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Electricity-driven water purification method may extend to saltier waters
Penn State researchers are working toward a realistic purification option that is portable, lightweight and easy to operate stimulated by battery- or solar-powered electricity.
Concept for low-cost battery developed
Made from inexpensive, abundant materials, an aluminum-sulfur battery could provide low-cost backup storage for renewable energy sources.
Natural gas could play key role for clean hydrogen energy
Researchers at West Virginia University are attempting to use hydrogen energy as a clean energy alternative.
Borehole to reveal viability of campus’s geothermal future
Cornell University is breaking ground on its geothermal energy efforts in order to be carbon-neutral by 2035 with a 2-mile borehole to determine feasibility.
Top 5 Plant Engineering content: May 30 to June 5, 2022
The most-viewed content from the past week covered Product of the Year winners, power factor, EAM systems, equipment scanning and predictive maintenance. Miss something? You can catch up here.
Top 5 Plant Engineering content: May 23-29, 2022
The most-viewed content from the past week covered Product of the Year winners, power factor, EAM systems, equipment scanning and predictive maintenance. Miss something? You can catch up here.
Lithium-ion battery market expected to grow
The global Lithium-ion battery market is moving into surge mode with an increase of more than 70% in 2021.
Research groups join consortium to propose hydrogen energy hub
Cornell and two Cornell research-startups have joined a consortium that aims to propose a Northeast research hub to make hydrogen a viable, clean-energy alternative to carbon-based fuels.
RNG benefits for fleet vehicles
Renewable natural gas (RNG) and liquefied natural gas (LNG) are being increasingly used by companies such as UPS for their fleet vehicles. Learn why.
CHP success stories
Combined heat and power (CHP) systems play a key role throughout the United States as a key source of power for facilities and several examples of how they improve a facility’s overall performance are highlighted.
Top 5 Plant Engineering articles April 4-10, 2022
Articles about geothermal heat-pump wells, additive manufacturing, predicting process events, AI-based predictive maintenance and material handling systems were Plant Engineering’s five most clicked articles from April 4-10, 2022. Miss something? You can catch up here.
Your questions answered: Dynamic UPS systems: How kinetic energy can protect sensitive processes and equipment
Dynamic uninterruptible power supply systems provide conditioned electrical power to mission critical facilities. Learn the basics, along with benefits of specifying
Lithium-ion battery production goes global
The latest research from Interact Analytics into the fast-moving lithium-Ion battery market offers a dual-track focus.
TMDs could be used for ultrathin, lightweight solar panels
Stanford University researchers have developed transition metal dichalcogenides (TMDs), which could be used in mobile applications such as from self-powered wearable devices and sensors.
Rubber material key fo long-lasting, safer EV batteries
Researchers at the Georgia Institute of Technology have found rubber could be an alternative to conventional lithium-ion batteries.
Top 5 Plant Engineering articles Dec. 13-19, 2021
Articles about securing reliable power for upstream production, cybersecurity and IT/OT convergence, reducing downtime and risk with effective alarm management, and more were Plant Engineering’s five most clicked articles from Dec. 13-19, 2021. Miss something? You can catch up here.
Secure reliable power for upstream production
Lithium-ion batteries, diagnostics and connectivity contribute to solution
3D concrete printing system tested
A 3D concrete printing system is a cleaner, more cost efficient way to create anchors as opposed to continued use of steel anchors
Renewable energy will increase security and lower geopolitical risk
As renewable energy assume a greater share of the energy mix, risks to the continuity of the U.S. energy supply will dissipate
Building a secure energy and power grid for the future
The power grid that keeps the world running has historically been stable and secure. With digital transformation and the rise of converging technologies, there are many ways to create a better power grid, but it comes with challenges.
How to spot the top three track busway qualities
What to look for in a track busway power distribution system
Lithium battery developments step forward for electric vehicles, more
A team of scientists at the U.S. Department of Energy’s Pacific Northwest National Laboratory has created a lithium-metal battery that lasts for 600 cycles, which brings it closer to a lithium-ion battery's lifecycle.
5 things to consider before implementing a UPS
Critical control systems feed the Industrial Internet of Things (IIoT) and require uninterruptible power supplies (UPS) to prevent momentary power interruptions that could cause an industrial PC or other industrial controller to crash. Here’s how to choose an industrial UPS.
Engine donation supports research to reduce greenhouse gas emissions
Caterpillar donated an industrial natural gas engine to West Virginia University to bolster research aimed at developing new technology that reduces greenhouse gas emissions and improves fuel consumption at natural gas production sites.
Metal-free, recyclable peptide battery developed
A multidisciplinary team of researchers from Texas A&M University has made a breakthrough that could lead to battery production moving away from cobalt with lithium-ion (Li-ion) batteries.
Leveraging the 5G network to wirelessly power IoT devices
Turning 5G networks into a wireless power grid for Internet of Things (IoT) devices that need batteries to operate could eliminate them altogether down the road.
Using hydrogen in industry
A look at hydrogen, from generation to injecting it into gas networks to the role it plays in decarbonizing the steel industry
Using natural gas for metal processing
Metal processing involves the shaping and reshaping of metal materials to create useful objects, parts, assemblies and large-scale structures by producing metal from smelting of ore or remelting of scrap and many finished products, which may require further processing such as heat treating
China to lead global chlorine capacity additions by 2025
GlobalData reports that chlorine capacity is poised to see considerable growth by 2025 with China leading the charge.
Safer, fast-charging aqueous battery developed
A 3D zinc-manganese nano-alloy anode has been developed, resulting in a stable, high-performance aqueous battery that uses seawater as an electrolyte.
Manufacturing biobased electronics for sensors, batteries
Researchers are studying how plant-based inks can be used to print low-cost, biodegradable and recyclable sensors.
Generating renewable hydrogen fuel from the sea
Membranes originally developed for purifying water in the reverse osmosis (RO) treatment process, commonly used in electrolyzers, are used to remove salt from water to help turn sea water into hydrogen fuel.
Understanding the growing importance of hydrogen
A look at hydrogen, from generation to blending with natural gas
Atomic dynamics help turn heat into electricity
An atomic mechanism that makes some thermoelectric materials efficient near high-temperature phase transition could help unlock better options for technologies reliant on transforming heat into electricity.
Mirror-like photovoltaics get more electricity out of heat
Heat-harnessing solar cells that reflect 99% of the energy they can’t convert to electricity could help bring down the price of storing renewable energy as heat and improve overall energy efficiency.
Cause and effect of record-low energy prices
An elevated supply of natural gas and increased use of renewables, along with COVID-19 changing everyday life, has made energy prices drop to record lows.
How nanomaterials are improving battery design
Graphene coating enables new electrode designs with potential for electric vehicles
Adhesive tape improves lithium batteries’ performance, lifespan
Rice University researchers turned adhesive tape into a silicon oxide film improve lithium metal technology and make them last longer.
Making plastic more transparent while adding electrical conductivity
University of Michigan researchers have made plastic conductive while also making it more transparent, which can improve large touchscreens, LED light panels and window-mounted infrared solar cells.
Spectrometry research advances could lead to safer rechargeable batteries
Researchers have found a way to advance safer rechargeable batteries with spectrometry. Their findings could improve batteries used for consumer electronics such as laptops and cellphones.
Nanoscale hollow structure formation could boost battery storage
Researchers at Georgia Tech, ETH Zurich and Oak Ridge National Laboratory have discovered particles can change a nanoscale hollow structure formation, which could be beneficial for lithium-ion battery storage.
Solar energy farms could give electric vehicle batteries new life
An MIT study shows that electrical vehicle batteries could have a useful and profitable second life as backup storage for grid-scale solar photovoltaic (PV) installations.
Double-walled nanotubes have electro-optical advantages
Rice University calculations show double-walled nanotubes could be highly useful for solar panels and other nanoelectronics applications such as photovoltaics.
Cutting carbon in California
Environmental and energy concerns are typically addressed in California first; for a preview of what’s to come regarding decarbonization, look West
Metal battery using Potassium could be alternative to Lithium-ion
Researchers from Rensselaer Polytechnic Institute have created a metal battery that relies on potassium instead of Lithium-ion, which could create more energy efficient batteries for consumers.
Wearable power generator for IoT devices developed
Researchers at Purdue University have created technology designed to address the thickness issue for wearable power generation for Internet of Things (IoT) devices.
Electrode design may lead to more powerful batteries
An MIT research team has devised a lithium metal anode that could improve the longevity and energy density of future batteries.
Energy solutions will define our futures
What you have seen in automotive, you will see in lift trucks.
Synthetic compounds could help produce more energy from biogas
Researchers at the University of Michigan have found that synthetic compounds, called siloxanes, could be harnessed to produce more energy for industries such as wastewater treatment plants and other energy-dependent industries.
Top 5 Plant Engineering articles November 4-10
Articles about Leaders Under 40, low battery self-discharge, optimized maintenance programs, Industry 4.0 success, and industrial fire systems were Plant Engineering’s five most clicked articles from November 4-10. Miss something? You can catch up here.
Low battery self-discharge: the hidden secret to long operating life
While much media attention has been focused on extending battery operating life through the use of low-power chipsets and communication protocols, the potential energy savings gained from all of these schemes fails to compare with the energy lost to annual self-discharge.
LDC Focus: Spotlight on Atmos Energy
Atmos Energy Corp. has experienced growth as an energy provider for the distillery market in Kentucky and Tennessee.
CHP is a cost-effective solution for cannabis production
Combined heat & power (CHP) is a reliable source of electricity and power for cannabis owners, which need a constant and reliable source to ensure their plants quickly grow.
Fueling asphalt production with LNG and CNG
Asphalt companies without a readily-available pipeline are turning to LNG and CNG.
Top 5 Plant Engineering articles September 2-8
Articles about hybridization benefits, control system connectivity, arc flash hazards, VFDs in injection molding, and IIoT baby steps were Plant Engineering’s five most clicked articles from September 2-8. Miss something? You can catch up here.
Interdisciplinary team awarded grant to research bioenergy conversion
Cornell researchers received a $2 million grant to study the combination of inorganic semiconductor nanoparticles and bacterial cells for more efficient bioenergy conversion.
Greenhouse gases transformed into liquid fuel
Rice University researchers have found a common greenhouse gas could be repurposed in an efficient and environmentally friendly way with an electrolyzer that uses renewable electricity to produce pure liquid fuels.
Hybridization as a disruptive, profitable energy strategy for manufacturers
The basic configuration of electrical power systems for industrial and commercial applications has altered little for decades, but hybridization could change this in a disruptive and positive way.
Achieving long battery life with remote wireless devices
A lower self-discharge rate leads to longer operating life for batteries and a lower cost of ownership for remote wireless devices.
What to do when a production fan fails
Catastrophic failure of a critical piece of air handling equipment can be devastating.
Europe expected to be fastest-growing market for lithium-ion batteries
Interact Analysis reports Europe will be the fastest growing market for lithium-ion batteries with energy storage being the fastest growing sector.
Researchers develop device that channels heat into light
Rice University scientists are designing arrays of aligned single-wall carbon nanotubes to channel mid-infrared radiation and increase the efficiency of solar energy systems.
Unclonable digital fingerprints developed for IoT devices
Rice University integrated circuit (IC) designers have developed unclonable digital fingerprints for Internet of Things (IoT) devices that allows their PUF to be more energy efficient than previously published versions.
Hybrid cathode developed for lithium batteries
Researchers at MIT and China have developed a hybrid cathode that is designed to improve the lifespan of lithium batteries as well as making them lighter and smaller.
Researchers improve solid-state battery design
Cornell University researchers have advanced the design of solid-state batteries by transforming liquid electrolytes into solid polymers inside the electrochemical cell.
NGV trucking outlook on the rise
Increasing fueling opportunities for over-the-road (OTR) trucks and the availability of improved truck technology with larger, more efficient engines make natural gas vehicles a cost-effective, environmentally responsible choice because of lower emissions.
Full steam ahead: Packaged boilers
Packaged boilers focus on safety, efficiency, and modularity.
ISA releases CAP Learning System demo
ISA has recently released a fully operational free online demo of its Certified Automation Professional (CAP) Learning System. The system is a comprehensive CAP exam preparation and professional development tool. The program combines printed textbooks with online review and testing tools to provide automation training. The CAP Learning System includes comprehensive print materials, including seven textbooks covering the entire CAP body of knowledge and the seven technical topics on the exam.
Proficy Enterprise Connector
Proficy Enterprise Connector 1.5 provides bidirectional enterprise integration between Proficy and ERP systems such as SAP. The introduction of this real-time capability allows manufacturers to establish flexible production operations, helping them remain competitive in the global economy. The Enterprise Connector enables the mapping of the external Business Systems requests to/from the Proficy...
Steam system software
Spirax Sarco’s HVAC Solution Steam Program Version 3.2. is created for engineers, designers and contractors to design and model HVAC steam systems using intelligent objects. HVAC Solution Steam is a Windows-based drag-and-drop program. The software allows for easy modeling of steam generation, steam distribution, steam utilization and condensate-handling systems.
How Horsepower Works
The word "horsepower" is constantly mentioned regarding car and industrial engines. This edition of How Stuff Works defines the term, and explains how to measure it.DefinitionThe term horsepower was coined by engineer James Watt, who is most famous for his work on improving the performance of steam engines.
2018 Engineering Leader Under 40: Adwait Palsule, 39
Project Manager, Panacea Technologies Inc., Montgomeryville, PA, United States
2018 Engineering Leader Under 40: Adam Cleary, 26
Automation and Controls Technician, Crofter's Organic, Parry Sound, Ontario, Canada
2018 Engineering Leader Under 40: Raniel Camacho, PE, 33
Project Manager, San Francisco International Airport, San Francisco, CA, United States
CHP, DG, and microgrids energize universities
Combined heat and power (CHP), distributed generation (DG), and microgrids keep university campuses energized—fueled by natural gas.
Knowledge is power management when it comes to standards
Differing IEC, ANSI requirements can impact compliance.
2015 Engineering Leader Under 40: Bryant Jackson, 28
Systems Engineer/Task Manager, Leidos Engineering; Walled Lake, Mich.; BS Electrical Engineering Technology, Michigan Technological University
2015 Engineering Leader Under 40: Scott Lawless, 35
Project Manager, Leidos Engineering; Walled Lake, Mich.; BS Electrical Engineering & Computer Engineering, Kettering University
2015 Engineering Leader Under 40: Hunter Longshore, 33
R&D Professional—Control Systems Engineer; Sandvik Mining; Alachua, Fla.; BS Electrical Engineering, University of Florida
2015 Engineering Leader Under 40: Bret Van Wyk, 32
Program Manager; Interstates Control Systems Inc.; Sioux Center, Iowa; BS Computer Science & Systems Administration, Dordt College
Expandable liner hanger system
System is designed for reliability in challenging deepwater environments with elevated temperatures
Innovation as a formal management process
Want light bulbs to go off? Create a way to encourage, act on new ideas.
2014 Engineering Leader Under 40: Kenneth Benedict
Project Manager; Avid Solutions; Winston-Salem, N.C.
2014 Engineering Leader Under 40: Jason Donath
Project Manager; Avid Solutions; Winston-Salem, N.C.
2014 Engineering Leader Under 40: John Glenski
Senior Controls Engineer; Process Plus; Cincinnati, Ohio
2014 Engineering Leader Under 40: Heather Johnson
Division Manager; Interstates Control Systems Inc.; Sioux Center, Iowa
2014 Engineering Leader Under 40: Thomas Keeports
Electrical Controls Engineer; JST Corporation; Harrisburg, Pa.
Even air gaps are not secure
Even if air gaps were workable in today’s industrial control environment, that could end up being a moot point as there is a malware prototype that uses inaudible audio signals to communicate and covertly transmit sensitive data even when infected machines have no network connection.
Understanding Flash Steam
Effective flash steam recovery can be a valuable source of heat.
Manufacturing consortium to focus on high-tech power electronics
Obama announces $140 million project at NC State; universities, companies to partner on research and development
Intelligent rack PDUs driving total global rack PDU revenue growth of 6% in 2013
Global rack power distribution unit 2013 shipments are projected to grow 3%, while 2013 global revenue is projected to grow over twice as fast, at a rate of 6.3%, according to a recent IHS Inc. report.
Fossil fuels sector loses steam in the medium- and high-power generator markets
The fossil fuels sector dominates the medium- and high-power generator markets, but the share of new generator sales that utilize fossil fuels may decline, according to research by IHS.
2013 Product of the Year finalists: Power Transmission
Finalists in the Power Transmission category for the Plant Engineering 2013 Product of the Year competition.
Steam tip: Ensure that your boiler is operating at its best performance
There are many things you can do to ensure your boiler is operating optimally.
PV inverter supplier base fragments in 2012 – Minimal impact from recent M&A activity in 2013
The market share of the 10 largest PV inverter suppliers fell from 62% in 2011 to 56% in 2012.
Using Lean to add value, achieve operational experience
Lean manufacturing can be measured for operational excellence in three ways to ensure manufacturers are getting the most efficiency and engagement from their workers and machines
Modular software to boost productivity
Part 2 in the "Staying ahead of the technology curve" series explains how leveraging modular software for more efficient machine automation engineering
Pipe joining systems get in the groove
Ease of maintenance cited as a major advantage
PV inverter after-sales service market to double by 2017
Despite PV inverter hardware profit margins being squeezed, the after-sales service market is forecast to more than double by 2017 to reach $1.7 billion, providing suppliers with a valuable additional profit source.
Connector system for limited spacing
The SpeedStack Mezzanine Connector System supports data rates of up to 40 Gbps and is designed for OEMs that contend with limited PCB real estate.
Thermal imaging camera kit
The thermal imaging camera kit features plug-and-play compatibility and sensitivity of <50mK and features everything needed for "out of box" deployment.
Photovoltaic module shipments surge in the fourth quarter of 2012
A new PV module shipment record of 11 GW was reached in the fourth quarter.
CMMS: Work out the kinks in maintenance
When it comes to maintenance, don’t underestimate the value of CMMS consulting and maintenance organization analysis.
Microinverters, power optimizers outpace PV inverters in 2011 – 70% growth predicted in 2012
IMS Research’s latest report “The World Market for Microinverters & Power Optimizers – 2012” revealed that shipments of the products grew by more than 180% last year and at the same time revenues surged by 160% to more than $200 million.
2012 Leader Under 40: Mohamed AbuAli, 30
Chief Operating Officer, FORCAM Inc., Cincinnati
PV module prices dive again in July as German rush ends
Photovoltaic module prices continued their downward trend in July, falling by more than 2% over June’s average prices and 44% down annually, according to IMS Research.
“UPS” and downs in backup power market
While it is customary to see sales decline in the first quarter of the new year as a result of the seasonal post-holiday slump, UPS sales were especially slow in 1Q 2012.
Time-honored technology has a new luster
Today, watertube units are dominant in many industrial applications. Fire-tube units, tubeless units, and hybrid boilers have their places, but when an industrial user needs medium- or high-pressure steam, and lots of it, watertube boilers usually get the nod.
Gas Technology: CHP does it all
We started talking seriously about cogeneration back in the 1970s. The idea was to find a use for waste heat from the engines or turbines used for on-site electric generation. This concept has found many adopters, and today is getting a serious foothold in the industrial energy market
Wireless evolves to meet a new range of challenges
Efficiency and productivity on the plant floor are crucial components to delivering consistent product quality, minimizing downtime, and improving customer satisfaction.
Booming China market creates opportunities for PV inverter manufacturers
The Chinese PV inverter market, driven by the introduction of the national FiT, grew by over 400% in 2011.
African Frontier: Shell buys Cove Energy
Safety and security are major initiatives for energy companies, but refiners will have to step it up a notch as Africa is becoming an oil and gas hotbed of activity.
Data center products a key factor in ABB purchase
An IMS Research analyst sees advantages after Thomas and Betts acquisition by ABB.
Air handler system
The 2012 AHR Expo took place Jan. 23-25, 2012 in Chicago. Among the new products introduced at the show were:
POY Finalist: Surface-mounted lifeline system
Finalist in Safety in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Cable protection system
Finalist in Safety in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Data matrix positioning system
Finalist in Automation and Control in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Flame-free press system
Finalist in Compressed Air in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Moving mast reach trucks
Finalist in Material Handling Systems in Plant Engineering’s 2011 Product of the Year competition
White paper: Flow measurement
Flow measurement solutions for a more energy-efficient world.
Details emerge on China’s first domestically developed MOCVD tools used in production
The Chinese LED manufacturer, Yangzhou Longyao, currently utilizes more than 10 Aixtron systems at two different facilities in Shanghai and Yangzhou. In addition to producing LEDs, it created a company focused on building MOCVD tools under the Yongsheng brand. MOCVD tools are the most critical tools for manufacturing LEDs.
Treating corrosion as a process variable
Corrosion, when examined as a process variable, can be both monitored and controlled in real time.
UK PV conference: Depressing, downbeat and dead?
The overall state of affairs for the PV market in the UK is an uncertain mood after the tariff system was halted in late 2010.
Best practices for ultrasound testing of steam traps
Follow these steps to use ultrasound testing for steam traps with inverted bucket operation, float and thermostatic operation, thermodynamic operation, and thermostatic operation.
Ford, GM work together toward recovery
After a rough decade, auto giants learn, change, and rebound
Firing up a burner system
Addition of new technology through safety instrumented system brings paper mill more advanced diagnostics and a big boost in security features.
AME event: Staying competitive in a global economy through sustainable lean execution
Workshop hosted by Ventana Medical Systems; May 5, 2011; Tuscon, AZ
It’s “Take a Congressman to work’ month
Plant Engineering Content Manager and Editor, Bob Vavra, discusses his experience at the 2011 Manufacturing/Automation Summit in Chicago, IL.
Schneider Electric receives Green Cross for Safety Medal
Schneider becomes first company to earn top two NSC safety honors
Beckhoff Automation increases turnover by 46% to $500 million in 2010
Growth fuels office and production expansion for Beckhoff in Verl, Germany
U.S. reactor back-up batteries weak
Almost all American nuclear power plants have backup batteries that would last only half as long as those at Japan's troubled Fukushima Daiichi plant did after a tsunami knocked out power there, an expert testified at a Senate committee briefing on nuclear safety.
Best Practices: The soft side of Root Cause Analysis
Eliminate the risk of recurrence of an undesirable event by identifying root causes and taking corrective action
U.S. nuke design could help Japan
The earthquake and tsunami exceeded the design basis of the plant
Cyber task force eyes power grid
A cyber-attack task force is forming to evaluate a way to help protect the U.S. power grid in the event of a web-based assault, said officials at the North American Electric Reliability Corporation (NERC)
Product package for special handling applications
Special Product Package from IFH Group is designed for applications involving corrosive chemicals and other abrasive fluids that require special handling for safety and efficiency
Reports determine New Jersey lost fewer manufacturing jobs
Manufacturers’ News, Inc. reports New Jersey lost 14,511 manufacturing jobs from December 2009 to December 2010, compared to 23,798 jobs lost over the 2008-2009 survey period
1.2 million power engineering initiative at NC State
ABB commits $632,000 over five years to support power engineering research, education at North Carolina State University
AMT elects 2011-2012 officers, directors
'We expect to see the support generated for manufacturing in the U.S. increase," said new association chairman, Eugene Haffely, PE.
AMT/AMTDA report: Manufacturing growth spurt continues
December 2010 growth doubles from 2009 levels; year closes up more than 85%
APC Symmetra PX 250/500kW supports parallel configurations up to 2000kW
The Symmetra PX250/500kW offers a modular, hot-scalable system consisting of dedicated and redundant modules.
Dust Collection Seminars offered for free
Camfil Farr APC delivers free seminars on dust collection, industrial ventilation basics from headquarters, regional offices
Management software enables revenue growth, reduced supply chain costs
Enhancements to the FlexNet Producer Suite facilitate revenue growth by empowering manufacturers to more quickly monetize high-tech devices throughout their lifecycle.
Embedded Vision System supports PoE
PoE support reduces cabling complexity for M40 processor by eliminating the necessity for camera power cables; reducing costs, enhancing system reliability.
Underground security system
The border-monitoring system, known as Helios, could watch the entire US-Mexico border continuously.
SC utility slow to fix nuclear safety equipment
Progress Energy Carolinas faces increased federal oversight as a result of problems cited by the U.S. Nuclear Regulatory Commission in a recently issued notice of violation.
ABB acquires Insert Key Solutions to software portfolio
Insert Key Solutions has been added to ABB’s Ventyx software portfolio, bringing comprehensive solutions for the power industry to the table
BREAKING NEWS: ABB’s acquisition of Baldor seen as a big bet on energy efficiency
ABB says deal "strengthen ABB’s position as a leading supplier of industrial motion solutions, and will also enable ABB to tap the huge potential in North America for rail and wind investments."
Static grounding dangerous, preventable
Clamps, cables must meet strict testing guidelines to forestall accidents
GAS TECHNOLOGY: Coil Tube Boilers
Solving the Industrial Boiler Replacement Riddle
ROCKWELL REPORT: Automation, technology seen as manufacturing assets
The overall need for a more pervasive use of automation and technology was not just the subject of show floor discussions, but also the topic for a research study released at Automation Fair by Rockwell Automation, the Fair’s sponsor, and the Opinion Research Corporation.
Global Plant Engineering: Enhance your alarm management analysis
Ebook includes news and features from around the world
Expanding our tools to tighten the Skills Gap
Issues concerning the recruitment and retention of the up-and-coming science, technology, engineering and mathematics (STEM) workforce have begun to take center stage – with no shortage of evidence to support the claim.
GAS TECHNOLOGY: New thermal oxidizer designs
The goal is to reduce emissions of volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). Examples of such exhaust stream sources are paint or solvent vapors, printing exhausts, petrochemicals, pharmaceuticals, and plastics manufacturing.
GAS TECHNOLOGY: CNG fueling for heavy-duty trucks
The U.S. EPA has issued rule modifications to make the conversion of gasoline and diesel engines to natural gas less restrictive and easier to achieve from engine family to engine family, and from year to year. Several federal bills are pending to add tax credits for bi-fuel (gasoline/CNG) and dual-fuel (diesel-natural gas) and to double the tax credits for CNG and LNG fueling structures.
Larger microturbines make inroads in industrial cogeneration
Microturbines have come a long way. These distant descendants of aviation auxiliary power supply turbines and automotive turbochargers were first developed in the 1990s. From the beginning, they have been recognized as an important technology for on-site electric generation. Beneficial use of the turbine waste heat has always been the key to successful installations.
Logistics software
The ERP SyteLine Shipping and Logistics module, developed in collaboration with solution partner Pacejet, provides enhanced shipping, warehouse and logistics controls for managing order fulfillment. ERP SyteLine Shipping and Logistics enables customers to speed and simplify picking, packing and shipping processes to reduce costs, eliminate errors and improve customer service.
Isolation switches
The RTS series bypass/isolation switches are UL labeled and listed for 30-cycle closing and withstand ratings based on testing per UL Standard 1008. Available in continuous current ratings from 100 to 3,000 A, these switches dramatically simplify the selective coordination of overcurrent devices in backup power systems for healthcare and other mission-critical facilities.
Direct drive motor/drive system
RPM AC Cooling Tower Direct Drive system eliminates the gearbox and mechanical transmission drive for cooling tower applications. The system combines a laminated-frame ac motor with permanent magnet salient pole rotor design and an adjustable speed drive. The fan couples directly to the motor, which is designed for minimal maintenance.
Power supplies – 2010-02-01
The NXT-400 series of compact ac/dc power supplies pack 400 W of power into a 1U high enclosure. The power supply is available in eight models that provide adjustable, single outputs from 2.5 Vdc to 48 Vdc. Standard features include 85% efficiency (typical), 0.5% line and load regulation and operating temperatures up to 70 C with airflow and a power factor corrected.
MAPI report: manufacturing recovery "in sight"
Leading index jumps above 50 threshold for first time in 18 months, signaling pending improvement
When updating your computer security, why patch?
Why should you be concerned about applying security patches to the computers in your manufacturing zone? Simply put, because no buffer zone provides a perfect security solution for your automation system. The reality is that in order to operate your manufacturing plant, data and people need to move between enterprise and manufacturing zones.
Thread sealant
The Loctite 5452 is specifically formulated for use on metal fittings found in high pressure hydraulic and pneumatic power systems. Curing four times faster than traditional anaerobic sealants even on stainless steel or inert metals, the 5452 sealant allows fittings under low pressure to be returned to service immediately.
Plant design and operation
Simulation software enables plant designers to view design scenarios in a virtual world without the expense, time delay and risk of testing it in the real world. This presents an ideal opportunity to test plant and maintenance issues early in the design phase, enabling plant engineers to compare, for example, how modifications in scheduling, downtime and maintenance strategies might reduce cost...
No-mix epoxy resin system
This UV curable, no-mix epoxy resin system has exceptional sealing and gap-filling properties and excels in applications such as aligning parts and bonding irregularly shaped surfaces.
Energy Dept. funds $155 million in industrial projects
Program focus is cutting energy waste in manufacturing
Searching for energy efficiency incentives?
Want money for becoming more energy efficient? Besides the obvious payoff of reduced energy bills, rebate and incentive dollars are out there if you know where to look.
Dual channel CompactFlash
The Dual Channel line of CompactFlash (CF) cards is designed for speed, durability and extended temperature operation. The CF cards are ideal for high performance embedded systems applications requiring high reliability and high tolerance to shock, vibration, humidity and altitude, as well as -40 C to 85 C temperature operation.
Submersible pressure transmitters for Class I, Div. 1
Submersible pressure transmitters are optimized for detecting the level of water or other media with similar density in challenging industrial environments including wastewater and irrigation systems and tanks containing liquids such as gas and diesel.
Groups bring expertise to co-located events at ISA
Seven organizations will co-locate their events at the 2009 ISA Expo on Oct. 6–8 at the Reliant Center in Houston. The Presentations at this year's ISA Expo include:
ISA announces seven co-hosted events at Houston Expo
ARC, NIST among groups presenting at conference
Next-generation RPM software
This mobile productivity solution sets up quickly to collect relevant data from production systems without any changes to the existing assets or disrupting the operations.
What’s Up With Wireless Safety? Comment: Failsafe, Yes, But a Nuisance?
Wireless communication has been around for several years, experiencing many ups and downs. Today - it’s largely considered just another communications bus with its own set of design and application criteria. Its maturity and acceptability has now created the launching pad for adding safety functionality over wireless.
Sensor simulator for testing
This sensor simulator installs in place of an ICP sensor and accepts test signals from a voltage function generator.
ABB conference highlights economics, services, and R&D
Automation & Power World event confronts economic issues
Celebrities help draw attention to skilled worker shortage
The data is there; now it's supported by folks like Jay Leno and John Ratzenberger
Zumtobel Lighting joins consortium
Highland, NY-based Zumtobel Lighting Inc. (www.zumtobel.us) has joined the Emerge Alliance (www.EMergeAlliance.org), a consortium whose focus is to address the growing need for flexibility, efficiency and sustainability. Comprised of experts in architecture, engineering and construction practices, the EMerge Alliance consortium was launched by Armstrong World Industries, Johnson Controls, Nexte...
Real recognition: Expert lists “Top 10” ways to keep auto workers productive
Roy Saunderson, president of Recognition Management Institute, a worldwide consulting firm focused on helping companies motivate their workforces to increase productivity thus profits, has prepared a “Top 10” for how HR professionals, department managers, frontline supervisors, and C-level execs can keep autoworkers focused on the job during the bailout/bankruptcy uncertainty.
Rockwell Automation puts emphasis on convergence at conference
Automation Fair focus is on plant/IT cooperation
Rack mount single-phase UPS
This double-conversion UPS is available in a rack mount design and up to four units can be installed in parallel.
Gas leak detector
The OptoAcoustic GLD-OA-01 gas sensor comprises two identical cells that act interchangeably either as a primary gas-measurement cell or as a secondary compensation cell. The dual-cell design eliminates the need for calibration. The secondary cell provides an active sensing element and a backup sensing element within one unit.
ARC Asset Lifecycle Management Forum takes on digital plant
The ARC Asset Lifecycle Management Forum will take place Oct. 13-15 at the Marriott Westchase Hotel in Houston. The “Digital Plant of the Future” forum will discuss optimizing asset lifecycle performance through better Asset Information Management (AIM).
HVLS fan maker, alarm company team up on smoke detection
Big Ass Fans, Xtralis enter into joint partnership to integrate early detection
Conditioning system
The DSC-2300 Series high-performance signal conditioning systems are programmable and network-centric systems, housed in a 3U, 16-slot rack-mountable chassis.
Low-temperature actuator
Valvcon ADC low-temperature actuators provide a torque of up to 3,000 inches per pounds in a packaged weight of only 31 pounds.
Two takes on VW’s Tennessee facility
Volkswagen’s move to Chattanooga seen as a boon to its new home, a challenge to the rest of the region
Laser system
The laser systems checks for operating efficiencies in roll and web lines, CNC cutting and milling equipment, lathes, stamping presses, injection molding machines, and extrusion systems.
Change management software
Proficy change management solution software version 5.8 tracks changes to critical assets. It offers a web-based client that provides access to common functions such as version reports, check in and check out, as well as a functional drag-and-drop interface. The scheduler allows the user to automate backup procedures.
Infrared camera – 2008-07-09
The EZTherm 880 portable infrared camera line strengthens the role of thermal imaging in any facility’s predictive maintenance program.
German Sedans Slip
Could Consumer Reports actually be correct in listing Japanese makes as tops in ratings for performance and reliability?
Inventory management software
FastPic4 inventory management software automatically displays a photo of the item the user is required to pick.
Government policy: Trade group wants R&D tax credit restored
A coalition of trade associations is urging Congress to act quickly in restoring the federal Research & Development (R&D) Tax Credit that was allowed to expire at the end of last year. A group calling itself The R&D Credit Coalition is using an Ernst & Young study on the impact of the tax credit to bolster its argument for its restoration.
Pelican acquires Blue i, launches sustainable lighting div
Advanced lighting systems manufacturer, Pelican Products Inc., has launched a new division focused on bringing to market environmentally sustainable, energy-efficient and powerful LED lighting products. Peli AALG Limited combines Pelican’s nearly 30 years of advanced lighting technology with the expertise and products of newly acquired Blue i UK Ltd.
Looming skills shortage prompts innovative workforce retention and recruiting strategies
A shortage of highly skilled manufacturing workers—the people running sophisticated equipment on the plant floor, as well as engineering and management professionals—poses a serious threat for North American industrial competitiveness. The shortage lies in the demographics as legions of baby boomers near retirement.
IBM investments: Telelogic acquisition finalized; EnterpriseDB gets backing
Almost a year after making its original $745M offer, IBM completed its buy of Telelogic AB in early April, and plans to play a larger role in the software development aspects of product life-cycle management (PLM). Under the deal, Telelogic will be folded under IBM's Rational software brand, which is known for tools used across all stages of the software development life cycle.
Economic trends: Manufacturers in upstate New York see both sides of globalization
Midstate Spring has made coiled wire forms and precision for nearly seven decades. But the soaring price it pays for steel and copper wire is set by global supply and demand trends, and that's put Midstate in a world of hurt. Across town, a scrap yard operated by Metalico Syracuse Inc. is enjoying good fortune. It sells mostly to nearby mills such as Nucor Steel in Auburn, N.Y., not to foreign countries, yet it nets a rising global price. Welcome to the increasingly complicated world of international trade.
Inventory tracking solution
Built on the company’s Sky-Trax indoor positioning system and the Skan-Free identification imaging system, the Total-Trax system automatically captures exact pallet location and identification, vehicle location, precise location and full path tracking of warehouse assets.
North American companies may miss REACH deadline
Despite a Nov. 30 deadline, many business leaders appear lax about taking steps to comply with the Registration, Evaluation and Authorization of Chemicals legislation, or REACH, according to a survey released March 11 by PricewaterhouseCoopers.
Kevin Parker: Innovation as a collective undertaking applied to newly pervasive technologies
Why is innovation the current king of management concepts? How has it become in manufacturing circles something akin to one of the “four big truths” or “five shining lights” that used to emerge with the five-year plans of command economies? According to Paths of Innovation: Technological Change in 20th Century America, by Mowery and Rosenburg, it wasn't till the second h...
Drum-top vacuum
Drum-top vacuum fits 30- and 55-gallon drums, and allows users to recycle drums.
Online UPS
The UniStar P series single-phase online UPS protects over a range of input voltages. The double-conversion UPS is available in 6-, 8- and 10-kVA models and protects from outages and irregularities in incoming line voltages from 160 to 280 VA at 45 to 65 Hz.
Heating systems
Thermo Rotation heating systems provide temperature distribution throughout a facility with variances ranging between two and three degrees from floor to ceiling. Coupled with ThermoMixer technology, the systems prevent condensation and do not introduce moisture into the building. Systems are available for natural gas, oil, LP gas, hot water and steam applications.
BMW announces plant expansion
The three-year construction project includes a new 1.2 million square foot assembly facility north of the existing factory, along with an expansion of the paint shop and renovation of the existing body shops.
Door system
The Speed-Commander 1400 SoftEdge is a high-performance, high-speed, roll-up door system, designed for use on interior openings measuring up to 14 x 16 feet.
Hand-vacuum suction cups
Industrial-duty hand-vacuum suction cups, suitable a variety of products and materials, are offered in more than 40 varieties for applications ranging from assembly to installation operations.
Workforce development leads to economic development: report
The economic development efforts in Minot, ND are on the upswing, and civic leaders convened a meeting of the North Dakota Workforce Development Council to look for new ways to develop economic opportunities in the region. Consultant Greg Newton told the group that workforce development is a key to economic development.
Parallel three-phase UPS
The RP36000/3 three-phase UPS enables attached servers to save all work in progress and initiate a shutdown in the event of power loss, and restores it with Thermal Logic power policies to ensure business picks up where it left off. The pre-racked UPS provides 36 kW of power or 24 kW with N+1 redundancy.
WORKFORCE DEVELOPMENT UPDATE
* Virginiagovernor touts skills development * Georgia college seeks $10.8 million from state* Consultant: Workforce development leads to economic development
DIN rail dc UPS
The 24 Vdc uninterruptible power supply is designed to provide maximum uptime and protection from unexpected dc power disruptions. It is intended for industrial computer, robotics, automation and process control applications.
What’s the ‘M’ in TPM?
It’s confusing, at times, when working with a number of sophisticated clients who are engaging my help to implement TPM because I see the same acronym used to drive change within organizations, but with so many different meanings. So I ask you, what’s the “M” in your TPM? The first time I asked this question, I got the strangest look.
ABB exhibits analytics solutions
ABB showcased some of its process analytics solutions at its booth (#1228) during ISA Expo 2007. These solutions provide precise measurements and monitoring for process industries, including hydrocarbon processing, gas processing and petrochemicals, as well as laboratory applications. Analyzers featured at the booth include: EasyLine3000 and ACX – these analyzers complement the Advance Op...
Modular UPS
Powerware BladeUPS is a rack-based UPS designed and optimized for today's high-powered blade servers and high-density computing environments. The three-phase system is efficient, scalable and flexible. The UPS provides 12 kW of power in only 6U of 19-inch rack space, including batteries. Patented load-sharing control distributes the workload among modules without requiring direct synchronizatio...
Ball-bearing housing
The pillow-block housing unit is available with either a set-screw or eccentric collar locking system. Designed to be more durable than previous models in both upright and upside-down mounting positions, the housing has flat feet to provide strength, eliminate stress points in recessed corners and prevent accumulation of ambient material under the feet.
A strategic move: Oracle buying S&OP specialist
In another shot across the bow to SAP, Oracle has acquired Interlace Systems, a provider of Integrated Business Planning tools, for an undisclosed sum. Interlace’s offerings help planners ensure that Sales & Operations Planning (S&OP) remains on target.
Schneider Electric backs Virginia Tech research effort
IDAPS project focuses on integrating distributed energy resources with demand-side management
High-speed camera system
Network-ready, the InLine high-speed digital camera system captures line stoppages and automatically downloads the images, via gigabit Ethernet, to a pre-selected computer for analysis. System cameras continually monitor operator-selectable areas of production lines. When a failure is sensed, the system stops recording and automatically downloads the images to a computer.
Mixing Lean and ‘green’ delivers sustainability for manufacturer
Not every company is as environmentally focused as Canyon Creek Cabinet Company in Monroe, WA. With a five-year plan to reduce toxic waste emissions, a mission statement that requires environmental considerations in major business decisions, a full-time environmental manager on staff and an environmental management system in place, the company clearly places a high priority on reducing waste, p...
Industrial vacuum
The CFM 125 is a lightweight, polypropylene-constructed industrial vacuum designed to help maintain a dust-free environment in the concrete industry. Powered by two 800-watt motors, the vacuum is suitable for use with surface preparation tools and equipment. Other features include an oversized main filter, an external filter shaker to help maintain maximum suction power and filtration performan...
Eaton to acquire MGE’s Small Systems business from Schneider Electric
Schneider Electric and diversified industrial manufacturer Eaton Corp. have entered into exclusive negotiations for the divestment of Schneider’s MGE uninterruptible power systems.
Ladder accessory kit
The Professional Ladder Utility System contains a ladder mount, a tool bucket with a carrying handle and a universal tool holder.
Vibration-damping breadboards
Versatile, high-performance breadboards provide a flat, stable surface for a variety of applications including mounting or assembling lasers, small optical systems, prototyping and precise inspections.
Tackle talent management to achieve high performance
Let’s be honest. Industrial products companies face a talent crisis. Despite the durable demand for products, a critical shortage of skilled labor threatens your ability to outperform the competition. Worse, your workforce is aging and the younger generation doesn’t think your industry is glamorous or 'high-tech.
MDSS becomes Factivity
MDSS has changed its name to Factivity Inc. to reflect its evolution from a provider of classic ERP inventory systems to total factory floor process solutions.
Flat-panel monitor
The FPM-3170G 17-inch SXGA TFT LCD flat-panel monitor has a 1280 x 1024 resolution and direct-VGA, DVI, video and S-video inputs. Direct VGA signal transmission upgrades the display without changing current systems. Other features include an OSD control pad on the front panel, an anti-reflective screen with tempered glass, a hard anodic coating to prevent panel abrasion and acid corrosion, a stainless-steel chassis and an aluminum front panel.
Reader Feedback – 2007-04-15
Does anyone care about the loss of manufacturing jobs, plants? There was an interesting article in the March 2006 issue of PLANT ENGINEERING. It was the cover story (The Future of Manufacturing), and I thought I would save it. Looking back one year, I wanted to see if any of it made sense. Here are my thoughts: I am about to retire from Goss International.
Compatible chemical program goes global
The original FGG/BM System Compatible Program, established in 2002, has been expanded beyond the United States, Canada and Mexico and now includes 25 European countries, the United Arab Emirates, India and China. The expanded program is designed to increase user confidence and help eliminate the guesswork as to what products are chemically compatible. The program’s updated name — FGG/BM/CZ System Compatible — reflects that it ensures chemical compatibility with FlowGuard Gold and Corzan water distribution systems, as well as BlazeMaster fire sprinkler systems. The FGG/BM/CZ System Compatible Program is designed to test and monitor ancillary products on an ongoing basis to ensure chemical compatibility with these three different CPVC piping systems. Products in the program display the FGG/BM/CZ System Compatible mark on their label, which identifies that the product is chemically compatible with the CPVC products.
Productivity board
The 4' x 6' production-efficiency-tracker magnetic whiteboard lets users track production goals, issues and performance figures by the hour utilizing color-coded magnetic status signals, management feedback magnets and magnetic star attention symbols in five colors. The system includes dry-erase pens and markers in four colors, PreciseLine chart line tape and adhesive letter and number sets for graphing. Board cleaner and conditioner, lint-free wipes and a magnetic eraser/pen holder are also included. Magnatag Visible Systems www.magnatag.com/productiontracker.
Nickel-cadmium batteries
Varta R-series nickel cadmium (NiCd) batteries include the RL (long duration), the RM (medium duration) and the RH (short duration) batteries. The batteries operate over a temperature range of -40 to 50 degrees C (-40 to 122 degrees F), and are designed to be especially effective at low temperatures and deep discharge applications.
Sony Ericsson finds productivity gains through MES
After implementing a new enterprise manufacturing execution system, Sony Ericsson saw its volume and yields increase. Hiroyuki Tanaka, vice president of planning and logistics control for Sony Ericsson Mobile Communications, said the InSite system from Camsrat delivered immediate improvement. “We shipped 8.5 million units in the third quarter of 2006, a 25% increase over the same period last year — this is supported by Camstar's InSite,” said Tanaka. Sony Ericsson's manufacturing operation necessitates extremely high production volumes and strict traceability requirements. The system processes high transaction volumes, continuously around-the-clock, with input from 9,000 operators working on more than 100 production lines.
Upcoming coverage in the Feb. issue of Plant Engineering magazine
• Senior Editor Kevin Campbell explains how manufacturers are making their systems more Lean-compliant, more flexible and more intelligent. • Registration is underway • • Bob Vavra talks about the right place and the right time in his insightful commentary. • • Making motors on demand • Sujeet Chand, Rockwell Automation’s CTO, explains what RFID is really about. • Managing Editor Jack Smith discusses how traditions in the process industries are evolving, and how their control systems much change as well.
Tester
The voltage performance monitor identifies voltage events and harmonics that can cause equipment damage and failures. By plugging into a circuit at the point of equipment connection, the VPM indicates when problematic voltage events occur and logs the time, duration and severity of the event without requiring a computer. Users can determine if equipment problems are related to voltage and if a circuit is safe for new or existing equipment.
Embracing RFID technology drives process improvements
Depending on who you talk to or what you read, radio frequency identification is either going to revolutionize business practices the way the Internet did, or it will simply become another information gathering technology that is routinely integrated into the manufacturing process. Either way, for manufacturers, distributors and retailers alike, the advances in RFID technology (and the conseque...
Fortune 500s, environmental groups unite for global climate change
On the eve of President Bush’s State of the Union Address, a diverse group of U.S.-based businesses and leading environmental organizations called on the federal government to quickly enact strong national legislation to achieve significant reductions of greenhouse gas emissions. The group said any delay in action to control emissions increases the risk of unavoidable consequences that could necessitate even steeper reductions in the future. This unprecedented alliance, called the U.S. Climate Action Partnership (USCAP), consists of market leaders Alcoa , BP America , Caterpillar , Duke Energy , DuPont , FPL Group , General Electric , Lehman Brothers , PG&E , and PNM Resources , along with four leading non-governmental organizations — Environmental Defense , the Natural Resources Defense Council , the Pew Center on Global Climate Change and the World Resources Institute . At a news conference Monday at the National Press Club , USCAP issued a landmark set of principles and recommendations to underscore the urgent need for a policy framework on climate change. The solutions-based report, titled A Call for Action , lays out a blueprint for a mandatory, economy-wide, market-driven approach to climate protection. “The time has come for constructive action that draws strength equally from business, government and non-governmental stakeholders,” said Jeff Immelt, chairman and CEO of General Electric.
Computers
The new Everest Series of rugged computers is suitable for forklift and fixed-mount applications. Designed to perform in extreme conditions, the computers are available with 10.4- and 12.1-inch screens. The Everest series offers an array of processor options, from a 600-MHz Celeron up to a 1.4-GHz Pentium M, and provides up to 1 GB DRAM.
Siemens VDO to acquire Ballard Power Systems’ electric drive business
Siemens VDO Automotive Corp. recently signed an agreement to acquire Ballard Power Systems, Inc. 's electric drive business located in Dearborn, MI.
Shrink wrapper
The Continuum integrated tray/shrink system is designed for packaging applications in the food and beverage industries. The system provides efficiency, flexibility, quick changeover and a low-maintenance design. It includes a large diameter range, making it suitable for both loose containers and multipacks in a variety of materials, including glass, PET and metal and fiber cans, among others.
Sheet membrane system
The Pyroflex sheet membrane system for vessels in corrosive chemical processing and mining facility construction is a manufactured, fiber-reinforced composite membrane system that remains permanently plastic. The system is an alternative to traditional asphaltic and fiber-reinforced resin linings, which can become porous and cracked.
Cardview system
Kanban CardView Systems help keep facilities running efficiently. The boards hold up to 828 cards in 17 different colors to effectively communicate to employees. Red and yellow taped card pockets are used to signal critical inventory levels or the need to immediately start or complete production of certain parts.
Schneider Electric president honored with achievement award
The Schneider Electric North American Operating Division recently announced that Chris Curtis, president of Schneider Electric USA , has been honored as a pioneer of sales and marketing with a 2007 Lifetime Achievement Award from Frost & Sullivan , a global growth consulting company. “I am honored to be chosen as a recipient of Frost & Sullivan’s 2007 Lifetime Achievement Award,” said Curtis. “Over the last three years, our North American Operating Division has made great progress in many areas of our business. Our collective efforts have helped us excel in key areas, including growth, profitability, and customer satisfaction improvements, and I am proud to be in a position to help drive the company’s top goals.” The Sales and Marketing Lifetime Achievement Awards are given each year to individuals whose careers are characterized by a legacy rich in accomplishments and achievements.
Maintaining sustainability at BMW Manufacturing
Sustainability is one of the most prevalent buzzwords being used in the manufacturing community today. Merriam-Webster’s online dictionary defines sustainability as, “of, relating to or being a method of harvesting or using a resource so that the resource is not depleted or permanently damaged.” At BMW’s U.S. factory in Spartanburg County in upstate South Carolina, sustainability is at the forefront of the manufacturing process. “We have eight indicators that we track every month,” said Briggs Hamilton, section manager, environmental services at BMW.
NEMA releases cable tray guidelines
Information on maintenance and system modification of cable tray systems can be found in the recently-published third edition of “VE 2-2006, Cable Tray Installation Guidelines” from NEMA. This practical guide for proper cable tray system installation also addresses shipping, handling and storing of cable trays. Cable tray system design must comply with “NEC Article 392,” “NEMA VE 1” and “NEMA FG 1,” and follow safe work practices as described in “NFPA 70E.” The guidelines in this publication are useful to engineers, contractors and maintenance personnel. “NEMA VE 2-2006” has been revised to reference the 2005 version of the NEC, and provides clarification for grounding and bonding cable trays, as well as recent cable tray product developments. “VE 2-2006” may be downloaded free, or a hardcopy purchased for $69.00 by visiting NEMA’s website at www.nema.org/stds/ve2.cfm or by contacting IHS at (800) 854-7179 (within the U.S.), (303) 397-7956 (international), (303) 397-2740 (fax).
Schneider Electric acquires APC
The announcement in November that Schneider Electric has agreed to purchase American Power Conversion for about $6.1 billion was seen as a complimentary purchase between a company that wants to expand its electrical distribution business and a company whose strength is in that market segment. “This acquisition allows us to greatly strengthen Schneider Electric in the fastest growing segme...
The making of a Top Plant takes more than machines
How do we get our plant to be a Top Plant so that we can improve our competitive position in global manufacturing? Many manufacturers apply various tools and strategies to achieve this, while others simply move to other countries to get cheaper labor. But is this really working? There are more important issues to address than the tools themselves: leadership, alignment, teamwork, innovation...
Infrared imaging system
The GS110 process imaging system for low emissivity glass is designed to monitor one-side coated flat glass. The system can also be used for non-contact infrared temperature measurement in other secondary glass-processing applications such as bending, forming and annealing. It features an automatic correction mode that adjusts the system to accommodate changes in emissivity due to different gla...
Help Smiley survive and prove your automation knowledge while you play!
Smiley is a survivor. Even though he's shipwrecked on a desert island, he has all the tools he needs to survive. But, he's going to need YOUR help! Smiley is the star of a new online game — Automation Survivor —sponsored by AutomationDirect.
BREAKING NEWS: Baldor to acquire Rockwell Power Systems business
Baldor chairman and CEO John McFarland said he has always admired the Reliance and Dodge brands from afar. He now has a chance to get much better acquainted with them. Baldor’s Nov. 7 announcement that it would acquire the two brands in Rockwell’s Power Systems division for $1.8 billion immediately doubled the size of Fort Smith, AR-based Baldor and diversified the company in the process.
Schneider Electric acquires American Power Conversion
Schneider Electric and American Power Conversion recently entered into a definitive merger agreement under which Schneider Electric acquires all outstanding shares of APC for an enterprise value of approximately $5.5 billion. The price per share is U.S. $31, and will be paid in cash for a total amount of approximately U.S.
It’s on the Vista: Business, process systems aligning
In a discussion of its new system, representatives of ICONICS and ARC Advisory Group talked about the emergence of manufacturing execution and manufacturing intelligence systems as a bridge between the plant floor and the enterprise. “The reality is that the business and process worlds are moving closer together,” said Mark Hepburn, VP of worldwide sales for ICONICS.
Mist collector
The WSO mist collector filters water-soluble coolants, straight oil and oily smoke. It adapts to application requirements with a change of the filter cartridge. Engineered with Synteq XP filter media and oblong cartridges that provide filtration efficiency and low operating pressure drop, the unit is available in machine-mountable, stand-mount or ducted cellular and central system configurations.
Water-based flooring system
AquArmor flooring systems are engineered using a water-based resin technology and offer 100 times the permeability of standard epoxy floor systems. It can be used underneath most flooring, including terrazzo and resinous floors, or as a standalone system. The low-odor flooring system has zero VOCs and can be applied to green concrete without taking moisture readings.
Distribution panel with ATS
The Smart Distribution Panel with Automatic Transfer Switch (ATS) integrates automatic transfer with electrical distribution to lower total cost of ownership and improve overall availability. Features include predictive failure alarms, runtime calculation based on remaining fuel and generator load, fluid level monitoring, integrated distribution panel and ATS and UPS coordination.
Online learning
Web Based Training online learning management system combines the proven techniques offered in Computer Based Training with the convenience and technology available via the Internet. The system allows companies to train large groups of people in a small amount of time; as many as 500 people can be trained simultaneously.
UHF RFID system
SIMATIC RF 600, an RFID system that operates in the UHF band, is designed for logistics and distribution. The system has three communication ports: Ethernet, RS-422 and RS-232. It transmits data to IT, ERP and SCM systems, to SIMATIC PLCs, or to PCs. The antenna is designed for IP65 and can be mounted on walls or frames.
Upswing due to new orders for non-defense aircraft and parts
Yesterday’s Commerce Department report that manufactured durable products increased by 7.8 percent in September and climbed to a record-high $226.7 billion shows that, “America’s industrial base is taking off on the wings of aircraft manufacturers,” said David Huether, chief economist for the National Association of Manufacturers. “The rise marks the biggest monthly gain in new orders for durable goods since manufacturing entered recession in mid-2000,” Huether said. The upswing in orders last month was largely due to new orders for non-defense aircraft and parts, which soared 183.2 percent in September, the largest single monthly gain in four years. “With over half of domestic aircraft production destined for markets overseas, today’s report is a good omen for U.S. exports, which is critical for the U.S. economy to maintain healthy growth in coming quarters,” Huether continued.
Particulate monitor
Model EM 70 particulate monitoring system is designed for cyclone overflow detection, chocking and efficiency monitoring. Its ability to operate in moist process environments makes the unit suitable for cyclone filter outlet monitoring. The company’s proprietary combination of induction sensing and a protected-probe provides reliability and early warning of cyclone plugging, according to ...
Performance monitoring system
Capable of monitoring fluid concentration, pH, conductivity, temperature and real-time biologic activity in most water-based metalworking fluids, the company’s performance monitoring system can monitor critical fluid parameters from up to four metalworking fluid central systems. Its biological activity reading alerts users immediately when preset, microbiological activity levels in metalw...
Letters to the editor – 2006-10-01
The “A View from Washington” column in the September 2006 edition of PLANT ENGINEERING by John Engler was titled “Sleepwalking schools are failing U.S. industry.” While I agree with Mr. Engler's view on the condition of schools in the USA and the need for our schools to meet the challenge of our new global competitors, I believe the title and conclusion of the article ar...
Why bother with wrenches?
Why bother with wrenches?Wrenches are almost never a part of a finished product, nor are they much of a concern of a design engineer unless he notices that a fastener is located in the manner that will make wrenching very difficult or impossible.Of course, some very cost-conscious companies have found that they can reduce the cost of assembly and the cost of maintenance by the appropriate selection of fasteners and by providing space for efficient access. Although unit construction, adhesives, welding and fastener redesign to use fewer stronger fasteners reduce the number of fasteners, they can never eliminate it because fasteners are required for joining subassemblies, providing access for inspection and maintenance, and for the ability to replace portions of the product. Another reason for considering wrenches and their associated fasteners is that this is an area that has not received much study in the past, which means it is more likely to provide opportunities for improvement or cost reduction. Wrenches and fasteners must work together (see Figure 1) to accomplish the job of either installing or removing fasteners.Good engineering requires specifying the installation torque of tension bolts to ensure their performance because bolts that are either over-tightened or under-tightened are prone to failure.Furthermore, removal torque is usually more than installation torque — often twice as much — that may result in wrench failure, which can cause injury or an expensive delay. Historically, wrenches and fasteners have not been thought of as a system, resulting in a lower-grade of performance and thus providing opportunities for improvement.Figure 1 shows the five components of the wrench/fastener system, which is most clearly illustrated by a socket wrench.The wall of the wrench has been counted as a separate part from the rest of the wrench.That is critical because most socket wrenches and other types of wrenches fail through the breaking of the wall. The faces of a wrench only transmit force, but the wall of the wrench must transmit torque and is subject to high circumferential stresses if not properly designed and mated to the other components.There are five possible modes of failure in the causality chain between the mechanic applying force and the fastener.In researching the various possibilities for improving wrench performance and reducing their size, Wright Tool has produced failure in every one of the five modes to learn how to increase strength without making wrenches larger, which is important in today’s designs. The original design of the fasteners’ engaging surfaces was square or hexagonal, which worked quite well but were bulky and expensive. For lack of design information, the fasteners were substantially over-sized.So the wrenches did not have to deal with high torques. Twelve-Point Wrenches Twelve-point wrenches were developed as a more convenient way of engaging with a fastener and are preferred by mechanics for that reason.Most mechanics also know that they are not quite as strong as 6-point wrenches.If the fit is snug, they are as strong but because of manufacturing clearances on both fasteners and wrenches and wrench wear, line contact tends to be the rule.Line contact not only can damage both wrench and fastener but it can combine with the high circumferential stresses in sockets to produce areas of failure. Wrench manufacturers can help this problem by making subtle departures from geometric designs.The best wrench design is one that produces a load pattern that avoids damaging the corners of the fastener or the corners of the wrench and, thereby, decreases strength and reduces life.The maximum strength and least wear when turning 12-point fasteners is produced by the shapes in Figure 2.Advanced 12-spline type design wrenches are stronger on both 6-point and 12-point hexagonal fasteners by 6% to 10%. The lower left corner of figure 2 shows three different wrenches applied to a 12-point, double-hex fastener.The relationships would be the same on a 6-point hexagonal fastener.The traditional double-hex wrench contacts only the corners of the fastener resulting in high contact pressure and a tendency to deform the fastener. Depending on the clearance between wrench and fastener, the location of the point of contact will vary.The high contact pressures will tend to cause a socket wrench to expand.If the point of contact is close to the inner point of the wrench, the wrench may slip on the fastener and shear the tip of the fastener teeth. Figure 3 shows the strength of the spline wrenches compared to the 12-point and 6-point wrenches.Twelve points are not twice as good as 6 points because the torque is limited not only by the teeth but also the ability of the socket to withstand the increased circumferential tension, which is, of course, proportional to the load.Because socket wrenches were not increased in diameter when the manufacturers went from 6 to 12 points, there is no strength in the body of the sockets to maximize load transmission. This failure to mate the design of the wrenches and fasteners is clearly shown in Figure 3, where the loads for 12-points are substantially better than a 6-point fastener but not double the load as one might expect.The premium wrench profiles do help. While these differences may seem subtle, the difference between success and failure may be just a few percentage points.
Continuous improvement systems to grow 12.7% annually
The market for continuous improvement (CI) systems was $211.5 million in 2005 and is forecasted to grow to $402.8 million by the end of 2010, with a strong compounded annual growth rate of 12.7%, according to the ARC Advisory Group. The results of surveys ARC has conducted among manufacturers show that 80% of them are applying one or more CI methodologies. The programs used most often are Lean manufacturing, Six Sigma, total quality management and theory of constraints, and manufacturers are looking to CI systems to improve operational performance in the areas of labor utilization, inventory levels, quality, asset utilization and cost of goods sold. Some proponents of traditional Lean manufacturing avoid systems, recommending a manual approach in order to keep people close to the process. However, many manufacturers are using technology to enhance their program’s effectiveness. “Adoption of technology to enhance continuous improvement programs allows manufacturers to take their business to a higher level of financial performance, in both their P&L and balance sheets,” said Ralph Rio, research director and principal author of ARC’s “Continuous Improvement Systems Worldwide Outlook.” The study examines the market for applications that manufacturers use to bring their programs to a new level of performance.
Invensys heading to Dallas for customer conference Dec. 4-7
Invensys Process Systems' 2006 North American Customer Conference will be held on Dec. 4-7 at the Hilton Anatole Hotel in Dallas. The Customer Conference will bring together users of Avantis, Foxboro, SimSci-Esscor, and Triconex products, software, systems, and services for a program developed in conjunction with Invensys' various customer user groups.
Vehicle mount computer
The vehicle mount computer features a rugged construction and the company’s fanless, mobile MPC 5/110, and a touchscreen PC for indoor and outdoor vehicles, including forklifts and construction machinery, in logistics operations. The optional 3M Near Field Imaging MicroTouch 10-inch touchscreen is designed to provide visibility, even in bright environments.
Liquid-cooled AC drive
The Allen‑Bradley PowerFlex 700L liquid-cooled drive withstands increasingly rugged environments while driving high-performance and energy-efficient liquid-cooled technology. It features a single cooling input and output to the IGBTs. This proprietary, liquid-cooled heatsink increases power density resulting in a drive that is up to 65 percent smaller compared with similar horsepower air-cooled drives, the company says.
ABB sees profit growth in 2Q; automation leads the charge
ABB reported a sharp increase in orders and profitability for the second quarter of 2006. Earnings before interest and taxes increased to $640 million from $371 million in the same quarter a year ago, reflecting good growth in the two product divisions. “We continued to deliver strong results in the second quarter,” said Fred Kindle, ABB President and CEO.
FKI Logistex consolidates manufacturing, engineering sites
FKI Logistex has consolidated some of its North American manufacturing and engineering locations within its Airport, Post and Parcel division to take advantage of operational efficiency opportunities. Manufacturing in the company’s Frederick, MD factory will be transferred to its manufacturing facilities in Danville, KY and Cincinnati, while engineering and support functions located in Da...
I Power introduces new low-emissions irrigation pump engine
I Power Energy Systems, LLC, recently announced the introduction of a new, 120-hp, natural gas-fueled industrial engine, designed for extended-duty applications requiring ultra-low exhaust emissions. Highly efficient emissions components and software incorporated into the new engine are based on the company's Greenergy technology, developed for a range of products from their traditional continuous-duty, on-site power generators to numerous industrial, agricultural and commercial engine applications. I Power's Greenergy technology is based on a systems engineering approach that combines induction system refinements, combustion chamber redesign, optimized air-fuel mixing, exhaust flow control and treatment and a power electronic engine controller incorporating a proprietary software tailored to meet specific application requirements.
FKI Logistex consolidates manufacturing and engineering locations
FKI Logistex announces the consolidation of some of its North American manufacturing and engineering locations within its Airport, Post and Parcel division to take advantage of operational efficiency opportunities. Manufacturing in the company's Frederick, MD factory will be transferred to its manufacturing facilities in Danville, KY and Cincinnati, while engineering and support functions located in Dallas will be consolidated within the company's facilities in Louisville, KY. "In our last business year, FKI Logistex sales grew by 14% but continued investment in our operational infrastructure, IT systems, people, and business processes now means that we can deliver this increased level of sales within a smaller operational footprint,” said Steve Ackerman, president, FKI Logistex North America. “We are therefore taking this opportunity to streamline our activities across fewer sites.".
Take seven successful steps to align your organization
Last month, we looked beyond the rhetorical statements about aligning an organization around goals and looked at why it is important to have a common strategy. In summary, the actions you might consider are: Let’s take a look at each of these: Communicate a common strategy If we are to align the organization to a common strategy and set of goals, then we must actually have a clear strat...
Organizational alignment: Why it is so important
In the US, manufacturing jobs continue to decline, typically moving to countries with lower labor cost. In my view, labor costs are not the chief impediment to U.S. manufacturers being competitive, but rather the root cause is a lack of productivity and insufficient focus on eliminating waste in their processes.
Digi, Rockwell Automation partner
Digi International has been accepted into Rockwell Automation's Encompass Program, a third-party product referencing program that helps Rockwell Automation customers find best-in-industry technologies compatible with Rockwell Automation products. The Digi Connect WAN family of industrial cellular routers has been recognized as best-in-class by Rockwell Automation.
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Gasket industry’s first trade show is March 29-31
The Gasket Fabricators Association, with the endorsement of the Independent Sealing Distributors, will be sponsoring the first trade show ever devoted exclusively to the gasket industry. The Gasketing/Converting Expo '06 will be held March 29-31, 2006 at the Omni Orlando Resort at ChampionsGate in Orlando, Florida.
XPS SIP cartridge seal cuts downtime
XPS pump seals reduce downtime, power consumption and operating costs. They are an alternative to mechanical seals and compression packings. Seals are replaced in seconds with SIP (serviceable in place) technology. Since there are no brittle faces, these seals are very tolerant of process upsets and dry running.
Clean diesel genset for load applications
Gen Set with ACERT Technology is designed for standby and load management applications. The generator set meets EPA Tier 2 requirements, delivers improved fuel efficiency and higher power density in a smaller footprint. Available in 60 Hz and 50-Hz models, the C32 clean diesel generator set is powered by a 32-liter, 12-cylinder, "V" configured engine with electronic fuel injection.
Software upgrade marries productivity, compliance
The Proficy Change Management Version 5.0 is an upgrade on the plant-wide automation management and control software that allows users to increase productivity and flexibility while also meeting regulatory requirements. Capabilities include security, version control, audit trails, central storage and automated backup and recovery.
System extensions allow improved efficiencies
Extensions to the IndustrialIT System 800xA include a flexible and scalable safety instrumented system, manufacturing management for improved batch production and real-time production intelligence for monitoring equipment efficiency. It allows customers to combine data from various automation applications to a single integrated information view in real time.
Fault tolerant UPS has voltage regulation
Galaxy 4000 uninterruptible power supply features precision voltage regulation, an IGBT rectifier that minimizes reflected input harmonics and power factor corrected input. Its fault tolerant architecture manages faults without compromising the UPS system. Battery management capabilities allow the UPS to determine battery parameters and alert operators before performance is affected.
Modulating infrared heater has diagnostics
Vantage Modulating heater is the first infrared fully modulating heater. It provides increased fuel efficiency by modulation, resulting in optimum combustion throughout the full range of burner inputs. The heater has comprehensive onboard diagnostics for fault and system status to provide information and ease of service.
Compressor has wide throttle range
Centac C700 is a centrifugal air compressor that provides 100% oil-free air. It is designed for maximum efficiency even at part load, increased throttle range, and enhanced reliability. Constant pressure control provides stable system pressure and smooth operation. The control system is state-of-the-art.
ABB reorganizes business structure
ABB has announced a reorganization of its core business units in what the company says is a move to improve business operations. The current two core divisions, Power Technologies and Automation Technologies, will be eliminated, and their respective business areas will become the new divisions as of January 1, 2006: Power Products (formerly the Power Technology Products business area), Power Sy...
Wonderware a Gold Partner with Microsoft
Wonderware, a business unit of Invensys Systems Inc., has achieved Gold Certified Partner level in the Microsoft Partner Program. The Microsoft and Invensys alliance was established to combine Invensys' strengths in process and manufacturing applications and expertise in key industry segments with Microsoft's platform, technology and enterprise products.
Human Side – 2005-10-01
Effective hiring practices saves trouble down the line "It's recruitment time and the stakes are high. So states HR Matters, published by Personnel Policy Service, Inc. The report goes on to cite an industry rule of thumb that asserts hiring the wrong person can be expected to cost three times the person's annual salary during the course of employment. The trick in recruiting is to bend over backwards to ensure that the person you too hastily hire doesn't slowly drag you to court some time in the future. "I can't get this point across too firmly," plant engineer Joe Hadley told maintenance foreman Chuck McDonald one bright sunny Monday morning in October.
Manufacturing community offers hurricane relief
The initial response by the manufacturing industry to Hurricane Katrina has been seen far and wide, and in many ways. Among the programs announced to date: The National Association of Manufacturers has set up a Hurricane Katrina Relief Resource Center at its website, www.nam.org. Links to all relief organizations, federal agencies, and employee information is included. Schneider North America pledged $1 million to support Hurricane Katrina relief efforts in Louisiana, Alabama, Mississippi and Florida's Broward and Miami-Dade counties.
Microturbines get a boost from energy bill
Microturbine technology incentives included in the Energy Bill signed by President Bush in August will help some companies take a second look at this emerging electric resource. Chip Bottone hopes the rewards, like the power, will be self-sustaining for years to come. "We're not in this for the short-term," said Bottone, president of Ingersoll-Rand's Energy Systems business, after the bill was ...
The Best of Tips & Tricks – 20 Years
Over the past two decades Plant Engineering magazine has been publishing the entrants and winners in our Tips & Tricks competition. Since 1994 we have limited the winners to three, 1st, 2nd and 3rd place. Out of these winners we have selected the "best-of-the-best" to present to you now. These winners present novel solutions to everyday problems encountered by plant engineers.
Human Side – 2005-07-01
In office dating, first determine if there's a conflict When two employees in the same department date each other it is often a source of concern to management. More so than ever when the romantic couple are a supervisor and subordinate. It is thus not surprising that some companies establish policies designed to ban such relationships. Declaring such practices verboten may seem a simple solution, but experience proves it can be anything but.
Dreaming of the future
Ray Connor is the future of manufacturing. Eight years ago, his final interview to be among the first employees at Kansas City's new Harley Davidson assembly plant coincided with his honeymoon. He called back to tell Harley he'd postpone the honeymoon. Eight years and three children later, Connor, 30, is a quality auditor for Harley, a poised professional with an encyclopedic knowledge of the p...
The Peters principle: Aim higher
Tom Peters is one of those management gurus paid a princely sum for stating the obvious. His books, including In Search of Excellence and The Pursuit of Wow! are great not just because they find and illuminate the best of our collective business wisdom, but because the message is so straightforward. Peters has a lot in common with PLANT ENGINEERING.
Condition-based approach rewrites the book on lubrication
Ask any maintenance manager how frequently his machinery is lubricated and you'll probably hear this reply: "We go by the book," referring to instructions in the factory manual that comes with new equipment. Lubricating by the book — preventive lubrication — may be the way it's been done since the dawn of the industrial revolution.
Bentley CEO sees acquisition, evolution coming in the future
As it touted its plant information products to users at its annual conference, Bentley Corp. is also looking to evolving the next generation of end users in the plant environment. To do that, Bentley CEO Keith Bentley says the pitch has to go directly to plant operators. "The majority of our plant reservations come from the owner-operator," said Bentley at a wide-ranging press conference at the...
Building successful containment piping
In the 1970s electronics manufacturers began placing their underground and aboveground hazardous chemical piping systems within an outer jacket for the sole purpose of preventing leaks from getting into ground water supply. Part of the reason was inadequate performance of single-walled piping components.
Human side – 2005-02-10
Voluntary stepdown What rate of pay? Class I Welder Juan Gomez had sensitive nostrils. He sniffed a change in the wind. He had too much time on his hands without jobs being assigned.
Digital CCTV network solutions
In 2005, a host of new technologies will be employed by plant managers to oversee their facilities. Despite a spate of digital CCTV product introductions during 2004, analog-based video system components remain the dominant choice.
Don’t cut capital costs
There is an old adage that goes like this: "Be careful what you wish for, you might get it." Consider the case of that all-too-frequent occurrence, the drive to cut capital expenditures. The dictum comes down: "We need to reduce our capital spending by 15% this year." Or "We need to limit capital spending this year to $10,000,000.
Analog addressable fire alarm systems compared to conventional systems
Advancements in technology are making analog addressable fire alarm systems appropriate for all sizes of applications — not just the large ones. Unlike older addressable systems, newer analog addressable products are just as easy to program as conventional systems, and are also easy to maintain.
Instruments & Controls – 2004-12-10
Localized UPS Quint Buffer and Quint DC-UPS uninterruptible power supplies ensure continuous operation of 24 Vdc control devices at the control panel during power interruptions. For power interruptions lasting up to 4 sec, the buffer module supplies the required current from electrolytic capacitors. Phoenix Contact, Inc. phoenixcon.com Write 324 on PE card Ethernet link to PC-based control T1H-EBC100 module provides an Ethernet link between the company's Terminator I/O products and PC-based control software.
Transforming your business with asset lifecycle management
The livelihood of manufacturing is production efficiency. Despite knowing this, the production, operation, maintenance, design, and marketing data necessary for making sound business decisions are not well integrated with business processes or business applications. For manufactures that have to maintain production plants, a strategy exists called asset lifecycle management (ALM) or process lif...
Basics of power management software
Powerful analytical tools — software, PCs, networks, and the internet — are within a click of the mouse. Power monitoring equipment captures data; software analyzes critical data required for responsible electrical energy management. Power management software tools provide control over how you manage your use of electricity.
Basics of power management equipment
Electrical power enters the plant, drives the equipment, shines the lights, conditions the air, makes the coffee, and runs the printer that prepares your paycheck — and the check to pay for all this electricity. Are you getting your money's worth? Probably not.
User’s view of steam traps
Steam traps are a pain in the neck to maintain. They are difficult to troubleshoot, numerous, geographically widespread, and often inaccessible.
Solutions – 2004-02-10
Making push-nuts Problem : A push-nut is removed from a shaft to make repairs. The nut is dropped and can't be found. What can you do to reassemble the parts and keep them on the shaft? Solution : Get a brass washer that fits on the shaft.
Electrical – 2003-07-14
Products Small terminals Small Hydent small-terminal product line offers ring and fork tongue terminals, flag-style and quick disconnects, and splices. The expanded product line also includes installation tools. Most connectors are UL and CSA listed, and are available in vinyl, nylon, and polyvinylidene-insulated, as well as noninsulated, versions. FCI-BURNDY Products fciconnect.com Write 324 on PE card Softstarters for low-voltage motors PST series softstarters are available for operating voltages from 208 to 690-Vac and full-load line currents of 30_ 1050 A.
Convergence, transparency seen as leading trends in electrical systems
PLANT ENGINEERING recently met with Jean-Pascal Tricoire, executive vice president, Schneider Electric International Div., and Chris C. Richardson, president and CEO, Schneider Electric - North American Div., to discuss trends in industry. Following are some highlights from that interview. Tricoire and Richardson see the convergence between automation and power as a major trend.
Wiring system design: Cable tray vs. conduit
To be useful, electrical wiring must get from one place to another. Distribution is a necessary phase of system wiring design in order to get power or impulse signals to their final destinations. Historically, wires and cables have been pulled through conduit.
An Introduction to Predictive Maintenance
The second edition of R. Keith Mobley's An Introduction to Predictive Maintenance is a welcome addition to the numerous books available on the subject. Mobley has taken his first edition, published in 1990, and thoroughly updated and expanded it. The current volume includes six new chapters. Although the book includes discussions of all the latest technologies, it's not a technical book so mu...
Industry margins fall below average
Inflationary pressures for manufacturers of factory operating materials and supplies are on the rise. The problem is that costs are high while the ability to hike prices has been weak. End result: industry margins for 70% of the industries in our marketbasket are below average. Consider the industry that makes metal fasteners like bolts, nuts, rivets, and washers.
Electrical
Maintenance program A nationwide program for power system maintenance called PowerCare Advantage has been introduced. Sponsored by an integrated power system manufacturer, it is designed to ensure the reliability of all brands of onsite power systems. Cummins Power Generation cumminspowerrent.com Write 323 on PE card Safety monitor The Safe 4 series of safety relays is designed to monitor emergency stop and safety gate applications.
Is project management software right for you?
Small or large, projects require discipline in planning and execution. The success or failure of a project depends on the skill and expertise with which it is managed. Although it cannot replace the intelligence that envisions and implements all of a project's phases, project management software can save plant engineers time and promote effective management by providing tools to simplify comple...
CMMS/EAM industry directions at the National Plant Engineering Show
Some industries are recession proof. But the application software industry is definitely not one of them. A software vendor's sales-lead pipeline usually starts to dry up at the first hint of an economic downturn. Unfortunately, software vendors have little choice but to ride out a downturn. There is only so much belt-tightening a vendor can do and still hope to be in a competitive position whe...
Winners
Winner of the 2001 "Maintenance Tip of the Year" is Brian Berg, Kolbe & Kolbe Millwork Co., Wausau, WI. He received $1000 for his suggestion on how to filter dirty air in a work area. Runners-up were Robert Hans, Sonoco-U.S. Mills, Inc., Menasha, WI, and Monte Hyler, ABB Automation, Analytical Div.
How Serial Ports Work
The serial port has been an integral part of most computers for more than 20 years. Serial ports provide a standard connector and protocol to let you attach devices, such as modems, to your computer.All computer operating systems in use today support serial ports. Parallel ports are a more recent invention and are much faster than serial ports.
How Parallel Ports Work
The parallel port is the interface most used for printers. They are also used to connect a PC to scanners, CD-writers, external hard drives, Zip removable drives, network adapters, and tape backup drives.Parallel port basicsIBM originally developed parallel ports to connect PCs to Centronics printers.
Suggestions & Solutions – 2001-12-01
How clean I am How to Filter Compressed Air , Bulletin 120, is a free, 16-p booklet that uses text and illustrations to describe types of compressed air filters, guidelines for selecting the correct filter for a particular application, and other helpful information. Deltech deltech-flair.com Write 251 on PE card Gas engine reduces emissions Brochure introduces a line of lean-burn gas engine/generator sets for prime and peaking power applications. Sized form 334 kW to 1.75 MW, these generator sets are powered by fuel-efficient, spark-ignited engines that reduce NO x emissions. Cummins Power Generation cumminspowergeneration.com Write 252 on PE card Pumps on CD-ROM A 2 CD-ROM set of the Goulds Pump Manual includes the 8thissue of the GPM catalog and the Goulds Pump Selection System. The set makes it possible to click-through the pump catalog, and make selections by the use of electronic tools. I TT Industries, Goulds Pumps gouldspumps.com Write 253 on PE card Recorders track overheating Temp-Plate irreversible temperature recorders provide a low-cost alternative to monitoring surface temperatures with sensors or probes.
Human Side of Engineering – 2001-11-01
Be careful what you ask in an interview Maintenance Supervisor Glen Gorsham had doubts about applicant Lou Polikoff sent to him from Personnel from the moment he set eyes on him. His application showed the experience required for the stockroom attendant's job. But for one thing, he struck Gorsham as shifty-eyed and somewhat sullen. For another, the guy walked with a severe limp which could slow him down on the job. Gorsham asked, "As a supervisor I'm obligated to inquire if you have any current or past medical problems that that could adversely affect your job performance?" The applicant's face flushed.
Harbec Chooses Microturbines for Prime Power
What does a company do when it can't afford a power outage? For instance, Harbec Plastics of Rochester, New York, produces highly engineered plastic parts with short lead times, using a computer numerical controlled (CNC) production process. A momentary power failure burdens Harbec with hours of reprogramming and production set up.
Lighting – 2001-11-01
Click on the above link to see Product of the Year finalists in this category.
Reader Forum – 2001-09-01
Firing worker over cartoon too harshThis is in response to the Human Side of Engineering, the June 2001 issue in the special supplement. I was shocked at the answer to the first scenario with Bill Lapper, the cartoon-drawing mechanic. There is a bigger issue here, and that is the aftermath of firing someone for hanging a cartoon.
Computer simulation helps solve SO2 scrubber problem in primary aluminum smelter plant
Computer simulation helped to solve a challenging problem in scrubbers used to remove sulphur dioxide from gas in the production of aluminum at the Reynolds Metal Co.
Exploring the world of ASPs: Software services, support for a monthly fee
Rent software by the month? Access software over the internet while a company somewhere-anywhere-in the world handles all the system administration, upgrades, and support? From The Wall Street Journal to Network World, business people and technologists are talking about application service providers (ASPs), the newest delivery model for distributing software applications. According to industry analysts, ASPs offer a win-win for users and application and network service vendors alike. Advantages for users include a 20-30% reduction in up-front IT costs, quicker software implementation, and an earlier return on investment. Application and network vendors benefit from greater customer exposure, ongoing revenue, and an ability to leverage competency in applications development expertise. Despite recent publicity, many people are still unaware of what an ASP is and what its potential service benefits are.
Sectional door
Workhorse sectional door minimizes maintenance costs, eliminates downtime, and reduces exposure to unsafe situations created by conventional sectional door damage.
Roof cooling systems
Color brochure illustrates applications and benefits of roof cooling systems that lower roof temperatures 60-80 deg F, and internal temperatures 6-10 deg F. The systems use PC/PLC-based control technologies and freeze-resistant sprayheads.
Vertical carousels
Brochure explains how the Industriever vertical carousel system can increase productivity in high throughput situations as much as 125% compared to standard storage systems.
Basics of plant radio systems
Wireless communications have become so commonplace in industrial plants that they are often taken for granted. But rapid advances in technologies and capabilities make periodic reviews of radio systems a smart move.
Rooftop duct furnaces
New 4-p color brochure features the complete line of WeatherHawk rooftop duct furnaces. The units operate on natural or propane gas and are certified for location upstream or downstream from cooling coils.
Fire suppression system uses water mist
Micromist is a cost effective, self-contained, skid mounted, single fluid, pre-engineered, water mist fire suppression system for the protection of machinery. The system is available in 70 and 107-gal. configurations, and protects spaces up to 9175 cu ft.
Making the right sensor choice
From proximity sensors to limit switches and from photoelectric sensors to machine vision sensors, an almost overwhelming array of sensors is available for a variety of plant applications.
Hot cable connection
Information in the Electrical Heat Tracing Systems Design Guide allows a user to design, specify, and select a complete bill of materials for applications such as freeze protection and process temperature maintenance.
Self-contained air conditioning systems
A 10-p brochure explains how a self-contained, indoor vertical air conditioning system offers flexibility for new and renovation building projects. Sized from 15-145 tons, the system offers a wide range of cabinet sizes, features, and options.
Electronic harassment
You don't have to insult a person to her face or before others to trigger humiliation and grief.
UPS has high efficiency
Axxium TriStar double-conversion, three-phase uninterruptible power system (UPS) has a range from 10-40 kVA for the protection of midrange computers, factory automation systems, and building management and security systems.
Do employees have to take vacation while on layoff?
The plant was going full blast from April through December. January through March was the slack time of the year. During this period, a third of the work force was laid off.
Framing system eliminates field welds
Long Bay System (LBS) is an innovative framing system that combines the best of conventional construction with metal building system design.
Service computer with screwdriver
PL-X900 Series touch operated panel computer is the first industrial personal computer available where all major working and moving parts are serviced in the field by using a small screwdriver. Users do not have to worry about voiding the warranty.
Effective power management
Recent advances in both microprocessor-based monitoring and control devices and computer networking have expanded the range of power monitoring equipment available and improved the functional capabilities of these devices.
Designing a block stacking storage layout
Block stacking of unit loads is the optimal storage philosophy in many facilities. This concept stacks unit loads on top of each other and places them on the floor in storage lanes (blocks), generally 2-10 loads deep.
Handheld IR system
PM 595 IR camera makes predictive and preventive maintenance inspections easier, faster, and more accurate. An 8-p brochure details specif- ications, applications, report generation capabilities, image and trending software, and more.
System monitors vibration and temperature
Model 4100 RF SmartSensor wireless condition monitoring system checks equipment vibration and temperature. The sensor is mounted at critical bearing locations to analyze the time waveform and spectral date to provide machinery condition assessment.
Clean generator produces chemical-free steam
Generator produces steam free of chemical contamination. Compact, vertical unit features a coiled tube heat exchanger bundle and bottom drop down arrangement for exchanger inspection.
Dual transducer design heightens sensor accuracy
Superprox Model CT1000 Series ultrasonic counting sensor features a dual-transducer design to eliminate miscounts caused by agitation, reversals, backups, and line stoppages.
Handheld IR camera meets any PdM program need
ThermaCAM PM 595 infrared camera is designed for predictive maintenance.
Software analyzes harmonic distortion problems
HI_Wave for Windows predicts distribution of harmonic voltages and currents throughout a power system.
Just the right temperature
New heating and cooling control system provides maximum occupant comfort in all types of applications.
Data acquisition recorder
Brochure describes the high-speed Dash 16u data acquisition recorder. The literature outlines features of the units, including a 10.4-in.
Avoiding bent lids
Problem: After repeatedly opening and closing a can that has a pry-off lid (such as plumber's putty or wood putty), the lid becomes dented and deformed and allows air to dry out the contents.
Thermal oxidation
A 4-p brochure describes a compact emission control system that makes regenerative thermal oxidation affordable for applications with low airflows.
Make allowance for anxiety activators
The news came to the maintenance crew as a bombshell. It was definitely scheduled. A date had been set. Some workers clustered in groups to gripe and grouse. Others hit the phones to call their spouses or sound out employment opportunities.
Life safety systems
An 8-p brochure highlights life safety systems that use intelligence to provide protection against fire.
Software manages power remotely
Monitor-Pac software facilitates comprehensive 24 x 7 PC-based remote supervision and control of uninterruptible power supplies and other electrical equipment.
Liquid filtration
Features and benefits of the Max-Load high efficiency, liquid filtration system are presented in a 20-p brochure. The literature discusses the design features of cartridge and bag filters, and explains how they provide greater solids loading.
Protective relays
A colorful, illustrated folder with individual product specification sheets covers a fully modular line of protective relays. The relays depicted provide complete protection, monitoring, and control in a single chassis incorporating 12 panel meters.
Narrow aisle truck has four steering modes
MDR-55 narrow aisle reach truck features lift heights to 29 ft, 48-V ac power system for fast operation, and four steering modes for increased maneuverability.
Office building system lowers cost
Modular building system allows greater physical and aesthetic flexibility for indoor applications that do not require load-bearing capability at a 10% cost savings over previous systems. Extruded aluminum posts provide tight tolerances for exacting fits.
Stairwell light comes on when needed
StairLite self-contained, motion detector-equipped system satisfies all stairwell lighting requirements in one fixture. The surface-mounted luminaire features general and emergency lighting and battery backup.Cooper Lighting, www.cooperlighting.
Tools plus
Tools, testers, supplies, and equipment for assembling, testing, and repairing electronic equipment are the subject of a 292-p catalog.
It’s in the mail
If you have paid even the smallest amount of attention to the internet and world wide web in the last few years, you no doubt remember all of the hype about "push" technology, one of the many next-best internet developments guaranteed to change how we used the web. Well, years have passed and you would be hard-pressed to find someone eager to utter the infamous "push" word, let alone find a full-blown implementation of the concept at the level to which prognosticators claimed we would take this stupendous technology. Remember Microsoft Bob? This is not to say that "push" technology, or variations of the concept, is not in widespread use.
Photoelectric sensors operate up to 250 V
Q45 universal voltage photoelectric sensors operate at 25-250 Vac, 50/60 Hz, or 12-250 Vdc (1.5W max).
Lubrication program faster, easier to use
Lube-It 2.5 for Windows lubrication management software reduces the risks of equipment failure caused by inadequate lubrication by automatically routing and scheduling lubrication tasks.
Lubrication for everyone
Lube-It 2.5 reduces the risks of equipment failure due to inadequate lubrication by automatically routing and scheduling tasks.
Rewinding to factory specs
An onsite generator rewind program provides an insulation system equal to factory manufactured approaches, yet is field installed.
Band saw blades
A 50-p catalog offers band saw blades, plus fluids and lubrication systems. The literature explains how new generation blades last longer, cut faster, and leave a smoother finish.
Digital discussions
Since its earliest days, e-mail has always been valued as a quick and easy two-way communication tool.
Steam generators
A set of three 4-p brochures presents packaged steam generators and thermal fluid heaters. The literature includes operating overviews, component descriptions, illustrations, and technical specifications.
SCM System Connects People, Computer Systems
Numetrix/3 software solution is deployable across both the internet and intranet and serves to connect people as well as disparate computer systems within and between enterprises.
Software Simplifies Water Treatment System Selection
R.E.D. Line automatic sizing and application program lets an engineer design a water treatment system on his own computer.
One instrument performs three test functions
The 43 Power Quality Analyzer combines power quality analyzer, multimeter, and oscilloscope functions.
System identifies, organizes, and stores O-rings
O-ring Security System compresses the time it takes to positively identify a replacement from hours to a few seconds.
Evaluate outsourcing closely: Before going outside, develop your resources within
Outsourcing, in my opinion, is the single most compelling business issue facing the plant engineering and maintenance profession today. I agree that it is, as one advertisement suggests "inevitable.
Vortex system offers enhanced flow measurement
+GF+ Signet vortex system measures and transmits flow rates in a wide range of industrial environments. Features include an eight-digit totalizer and pushbutton programming for easy configuration and system setup.
Talk the same language
A glossary of uninterruptible power systems provides data on industry terms and definitions, company and industry abbreviations, and acronyms. A reference document explains the preparation and response to bid specifications. Best Power
Filter removes excess oil from airlines
Encapulator high efficiency filtration system is used in applications where there is an excessive amount of oil or other contaminants passing through compressed airlines.
Analytical services
A 6-p brochure describes analytical services offered in areas such as fitness for service assessments, condition monitoring systems, root cause failure investigations, component repair and replacement design, turbine generators, and engineering software.
Welder/generator controls dc output
Ranger 275 engine driven welder/generator with Chopper Technology controls the dc output to create an arc with improved welding performance. The unit supplies 275 amps of dc welding power at 100% duty cycle and 9000 W of ac auxiliary power.
Vibration system monitors and analyzes
ML4000 real-time synchronous vibration monitoring system also provides fault diagnosis of rotating equipment. The system has high-level analysis and monitoring capabilities with phase-synchronized vibration data for every measurement channel.
Uninterruptible power systems
An 8-p brochure plus two data sheets feature additions to a new line of UPSs. The literature covers both tower and rackmount models with ratings ranging from 750-2250 VA.
Dust monitor continuously measures filter emissions
Dust Detect 1000 triboelectric sensor continuously measures the flow of particulate emissions through an air filtration system. The alarm is switch selectable for instantaneous or 1-min averages.
Audible signal devices
A new catalog covers transducers, indicators, and piezo sirens and backup alarms. The 68-p catalog includes a quick reference section, dimensional drawings, frequency characteristic charts, and specification charts for each type of device.
Don’t get caught with your UPS down
Runtime calculator software helps users determine the optimal configuration of their uninterruptible power system options and battery packs.
Humidification
A 16-p catalog details ultrasonic fog generator humidification systems. The literature highlights microprocessor controls and all-stainless steel construction of the equipment.
Heat transfer fluid replaces glycol
GR-40 biodegradable heat transfer fluid can directly replace ethylene or propylene glycol without system modification in applications from -40-350 F. Heat transfer efficiency is 35-55% better than ethylene glycol and 60- 150% better than propylene glycol.
Vertical storage system has two-bay access
A dual-bay, automated, vertical storage and retrieval system provides more throughput and better accessibility than single-bay units. Both bays are serviced by one extractor operated by a single control system with PC interface.
Hey buddy…got an O-ring?
O-Ring Security System features three kits that organize 1613 O-rings into 77 easily verifiable sizes, sorted by cross-section with an ID range from 1/8-1 3/4 in., within a space less than 1 cu ft.
Compressed air piping system installs quickly
Transair provides an innovative way to install or modify a plant's compressed air piping system, which reduces downtime and increases efficiency compared to threaded steel, soldered copper, or glued plastic.
Harmonic filters
Active harmonic filters providing up to 200% more cancellation than passive harmonic products are presented in a 6-p brochure.
Battery serves UPS applications
Sprinter line of valve-regulated lead-acid batteries are used for high-rate uninterruptible power supply (UPS) applications. The batteries offer a high burst of energy for a short time when maintaining power is critical.
Valve design offers easy field conversion
Valve series offers simplicity and high sanitary performance, and is easy to assemble, disassemble, and convert in the field. The valve can be upgraded easily to proximity or micro switch position sensing.
Networking products
An industrial line of network products, fiber interfaces for various bus systems, and interconnections to cable systems and sensor/actuator devices is depicted in a 16-p brochure.
Machine monitoring
A 10-p brochure depicts a new generation of handheld data loggers incorporating three condition monitoring methods: shock pulse, vibration severity, and evaluated vibration analysis.
InConcert
InConcert workflow software improves productivity and reduces costs by improving the efficiency of the processes.
Universal lift converts to eight configurations
Universal-Lift multi-purpose handling system takes on most work loads because of its versatile attachments.
Rotary UPS
An 8-p brochure explains a line of UPS systems based upon rotational energy storage. Basic flywheel-enhanced ride-through MG sets to advanced dynamic systems with diesel backup are discussed and illustrated. International Computer Power www.rotoups.com
Integrated Condition Assessment System (ICAS)
Integrated Condition Assessment System (ICAS) online integrated condition assessment and diagnostic monitoring system minimizes costs, optimizes availability, and improves productivity. System can be merged with plan DCS and CMMS systems. IDAX, Inc.; www.
Electric power seminars
A 12-p brochure describes five electric power system seminars and workshops that range from 1-2 1/2 days.
City that never sleeps
Here's a city you may not have visited yet. "HVAC-City was formed by Air Conditioning Contractors of America (ACCA) and Wrightsoft Corp. to provide an easy way for HVAC companies to have a presence on the Internet.
Communicate safely in hazardous locations
Contractor Kit is a confined space communication system configured specifically to increase overall safety and efficiency while working in tanks, towers, and other vessels.
