2: Operators can get immediate real-time data on a variety of devices, such as smartphones and other handheld devices.
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AUTOMATIONSOLUTIONS
With many SCADA systems, alarm limits can also be saved in separate worksheets with tag names, making it easy to view and adjust settings as necessary. Alarm worksheets, also known as configuration sheets or pages, are used to configure the setpoints and limits for the tag names, such as a HiLimit of 110 degrees for the Temperature tag with a nominal setpoint of 100 degrees. By spending time to set the alarm limits and deviations correctly, fewer nuisance alarms will be generated. The alarm worksheets also contain message sections that correlate to the alarm, the priority, and the selection fieldall to provide the operator with more information on the alarm. For example, for a HiLimit temperature alarm, within the worksheet users can set a message (Too Hot), a priority (0-255), and a selection that is a user-defined field such as Tank2. All the items in the alarm worksheets can be set as well as changed. Later on, well see how by including values in the messages, the worksheets enable easy filtering.
By filling in one field in the Filters Dialog, the user can either trigger the same dialog during runtime, or change the dialog in response to operating conditions.
Alerting operators
The information on the alarm worksheets should appear on the screen as an alarm object. Once imported into the SCADA system, the worksheets should provide functionality to automatically e-mail alarm messages. Furthermore, the SCADA system should provide settings to control exactly when and how these alarm messages are sent. Some common settings are frequency, number of alarms, message format, response times, and escalation procedures. Typically, the SCADA system default setting shows all active alarms, but these settings can be changed to only show certain alarms. The ability to have the online alarm object as the default setting, meaning it doesnt need to pull
By spending time to set the alarm limits and deviations correctly, fewer nuisance alarms will be generated.
at 110 degrees, and the LoLimit tag property might be set at 90 degrees. When creating alarm limits, some or all of the following items are typically included: HiLimit, the first high alarm point reached on an increasing value HiHiLimit, the second high alarm point reached on an increasing value, indicating an escalating condition LoLimit, the first low alarm point reached on a decreasing value LoLoLimit, the second low alarm point reached on a decreasing value, indicating an escalating condition DevSetpoint (Deviation), the allowable deviation or variation above and below the desired setpoint Dev+Limit, the allowable deviation plus the alarm limit Dev-Limit, the allowable deviation minus the alarm limit DeviationDeadband, the range through which a deviation can occur without initiating an alarm. There are many ways to set alarm limits and display them. Alarm limits can be set for each of the items listed above, and more. Alarm limits can be displayed on SCADA screens using numerical values, or via graphical representations such as sliders.
Benefits of using an alarm management system:

Ensure critical alarms get a timely response Avoid operator fatigue from too many low-level alarms Send real-time data to operators for immediate response Get detailed information from alarm worksheets Identify root causes quickly through alarm filters with string tags.
38 May 2013
PLANT ENGINEERING
information from a database, is vital. This is important when operators only need to view current alarms as opposed to all active alarms over a longer time period (Image 2). The SCADA system should also provide functionality to allow alarm data to be pulled from a database to get a view over a selected period of time, as this is often useful for troubleshooting by maintenance personnel and others. Characteristically, this functionality permits viewing of all alarms that have been logged. With many SCADA systems, alarms can be logged using a built-in PDF writer that turns alarms into a PDF document. This document can then be saved, e-mailed as an attachment, or printed as a report.
INTERACT
www.plantengineering.com/interact
Q: Is alarm management an important part of your automation strategy, or do you consider them nuisances? ity to build strings based on key criteria can help operators locate the root cause of the problem quickly. For example, temperature alarms may start appearing with messages saying, Tank 1 temperature too high or Pipe 1 pressure too low. Operators must now quickly determine the root cause of why the temperature in Tank 1 is too high. The ability to filter all messages with a single word such as hot, or with a phrase like valve closed, can help them discover why the tank temperature is soaring. Wild card expressions can also be used to sort through words or individual phrases in the messages. Unfortunately, many operators and even some plant managers have found managing alarms so burdensome they have almost considered them nuisances. This attitude can lead to important alarms being missed or ignored--a dangerous situation. It doesnt have to be this way, as alarms are a key part in monitoring plant operations and can be managed effectively using off-the-shelf software tools. One of the keys to effective alarm management is selecting the right SCADA system, one that offers advanced and easily configurable alarm management features. These features should include alarm prioritization to alert operators of conditions that require quick responses. Filtering features are also needed to enable operators to quickly locate root causes. Implementing these and other features of modern SCADA systems as part of an effective alarm management program will improve response to alarms. This will minimize downtime, increase safety, and keep minor alarms E from escalating into major incidents. P Fabio Terezinho is vice president of consulting services and product manager for InduSoft www.InduSoft.com.
PLANT ENGINEERING
Using filters to manage alarms

Filters are one of the most important features for preventing alarm overload and insufficient prioritization of alarms. Most modern SCADA systems provide easy configuration of features that offer a wide variety of sorting and filtering mechanisms. One of the biggest alarm management issues is that operators are inundated with low-priority alarms and therefore miss critical high-priority alarms through alarm fatigue and the inability to quickly distinguish an alarms urgency. This is where a SCADA system with superior filtering mechanisms becomes highly valuable. The first step in filtering was discussed in the worksheet section in which information can be prioritized to have only certain alarm limits appear. For example, the screen might display only Priority 10 and above alarms, or only the HiHiLimit alarms. In addition to setting alarm priorities, plant personnel should consider SCADA systems that offer a filter dialog that includes an expression to let users customize the filter. For example, only HiHiLimit alarms that have the word Hot in the message are displayed on the screen in response to certain conditions. This expression can be hard coded, but to increase effectiveness its often better to create a string tag that changes values during runtime depending on specific operating conditions. When an incident occurs, hundreds of related alarm messages can be quickly generated. Usually, only one alarm is the root cause, and the rest are symptoms of the problem. This is where many SCADA systems fail because the operators have no way to distinguish the root cause from the symptoms. But, the abilwww.plantengineering.com
Many operators and even some plant managers have found managing alarms so burdensome they have almost considered them nuisances. This attitude can lead to important alarms being missed or ignoreda dangerous situation.
May 2013 39
The Safety and Productivity Advantages of Intelligent Lifting Devices

Thursday, May 30, 2013
2 p.m. EST/1 p.m. CST/11 a.m. PST This webcast will explore the safety and productivity benefits of Intelligent Lifting Devices (ILDs).
Among the topics discussed: n A brief history of the evolution of ILDs and how these systems differ from their traditional lifting counterparts. n Benefits of applying an ILD in a variety of real world environments, and the specific drivers that led businesses to adopt the technology. n Real world examples illustrating why tooling integration is a key benefit of ILD solutions. n Research and examples that demonstrate how increased productivity and reduced product damage from ILDs can deliver a quantifiable return on investment. Speaker: Mark Grandusky, Gorbel Product Manager, G-Force Systems
To register today, visit :
www.surveymonkey.com/s/WTCWX66
If youre busy on the date of the webcast, register anyway and view the event on-demand
S P O N S O R E D BY:
SPECIAL REPORT: INDOOR AIR QUALITY
Breathe easythere are solutions for air quality issues
The air up there
he air we breathe is very much like an offensive lineman in football: we dont pay any attention unless something goes wrong. As it turns out, a lot CAN go wrong with air. On hot days it can hang on you like a wet overcoat, making every movement exhausting and difficult. The temperature inside many plants can soar, especially older plants and especially in the summer. Its unhealthy at a basic cardiovascular level, but theres also a mobility and safety issue. Condensation creates a slippery plant floor, and that can turn concrete into hot icea dangerous situation thats hard to spot. You also have to be aware of air pressure within your building. With bay doors open and air moving around large spaces, the air pressure can change in an instant. In plants where the environment is a vital part of the operational machinery, that can create dangers from a production and safety aspect as well. Finally, theres air quality at a basic level 42 45 49 52 55
removing the particulates and impurities that every plant must deal with. Dust and dirt clog lungs, of course, but they can clog equipment, too. Neither one should suffer; but both can affect your operational efficiency while driving up your costs. Yet as we said at the outset, we normally dont give air a second thought. This month, we did. Weve collected five different perspectives on air quality, from the technology and science behind draft fans to a couple of looks at the use and usefulness of HVLS fans to the important issues of dust collection and air filtering that can impact the short-term and long-term health of workers in any facility. In each article, the goal is to make you think a little about the air you and your co-workers breathe within a plant each day, and how that air affects your operational success. Following through on these ideas can turn air into another efficient part of your operation. Bob Vavra, Content Manager, Plant Engineering
Manufacturing comfort: Air movement needed in supply chain facilities Pressurizing with dust collectors: Making the right decisions Active filter cleaning technologies extend filter life, improve efficiency Decoding efficiency for mechanical draft fans HVLS fans deliver energy savings from the top down
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All images courtesy of Big Ass Fans.
Manufacturing comfort
Air movement needed in supply chain facilities
By Nina Wolgelenter Big Ass Fans
T
Comfort
PLANT ENGINEERING
hat comforting feeling created by an outdoor breeze on a hot summer day is equally satisfying to workers within a warehouse setting where fluctuating temperatures and stagnant air are the norm. Considering your equipment is only as good as the people using it, creating a comfortable work environment with the simple addition of air movement improves the health, safety, and sanity of those within. Supply chain facilities are prone to these fluctuating temperatures; its an unfortunate reality of warehouse design. Air-conditioning and ventilation systems, while effective up to a certain point, can be greatly enhanced by the addition of proper air movement. When interior conditions are such that workers can no longer concentrate on the job at hand, personal comfort must be addressed.
Human thermal comfort takes into account numerous environmental factors including temperature, thermal radiation, humidity, and air speed as defined by ASHRAE Standard 55-2010, along with personal factors including activity level and clothing type. Studies have shown that improved occupant comfort leads to increased productivity, with worker productivity decreasing as temperatures rise above 77 F.
The spin
In warmer months, operating between 60% and 100% of maximum speed, 6- to 24-ft diameter fans improve comfort with either an evaporative cooling effect or the added effect of heat transferwhen skin temperature is warmer than air temperature. Although fans do not lower the air temperature in a space, the perceived cooling effect can make a person feel up to 10 degrees cooler. In the winter months, operating at 10% to 30% of the maximum speed, large-diameter, low-speed fans successfully destratify tall spaces, mixing the warm air at the ceiling level with the cooler air at the occupant level, creating a more uniform temperature.
Figure 1 (above): Temperature and air quality are two important factors that require attention when considering plant productivity.
In terms of employee comfort, its important to understand that the sensation of feeling comfortable is not dependent on air temperature alone.
42 May 2013
The addition of air movement offers multiple benefits that improve the well-being of occupants and, in some cases, of products and machinery as well, by aiding in the following: Reducing heat stress on employees Reducing condensation to preserve product integrity Improving indoor environmental quality (IEQ), when mold or toxic fumes are airborne Providing year-round comfort.
Heat stress
OSHA standards indicate temperatures of 100.4 F and above are dangerous for workers while air temperatures that exceed 95 F significantly increase the heat load on the body. When temperature and humidity rise, the bodys ability to cool itself decreases, severely affecting worker productivity. In the manufacturing industry, reducing activity level is generally not an option, but applying gentle, nondisruptive airflow from large-diameter, low-speed fans bring about the evaporative cooling process. Properly designed large-diameter fans with airfoils and winglets disturb the thin film of stagnant air on the metal surface, which in turn dramatically reduces the likelihood of condensation. This is highly beneficial in areas of high humidity where moisture buildup can result in mold and mildew. Where condensation is a concern, the temperature of a concrete slab will trail the air temperature by about a month. For example, as Aprils air warms to 70 F, the concrete is still stuck at roughly 50 F, from the month before. Given the vastness of most facilities, the steady, even air movement from large-diameter, low-speed fans helps move the stagnant warm air off the cold surface before it has a chance to cool down enough to leave puddles. Fans with additional blade-ending fins can help direct the fans airflow toward the floor, maximizing the fans coverage area.
Figure 2: Condensation is another issue that HVLS fans can help solve. Condensation is an issue of safety, especially on concrete floors.
A Texas-size problem
A Texas-based McGraw-Hill textbook distribution center faced up to 15 heat-related incidents each summer in its 900,000-sq-ft facility. The 200 workers who boxed and shipped textbooks needed to ramp up productivity during this time in preparation for the fall semester, but the extreme Texas heat made this a tricky proposition. Thirty 24-ft diameter fans were installed to help circulate the air. It was an oven in this concrete building, and when workers were hot, they slowed down, said Mike Price, maintenance manager. Weve noticed a big difference (installing the fans). One hundred and five is still hot, but its manageable inside with the fans.
A slippery mess
John Rock Inc. of Coatesville, Pa., goes through 250,000 ft of green hardwood and 9,000 lbs of nails to create 20,000 pallets every shift. Greenwood hardwood is between 30% to 45% moisture, which was causing condensation within the facility. At our old facility, the floor was so rough and beat up, it didnt matter if it was wet, there was still lots of traction, said Penn Cooper, business development and purchasing manager. Here, we spent a lot of money to make sure we had a very smooth floor so we could move efficiently. We created a huge skating rink issue, just because it was wet. People were getting hurt. On top of the slip-and-fall risk, the moisture also allowed mold to flourish on the newly constructed wooden pallets. Both issues were addressed by the addition of air movement from six 24-ft diameter, low-speed fans used to thoroughly mix the air.
Blowing condensation to bits

Condensation within a warehouse space can prove detrimental to employee safety (e.g., forklifts on wet concrete) and negatively affect product integrity. Dehumidification systems (air conditioning) can decrease moisture content of the air, while heating systems help increase air or surface temperatures to help reduce moisture buildup. The downside however, is that large industrial spaces are often impractical, or at the very least expensive to heat and cool. Air movement, on the other hand, does not depend on any external conditions to be effective.
Studies have shown that improved occupant comfort leads to increased productivity, with worker productivity decreasing as temperatures rise above 77 F.
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May 2013 43

The result is only a slight temperature difference from floor to ceiling and reduced opportunity for condensation to form. Rather than using dozens of small fans to blow directly on the ends of the pallet rows, the 24-ft diameter overhead fans efficiently and effectively circulate air throughout the space. If the pallets sit here too long, they mold. At one point, we had 4,000 pallets in the warehouse, and over half of them got moldy, said Vincent Hoy, facility manager. We have to rewash anything that has mold on it or touching it, so thats two days of work lost. The air movement from the two 20-ft diameter, low-speed fans that were installed disturb the thin sheet of stagnant air surrounding each pallet, helping to prevent the establishment of mold by speeding up the drying process on surfaces on which mold can form. About 95% of the stock we put under the fans never molds, Hoy said. We put everything we wash and sort under the fansthats the premium real estate. Whereas most warehouse-style facilities dont have air conditioning, they do employ heating systems in the winter months. On the human front, adequate IEQ is typically a concern between 3 and 72 in. from the floor, which is considered the occupant breathing zone. When using a traditional HVAC system in the winter, only about 80% of the fresh air brought into a space reaches the designated occupant level, which means the system must compensate for the lost air to create a space that complies with ASHRAE Standard 62.1-2007, Ventilation for Acceptable Indoor Air Quality. The addition of large-diameter, low-speed fans to circulate the air down to the occupant level not only helps to keep IEQ levels in check but reduces reliance on the HVAC system altogether.
Product integrity case in point

Kentucky-based Owensboro Brick & Tile manufactures 35 million bricks annually, running its kilns at 1,950 F. The staging area holds 300,000 to 400,000 bricks at a time as they dry before going into the kiln. We have to get a certain percentage of moisture out of the brick before we can fire it, said Mark Sexton, plant manager. As one set of bricks would come out the kiln, the steam would keep the area hot and perpetually wet, preventing a thorough drying. The four 16-ft diameter, low-speed fans were installed to increase the air speed in the drying area, helping to evaporate the moisture from the green bricks waiting to be fired, while also dissipating heat and moisture from the steaming bricks exiting the kiln. These fans are helping to remove the moisture from the brick, Sexton said. So its actually letting me run our kilns a little faster to get more product out, because the bricks are drier.
Figure 3: The use of HVLS fans in supply chain facilities can improve worker comfort.
Improving IEQ
Fortunately, there is a middle ground between surrendering to the expense of air conditioning and suffering the continual loss of profits due to comfort-related problems.
All buildings, regardless of age, are susceptible to deficiencies in indoor environmental quality (IEQ). New and renovated construction are prey to tighter building envelopes that can reduce ventilation system effectiveness, and humidity and moisture buildup can cause unforeseen effects for building occupants in regard to bacteria and mold growth. Large-diameter, low-speed fans play a significant role in improving IEQ by turning the air in the space over several times per hour, ensuring good air distribution. This increased air circulation allows for more constant, uniform temperatures that help inhibit mold growth.
Airing on the side of safety and comfort

Fortunately, there is a middle ground between surrendering to the expense of air conditioning and suffering a continual loss of profits due to comfort-related problems. According to the Center for the Built Environment, temperature and air quality are two of the most important factors when considering productivity. At the forefront, using large-diameter, lowspeed fans is cost effective both in terms of worker productivity and reduced operating costs. Ideally, worker comfort leads to safer working conditions as employees can spend more energy on the task at hand without experiencing heat discomfort or exhaustion. This in turn results in increased worker productivity, positively affecting the bottom line, considering fewer days are missed due to illness and accidents. Following that same agenda, businesses are able to keep workers comfortable in a far more energy-efficient manner, reducing operating costs and dependence on expensive heating E and cooling systems. P
Moldy proposition
WestWind Logistics in Omaha, Neb., washes and then stacks up to 50,000 wooden pallets to dry before putting them back into service. Any pallet that sprouts mold must be rewashed, costing time and money. Unfortunately, the warm, humid warehouse was the perfect environment for mold, and wood is among molds favorite places to set up shop.
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Images courtesy of Camfil APC
Figure 1: A cartridge dust collection pressurizing system is installed on the roof of a maintenance building in the harbor of a European coal power plant to prevent ambient coal dust from entering the building. The unit is installed in front of a ventilation system and uses a water and moisture eliminator filter at the intake to keep rain from entering the unit.
Pressurizing with dust collectors:
Making the right decision

Choosing positive or negative pressure, a multifaceted decision
By Pablo Rocasermeno Cam l APC
ressurization is a well-known ventilation technique in which a positive or negative atmospheric pressure is maintained in an isolated or semiisolated environment. A clear way to illustrate this principle is the example of the healthcare industry, where pressurization has been used for many years for infectious disease control. A patient with an immunodeficiency disorder will typically be housed in a positive pressure isolation room, which maintains a flow of air out of the room, thus protecting the individual from contaminants and pathogens which might otherwise enter. Conversely, a patient with a contagious disease will be
housed in a negative pressure isolation room, which maintains a flow of air into the room to keep the infection from spreading to other patients and healthcare workers. In industrial settings, positive pressure is similarly used to keep particulate or gaseous contaminants out of a room, creating an air barrier between the outside and the inside. If you walk into a positively pressurized environment and open the door from outside, you will feel the whoosh of air escaping due to the higher air pressure in the room. This is the desired effect when you are trying to protect the contents of the room from dirty outdoor air conditions, from dust or fumes generated by an adjacent production process, or even from excess humidity that might seep in through walls or other openings. Offices, labs, and electrical and server rooms in industrial facilities are especially prone to dust infiltration that can create unpleasant working conditions while causing problems with critical equipment, especially electronics. Conversely, in a pharmaceutical facility where potent compounds are used, negative pressure may be appliedsometimes in conjunction with containment systemsto prevent the dust generated in a manufacturing space from cross-contaminating other areas of the plant. To guard against cross-contamination and maintain desired air quality during either positive or negative pressurization, proper air filtration is a necessary component of the process. High-efficiency HVAC filters (ASHRAE-grade or HEPA filters) are the most common solution, but cartridge-type industrial dust collectors can offer an effective and sometimes overlooked alternative for applications where dust loads are extremely heavy and filter life is prohibitively short. Pressurizing with dust collectors is applicable to many industries, including cement and lime production, metal and coal mining, pharmaceutical processing, grain processing, or potentially anywhere that high volumes of dust are generated. Areas that are most commonly protected through pressurization include:
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Deciding when to pressurize
How does a plant engineer decide whether pressurization is a good choice? The decision cant be based solely on the volume of dust to be controlled, because other factors come into play such as the type of dust, conditions inside and outside the space, and what (or whom) you are trying to protect. If there is nothing much of value inside the space, pressurization may not be worth the expense. But if you are protecting electrical equipment that costs $100,000 from damage or from creating a safety hazard due to contact with dust, it will be worth investing in a $20,000 pressurizing system to protect that equipment. Similarly, if workers in an office area are exposed to unhealthy levels of dust or fumes, you will want to keep the area clean to protect occupants against the well-known health hazards associated with dirty indoor air and comply with OSHA regulations for exposure. Not only will you be in compliance and preserve their health, but morale and productivity will also be enhanced. Climate considerations might also impact your cost analysis. In the tropics, if you inject large amounts of warm, moisture-laden air from outside to pressurize a building, the additional air conditioning load could be costprohibitive. However, in colder climates or during winter season, you can take advantage of the free cooling and use your pressurizing system for conditioning, saving substantially on air conditioning costs required to keep servers and electrical equipment from overheating. Return on investment should typically be less than two years for pressurization to be cost-effective, and field experience shows that the payback is often much faster. Though as stated before, in many cases the main justification is to guarantee a certain air quality in a space to protect something or someone valuable. The technology is best applied to new construction, expansion, or renovation projects. Retrofitting of existing facilities, while possible, can be more costly and complex depending on the setup and location.
Figure 2: A 16-cartridge dust collector pressurizes and ventilates a compressor room in a power generation plant in South America. Wall louvers allow for air exchange and are calibrated to maintain a specific pressure inside the facility.
Figure 3: Dust collection system is used to pressurize a control room at a gold mine. The collector is connected to a ducting system in a very similar configuration as if an air conditioning unit performed the same function.
Control rooms Clean rooms Compressor rooms Offices Quality control labs Substations Electrical equipment and motor control center (MCC) rooms Server rooms
Deciding how to pressurize

As noted earlier, pressurization with dust collectors is best suited to heavy dust loading applications where HVAC filters will not have an acceptable life. In extremely dusty conditions, high-efficiency HVAC filters can quickly become overloaded and may require changeout every few months or every few weeks in some cases, even with pre-filters
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in place to protect the more expensive primary filters. Cartridge dust collector filters, by contrast, are designed specifically to handle high dust loads in industrial environments. A dust collector has the capability to automatically pulse-clean its filters using very brief bursts of compressed air that blow dirt off the filter surfaces and down into a collection device. When used in a pressurization system, highefficiency cartridge filters can last for years before needing replacement. To determine the best choice for your application, begin with a cost analysis that evaluates the space to be pressurized and compare the two filtration technologies (i.e., HVAC vs. dust collection filters). What will be the initial cost of the equipment/hardware and the filters themselves? What will be the cost of electrical energy required to operate the system? What is the life expectancy of the filters under the anticipated dust loading conditions? Based on expected changeout frequency, you can arrive at an annual cost estimate that takes into account not only the price of the filters but such factors as labor cost to change the filters, equipment downtime, inventory, disposal, etc. If you are in a highly regulated industry, there may also be restrictions as to what types of filters or what level of filtration will comply with industry standards. This may be true for food-grade or pharamceutical-grade applications.
Dust collection equipment selection

If your analysis determines that dust collection is the most cost-effective approach, here are some general guidelines on the types of equipment best suited to pressurizing. Type of dust collector: Cartridge style dust collectors are the system of choice because they typically offer much higher filtering efficiencies than traditional baghouse collectors, a necessity when protecting workers or sensitive equipment from high levels of fine dust. Cartridge collectors also operate at lower pressure drop, for more efficient performance. The dust collector will be located outdoors, so make sure it is equipped with weather-resistant components and controls. Wet scrubbers: When pressurizing to protect a space from gaseous contaminants, a wet scrubber system should be used. If dust is present, however, you will still need the cartridge dust collector for particulate filtration installed upstream of the wet scrubber.
Filter media: A very-high-efficiency filter (MERV 15 or 16) is recommended for pressurizing applications. Cartridge filters using nano fiber or other high-efficiency filtration media are especially well suited to this use. Typically, an outer layer of extra filtration fibers will ensure the maximum efficiency of the media from the very first day. This technology increases the efficiency and allows maximum filtration with low pressure drop, thus improving the energy performance of the system. Dont rely solely on MERV values or filter efficiency percentages to predict performance, however. Although these measures are useful for comparing different filters, it is more important to ascertain that emissions will be at or below required thresholds. Ask the filter manufacturer for a written guarantee of emissions performance stated as grains per cubic foot. As noted, cartridge filters will need infrequent change-out in pressurizing applications, but it is good practice to replace filters every two to three years. An older filter may develop a hole or leak after time and will no longer deliver the guaranteed efficiency. HEPA or safety monitoring filters: HEPA or after-filters, also known as safety monitoring filters, may be added to the ductwork downstream of the collector to provide an extra measure of protection for critical applications. In the unlikely event of an air leak through the dust collector filters, the after-filters will provide backup protection. In certain cases, HEPA filters will be required to comply with regulations of a specific industry. Carbon after-filters: This option is available when odor control is desired. For exam-
Figure 4: A 10-cartridge dust collector is installed on the roof of an MCC room to protect the equipment inside from dusty conditions created by the desert environment.
To determine the best choice for your application, begin with a cost analysis that evaluates the space to be pressurized and compare the two filtration technologies (i.e., HVAC vs. dust collection filters.)
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Uncontrolled pressure could have negative effects, creating highvelocity conditions that result in slamming doors and back drafts.
openings and their corresponding pressures, see Table 7-1 of the ACGIH Industrial Ventilation: A Manual of Recommended Practice.) If the space to be pressurized requires heating or cooling, dust collector airflow should average between 10% and 20% of the HVAC unit airflow at a given capacity. This approach assumes the HVAC system has been properly sized to account for infiltration and will ensure you do not overwork the HVAC system by injecting too much humidity. It is important to use heavy-duty air handling components to withstand the dirty conditions, a sometimes overlooked step. General ventilation guidelines for industrial applications recommend a difference of 5% between the supply and exhaust airflow. For most industrial applications, a good standard is to set a pressure differential of 0.04 +/- 2 in. wg. (For more details, see section 7.5 of the ACGIH industrial ventilation manual.) Uncontrolled pressure could have negative effects, creating high-velocity conditions that result in slamming doors and back drafts. Most designers recommend a pressure sensor inside the room to adjust the supply air using a VFD on the fan of the pressurizing unit. For example: To treat an area with office workers using an extraction system mounted on top of a building, you will need a certain number of air changes per hour, which will determine the airflow. You should then add 5% to 10% more on top of that airflow to create pressurization. So it you need to extract 1,000 cfm from the room, you will want a dust collector with 1,100 cfm capacity to make sure you are injecting more air than you are extracting. If there are some openings or potential leak paths, it isnt a bad idea to oversize the dust collector slightly or calculate your infiltration and add it to the formula. And as noted, a VFD and pressure sensor should again be E used as controls. P Pablo Rocasermeno is Camfil APCs regional manager for Latin America. He is a mechanical engineer with expertise in ventilation and dust collection systems. The author can be reached at filterman@farrapc.com; Website www.camfilapc.com.
Figure 5: A small cartridge collector is used to pressurize an electrical room. Located in a warm climate, the room has its own backpack-type A/C unit for cooling, and the dust collector is sized for 10% of the capacity of this unit.
ple, for occupied spaces it may be a good practice to use carbon after-filters to prevent outside odors from entering the pressurized space. Variable frequency drive (VFD) and pressure sensor: A VFD drive provides precise electrical control of dust collector fan speed and is highly efficient in maintaining the desired airflow through the collector. It is a must for pressurized applications, and should always be used in conjunction with a pressure sensor in the room. The two devices will work in tandem to monitor and control pressure.
Air conditioned vs. non-air conditioned spaces

Finally, the approach to pressurizing will vary depending on whether or not the space to be pressurized is air conditioned. If the space does not have to be heated or cooled, dust collector airflow should be calculated based on ventilation needs for indoor air quality + air leakage through cracks and openings (i.e., using standard formulas for infiltration). False ceilings, raised floors, and other construction details may also impact the calculations. (For suggested velocities across
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Active filter cleaning technologies extend filter life, improve efficiency

By Karen Wear Donaldson Torit
All images courtesy of Donaldson Torit.
arly dust collection systems used passive filtration to separate dust from various airstreams. Filters inside a collector gradually loaded with dust and, over time, the pressure drop across the filter media increased until there was so much resistance the airflow through the system dropped below an acceptable level. The filter media then had to be removed, disposed of, and clean filter media installed in order to return the system to the original operating airflow conditions. Clean filters return a system to a lower pressure drop condition. A key improvement in dust collection occurred when active cleaning was developed to recondition filter media that stayed in the collector. Over the years, various methods of active cleaning were applied to dust collectors, including both mechanical and reverse air methods. Each method provided filter cleaning with varying degrees of success. The objective in each method was to remove any built-up dust cake from the surface of the filter, thereby reducing the
pressure drop across the filters and extending filter life, in effect extending the time between actual filter media changes.
Mechanical cleaning
Mechanical cleaning was introduced to the industry early as a low-technology form of active cleaning. Mechanical cleaning involved shaking or shocking filters to dislodge the built-up dust cake. This cleaning method allowed a portion of the built up dust to be removed periodically to extend filter life. Mechanical cleaning systems (see Figures 1 and 2) could be manual (i.e., a hand lever or foot lever to shake or bend the filters) or automated (motor-driven device to shake or vibrate the filters). This was an improvement over passive cleaning but was still limited in effectiveness because it required the airflow through the system be shut off prior to cleaning. This pattern of shutting down the collector categorized it as an intermittent duty cleaning system; cleaning only occurred when the dust collector was shut off and all filters were cleaned at the same
Figure 1: Manual pedal cleaning

Figure 2: Mechanical shake cleaning
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filtered airstream (see Figure 4). The reversed airflow blew the dust cake off of the surface of the filter media during the cleaning process. Typically, the reverse air fan was run continuously with only a few filters being cleaned at any given time. This method of cleaning produced what was considered a continuous duty system because the dust collector did not have to be shut down during the actual filter media cleaning process.
Pulse jet cleaning

The more common form of reverse air cleaning used in many collectors today is called pulse jet. This cleaning technique uses a stream of reverse air pulsed in the opposite direction of the filtered airstream. The pulse of cleaning air tends to expand the filter media, mechanically disturbing the dust cake on the filter and then blowing it from the filter. The pulse air pressure can range from medium (generally less than 15 psig) to high (60 to 90 psig) depending on the specific cleaning system design (see Figures 5 and 6). Pulse jet cleaning is very effective at cleaning filter media and is also considered a continuous duty system. Continuous duty, or on-line cleaning, provides an advantage by not disrupting the primary airflow during cleaning, allowing the dust collector to operate during the actual cleaning cycle. Only a few filters are cleaned at any given time, though the system will eventually clean all the filters. Some cleaning systems will run 100% of the time, like the low-pressure reverse air systems. Others are dependent on the observed filter condition (pressure drop) and will not initiate cleaning until the pressure drop reaches a specific high setpoint. Over time, as dust loading increases on the filter media, the pressure drop-dependent cleaning systems may start to run more constant cleaning cycles due to the heavier dust loads or the filters reaching the end of their effective life. Pulse jet cleaning has been refined for years in order to optimize the effectiveness of the cleaning system. Initially, a pulse of compressed air was just aimed at the filters, and the higher force of the compressed air increased the level of cleaning compared to a fan because a larger burst of energy pushed more dust off the filter media. This process was improved again by the addition of a blow pipe (nozzle) or jet tube in the clean air plenum of the dust collector. The blow pipe was used to help concentrate or manage the pulse energy to direct it towards the filter.
Figure 3: Normal airflow compared to cleaning cycle airflow
time. The airflow in the system would therefore show a pattern as pressure drop decreased after cleaning (airflow increased), then over time the pressure drop would climb again (airflow decreased). Overall, the performance of the cleaning system was very dependent on how often the collector could be shut down.
Reverse air cleaning

Reverse air cleaning introduced an airflow in the opposite direction of the filtered air (see Figure 3). The reverse airflow would penetrate the filter media from the clean filter side and knock the dust cake off the outer surface of the filter. Multiple methods were used to accomplish the reverse flow, including both fans and compressed air. Low- to medium-pressure reverse air cleaning systems typically used a continuously running fan blowing a large volume of lowpressure air in the opposite direction of the
Figure 4: Reverse air fan
Figure 5: Medium duty cleaning
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Figure 6: Compressed air cleaning
Filter cleaning optimization maximizes the life of the filter media while minimizing the amount of energy needed to achieve the best possible cleaning cycle.
Figure 7: Blow pipe and venturi Figure 8: Compact pulse shape
Another improvement was the addition of a venturi in the clean air plenum (see Figure 7). The venturi affected how the compressed air flowed into the clean side of the collector, how air followed the pulse of cleaning air, and how the cleaning air passed into the clean side of the actual filter. The venturi directed the flow of compressed air into the filter and optimized the cleaning power.
Advanced pulse energy cleaning

Advanced pulse energy shaping represents the next advancement of pulse cleaning, first introduced with the addition of a compact, efficiently designed filter pack which allowed refinement of the pulse cleaning system. It results in a filter that handles heavy loading and recovers efficiently from system upsets. One way this was accomplished was through a pulse accumulator that shaped the compressed air and optimized the pulse energy contacting the filter pack without restricting airflow or wasting energy (see Figure 8). Another technique is to control and optimize the direction of compressed air into the filter media using a zero-turn pulse design. The pulse flows with maximum cleaning energy in straight-line paths through the media (see Figure 9) allowing the dust to easily pulse out of the fluted channels.
Figure 9: Zero turn pulse
The transition from passive filtration to active cleaning in the dust collection industry has produced a variety of cleaning systems used in dust collectors. On-line cleaning, pulse jet technology, and new filter designs have all led to improved cleaning systems. Filter cleaning optimization maximizes the life of the filter media while minimizing the amount of energy needed to achieve the best possible cleaning cyclea win-win for dust collector E owners and operators. P Karen Wear is a Torit product manager at Donaldson Company Inc. Contact her at karen.wear@donaldson.com.
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Decoding efficiency for mechanical draft fans

By Nurul Moni Talukder, PE ProcessBarron
fficiency is a buzzword in todays economy. We are on a constant quest to improve efficiency in all aspects of our lives. We are obsessed with green energy, energy-efficient cars, the optimization of our power grid systems, and with improving the efficiency of our household appliances. Our daily interactions with everything around us demand that we become energy conscious. In the industrial sector, efficiency is also a hot topic, and one increasingly relevant to the design of mechanical draft fans. Mechanical draft fans are used in heavy industrial process operations to move fluid medium from one point to another (see Figure 1). They create draft in a process system so that flow medium can be induced, forced, and boosted. These machines consume a large amount of power, so understanding their efficiency dynamics is important.
question. This article explains each of these ratings and provides some working guidelines for assessing fan efficiency.
Defining efficiency
Efficiency is a calculated value. A fans total efficiency is defined as the ratio of theoretical air horsepower (AHP) to the actual brakehorsepower (BHP) input to the fan shaft. The equation that describes fan total efficiency can be expressed as:
t = (AHP/BHP) X 100
Losses between AHP and BHP can be attributed to skin friction, turbulence, leakage, and mechanical friction.1 So, total efficiency can also be expressed as a culmination of hydraulic, volumetric, and mechanical efficiency.
Efficiency matters
While there is a lot of talk about efficiency improvements, we often lose sight of how this parameter is derived and defined. Oftentimes, project specifications call for efficiency and competing fans are evaluated without proper qualifications and constraints. Equipment manufacturers are faced with the dilemma of deciding which efficiency rating to use when quoting to their clients. Often, projects are awarded based on superior efficiency ratings without giving much consideration to the way in which those ratings are derived. Currently, there are many different types of fan efficiency ratings prevalent in discussions of draft fan engineering. For instance, a centrifugal fan is selected and sized for certain flow characteristics requiring a finite brakehorsepower. For a given point of operation, while the brake-horsepower remains the same, the efficiency may take different forms. More specification is required, then, and ratings need to be explained and evaluated to see if they are relevant to the projects in
t = h x v x m h = Hydraulic efficiency v = Volume efficiency m = Mechanical efficiency

Hydraulic efficiency accounts for the imperfection of the flow path. Volumetric efficiency takes into account leakage through shaft seals and recirculation around the inlet cones and fan casing. Mechanical efficiency accounts for mechanical losses in the bearing, coupling, and seals in a fan system. Total efficiency can be used to calculate another important variable, a fans static efficiency, which is defined as the ratio of fan static pressure (FSP) to fan total pressure (FTP), multiplied by the fan total efficiency.
s = t (FSP/FTP) FSP = Fan static pressure FTP = Fan total pressure

It is important to note the difference between these two efficiencies. Fan total efficiency gives a higher number while static efficiency calculates a lower number. Paradoxically, a calculated higher efficiency does not demand
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a lower horsepower motor. Motor horsepower requirement for a given fan stays the same. The efficiency numbers are really a fluid dynamics phenomenon. The higher total efficiency is a function of total pressure, which combines static and velocity pressure components, whereas static efficiency only accounts for static component.
Deriving efficiency
The power required to drive mechanical draft fans is viewed as parasitic load. Therefore, minimizing input power to the fan will offer direct economic benefit to the plants. The intellectual knowledge base about the power and efficiency is bound to help engineers to properly specify a fan and manufacturers to optimize and design a better fan. The origin of production or consumption of power for fluid machinery has its roots in the fundamental thermodynamic relation: w = - v dP w = Work v = Specific volume dP = Change in pressure The AHP for a steady one-dimensional streamline flow can be derived from a classical energy equation, the simplified version of which can be mathematically expressed in the following form:
= QghS AHP = mw s Q = Volumetric flow rate, ft3/s = Density, slugs/ft3 hs = Head, ft
= (Q x SP x Kp)/ (CONST x BHP)

As a practical expression, this equation shows that fan efficiency is a function of volume, system pressure, and input power to the fan shaft. The other factor that affects this relation is the compressibility (Kp) of the fluid. Compressibility accounts for relative volume change due to a change in pressure inside the fan casing. This number generally varies from 0.90 to 0.99 for mechanical draft fans.
Figure 1: An example of a centrifugal type mechanical draft fan. All figures courtesy of ProcessBarron.
Efficiency ranges
The efficiency and power requirements of a draft fan depend on the type and style of the blades used in a particular application (see Figure 2). These two variables have an opposite relationship to each other. For example, a fan with a low horsepower demand will have a high calculated efficiency. Classically, fan blade designs are categorized in three major groups with relative efficiencies and degrees of power:
However, the actual input power (BHP) to drive a fan is described by the following mathematical relation:
Q = Volumetric flow rate (ft3/min) SP = Static pressure (w.c.) Kp = Compressibility constant CONST = Conversion constant, input power = 6353 BHP Draft fan engineers are most familiar with this formula and use it frequently to rate a fan. This equation can also be used for calculating hydrodynamic horsepower in a ducted flow. Rearranging the equation to calculate for efficiency, efficiency then becomes:
= Efficiency (%)
BHP = (Q x SP x Kp)/ (CONST x )
1. Radial
Straight radial blade (RB): Lowest efficiency (65% to 72%) and therefore highest horsepower demand. Radial tip (RT): Low efficiency (72% to 78%) and therefore high horsepower demand.
Fan total efficiency gives a higher number while static efficiency calculates a lower number. Paradoxically, a calculated higher efficiency does not demand a lower horsepower motor.
2. Forward curved
Forward curved (FC): Lower efficiency (72% to 76%) and therefore higher horsepower demand.
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Images courtesy of ProcessBaron

3. Backward inclined (BI)
Single thickness backward inclined flat (BF): High efficiency (79% to 81%) and therefore low horsepower demand. Single thickness backward curved (BC): Higher efficiency (80% to 82%) and therefore lower horsepower demand. Dual thickness airfoil (AF): Highest efficiency (83% to 88%) and therefore lowest horsepower demand. Fan static efficiency ( S) is calculated utilizing fan static pressure: S < SPR < t The Air Movement and Control Association (AMCA), an association of air system equipment manufacturers, provides rating guidelines to ensure a common platform for the engineers, manufacturers, and users. However, each project is unique and ultimate project execution goals are subject to the interpretation of the players involved.
Evase effects
When calculating efficiency, static pressure regain due to an evase at the fan outlet may also be accounted for. Evase output = Static pressure + (VP1 VP2) x Conversion efficiency Conversion efficiency may range from 60% to 80%. This has a dramatic effect on calculated efficiency and power input for some mechanical fan applications. Evase effectively reduces a fans working pressure requirements and thus reduces input power to the fan shaft. In order to avoid any confusion and to support fair comparisons, project specifications need to be abundantly clear if evase is to be considered when evaluating fans for efficiency.
Efficiency variations
A mechanical draft f a n s e ff i c i e n c y i s dependent on the system pressure used in each calculation. System pressure requirements can take many different forms, leading to an array of ratings. The primary variations are defined below: Static pressure rise: Static pressure differential between the fan outlet and inlet: SPR = SP2 SP1 (SPR = Static pressure rise; SP1 = SP2 = Static pressure at fan inlet and outlet) Fan total pressure: Total pressure differential between the fan outlet and inlet: FTP = TP2 TP1 (FTP = Fan total pressure; TP1 = TP1 = Total pressure at fan inlet and outlet) Fan static pressure: This represents the pressure difference between the fan total pressure and the velocity pressure at the fan outlet: FSP = FTP VP2 (FSP = Fan static pressure; VP2 = Fan outlet velocity pressure) There are corresponding efficiencies associated with each of these pressures: Static efficiency (SPR) is calculated utilizing static pressure rise. The relative comparison with other efficiencies can be mathematically expressed in the following form: S < SPR < t Fan total efficiency ( t) is calculated utilizing fan total pressure and bears the following relationship to static efficiency and fan static efficiency: t > SPR > S
Figure 2: Centrifugal fan characteristics curve.
Conclusion
Understanding the concepts of power and efficiency and their appropriate use in evaluation of the mechanical draft fans will undoubtedly help plants and engineers to clearly define the requirements and in return they will receive better response from the manufacturers. Evaluation of mechanical draft fans based on efficiency may not offer the desired benefit to the clients. As discussed in this article, an apparent higher efficiency does not necessarily mean a lower input power to the fan. The clients are the rate payers and they pay for the actual power used to drive the fans. So, for relative comparisons, input power to the fan should be evaluated rather than the calculated E efficiency. P Nurul Moni Talukder, PE, is a chief engineer in the Air Handling Group at ProcessBarron in Pelham, Ala. ProcessBarron is a leader in the design, manufacturing, installation, and maintenance of air and material handling equipment for heavy industry. Moni can be reached at mtalukder@processbarron.com.
Evaluation of mechanical draft fans based on efficiency may not offer the desired benefit to the clients.
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Figure 1: When the warehouse operation at Dot Foods in Mt. Sterling, Illinois was redesigned, they paid careful attention to how air movement within their facility was managed.
D
Photo courtesy: Rite-Hite Fans/AME
HVLS fans deliver energy savings from the top down

Food redistributor overcomes high ceiling and high energy costs to better manage heat.
By Dan Anderson Rite-Hite Fans
ot Foods, the nations largest food redistributor, offers nearly 105,000 products from over 600 food industry manufacturers. Originally called Associated Dairy Products, the company was founded in 1960 by Robert Tracy, who started by selling products out of the family station wagon. Over the past 50 years the company has grown from a regional, dairy products-only provider into a national operation handling all types of foods, virtually inventing the redistribution business model in the process. Today, it buys from food manufacturing companies and delivers to distributors nationwide in less-than-truckload (LTL) quantities. This redistribution model gives independent foodservice distributors access to products with lower purchase minimum requirements and shorter lead times. Customers can buy a mix of products (including dry, refrigerated, and frozen) with a combined minimum of just 5,000 lbs. Warehouse operations have always been a key to this innovative, customer-centric formula, as summarized in Dots Trusted Values. Innovative Solutions. Shared Growth. brand promise. Dot Foods views its warehouse space as an extension of its customers facilities, allowing them to sink less money into buildings and inventory and more into building sales. The company currently has 2.8 million sq ft of warehouse space in eight distribution centers around the country, serviced by a fleet of 1,320 trailers and 830 tractors.
An innovative solution
This dedication to innovative, quality warehouse space was evidenced recently when Dot underwent a massive, 145,000-sqft warehouse expansion at its Mt. Sterling, Illinois, headquarters. While any expansion of that magnitude poses challenges, this one was uniquely complex from an energy consumption standpoint. Not only did Mt. Sterling endure cold Midwestern winters, the facility had extremely high ceilings47 to 64 ft tall,
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I certainly wasnt interested in heating the ceiling.
Nadir Khalil, Dot Foods
which meant pushing heated air to the employees levels would be an issue. To make matters worse, the new section was going to be even taller, with ceilings up to 67 ft high. Another significant consideration was the areas energy supply; the community did not have natural gas, which is generally considered the most efficient energy source for heating. Dot Foods only obvious option was electric heat, a less efficient alternative. I certainly wasnt interested in heating the ceiling, particularly with electric heat, said Nader Khalil, Dot Foods corporate engineering manager. We needed to look at all available options to keep our energy costs down. As he began analyzing ways to design the most efficient HVAC system possible, Khalil learned of an incentive being offered by the local utility, Ameren Energy Illinois. Through its ActOnEnergy program, Ameren was offering customers a five-cent per kilowatt hour reduction of electric costs for each kilowatt hour the customer saved. Considering that the existing Mt. Sterling warehouse was using more than 25 million kWh of electricity per year, its understandable why this got Khalils attention. Determined to find an engineering approach that would qualify for this incentive, Khalil soon became intrigued with the potential of incorporating high-volume, lowspeed (HVLS) fans to complement the facilitys new heating system. Though the existing warehouse had made some use of traditional
high-speed fans, he felt that HVLS fans had much more potential to improve air movement and reduce energy use.
Better use of heated air

HVLS fans help save energy and improve comfort during the colder months of the year because they make better use of heated air. During the heating season, there is often more than a 20 F floor-to-ceiling temperature difference at most manufacturing plants and warehouses as a result of warm, light air rising and cold, heavy air settling. Typically, the air temperature will be one-half to one degree warmer for every foot in height. As such, a heating system must work hard for extended periods to maintain the temperature near the floor or at the thermostat setpoint, wasting precious energy and dollars. HVLS ceiling fans address this issue by gently moving warm air near the ceiling back down toward the floor where it is needed. When the air reaches the floor below the fan, it then moves horizontally a few feet above the floor and eventually rises to the ceiling, where it is cycled downward again. This mixing effect, known as destratification, creates a much more uniform air temperature with perhaps a single degree difference from floor to ceiling. With the use of an HVLS fan, there is less of a burden on the heating system, saving energy and dollars. Conventional high-speed ceiling fans have been used to help circulate air for many years. However, these smaller fans are less effective in moving the warm air from ceiling to floor. A typical high-speed ceiling fan spreads out the air quickly as it moves away from the fan. The result is that little, if any air, reaches the floor. Because HVLS fans can move air up to 22,000 sq ft, they can replace 10 to 20 smaller traditional fans. And with their smaller motor and lower operating speeds, they cost only pennies an hour to operate. After analyzing the potential of incorporating HVLS fans into the project, Khalil developed projections of HVAC system energy consumption both with and without the fans. These projections showed that Dot Foods could save 184,000 kWh in the first winter season alone by incorporating the fans. Based on that, the decision to purchase HVLS fans for the expansion project became what Khalil called beyond obviousand Ameren Illinois agreed.
Assess your facilitys energy upgrade potential
acility managers considering energy-efficiency upgrades dont have to do their ROI calculations in a vacuum. There are plenty of resources available, including sources from utility companies and equipment manufacturers. For example, Rite-Hite offers several different customized energy-saving assessment programs, including calculations focused on loading dock areas, interior doors, and HVLS fans. All use standard industry procedures; in the case of fans, Rite-Hites ROI Analysis Calculator incorporates ASHRAE fundamentals, national weather data, and buildingspecific variables to calculate potential energy (and cost) savings. While potential savings vary from facility to facility, they can be quite significant. For example, upgrades to dock equipment (such as shelters or leveler seals) can save a company as much as $1,000 annually, while interior and exterior door upgrades can generate annual savings up to $10,000. HVLS fan installations can help companies reduce heating and cooling costs as much as 20% to 30% annually, depending on the climate.
PLANT ENGINEERING
56 May 2013
Ask your utility about incentives
any states and local utilities offer incentives and rebates for facility equipment upgrades or custom expansion projects. While these incentives differ from utility to utility, most are based on the customers ability to demonstrate its reduction in consumption of kilowatt hours. Having an energy-efficient facility may also qualify a company for more favorable pricing or even free kilowatt hours. One handy resource for plant managers is the Database of State Incentives for Renewables & Efficiency site (www.dsireusa.org). As its name implies, the DSIRE site provides information about renewable energy and energy-efficiency incentives and policies across the United States. Relevant incentives established by federal government, state government, local government, and nonprofit organizations and utilities are included; however, utilities with less than 30,000 customers are generally not covered. Clicking a state on the DSIRE homepage provides a list of incentives offered by the type of program (e.g., tax credit or rebate), implementing sector (state or utility), eligible sectors (commercial), and eligible technologies (insulation) in that state. A search tool on the homepage also exists for plant managers looking for specific criteria (e.g., state, technology and type of incentive). Summary maps provide a geographical overview of certain financial incentives, while summary tables provide an overview of renewable energy and energy-efficiency incentives. Here are several examples of energy-efficiency incentive programs from different parts of the country: Wisconsin: The Focus on Energy program provides financial incentives for commercial building upgrades ranging from agricultural to municipal to industrial. Specifically, it helps offset costs associated with purchasing efficiency-enhancing replacement equipment like lighting, motors, and HVAC, or up to 30% of the project costs for nonstandard energy conservation measures. Any facility using up to an average of 1,000 kW per month in the past year is eligible for the program; some plans need to be pre-approved. Businesses will receive a check from Focus on Energy if paperwork is submitted within 60 days of installation of energy-efficient equipment. California: Silicon Valley Powers Commercial Energy Efficiency Rebate Program provides commercial business customers with up to a $47,500 rebate if their building meets LEED criteria and exceeds Title 24 energy requirements by at least 10%. All projects must be pre-approved; a pre-site inspection must be completed within six months of new equipment installation and a post-site inspection must be conducted within one month of installation. Detailed dated copies of all invoices must be submitted along with pertinent equipment data/cut sheets within two months of installation. Texas/Austin Energys Commercial Energy Management Rebate Program offers various ways for businesses to save money if energy-efficiency steps are taken, including HVAC equipment upgrades. Austin Energy can offer between $150 and $300 for every kW in energy saved, up to $200,000 or 50% of the projects cost, whichever is less. An application must be submitted before any work is done, as well as a pre- and post-site inspection.
With the use of an HVLS fan, there is less of a burden on the heating system, saving energy and dollars.
Ameren Energy was equally impressed with the warehouse destratification project and other energy-efficiency initiatives that Dot Foods had undertaken. We are pleased that Dot Foods has teamed with ActOnEnergy to achieve their energy-efficiency goals, said ActOnEnergy Business Program Manager Cheryl A. Miller. Clearly the partnership between ActOnEnwww.plantengineering.com
ergy and Dot Foods has been a win/win for all stakeholdersincluding the local E environment. P Dan Anderson is a product manager for Rite-Hite Fans. This article originally appeared in Target, the official magazine of the Association for Manufacturing Technology, a CFE Media partner.
PLANT ENGINEERING
May 2013 57
IN NOVATIONS
Cordless drill/driver series
The D5140 1/2-in. drill/driver has been added to the IQV20 Series cordless tool line. This tool offers the same durability and high-power performance as the other IQV20 Series products and the versatility to switch between drilling and fastening functions in seconds. The durable drill/driver is engineered to stand up to harsh operating conditions. The D5140 has a 16-position clutch that gives users more control over drilling and fastening applications. The clutch enables the operator to apply the right speed and pressure to complete tasks without damaging surface areas. As a result, the D5140 can be used on any materialincluding metal, wood, or plastic.
Ingersoll Rand www.ingersollrand.com
Input #200 at www.plantengineering.com/information
Washdown ac motors
WSS stainless steel ac motors are constructed with the windings doubleddipped and cured in polyester insulating varnish, anti-rust coated rotor to protect against corrosion, and double-lip seals plus V-ring shaft slingers. These 3-phase industrial grade washdown duty motors come in sizes from 1/3 to 2 hp and 1800 rpm. Other features include a TEFC enclosure, Class F insulation, and O-rings installed on the endbells to eliminate moisture. They are designed for water treatment, air/environmental control, and machine shops.
Omega Engineering, www.omega.com
Two-hand safety device Mobile iPad app

T&B Mobile is an iPad app that provides full access to the companys product, application, and industry information and insight, as well as distributor services, multimedia presentations, and electrical industry news and information. Once the application is downloaded, information is organized by markets, solutions, and products, and easily accessible. Information about the Signature Service program for distributors is also available through the Channels button. There are links to building information modeling objects, two- and three-dimensional models in computer-aided design formats, and the Floor Box Selector, which identifies the appropriate Steel City or Carlon floor box assembly for the specifications entered by the user.
Thomas & Betts www.tnb.com
OpGuard is a two-hand control that is also able to instantly adjust its height. OpGuard reduces workers strains by adding a flexible arm to the two-hand controls, enabling operators to reposition their controls to an ergonomic height. The arm has 11 in. of vertical adjustment, enabling the device to accommodate users of all heights. Additional features include availability with electric or pneumatic buttons and under-counter or wall surface mounting options. OpGuard has easy integration with machine controls and is made of durable steel and die-cast aluminum construction. Adjustable arms can be purchased independently with brackets to connect existing anti-tie down devices.
Easton Lean Tools www.eastonleantools.com
58 May 2013
PLANT ENGINEERING
Send New Product releases to: peproducts@cfemedia.com
Wire pulling, splinter protection

Splinter Guard Fish and Glow Rods come with a proprietary protective coating to keep hands free of fiberglass splinters when wire pulling. Raw fiberglass shards become exposed when rods scrape against the sharp edges of electrical boxes, wire trays, and threaded rod. Splinter Guard Rods are available in 5/32., 3/16, and -in. flexibilities and a variety of lengths. Sets include bullet nose and hook attachments to attach and grab wires. The sections can be threaded together to customize the length needed. In addition, the improved luminescent rods glow two times longer and twice as bright in dark workspaces.
Klein Tools, www.kleintools.com
Rotary disconnect switches

A new line of fused and nonfused rotary disconnect switches from 16 A to 1200 A also includes open and enclosed options to meet UL508 and UL98 requirements. This complete line of load break disconnect switches is built to serve as a main disconnect, provide branch circuit protection, or handle the equipment and motor loads often found in industrial or manufacturing applications. Open fused and nonfused disconnect switch models provide the flexibility of point-of-use configuration when designing and assembling custom panels. A complete offering of accessories, from handles and shafts to door mounting kits, allows users to custom build the exact configuration needed.
Cooper Bussmann www.cooperbussmann.com
Diesel lift truck

The DP40N1-DP55N1 Series features a new diesel engine that provides a 21.6% increase in fuel efficiency in addition to increased performance, reduced emissions levels, and a lower total cost of ownership. These new diesel lift trucks also offer customers a range of features and benefits, including increased energy efficiency and performance, maintenance-free emissions system, and Tier 4 final compliance. To meet these regulations, advanced technologies have been incorporated into the new Perkins 845F engines in the DP40N1-DP55N1 Series to lower the amount of Particulate Matter or soot that is released into the environment.
Cat-Lift Trucks, www.cat-lift.com
LED series fixtures

The WFH LED luminaire offers an LED light source tested and rated for 60,000 hours of maintenance-free use and carries a 5-year warranty against manufacturers defect and lumen output loss. It features a watershed design, heavy-duty aluminum construction, FDA accepted baked-on finish, and is rated for temperatures from -20 F to 122 F). Available with a 2 x 4 housing, welded aluminum lens frame, captive stainless steel hardware, and a watershed design, it offers true industrial performance in the most demanding environments. It is also available with either a clear or a prismatic acrylic lens.
Rig-A-Lite, www.rigalite.com
PLANT ENGINEERING
May 2013 59
IN NOVATIONS
Plinth/base assembly
Send New Product releases to: peproducts@cfemedia.com
The new Flex-Block plinth/base assembly is designed specifically for free-standing enclosures as well as liquid cooling packages. The Flex-Block design makes it possible to quickly clip together the plinth/base components and attach accessories like casters, leveling feet and cable management pieces without special tools. The base/plinth system comprises four corner modules and covers made of strong, fiberglass reinforced plastic, plus sheet steel side trim panels. The modular design and increased assembly space allow the four corner pieces, which support the entire weight of the enclosure, to be quickly and easily fitted underneath the enclosure.
Rittal, www.rittal.com
Wireless transmitter/receiver
The WRT Series Wireless Data Transmitter/Receiver provides a self-managed mesh network that works with any RS485 network protocol. The system allows for wired and wireless equipment mixes to avoid radio signal obstacles. It is also simple to configure for existing network packet parameters, provides LED indication of network status, and is completely transparent to present equipment. It has wireless data transmission of up to 100 m between receivers, and data transmissions up to 800 m transmissions are possible with multiple hops. The WRT series offers automatic route detection, self-forming and self-healing networking, and supports 100 nodes per network maximum through 15 channels.
NK Technologies, www.nktechnologies.com
Rotary hammer
The M12 Fuel 5/8-in. SDS Plus Rotary Hammer provides efficient run time, up to 75% more speed, and the largest SDS Plus bit capacity in its class. It also comes with Powerstate brushless motor, Redlithium battery pack, and Redlink Plus intelligence. The Electro Pneumatic Design allows for drilling of up to 5/8-in. holes in concrete and masonry. The tool also features 2-Mode Operation, Rotary Hammer and Hammer-only, which enhances its versatility. The M12 FUEL 5/8-in. SDS Plus Rotary Hammer is compatible with the entire M12 System.
Milwaukee Electric Tool Corporation, www.milwaukeetool.com
Unmanaged switches
Brad Direct-Link switches are available in 5- and 8-port modules, both featuring push-pull technology. The IP67 sealed Direct-Link switch modules provide a fast, simple, and secure onmachine Ethernet switch solution reducing network cabling and installation costs. The small footprint, field-proven, and rugged design make the Direct-Link switches ideal for heavyduty transportation and military vehicle applications. Direct-Link Ethernet switch modules allow users to quickly convert from traditional in-cabinet to on-machine mounting. Relocating the switch closer to the machine reduces installation time and costs for lengthy wiring runs, cabling, and protected cabinet enclosures.
Molex, www.molex.com
60 May 2013
PLANT ENGINEERING
PRODUCTMART
Why Should You Filter Your Water?
Scale formation reduces the heat transfer rate and increases the water pressure drop through the heat exchanger and pipes. In fact, one study has shown that .002" fouling will increase pumping needs by 20%.
The Best Engineered Water Filtering Solution Always Costs Less

2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A ( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8 w w w. t e k l e e n . c o m info@tekleen.com
Input #100 at plantengineering.hotims.com Input #101 at plantengineering.hotims.com
PORTABLE FALL PROTECTION

The Industry Leader!
F R E E C ATA L O G !
3.5" wide x 4.5" high New Capabilities, Brochure Outlines Our Total Process Solution. Pantone 382c
Rosler is pleased to present our new Capabilities Brochure. This full-color, four page catalog details all our mass nishing and shot blasting solutions in one easy-to-read piece. It starts with an overview of Roslers Battle Creek Test and Demonstration Laboratory and a description of our exclusive Total Process Solution. Weve included product photos and descriptions of vibratory and drag nishing, shot blasting and peening, consumables and efuent treatment products. Manufacturing in the United States and serving North American customers in virtually every industry including automotive, aerospace, medical, machining, steel fabrication and green energy, Rosler is backed by a global network of locations providing worldwide support and over 60 years of experience. For a free copy of our Capabilities Brochure, or more information on how Rosler offers special solutions for your specic challenges, please call 1-269-441-3000 or visit us on the web www.rosler.us.
Input #104 at plantengineering.hotims.com
No Holes! OSHA Compliant
763-694-2614
www.railguard.net
OIL MIST & SMOKE IN YOUR SHOP?

www.mistcollectors.com Tel: 1-800-645-4174
PLANT ENGINEERING
May 2013 61
For more information on how to advertise in Plant EnginEErings Internet Connection, call Jim Langhenry at 630-571-4070 x2203
alliedelec.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical products with over 50 sales offices across the United States and Canada. Allied Electronics
exair.com
Exairs product line includes Vortex Tubes and products utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination. Exair Corp.
automation.siemens.com
Siemens is a leader of automation technology products for all industrial sectors. Learn more about our unique range of products and systems. Siemens Automation Group
atlascopco.us
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco
flexicon.com
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.
tnb.com
Thomas & Betts supplies over 70% of the items used in a typical electrical application and provides market-leading commercial heating and ventilation products, supplying over 70% of the items used in a typical electrical application. Thomas & Betts Corp.
automationdirect.com
AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including PLCs, operator interfaces, sensors, and more. AutomationDirect
fluke.com
Fluke is the world leader in the manufacture, distribution, and service of electronic test tools and software. Fluke Corp.
ustsubaki.com
U.S. Tsubaki is a leading manufacturer and supplier of power transmission and motion control products and is the worlds market share leader in roller chains. U.S. Tsubaki, Inc.
gardnerdenver.com
Gardner Denver is a global manufacturer of industrial compressors, blowers, pumps, loading arms, and fuel systems. Gardner Denver Inc.
baldor.com
Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.
vaisala.com
Vaisalas core business is environmental measurement, especially weather measurement and chosen industrial measurements. Vaisala
gorbel.com
Gorbel provides a wide variety of overhead handling solutions that handle loads from 50 lbs up to 40 tons. Gorbel Inc.
bannerengineering.com
Banner Engineering helps customers increase efficiency, reduce costs, ensure quality, monitor and control processes, and safeguard employees. Banner Engineering Corp.
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.
lincolnelectric.com
Lincoln Electric is a leader in the design, development and manufacture of arc welding products, robotic arc-welding systems, plasma and oxyfuel cutting equipment. Lincoln Electric Co.
binsfeld.com
Binsfeld Engineering specializes in creating leading technology for transmitting data from rotating sensors. Binsfeld Engineering Inc.
lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.
camfilfarr.com
Camfil Farr is the worlds largest and leading manufacturer of filters and clean air solutions. Camfil Farr
diamondchain.com
Diamond Chain provides expertise in drive systems and design, wear and fatigue performance, and superior ROI with the consistent performance of its products. Diamond Chain Co.
nidec-motor.com
Nidec Motor Corp. is a leading manufacturer of commercial, industrial, and appliance motors and controls. Nidec Motor Corp.
ridgid.com
Every tool that bears the RIDGID brand is engineered to the same high standards of quality, strength, and endurance as was the first heavy-duty pipe wrench. RIDGID
donaldson.com
Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.
62 May 2013
plant engineering
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Allied Electronics 800-433-5700 Atlas Copco Compressors 866-688-9611 AutomationDirect 800-633-0405 Baldor Electric Company 800-828-4920 Banner Engineering Corp 888-373-6767 Binsfeld Engineering Inc. 800-524-3327 Camfil Air Pollution Control 800-479-6801 CompAir 800-372-2222 DIAMOND CHAIN COMPANY 800-872-4246 Donaldson Co., Inc 800-365-1331 Exair Corp 800-903-9247 Flexicon Corp 888-353-9426 Fluke Corp 888-443-5853 Gorbel, Inc 800-821-0086
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Lincoln Electric 888-935-3876 Lubriplate Lubricants Co 800-733-4755 Nidec 888-637-7333 Plant Engineerings Electronic Newsletters 630-571-4070 RIDGID 800-769-7743 Siemens Industry, Inc. 800-241-4453 Solutions For Engineers 630-571-4070 The Safety and Productivity Advantages of Intelligent Lifting Devices Webcast 630-571-4070 Thomas & Betts Corporation 901-252-8000 U.S. Tsubaki 800-323-7790 Vaisala, Inc. 888-824-7252 Yaskawa America, Inc 800-927-5292
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PLANT ENGINEERING
May 2013 63
INCONCLUSION
Trust, but verify a motto we can live with
T
Bob Vavra
Content Manager
The distributors of these counterfeit products want only the profit. The safety of the workers, they must reason, is someone elses problem.
he very worst part of the world we live in today is that we have become suspicious of one another. One perspective on the events of Boston in April is that two young men walking down the street carrying backpacks used to be no big deal. We dont have that feeling today. We can feel safe, but we probably wont for a while. The fertilizer plant explosion in West, Texas, is cause for more unease. Anyone who saw the harrowing video of the plant fire suddenly knocking over a family with the sheer force of the blast wave from a mile away cannot forget it. The workplace has specific hazards; this kind of event falls well outside those expectations. Circuit breakers are commodities. They are produced in the hundreds of thousands each year, and the great plants produce them all to the highest quality, to the most stringent tolerances. They do this because to do otherwise would jeopardize their business and their customers, and no amount of profit margin is worth that risk. Yet there are less reputable manufacturers who factor those risks into the cost of doing business. Worse, there are those who will make cheap knockoffs of the real thing and sell them to unsuspecting customers. The result can be dangerous, even deadly, but the distributors of these counterfeit products want only the profit. The safety of the workers, they must reason, is someone elses problem. So, as our cover story this month points out, we must be suspicious. We must be cautious. We must do for ourselves and our workers what those who would sell these phony items will not do for us. Take the case of Nick Toldy of Austin, Texas. According to the court documents, Toldy took American circuit breakers with him to China, and worked on having knock-off versions of the circuit breakers manufactured in China with the trademarks of several wellknown circuit breaker manufacturers. He also added the official trademark of Underwriters Laboratories and began selling the bogus circuit breakers not only as a legitimate product, but a product that bore the UL label. The Homeland Security Investigations division of the U.S. Immigrations and Customs Enforcement agency raided Toldys Pioneer
Breaker and Control Supply warehouse in Austin in April 2011 and seized 19,000 counterfeit breakers. A subsequent raid in Laredo, Texas, yielded another 77,000 phony breakers. By December 2011, Toldy had pled guilty to mail fraud and selling the phony breakers. In November 2012, he was sentenced by a federal judge to a year and a day in prison and ordered to pay almost $60,000 in restitution. At the time of Toldys guilty plea, Susan McCormick, the special agent in charge of the the U.S. Immigrations and Customs Enforcement investigation out of the Jacksonville, Fla., office, had some harsh words about Toldy. This individual, motivated only by greed, has allowed these potentially dangerous counterfeit circuit breakers to be bought and used in homes and businesses around the country, she said in a press release. These items, which have not been properly manufactured or tested, could lead to costly repairs, property damage, and even serious injury or death. The case of Nick Toldy ought to be a cautionary tale for the counterfeiters, except that his sentence of 366 days in jail, given federal sentencing guidelines, means that if he was sentenced last November, he ought to be getting out right aboutnow. The real cautionary tale is for the rest of us. Our story this month points out several things to look for with counterfeit breakers, and an experienced electrical manager probably can spot a phony. As it is with the products you manufacture, the product price is but one factor to consider. Know your supplierand if your supplier doesnt know you, look for another supplier. Examine your shipment when it comes through the door, and again before it goes in the machine. Trust, but verify, is a quote attributed to Ronald Reagan during the end of the Cold War and the negotiations with Russias Mikhail Gorbachev for an arms treaty. Ironically, its an old Russian adage, and as the story goes, when Reagan first spoke it to Gorbachev, he spoke it in Russian. Reagan knew that if he was going to use the phrase, he was going to give proper credit to its place of origin. Trust, but verify is a great way to reconcile our current world, inside and E outside our plant. P
64 May 2013
PLANT ENGINEERING
NOTHING GOOD HAPPENS AFTER MIDNIGHT
Nobody wants that middle-of-the-night-call telling you systems are down. Not you. Not us. And, certainly not the guy with the problem. Thats one of the reasons you should turn to Yaskawa for drives and motion control. Trust your operations to Yaskawa and the phone wont ring at night. The boss wont be in your ofce. And, maintenance wont be breathing down your neck with another re to put out. Trust Yaskawa and youll get a good nights sleep. Rest easy tonight. Call Yaskawa today.
YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M

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For more info:
2013 Yaskawa America Inc.
Together
Well Do BIG Things.
Baldor now offers the most complete line of large AC motors in the world. BaldorReliance motors deliver ratings to 1,500 Hp from stock and custom motors available to 15,000 Hp, alongside ABB induction and synchronous motors up to 100,000 Hp. Every large AC motor is designed and built for superior reliability, energy savings and rugged performance. Plus, our large AC motor line includes both NEMA and IEC configurations assuring you the motor you need meets frame, enclosure and duty cycle standards for any applicationanywhere in the world. One source for all your global motor needs. Only from Baldor and ABB. baldor.com 479-646-4711
NEMA and IEC Designs
Unmatched Quality
Superior Reliability
Global Sales and Support
2013 Baldor Electric Company
Download a QR reader app and scan this code for more information. http://qr2.it/Go/1031261

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SPECIAL REPORT: Air quality from the top down 41

Stainless Steel AC Motors

... with IP56 environmental rating

Ready for washdown and harsh environments!

Marathon Inverter-duty AC motors up to 100 hp, starting at $143

AR13-21 The Lincoln Electric Co. All Rights Reserved. www.lincolnelectric.com

NEVER SETTLE FOR

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41 Indoor air quality

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LED lighting from Banner.

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12. Emergency planning and response

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input #12 at www.plantengineering.com/information

A new angle in conduit connections

LU Universal Conduit Elbows: a 4-to-1 reduction over conventional conduit bodies

Compression crimping avoids need for exothermic grounds in any weather

665-AV2 Floor Boxes

Modular Metal Framing

input #13 at www.plantengineering.com/information

6. Taking a suite approach

input #14 at www.plantengineering.com/information

Equipment condition, not calendar, should drive maintenance