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 table of contents
NOVeMbeR 2010 / VOl. 31, NO. 11

features
24 / COVER STORY 38 / POWER DiSTRibuTiOn
Time to Ripen The Pulse of the Plant
Green initiatives often need An electrical energy survey
room to grow before they bear can provide guidance for
financial rewards reducing utility bills and
greening of industry
31 / LighTing
Where’s the Energy 44 / COMPRESSORS
Money? Design a better System
5 practical approaches to VSDs and controllers can
higher efficiency improve air system efficiency

specialists
17 / huMan CaPiTaL
Data mining and analyzing the information found in a CMMS Mind Your Steps
can lead to the ability to predict machinery failures on new Paths
Take a pragmatic approach to the repair/replace decision. Determine the reasonableness
www.plantservices.com/articles/2010/10failureprediction.html of policies you impose
23 / TEChnOLOgY TOOLbOx
active Energy Conservation
Cut power consumption during
periods of peak price or demand
58 / EnERgY ExPERT

integrate the maintenance organization into the rest of 19 / aSSET ManagER The Costs of Poor
the plant to achieve better reliability Data Quality — Part i Energy Management
The maintenance organizational structure can provide benefits. 16 characteristics of numbers Invest in energy improvements
that can be trusted during good times to avoid the
www.plantservices.com/articles/2010/10roadtoreliability.html
bad times

‘Reliability’ ain’t just another word for maintenance

Reliability management spans the life cycle of an asset or process
and affects, and is affected by, the entire value stream of the columns and departments
organization. 7 / FROM ThE EDiTOR 15 / YOuR SPaCE
community.plantservices.com/content/reliability-aint-just- One With Everything Legacy upgrade
another-word-maintenance Maintenance professionals are Optimize production flow
part of something bigger and ROI with control system
Managing energy and carbon in industrial operations investments
This webcast will identify which technologies companies are 9 / CRiSiS CORnER
investing in to improve visibility into key energy and carbon Fix it Forward 49 / in ThE TREnChES
metrics for intelligent decision-making and reporting. Maintenance and reliability Medical Marijuana in the
http://video.webcasts.com/events/putm001/36387/ are keys to industrial Workplace
economic prosperity Acme considers an employee
with a prescription for a
PlANT SeRVICeS (ISSN 0199-8013) is published monthly by Putman Media, Inc., 555 West Pierce Road, 11 / MR. SuSTainabiLiTY pharmaceutical
Suite 301, Itasca, Il 60143. Phone (630) 467-1300, Fax (847) 291-4816. Periodicals Postage paid at Itasca,
Il and additional mailing offices. Canada Post International Publications Mail Product Sales Agreement No. The E3 initiative
40028661. Canadian Mail Distributor Information: Frontier/bWI,PO box 1051, Fort erie, Ontario, Canada, l2A
5N8. Printed in U.S.A. POSTMASTeR: Send address changes to PlANT SeRVICeS, Putman Media, Inc., PO Put your government to work 52 / PRODuCT FOCuS
box 3435, Northbrook, Il 60065-3435. SUbSCRIPTIONS: Qualified reader subscriptions are accepted from
PlANT SeRVICeS managers, supervisors and engineers in manufacturing plants in the U.S. and Canada. To for you
apply for qualified-reader subscriptions, please go to www.plantservices.com. To non-qualified subscribers in the 56 / CLaSSiFiEDS / aD inDEx
U.S., subscriptions are $96 per year. Single copies are $15, except the November and December issues which
are $36. Canadian and foreign annual subscriptions are accepted at $145 (Foreign airmail $200/yr). Single 13 / WhaT WORKS
copies are $81. © 2010 by Putman Media, Inc. All rights reserved. The contents of this publication may not be
reproduced in whole or in part without consent of the copyright owner. In an effort to more closely align with our Ferrous Metal in the Oil
business partners in a manner that provides the most value to our readers, content published in PlANT SeRVICeS
magazine appears on the public domain of PlANT SeRVICeS’ Website, and may also appear on Websites that In-house oil analysis helps
apply to our growing marketplace. Putman Media, Inc. also publishes CHeMICAl PROCeSSING, CONTROl,
CONTROl DeSIGN, FOOD PROCeSSING, INDUSTRIAl NeTWORKING, THe JOURNAl, PHARMACeUTICAl plant avoid catastrophic failure
MANUFACTURING and WellNeSS FOODS. PlANT SeRVICeS assumes no responsibility for validity of claims
in items published.

www.PLANTSERVICES.Com NoVEmbER 2010 5

PS1011_05_TOC.indd 5 10/28/10 8:33 PM

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 PUTMAN MEDIA, INC.
555 W. Pierce Rd., Suite 301,
Itasca, IL 60143
FROM THE EDITOR
MIKE BACIDORE, EDITOR IN CHIEF
(630) 467-1300 Fax: (630) 467-1120

MIKE BRENNER
Group Publisher
mbrenner@putman.net

EDITORIAL STAFF
PAUL STUDEBAKER, CMRP
ONE WITH EVERYTHING
Editorial Director
pstudebaker@putman.net
Maintenance professionals are part of something bigger
MIKE BACIDORE
Editor in Chief
mbacidore@putman.net While in Milwaukee for the SMRP ment, conducts skill-based testing and
RUSSELL L. KRATOWICZ, P.E. CMRP conference, I saw a Buddhist monk certification, and recognizes excellence
Executive Editor ordering a hot dog. Intrigued, I eaves- through a variety of awards.
russk@putman.net
dropped. “Make me one with every- During her presentation, Suzy
ALEXIS GAJEWSKI thing,” he said and handed the vendor Jamieson, executive director of ICML,
Associate Editor, Digital Media
agajewski@putman.net a $20 bill. When he received only his explained the important role that lubri-
hot dog, the monk asked, “Where’s my cation professionals play in the grand
STEPHEN C. HERNER
V.P., Creative Services change?” Of course, the vendor ex- scheme and reinforced it with best prac-
sherner@putman.net plained change must come from within. tices from winners of the Augustus H.
JENNIFER DAKAS This bit of wisdom was so simple, and Gill Award, given out annually to recog-
Art Director yet it echoed from every maintenance nize commitment to education, mainte-
jdakas@putman.net
and reliability professional and every
DAVID BERGER, P.ENG. solution provider I met at the conference. “YOUR CULTURE IS THE SUM
Contributing Editor
“When change comes from the top
PETER GARFORTH down and then that leader leaves, we OF INDIVIDUAL AND
Contributing Editor
tend to revert back,” said S. Bradley COLLECTIVE BEHAVIORS.”
SHEILA KENNEDY Peterson, founder and CEO of SAMI
Contributing Editor
(www.samicorp.com) and one of the
JOEL LEONARD conference presenters. nance culture and management support,
Contributing Editor
Peterson suggested organizations the use of standardized procedures and
BOB SPERBER move toward goals such as predictable, performance measurements, proactive/
Editor at Large
improved production, high equipment predictive maintenance, technology inte-
availability, reduced waste and operating gration, contamination control, lubrica-
PUBLICATION SERVICES
expense, world-class worker productiv- tion management, oil analysis strategies,
CARMELA KAPPEL ity, 100% regulatory compliance, and a the use of information technology, and
Assistant to the Publisher
ckappel@putman.net safe and productive work environment. continuous improvement.
JERRY CLARK
But reaching those ends doesn’t come “The organizations that win the award
V.P., Circulation without culture change. work hard on their cultural issues,” said
jclark@putman.net “If you’re not measuring behaviors, Jamieson. “They understand that not
JACK JONES you’re missing the most important ele- everyone accepts technology equally and
Circulation Director ment of change,” said Peterson. “Your it sometimes is a gradual process.”
jjones@putman.net
culture is the sum of individual and col- Oil analysis alone is limited to only
RITA FITZGERALD lective behaviors in your organization” lubricated components. Gill Award win-
Production Manager
rfitzgerald@putman.net You put work into a funnel, said ners report using oil analysis, vibration
JILL KALETHA
Peterson. “Different kinds of work tend analysis, thermography, motor circuit
Reprints Marketing Manager to have different viscosities,” he said. evaluation, and acoustic emission. Tech-
Foster Reprints “Emergency work goes right through. nologies are integrated, and, in some
(866) 879-9144 ext.168
jillk@fosterprinting.com RCM is a management tool. Who affects cases, the same technicians are trained
the reliability in a plant? Who doesn’t?” in multiple technologies. Each techni-
ADMINISTRATIVE STAFF Lubrication professionals are a perfect cian is, indeed, one with everything.
JOHN M. CAPPELLETTI example. The International Council for
President/CEO Machinery Lubrication (www.lubecoun-
JULIE CAPPELLETTI-LANGE cil.org), a not-for-profit, vendor-neutral
Vice President organization that champions lubrication Mike Bacidore, Editor in Chief
KEITH LARSON and oil analysis standards develop- mbacidore@putman.net, (630) 467-1300 x444
V.P., Content

ROSE SOUTHARD WWW.PLANTSERVICES.COM NOVEMBER 2010 7

IT Director

PS1011_07_Editorial.indd 7 10/28/10 8:33 PM

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PS1011_FPA.indd 8 10/28/10 9:05 PM

Fix it Forward
Maintenance and reliability are keys to industrial economic prosperity
if you had a chance to speak before thousands, what would
you say to overcome the stigma and stereotype of the engineer-
ing and maintenance profession, to inspire more to pursue the
education that addresses our maintenance crisis challenges,
and to make a difference?
Our National Mall is hallowed ground as that’s where
millions have gathered to urge social change. The speech
Martin Luther King, Jr., delivered there led to civil rights
changes that still echo today in our national conscious.
I’m supporting the inaugural National Science and Engi-
neering Festival on the National Mall. The organizers played
my songs during intermissions. Yes, I, too, have a dream,
that I hope will inspire much-needed change, remove
stigmas and stereotypes that impede our progress, and help
advance our profession. Well, this might be considered a
pipe dream, but a worthy one, nonetheless.
Despite the daily news of pipeline leaks, train derailments,
exploding natural gas lines, and thousands of water main
breaks, the general populace still has a dim, and wrong, view
of the maintenance profession. Most consider it merely a job
to fix the toilets, and they don’t understand or appreciate the
complexity, knowledge, responsibility, discipline, and energy
required to deliver reliablity. Too many companies focus on
quarterly stock performance and have deferred maintenance
to almost critical levels. And they’ve pruned staff and drasti-
cally reduced training programs.
Because of low enrollments in industrial curriculums and
the high cost of industrial training equipment, many com-
munity colleges became four-year preparatory schools and
phased out the focus on future industrial technicians.
We need to remind society that, if we don’t act, competent
technicians won’t appear. As John Gardner, the former U.S.
Secretary of Health, Education, and Welfare, put into words
more than 30 years ago, “The society which scorns excellence
in plumbing as a humble activity and tolerates shoddiness in
philosophy because it is an exalted activity will have neither
good plumbing nor good philosophy. Neither its pipes nor its
theories will hold water.”
After the Gulf Coast crisis and more than 100 days of oil
leaks, when are we going to do something to prevent fail-
ures, as opposed to ignoring alarms and marshalling anemic
responses after the most serious damage already occurred?
If the United States shifted its view of maintenance and
reliability programs from being a cost to being a profit-con-
PS1011_09_Crisis.indd 9
Crisis CornEr
Joel leonard
tributing value-added service, our nation’s economic status
would change and long-term sustainability would increase.
The Netherlands realized that its urban sprawl strategy for
growth has been played out. Population has grown beyond the
land use potential. To fight the possible exodus of factories to
China, the country upgraded its view of maintenance and has
been putting government subsidized Ph.D.s into its factories
wE nEEd to rEMind soCiEty
that, iF wE don’t aCt, CoMpEtEnt
tEChniCians won’t appEar.
and implementing predictive maintenance to control energy
costs. The Dutch developed condition monitoring programs
to increase uptime. They’re funding interactive 3-D training to
build a solid pipeline of future technicians.
If the United States converted maintenance from an after-
thought to forethought, we’d see performance upgrades in
equipment and infrastructure performance, as well as enjoy
greater economic gains and stock market performance. If we
glorified engineers and technicians like we do athletes and
entertainers, we’d no longer see critical job positions go un-
filled. The capability of those positions would grow, as well.
The fact is we must “fix it forward” if we’re going to
remain an economic powerhouse. Talk is cheap, so let’s get
out and formalize our mentorship programs, upgrade ap-
prenticeships, change community colleges back to fulfilling
their original charters of developing technicians. We must
educate future executives with MBA programs that value the
contribution maintenance makes.
Perhaps we need tax incentives to reinforce reliability
and sustainability program performance. We must invest
billions in converting ideas into cutting-edge future results
and must polish the rusty edge of technology to maximize
performance today.
We must fix this mess, and we can, especially if more of
us help to fight the Maintenance Crisis. As we all know, it’s
better to prepare and prevent than to repair and repent. And
thanks again for your past support to urge me onward. Feel
free to send me your ideas to advance our performance.
E-mail Contributing Editor Joel Leonard at joel@skilltv.net.
www.PLANTSERVICES.Com NoVEmbER 2010 9
10/28/10 8:34 PM
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The e3 InITIaTIve
Put your government to work for you
Sustainability is simple in concept: Just leave the world
for the next generation as you would have had the previ-
ous generation leave it for you. But it can be complex to
implement, especially within the priorities and constraints
of the industrial environment. Facilities and maintenance
professionals can easily identify a multitude of opportuni-
ties to save energy, reduce waste, protect the environment,
and preserve jobs while improving long-term viability and
profitability. But which should be done now, which later, and
which perhaps not at all?
Improving sustainability quickly becomes a task of cal-
culating costs vs. benefits, determining feasibility, setting
priorities, and gaining approvals. Converting a plant full of
possibilities into a rational plan can be a challenge, espe-
cially for small- and medium-sized companies. Add in the
potential for multiplying the benefits by involving the com-
munity, and the challenge can be overwhelming.
Your government would like to help. In September, the
U.S. Department of Energy (DOE) joined the U.S. Depart-
ment of Commerce (DOC), the U.S. Environmental Protec-
tion Agency (EPA), the U.S. Small Business Administration
(SBA), and the U.S. Department of Labor (DOL) in signing a
memorandum of understanding in support of the Economy,
Energy, and Environment Initiative (E3 Initiative). Its stated
goal is to help small- and medium-sized manufacturers to
become more efficient, competitive, and sustainable through
public-private partnerships.
In pilot programs during the past year, the federal agen-
cies worked with local utility companies to strategically
coordinate and target concrete assistance, including:
• plant-specific assessments to identify and prioritize
opportunities to reduce costs and waste, improve pro-
ductivity and efficiency, and measure greenhouse-gas
emissions
• training for partners to prevent pollution and reduce
toxic chemical use
• recruitment, screening, and referral services to help
employers hire skilled workers
• assistance in making adjustments to business and strate-
gic plans to incorporate assessment recommendations
• tailored information on available financial resources and
training
• pre-participation financial stability assessments of po-
tential E3 participating companies
PS1011_11_MrSustain.indd 11
MR. SuSTaInabIlITy
paul studebaker, cmrp
• ongoing opportunities to report progress and network
with others about benefits and challenges.
The initiative already has successful pilot projects under-
way in Alabama, Michigan, North Carolina, Ohio, South
Carolina, Texas, West Virginia, and Wisconsin. Now it’s
poised to help your facility. “Working together, the signa-
tories to the E3 agreement offer a holistic, integrated, and
practical approach to tackling a range of sustainability
issues, saving time, building off of each other’s strengths,
ConveRTIng a PlanT full of
PoSSIbIlITIeS InTo a RaTIonal Plan
Can be a Challenge.
and reducing complexity for manufacturers seeking to lower
their energy costs and sharpen their competitive edge,” ac-
cording to an announcement by the DOE’s Office of Energy
Efficiency and Renewable Energy (EERE).
DOE’s participation in E3 is being coordinated through
EERE’s Industrial Technologies Program (ITP). In addition
to offering tools and resources for use in E3 projects, ITP is
engaging the DOE-sponsored Industrial Assessment centers
to provide E3 partners with on-site energy assessments. The
energy assessment program offers a treasure trove of energy-
saving best-practice case histories accessible from the ITP
site (www1.eere.energy.gov/industry).
Perhaps the most critical aspect of the initiative is that each
project works with a range of experts and stakeholders at the
state and local level, including state pollution-prevention pro-
grams, state energy offices, mayors and local county executives,
utility companies, manufacturing enterprises, and universities.
These resources may help you and your plant to recognize and
implement opportunities that extend beyond your fence and
into the local community, such as center-of-excellence, recy-
cling, waste-to-energy, and district energy projects.
To get started, see the E3 fact sheet (www.epa.gov/green-
suppliers/e3.html). If the strong whiff of bureaucracy doesn’t
daunt you, take a look at the project charter template. Then
e-mail or call the listed contacts.
What have you got to lose?
Contact editorial Director Paul Studebaker, CMRP, at
pstudebaker@putman.net.
www.PLANTSERVICES.Com NoVEmbER 2010 11
10/28/10 8:35 PM
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Ferrous Metal in the oil
in-house oil analysis helps plant avoid catastrophic failure
the Gorgas steam Plant is located on the Mulberry Fork
of the Warrior River, some 35 miles northwest of Birming-
ham, Alabama.
Its first unit began operation in 1917. It’s the oldest coal-
fired plant system at Alabama Power (www.alabamapower.
com), a Southern Company subsidiary. Today, units 6, 7, 8, 9
and 10 provide about 1,250 MW.
In 2002, a selective catalytic reduction (SCR) unit for
controlling nitrogen oxides was installed on Unit 10, a 750-
MW super-critical unit. An Advatech flue gas desulfuriza-
tion (FGD) system, or “scrubber,” was added to the unit in
2007 in the first worldwide attempt to scrub multiple units
through one system.
In the plant’s Unit 10-B pulverizer, the vertical shaft
thrust bearing supports the weight of the mill’s rotating
parts and the downward grinding force exerted by the
grinding rolls. The thrust bearing isn’t designed to with-
stand radial loading.
“Lubrication contamination is a big problem,” says James
“Pete” Peterson, condition-based maintenance specialist at
Alabama Power. “Most of our units are from the ’50s, ’60s,
and ’70s. A good lubrication program that includes on-site
oil analysis enables you to trend data on your equipment.
It provides for a rapid response, if needed, and can save big
a siMilar ProbleM in 1999 resulted
in a CatastroPhiC Failure, whiCh
required a total rebuild and Cost
More than $400,000.
dollars. When combined with other technologies, it can help
a plant be the best that it can be.”
The plant uses the CSI 5200 Machinery Health Oil Ana-
lyzer from Emerson Process Management. It has a micro-
scope attachment for checking wear debris.
“Routine oil analysis revealed a high ferrous index on the
10-B pulverizer gearbox,” explains Peterson. “We have six
8-ft gearboxes; one of them is redundant.”
The first indication of trouble came during a routine
monthly oil analysis. “The software screen that comes with
the 5200 went from a zero to a 352 reading for ferrous,” says
PS1011_13_Works.indd 13
what works
steaM Clean
alabama Power’s Gorgas steam Plant uses an in-house oil analysis
system to avoid catastrophic events by checking machinery health.
Peterson. “And the next day it read 443. The fact that the
previous month’s analysis showed zero ferrous told me we
had a problem.”
After calling for help from a more experienced colleague,
Harold Dobbins, it was determined that the system owner
should be brought into the discussion. “A major outage was
to begin in the next day or two on Unit 10, so the pulverizer
representative was already on the plant site, and we decided
to let him look at the data,” explains Peterson.
After draining the gearbox and examining the internals,
they found that the thrust bearing had deteriorated to the
extent that gearbox failure was imminent and that the 10-B
pulverizer would not have made it into peak season.
The bearing was replaced without a major event. Two
months after the initial red reading and discovery of ferrous
content, the replacement had been completed. The oil was
resampled and cleared with a green light.
When Alabama Power had experienced a similar prob-
lem in 1999, prior to its on-site lab setup, it resulted in
catastrophic failure of the gearbox, which required a total
rebuild and cost more than $400,000. “With the ability to
catch this before a catastrophic failure could occur, the cost
was only $30,000 — $20,000 for the bearing and $10,000 for
the installation,” says Peterson.
www.PLANTSERVICES.Com NoVEmbER 2010 13
10/28/10 8:36 PM
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PS1011_FPA.indd 14 10/29/10 10:45 AM


Legacy Upgrade
Optimize production flow and rOI with control system investments
In a no-spend environment, it’s tempting to continue
repairing aging or outmoded process controls. Budget
constraints and maintenance contracts might preempt any
discussion about upgrading controls until you reach the
point where you simply can’t fix them anymore.
If you’re trying to save money on an outdated process
control system that way, you’re investing in false economies.
Eventually, upkeep becomes more expensive than purchas-
ing a new system.
Graham Packaging worked with automation and controls
specialists to maintain our edge in customized packaging.
We operate a tabletop conveyor depalletizer system and an
aseptic, water-wash line in a Class 100 clean room. We’re
moving 24,000 bottles/hr, and we struggled with nuisance
trips and jams. The operators didn’t understand that the
problem was the information the machine gave them.
They’d have to try several solutions. This equipment has
five access doors, and it didn’t identify which was open, so
we’d have to operate each door to find out. This machine has
pumps and valves. If one had a problem, it didn’t tell what to
look for or which valve was the problem.
Connell Industries (www.connell-ind.com) helped us
identify needs and opportunities to be addressed through
system upgrades and replacements. Upgrading saved us four
hours to six hours of downtime each month. We didn’t have
a lot of catastrophic failures, but if you’re getting so much
downtime, you’ve got an problem.
Connell looked at revamping and upgrading the controls
and operator interface. We wanted the most up-to-date
industry-standard equipment, so we could get replacement
parts. We upgraded to a touchscreen HMI, Rockwell Auto-
mation’s Allen-Bradley on-machine PLC, and two Allen-
Bradley VFDs/encoders. We added remote monitoring so
management could watch process variables.
The ROI matches what one expects from a retrofit or
upgrade. One primary benefit of upgrading controls is
system reliability. That translates into other benefits, such as
product quality, uptime, and production capacity.
Key metrics are how much labor we use to get packages
out the door and the time it takes to repair. Better diagnostic
tools let us measure that. The data monitoring system allows
us to react more quickly and keep ahead of problem areas.
Even when you’re not there watching the equipment, you
can see an increase in events. By having insight into the
PS1011_15_Yours.indd 15
yOUr space
equipment as it’s running and being able to monitor key
components in the line, we don’t rely on perception-based
or importance-based decisions. Instead of spending time
on reactive maintenance, we watch trends. Everyone does
PMs, SIPs and CIPs. The more invisible we are, the better off
everyone is. The automated delivery of reliable information
via advanced interfaces enables more appropriate system
support. We don’t rely on human interpretation. Trouble-
TrOUbLeshOOTIng and faILUre
anaLysIs can sUffer when
IndIvIdUaLs deveLOp TheIr Own
anaLyses and sOLUTIOns.
shooting and failure analysis can suffer when individuals
develop their own analyses and solutions. If five people look
at a problem, we’d get five interpretations and solutions.
Intelligent process controls can identify problems and
the events that led to them. This streamlines our ability to
integrate, troubleshoot, identify, and evaluate efficiencies
and opportunities. Process data reveals trends that let us
schedule timely maintenance. We know how products affect
the production line and how some cause more wear and tear.
Some of the feedback comes from advanced network
communications, including SCADA systems. Higher system
integration is more attainable through Internet-based sys-
tems that use the existing Ethernet communication network
installed in most facilities.
In some senses, improved system reliability is like an
iceberg, with uptime and productivity improvements
representing the visible and, to many companies, the most
important cost benefits. Savings on system maintenance
and repair can be tied to appropriate automation-control
upgrade programs because of the ability to get system-wide
feedback. This gives new opportunities to institute improved
maintenance programs, whether preventive maintenance or
corrective maintenance. This information also gives added
flexibility in maintaining equipment.
Michael deitz is project manager at graham packaging, which de-
signs and manufactures blow-molded plastic containers. contact
him at michael.deitz@grahampackaging.com.
www.PLANTSERVICES.Com NoVEmbER 2010 15
10/28/10 8:37 PM
 there’s a fine line between liability and reliability.
For 50 years, Ingersoll Rand has helped the power generation industry transform
adversity into advantages. Our product breadth assures one source for air
compressors, tools, fluids and material handling, all backed by a worldwide
service network. Plus, our audit capabilities, risk mitigation expertise and project
management assure that your business remains efficient and productive. From
installation and maintenance, to programs that boost innovation and energy
efficiency, Ingersoll Rand provides the power to weather any challenge and
improve your business landscape.

IngersollRandProducts.com

18274.indd 1
PS1011_FPA.indd 16 10/15/10 9:07
10/28/10 11:11
PMAM

Mind Your StepS on new pathS
determine the reasonableness of policies you impose
here in Florida, there are certain weather events — hur-
ricanes — that occasionally interact with us. The area where
I live was hit with a series of hurricanes in 2004 and 2005,
which caused a sustained period of blue roofs of temporary
tarps and damaged many other structures. Over time, the
repairs were made. However, the lower priority repairs took
some time to complete. Among these lower priority repairs
was a particular beach crossover.
When I walked out to the crossover, many months after
the hurricanes, I noticed a sign — “BEACH ENTRANCE
CLOSED” — where the stairs leading to the beach had been
removed. Standing on the stunted boardwalk, I noticed
another sign that read, “KEEP OFF DUNE.” More interest-
ing was the well-worn pathway between that sign and the
crossover, which clearly meant people weren’t paying atten-
tion to the sign. So, the question I asked myself was, “Why
would people disobey a sign such as this?”
The folks that blazed that trail wanted to get to the beach. Af-
ter all, the beach wasn’t closed. People knew they weren’t likely
to be challenged in disobeying the sign because this wasn’t a
busy area. If there was no reasonable alternative for getting to
the water, they didn’t see any reason to worry about the conse-
quences of a small strip of disturbed dune.
I’m bringing up this seemingly insignificant situation to
illustrate a point. Many new supervisors or managers react
to problems by putting in place rules and policies to deal
with various “problems” they perceive. Often, they impose
these rules and policies through knee-jerk reactions that
haven’t been thought through. The supervisor or manager
might be thinking swift action needs to be taken.
It’s important to think through any policies you impose.
Questions you should ask yourself include:
PS1011_17_Human.indd 17
huMan CapitaL
Tom moriarTy, P.E., CmrP
• What’s the problem I’m trying to solve?
• Can I explain my reasoning so it makes sense to others?
• How do I gather input from the other stakeholders?
• Do I have the resources that enable people to comply?
• How can I monitor conformance?
• How do I determine the policy’s effectiveness?
• Do I have the authority, or influence, to correct non-
conformance?
GaininG input FroM thoSe who wiLL
be aFFeCted aLLowS You to ConSider
thinGS You MiGht have MiSSed.
When you impose a policy, be clear about why you’re doing
it, and you need to be able to communicate those reasons. U.S.
President Abraham Lincoln, whenever he was angry, disap-
pointed, or otherwise in a situation that clouded his thinking,
wrote out what he intended to do. Then he would place the pa-
per in his desk until the next day. If, on the second day, his re-
sponse still seemed reasonable and proper, he carried through
with it. Often though, he found that after a bit of solitude he
would come to a better choice on what to do.
Gaining input from those who will be affected allows
you to consider things you might have missed. Two heads,
or three or four, are most often better than one. Their input
often saves their supervisor’s butt. Don’t assume you’ve
thought of everything or that only you have the answers.
Having the resources to inform, train, and enable people to
comply is something supervisors and managers underestimate.
Managers sometimes exhibit a blind spot, believing everyone
else thinks like they think and knows what they know.
If there’s no way to monitor compliance and measure the
policy’s effectiveness, there’s no justifiable reason to impose
the policy. Having the authority or influence to impose
corrective action and following through on those corrective
actions ensures the original problems are being addressed.
These guidelines should allow you to show that your poli-
cies are reasonable. Reasonable people will act in accordance
with the policy, and they won’t walk a different path.
tom Moriarty, p.e., CMrp, is president of alidade Mer. Contact
him at tjmpe@alidade-mer.com and (321) 773-3356.
www.PLANTSERVICES.Com NoVEmbER 2010 17
10/28/10 8:39 PM
 “Our business changes
every six months.
Our systems take a year
to catch up.” Customer mandates, regulation and
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PS1011_FPA.indd 18 10/28/10 9:08 PM


Data Quality — Part i
16 characteristics of numbers that can be trusted
if you’ve ever been surprised by the results of a query or
report your CMMS generated, there are several possible rea-
sons. Perhaps you misread the numbers or pressed a wrong key.
Maybe you weren’t aware of certain information, your expecta-
tions were unrealistic, or you were in denial. Unfortunately and
all too often, data quality is the culprit — “garbage in, garbage
out.” If indeed that is the reason, your CMMS software is not
worth the cost of the computer on which it runs.
It’s astonishing just how much management relies on a
CMMS to provide information such as budget variances,
asset availability and performance, energy consumption,
payroll hours consumed, and work backlog. Despite our
thirst for information, there’s sometimes little thought as to
where the data is coming from and whether it reflects reality.
It’s our inexplicable blind faith in technology that is our
weakness — as if anything the CMMS outputs to screen or
paper must be accurate because a computer processed it. As
many maintenance managers discovered over the years, the
quality of data input into the CMMS can be sadly lacking.
Consider the definition of data quality, including ex-
amples of how it can be compromised. Many terms can be
clumped under the umbrella of data quality, in whole or in
part. Each is defined below. In general, data quality is infor-
mation that meets our expectations.
Integrity ensures that data is preserved, from source to
consumer, without distortion from accidental or malicious
intervention. Spare parts records can be bad because a barcode
scanner read a damaged label incorrectly, or someone stole
parts, hacks into the CMMS, and falsifies the number of spares.
Validity ensures data conforms to business rules such
as format, range, and logic. For example, when entering a
meter reading to determine if a PM is due, it must be four
numeric digits with a value greater than the last entry, but
by no more than 1,000 miles.
Accuracy refers to data correctness and conformity to a
given standard. For example, a technician works on a job
that should take no more than three hours, but instead
enters five hours on the work order because of human error
or a deliberate distortion of the facts.
Precision refers to the data’s granularity. For example,
when performing an inspection that requires measuring, a
technician records the reading as “1/2” instead “0.4532.”
Credibility refers to data reasonableness and believability.
For example, technicians vary in experience and diagnostic
PS1011_19_20_AssetMgr.indd 19
asset manager
david berger, P.eng.
capability in determining a root cause of failure — data
from one might be more credible than from another.
Timeliness means that data might be of no value although
its perfect in every way, but not current or comes at the
wrong time. For example, if work order information is en-
tered at the end of the week instead of at the end of the job,
equipment history reports generated throughout the week
might not reflect reality and lead to poor decision-making.
Completeness becomes a problem if users choose to use
fewer fields or enter less data into the CMMS, either to save
time or cost, but ultimately, decision-making capability
it’s our inexPlicable blinD faith in
technology that is our weakness.
can be compromised. For example, CMMS users don’t use
standard job plans for repetitive work, including estimated
hours to complete the job, safety procedures, standard parts
required, and so on. The lack of standardized processes re-
sults in poor productivity and an inability to track variance
analysis on performance and quality standards.
Conciseness and high-quality data implies brevity and
more succinct data entery — for example, using a descriptive
field to enter “I took out the old motor and put in a new one”
vs. using a coded action field to select “replaced motor.”
Redundancy, multiple entries of the same data, is a com-
mon problem with a large database — for example, entering
a new vendor under the name of “ABC Bearings of Canada
Ltd.,” when the existing CMMS entries, “ABC Bearings” and
“Ontario 1234567,” already refer to the same vendor. This
also is common in entering multiple part numbers referenc-
ing the identical part carried by different suppliers.
Consistency refers to the level of data repeatability —
would someone enter the same data under the same circum-
stances in the future? For example, technicians aren’t always
consistent when selecting problem, cause, and action codes.
Objectivity means it’s possible to introduce biases into the
data as humans enter, approve, or manipulate CMMS data,
producing distortions that might be recognizable. For example,
a technician who is anxious to replace a piece of equipment
that’s perceived as problematic might color the description of a
failure or exaggerate the downtime recorded.
Utility refers to the data’s applicability and usefulness.
www.PLANTSERVICES.Com NoVEmbER 2010 19
10/28/10 8:44 PM
 assEt ManagEr

For example, there are hundreds of reports available on a
CMMS, but not all reports have the same utility; compa-
nies find it difficult to prioritize and focus on a small set of
measures that trade off, such as tracking asset availability,
utilization, performance, reliability, quality of output, and
total cost of ownership for critical assets.
Accessibility means that CMMS data should be available
and easy to obtain for those authorized to enter or retrieve
it. For example, when using mobile devices in remote re-
gions of the country, technicians should have some means of
entering data and accessing work orders, GIS maps showing
asset location, equipment history, and so on.
Usability, one of the most critical aspects of data quality,
refers to the intuitiveness and ease of use of data, including
ease of learning and remembering. For example, technicians
might use shortcuts to save time when entering work-order
or master-file data; this is fine if data can be found afterward
and understood by everyone.
Traceability is important when you need to know the
source of the data to determine its credibility and to obtain
further information. For example, a maintenance supervisor
drills down on a major budget variance and discovers that a
new technician is working on an unfamiliar piece of equip-
ment, so more training is required.
Flexibility means higher-quality data won’t be compro-
mised when the process or the CMMS database supporting
it are changed. For example, upgrading your CMMS to a
new and improved version shouldn’t compromise the accu-
racy or integrity of the data converted to the new system.
As you see, there are so many ways to corrupt or distort
CMMS data, despite our growing trust in, and dependence
on, computer systems. This underlines the importance of
maintaining a healthy skepticism when making decisions
based on data the CMMS presents. In next month’s column,
I’ll examine ways to achieve and maintain higher levels of
data quality. Next month, I’ll explain what can be done to
detect, prevent, and rectify data-quality problems.
E-mail Contributing Editor David Berger, P.Eng., partner, Western
Management Consultants, at david@wmc.on.ca.

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PS1011_19_20_AssetMgr.indd 20 10/28/10 8:44 PM

PS1011_FPA.indd 21 10/28/10 9:08 PM
 To resolve stubborn
system problems,
we dig deep.

Think about ITT.

Bad-acting pump systems are like weeds. If you don’t get the root, they just
keep coming back. And keep eating a disproportionate share of your repair,
maintenance and energy budget. Plus dollars due to lost production. But
you don’t have to live with them. Call ITT. Our REsolve service specializes
in eliminating bad actors by performing a root cause analysis that solves
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PS1011_FPA.indd 22 10/28/10 9:08 PM


AcTive energy conservATion
cut power consumption during periods of peak price or demand
Demand response is the ability to curtail power consump-
tion during periods of peak price or demand to reduce costs or
receive incentive payments. Plants with the flexibility to shut
down or idle production or switch to backup generation are
prime candidates, as are large facilities with building controls
that automate electricity usage reductions. Those with on-site
generation capabilities can sell excess electricity to the grid.
The benefits aren’t only financial, but societal, as well:
actively controlling and sharing power improves service reli-
ability for all electricity consumers and eases the integration
of additional renewable power sources to the grid. Software
and technology that measures, monitors, and controls en-
ergy in real time are making demand response easier.
Demand Response 2.0: Early adopters of demand response
were consumers selling electricity back to the utilities with
advance notice, but it was a manual task. If the person being
notified was busy or off duty when the time came to reduce
consumption, the program’s effectiveness declined.
The paradigm shift is Demand Response 2.0, says Ross
Malme, demand response director at Schneider Electric. It sup-
ports variable, unpredictable demand with energy management
controls that modulate use based on the needs of the market-
place, while keeping the grid in sync. “A consumer can be an
energy resource for 10 minutes at a time, 10 times per month,”
he says. Automatically sent microinstructions scale back vari-
able frequency drives or dimmable ballasts, or control a chiller’s
floating set point, for example. “It’s not just about energy
efficiency,” adds Malme. “It’s about making the energy bill
an asset that can be monetized. With electricity costs rising
and volatile prices, pushing the price risk on customers, it
becomes more attractive to control costs and make money.”
Enabling technology: Large consumers can participate di-
rectly in the wholesale market, but smaller energy customers
face barriers to participation. Now that the Federal Energy
Regulatory Commission has removed the barriers, aggrega-
tors can give small companies the same opportunities.
Software that manages demand response in real time is
the Demand Response Business Network (DRBizNet ) from
Utility Integration Solutions (UISOL). The software is used
in three wholesale markets in the United States to support
multiple demand-response aggregators simultaneously.
The market potential for distributed generation and
distributed storage is huge and global, explains Ali Vojdani,
CEO of UISOL. “As more of us buy solar panels and other
PS1011_23_TechTool.indd 23
Technology Toolbox
Sheila Kennedy
technologies that connect to the grid, demand response
becomes even more important, requiring sophisticated de-
mand response management software,” says Vojdani.
On the hardware side, there are devices that receive
demand response signals at the customer site and automati-
cally execute load control actions through the building auto-
mation system or direct control of equipment. An example is
Constellation NewEnergy’s Load Control Unit developed in
conjunction with Lynxspring.
The benefiTs Aren’T only finAnciAl,
buT socieTAl, As Well.
Revenue stream: In California, if you eliminate 100 kW or
more on short notice, you get paid as if you were generating
that power. The Proxy Demand Resources (PDR) program at
California ISO (CAISO) uses the DRBizNet platform to treat
the reduction the same as electricity provided by a power plant.
Rather than a fixed price, PDR uses prices set on the open
market. “The consumer can bid in our day-ahead market or
real-time market — offering to reduce demand by X number of
megawatts according to resource-specific variables,” says Gregg
Fishman, senior public information officer for CAISO.
Payback: Alcoa’s Warrick Power Plant supplies energy
to its aluminum smelter and fabricating facilities and sells
excess capacity to the Midwest ISO wholesale market using
OSIsoft’s PI System infrastructure. Weekly payments from
the ISO helped sustain the aluminum plant through the
economic downturn, and payback for the project took four
months, according to Brian Helms, power markets coor-
dinator for Alcoa Power Generation, in his presentation
at OSIsoft Users Conference 2010. He recommends using
demand response to set you a little above your competitors.
If you’re a marginal facility, it could save your business.
e-mail contributing editor sheila Kennedy, managing director of
Additive communications, at sheila@addcomm.com.
reference Web siTes:
www.schneider-electric.com www.caiso.com
www.uisol.com www.osisoft.com
www.lynxspring.com www.alcoa.com
www.PLANTSERVICES.Com NoVEmbER 2010 23
10/28/10 8:46 PM
 Time
to
Ripen
Green initiatives often need
room to grow before they
bear financial rewards
By Stephen P. Ashkin, The Ashkin Group

PS1011_24_28_CvrStry.indd 24 10/28/10 8:46 PM


P robably more than most businesses,
industrial facilities and manufactur-
ers focus on the bottom line. In most
cases, changes to business practices
and operations are implemented only
because they can save money, improve
worker productivity (another form of
cost savings), or help a manufacturer
make products less expensively.
Until recently, rarely would an indus-
trial facility or manufacturer consider
incorporating green or sustainable prac-
tices as a way to reap financial benefits.
After all, it wasn’t that long ago that
building a green, more sustainable facil-
ity would cost significantly more than
constructing a comparable conventional
facility. Operating a green facility could
be more costly, as well.
While this cost differential between
green and conventional practices has
narrowed significantly or often been
eliminated completely, there are some
sustainable building practices that
might not prove to be a significant
cost savings or offer a significant re-
turn on investment (ROI) for several
years to come. For instance, the ROI
for retrofitting a facility with a green
roof depends greatly on whether
the facility can claim tax credits for
installing it, the overall cost of the
project, the life expectancy of the
current roof, the type of green roof
selected, the climate and geographic
location of the facility, and the age of
the building.
Although the return on the installation
of a green roof might have several vari-
ables, other sustainable measures and in-
stallations are more likely to prove their
value in cost savings more quickly and
significantly. In some cases, these returns
might be quite tangible, for instance, a
PS1011_24_28_CvrStry.indd 25
MANAGEMENT / SUSTAINABILITY
reduction in utility bills. In other cases,
the returns might be less noticeable, at
least initially, but prove valuable in the
long run. There are three noteworthy
sustainable measures that are relatively
economical and financially beneficial.
These include:
• systems and strategies that save
energy
• products and procedures that con-
serve water
• the adoption of green cleaning
systems.
However, before discussing these sus-
tainable practices, let’s concentrate on the
issues confronting plant managers as they
consider the entire concept of building,
retrofitting, and operating a facility in a
more sustainable manner. Conducting
a rigorous analysis of the issues and op-
tions now can help ward off mistakes and
potential problems down the road.
CoMplEx quEsTioNs ANd issuEs
According to the U.S. Green Building
Council (USGBC), a property’s value
increases by $12.50/sq ft for every $1/sq
ft saved in operating expenses as a result
of incorporating green and sustainable
measures. While this highlights the
benefits of sustainability, deciding on
which practices or programs to select
can be daunting. One way to move for-
ward is to ask these questions:
• What are the costs that are associ-
ated with each green or sustainable
alternative?
• Will there be a payback or ROI for
the greener choices, and how much
will this likely be?
• What are the most sustainable op-
tions and choices for the facility?
• What choices most significantly re-
duce the facility’s carbon footprint?
www.PLANTSERVICES.Com NoVEmbER 2010 25
10/28/10 8:47 PM
 ManageMent / SUSTAINABILITY
Based on the answers, plant managers form specific
conclusions as to which equipment, building materials,
products, and procedures should be replaced, installed, or
implemented to make the facility more sustainable and show
a worthwhile ROI. Rather than embarking on a broad range
of sustainable initiatives, focus your efforts on key areas,
such as water, energy, and green cleaning that will likely
produce the most immediate, cost-effective results.
Cost savings and sustainability
through energy savings
The costs of oil and natural gas and related petroleum-based
products have risen significantly during the past decade.
Although there’s been some dip in these costs lately because
of the downturn in the economy, you can bet that almost as
quickly as the world economy shows signs of improvement,
the charges for oil and gas also will rise.
These increasing costs have a negative effect on companies
around the world, in good times and in bad, but they’re becom-
ing especially harsh for U.S. manufacturers at a time when
many are just now starting to show economic life and profit-
ability. A study by the National Association of Manufacturers
(NAM) in 2004, when the U.S. economy was relatively robust,
found that U.S. manufacturers had a 22% cost disadvantage
compared to their overseas competitors in a number of areas,
with the cost of energy being one of the chief culprits.
Any controls or systems that aggressively reduce energy
consumption now, at least until less expensive alternatives
are viable, can improve any bottom line. For example, Steris
of Mentor, Ohio, manufacturer of products and services for
health care, pharmaceutical, scientific, and industrial facili-
ties achieved significant energy savings by:
• installing additional insulation to existing facilities
more resources at www.plantservices.com
toPiC searCh
energy and waste “grow greener plants”
management
sustainability “greener than thou”
going green “does it pay to be green?”
green flooring “step in the right direction”
shortage of energy expertise “the reality of green jobs”
sustainable energy and “fields of green”
economy
green overview “growing green plants”
leeds certification “sustain a house of green”
used equipment “More than one kind of green”
lighting efficiency “greenbacks for green lighting”
recycling trash “different types of green”
for more, search www.Plantservices.com using the
keywords green, retrofitting, and sustainability.
26 November 2010 www.PLANTServICeS.Com
PS1011_24_28_CvrStry.indd 26
defining sustainability
The word “sustainability” is bantered around quite
a bit these days, causing some confusion as to what
the term really means. The best definition of sustain-
ability, and the one that most professionals use, was
coined in 1983 by the United Nations Commission on
Environment and Development. It defined sustainabil-
ity as “meeting present needs without compromising
the ability of future generations to meet their needs.”
In recent years, the concept of sustainability, as
it applies to businesses, has evolved into the “triple
bottom line.” This refers to economic, social, and
environmental benefits for businesses when they oper-
ate their facilities in a more sustainable manner.
• upgrading or replacing older HVAC, steam, or com-
pressed air systems
• retrofitting lighting throughout and increasing use of
day lighting systems
• installing or upgrading building control and manage-
ment systems.
While the costs for these upgrades weren’t revealed, the
company indicates that cost savings from these and other
improvements total nearly $1 million annually. Although
the ROI for Steris’ improvements can’t be determined pre-
cisely, one thing is certain: As the cost of energy increases in
years to come, the savings will likely increase, as well, mak-
ing these sustainable measures a worthwhile investment.
In another case, when the National Renewable Energy
Laboratory in Golden, Colorado, invested $10,000 in day
lighting systems, which turn lights on and off based on the
amount of sunlight entering the facility, it saved more than
$4,000/year in energy costs.
Cost savings and sustainability
through water savings
Even though some studies indicate that water use in indus-
trial facilities is actually on the decline, estimates indicate
the amount of water used in plant, industrial, and manu-
facturing facilities amounts to about 10% of total U.S. water
use. Water reuse and conservation practices — along with
measures to reduce water disposal and the energy necessary
to pump, heat, chill, and distribute water to and throughout
a facility — can result in significant savings.
In some cases, non-potable water can be reused for landscap-
ing and irrigation, which can prove to be a significant water
savings. Low- and no-flow faucets and fixtures in restrooms
also can prove to be a source of significant water savings. For
instance, the state of Massachusetts wanted to know what
would happen if it replaced conventional urinals with waterless
urinals in its state facilities and how much water and money it
would save. It determined that if waterless urinal systems were
installed, there would be a water savings of approximately 1.6
10/28/10 8:47 PM
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PS1011_FPA.indd 27 10/28/10 9:09 PM

 ManageMent / SUSTAINABILITY

as green as gold

Vacon’s 66,998 sq ft, single-story “Striving for LEED Gold Certification

structure in Chambersburg, Pennsylva-
nia, was designed in four months and
constructed in just eight months. The
building contains 16,323 sq ft of office
space and 50,675 sq ft of lab, testing,
assembly, and distribution space.
Vacon can expect a reduction of more
than 18% in energy costs because of
the environmentally friendly features
of the building, which was designed to
reduce potable water use and includes
environmentally friendly mechanical
and HVAC systems. In the construction
of the building, construction waste was
diverted from the landfill, local materi-
als were used to reduce the shipping of
outside materials, and Forest Steward-
ship Council-certified wood was used.
The building also has priority parking
for fuel-efficient vehicles. Energy ef-
ficiency measures include an improved
thermal envelope, high-efficiency
glazing, reduced interior lighting power
density, and demand control ventilation.
The Vacon plant, which manufac-
tures AC drives, received the LEED
Gold Certification Award, estab-
lished by the U.S. Green Building
Council (USGBC) and verified by the
Green Building Certification Institute
(GBCI). The gold certification is the
second-highest level of energy-efficient
building design the USGBC awards.
was a natural step for our company”
says Tom Doring, president of Vacon
(www.vacon.com). “Vacon’s business
is about helping customers’ sustain-
ability and going green. Our products
improve productivity and increase
energy efficiency. If we’re going to help
our customers be more energy efficient,
we have to live by our own standards.”
The LEED program recognizes the
design, construction and operation of
high-performance green buildings.
“With each new LEED-certified build-
ing, we get one step closer to USGBC’s
vision of a sustainably built environment
within a generation,” says Rick Fedrizzi,
president, CEO and founding chair,
U.S. Green Building Council. “As the
newest member of the LEED family of
green buildings, Vacon is an impor-
tant addition to the growing strength
of the green building movement.”

million gal annually for every 1,000 male workers. Addition-
ally, for every 1,000 male workers there would be a cost savings
of approximately $21,000 in water and sewer costs (based on
June 2008 charges).
Other ways industrial facilities reduce water use is through
the use of new cooling towers that minimize drift and evapo-
ration. Further, many facilities are now collecting rainwater
runoff from rooftops, using it for plants and landscaping.
Cost savings and sustainability
through green Cleaning
At one time, green cleaning products cost more than con-
ventional cleaning products. However, with new technolo-
gies, greater product concentration, and other improve-
ments, any additional costs for green cleaning products are
negligible, making them cost-neutral.
Oftentimes, any additional costs for the green products
are offset, in many cases significantly, by savings in other
areas. For instance, a University of San Diego study released
in September 2009 found that employees working in green
buildings are more productive than their counterparts in
non-green facilities.
The study involved more than 2,000 workers employed or
working in 154 green buildings. A green building was de-
fined as one that was LEED-certified or Energy Star-labeled,
meaning it was designed to use considerably less energy
than a comparable facility. Formerly, these staffers worked
in conventional, non-green facilities. The researchers looked
at two key measurements to compare productivity: the num-
ber of sick days the workers took and self-reported produc-
tivity percentage changes.
Among the key findings were that 45% of respondents
reported an average of 2.9 fewer sick days in the new green
location. Further, nearly 43% of the employees agreed they
were more productive in green buildings, and 12% strongly
agreed they were more productive in the greener, more
sustainable buildings.
At first sight, these cost savings aren’t as obvious as, say, a re-
duced utility bill resulting from additional building insulation;
yet they can be just as significant. Employers know that fewer
sick days and greater worker productivity are like money in the
bank, especially in a manufacturing or industrial setting.
As plant managers gain greater insight into the green
and sustainable opportunities available to them, and with
mounting pressure to operate facilities in a more sustainable
manner, they’re likely to discover many ways to embrace
sustainability while realizing cost benefits. Going green has
evolved into a win-win-win situation: natural resources are
protected; facilities are operated in a more efficient, healthier
manner; and the bottom line experiences a positive kick.
stephen P. ashkin is president of the ashkin group in blooming-
ton, indiana. Contact him at steveashkin@ashkingroup.com and
(812) 332-7950.

28 November 2010 www.PLANTServICeS.Com

PS1011_24_28_CvrStry.indd 28 10/28/10 8:48 PM

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 EFFICIENCY / LIGHTING

WHERE’S THE
ENERGY MONEY?
5 practical approaches to higher efficiency
By Tom Pincince, Digital Lumens

Industrial facilities have more opportunities than
ever to increase energy efficiency and reduce energy
consumption — from refrigeration, HVAC, and lighting
to materials handling, water usage, and recycling. Techno-
logical innovation makes the decision to adopt improved
energy-efficient solutions and strategies a no-brainer.
However, facility managers and sustainability executives
still face funding obstacles and challenges that can form
barriers to adopting these new measures.
Finding practical approaches to funding energy ef-
ficiency and ensuring a successful program shouldn’t be a
daunting process. Especially when maintaining the status

WWW.PLANTSERVICES.COM NOVEMBER 2010 31

PS1011_31_36_Light.indd 31 10/28/10 8:49 PM

 EfficiEncy / Lighting
quo puts your facility and organiza-
tion at risk or competitive disad-
vantage because of rising or un-
predictable costs. The top-of-mind
questions that usually arise when
considering a project include:
• Where do I start — which areas
can benefit most quickly from
energy-efficient solutions?
• How do I fund the solutions —
from acquisition and installation
to maintenance?
• What will be the payback, and
how can I measure ROI and TCO?
• How do I know if my decisions
will have and impact and achieve
the projected savings?
Following are some proven strate-
gies for tackling those questions and
driving down energy consumption.
Lighting first
Start with lighting to free up funds
for other projects. According to
AMR Research’s 2010 report,
“Illuminating the Sustainability
Challenge: Delivering Sustainable
Business Strategies through Dis-
ruptive Innovation and Technol-
intELLigEnt Lighting systEms providE morE
Light and onLy whErE and whEn it’s nEEdEd.
ogy,” lighting remains the largest
user of electricity in buildings. In
warehouses and industrial facilities,
lighting typically costs $1/sq ft/year,
but reducing that number frees up
funds that can defray other energy-
efficiency projects. Additionally,
because it’s relatively easy to retrofit
lighting fixtures, it’s an easy first
program to take on.
Lighting is essential to any facility
to provide a safe and comfortable
workplace. However, legacy lighting
fixtures are inefficient, expensive
to maintain, and basically “dumb.”
With smart technologies and the
evolution of highly controllable
LEDs for high-intensity applications,
32 November 2010 www.PLANTServICeS.Com
PS1011_31_36_Light.indd 32
more resources at www.plantservices.com
topic sEarch
Lighting interface “hello daLi”
tuned lighting “Engineer quality lighting”
Lighting upgrades “Efficiency and beyond”
LEEd lighting “Leveraged lighting control”
trends “Lighting your way to energy savings”
photoluminescence “when the lights go out”
LEEd certification “sustain a house of green”
steam audits “get a grip on the steamer”
Level 1 audits “profits and compressed air”
for more, search www.plantservices.com using the keywords lighting, sustainabil-
ity, and cost justification.
you can achieve massive reductions • Does your lighting give off excess
in energy use and costs — as much heat, which consequentially forces
as 90%. Intelligent lighting systems your chiller to work harder to
provide more light and only where keep things refrigerated?
and when it’s needed. They also • Does the lighting require a
reduce maintenance and improve certain amount of warm-up time
operational control to enable new before generating full output?
levels of sustainability. • Are you spending significant time
What kind of savings does that and money on lighting mainte-
translate into? A 90% decrease in nance, including ballast and bulb
energy use in a 250,000-sq-ft facility replacement?
reduces lighting costs from $250,000 The findings will help drive dis-
cussions on funding lighting as the
first step on much improved energy
efficiency.
funding options
You have several options available
to $25,000, enabling a large percent- to finance energy-efficient solutions
age of the project cost to be funded — from capital expense to leasing to
through savings. shared savings models.
How do you know if your lighting Capital expense: For many orga-
needs to be updated? Analyze your nizations with low capital costs, this
electric bill to ascertain how much can be an appealing strategy, espe-
lighting is costing you. Then ask cially if the expected payback period
yourself some basic questions. on the investment is rapid.
• Is it bright enough? Or do you Leasing: Another approach is
have lamps out that need to be leasing new equipment, which has a
replaced, or do you have dimin- couple of variants. An operating lease
ished fixture outputs? requires that the equipment be re-
• Can you control lighting easily to turned at the end of the lease or that
maximize efficiency when no one an agreement is reached to extend the
is in an area of the facility? lease or be purchased at fair market
• What kind of data are you able to value. A capital lease is structured so
retrieve to measure and manage the equipment is paid off in install-
electrical energy usage? ments and, at term end, the lessee
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 EfficiEncy / Lighting

owns the energy-efficient solution. Total Cost of Ownership – 5 Years

The advantage is that a capital lease
doesn’t involve any, or very little,
capital outlay.
Energy service companies (ESCOs)
are potential lessors. The agreement
might involve either sharing in the
savings — for example, the ESCO
buys the new lighting and then shares
part of the project savings — or the
ESCO determines a guaranteed sav-
ings for the contracting organization
and keeps the rest.
Performance contracting: Typi-
cally involving an ESCO or other
energy-efficiency provider, perfor-
mance contracts assign a third party
to manage a group of efficiency
projects from end to end, includ-
ing financing. The advantage is no
upfront costs or debt for the bal-
ance sheet. The disadvantage can be
losing a substantial portion of the
savings to the ESCO. This approach
might be best considered if you
are looking at a large and complex
project and have a limited ability to
spend capital budget or take on debt.
REbatEs and incEntivEs
Utility companies in most areas offer
compelling rebates and incentives
that can defray a significant portion
of your energy-efficiency projects —
as much as 50% of the costs. Why?
Reducing load to accommodate
you havE sEvERal options availablE
to financE EnERgy-EfficiEnt solutions.
growing demand postpones the need
to build additional capacity — an
expensive prospect. An essential first
step for any project is to check with
your local utility to understand the
options available for a given project
type and any product requirements
or measurement-and-verification
requirements around the incentive.
In addition, the 2009 American
Recovery and Reinvestment Act
total cost of ownERship
$600,000
$500,000
$400,000
$300,000
$200,000
$100,000
$-
0 1 2 3
figure 1. this analysis makes a series of assumptions. First, 200 existing hiD fixtures are
being replaced with HID
hiF 400
or iLS
W in a 1-for-1 retrofit. the
HIF 6LT5
maintenance costs whereas iLS doesn’t have relamping or maintenance. Estimated hVAC
savings is included for hiF and iLS, energy incentives are excluded in the calculations.
the utility cost is $0.134/kWh.
introduced numerous opportuni-
ties at the federal and state levels for
promoting energy-efficiency projects
through the U.S. Department of En-
ergy. This includes specific program
grants for industrial energy-effi-
ciency programs. Each state has its
own programs to be investigated for
funding assistance and incentives,
such as the New York State Research
and Development Authority (NY-
SERDA).
Useful resources you might want
to consult are the U.S. Department
of Energy’s database of State Incen-
tives for Renewables and Efficiencies
(DSIRE) and the American Council
for an Energy-Efficient Economy.
Making thE businEss casE
When considering any project, the
rubber hits the road when the num-
bers hit the spreadsheet. The essential
numbers — itemized upfront costs to
acquire and install new equipment,
4 5 6
Years
hiD andLighting
Intelligent hiF include relamping/
System
rebates, tax credits, and anticipated
energy and maintenance savings —
need to be gathered. Then the number
crunching begins in earnest. The
most common question is how quick-
ly the energy and maintenance sav-
ings will offset the initial investment.
The two most prevalent approaches to
consider are payback and total cost of
ownership (Figure 1).
Payback is the type of analysis most
people focus on when considering a
purchase. Divide the upfront costs
by the annual energy savings, with
an eye toward when the anticipated
savings cover the initial purchase
price (time horizon). But this analysis
doesn’t capture the whole story and
can skew toward a short-term solu-
tion that will deliver smaller energy
savings over time.
Total cost of ownership (TCO) is
the most comprehensive approach;
it captures every variable across the
project’s lifetime. TCO is determined
by analyzing the total costs — instal-
lation, operation, and maintenance —
less the annual energy, maintenance,
and cooling savings. For example,
when upgrading lighting, determin-
ing how often lights will be off be-

34 November 2010 www.PLANTServICeS.Com

PS1011_31_36_Light.indd 34 10/28/10 8:50 PM

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PS1011_FPA.indd 35 10/28/10 9:10 PM

 EfficiEncy / Lighting

cause of a lack of activity will be a key factor in generating
chiller savings through reduction of lamp heat generation.
Choosing a solution with smaller upfront costs might
seem appealing, but if the energy savings are smaller, they
increase the TCO, sometimes significantly. If a proposed
project has greater upfront costs, but much greater annual
energy savings, the savings will accumulate continuously
over time, and the TCO will be much more advantageous.
The goal is to minimize TCO while staying above the
minimum corporate ROI threshold.
SnapShot of EnErgy EfficiEncy iSn’t Enough
Leadership in energy and environmental design (LEED)
certification and other systems that analyze and rate en-
ergy-efficiency steps are important, but they’re based on a
single point in time, a snapshot. Ensuring energy efficien-
cy over time requires ongoing measurement and neces-
sary adjustments — known as continuous commission-
ing. This process ensures a system aligns with needs and
maximizes savings. Buildings need to be recommissioned
every year or risk an annual 15% increase in energy use
as building usage shifts, so energy efficiency solutions
should provide ongoing commissioning capabilities. This
avoids the set-it-and-forget-it mentality, which is subject
to savings erosion over time.
Facility managers want to reap the financial and sustain-
totaL coSt of ownErShip iS thE
moSt comprEhEnSivE approach;
it capturES EvEry variabLE acroSS
thE projEct’S LifEtimE.
ability benefits of energy-efficiency improvements. With
a range of innovative systems and a variety of financing
strategies available, funding shouldn’t be a barrier to mov-
ing forward.
Any energy-efficiency investment — from lighting to
chiller upgrade or solar PV panels — that makes business
sense should be within reach. It’s simply a matter of find-
ing the most practical approach.
tom pincince is president and cEo at Digital Lumens (www.
digitallumens.com). contact him at (617) 723-1200.

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36 November 2010 www.PLANTServICeS.Com

PS1011_31_36_Light.indd 36 11/1/10 9:48 AM

 © 2009 Swagelok Company

In times like these, you need more than the right product in the right place. That’s
why, at Swagelok, we take training to heart. Working side by side with you to improve

Because “show me”

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swa4778-04_PlantServices_AR_20090904.indd
PS1011_FPA.indd 37 1 9/4/09
11/1/103:28:57 PM
9:52 AM
 ENERGY / POWER DISTRIBUTION
Pulse
The
Plant
of the
Facility professionals are finding savings opportuni-
ties by better understanding when, where, and how energy
is being used. It’s the necessary first step in managing utility
bills. Powerful handheld instruments are ideal for facility
energy studies and carbon footprint calculations, taking for-
ward/reverse energy measurements for grid-tied alternative
energy systems, and for complying with public and private-
sector energy initiatives.
As the world’s largest energy consumer, the United
States used around 100 quadrillion BTUs, or 105 exajoules,
of energy in 2005 — three times what it was back in 1950.
THE DIFFERENCE BETWEEN OBSERVED
PERFORMANCE AND BEST PRACTICES IS
THE TWILIGHT ZONE WHERE POTENTIAL
ENERGY AND COST SAVINGS RESIDE.
The U.S. Department of Energy claims that industrial and
commercial buildings account for nearly 50% of that, to
the tune of more than $200 billion annually. Little wonder
that recent years have seen the proliferation of a bewilder-
ing array of public and private-sector energy initiatives
designed to micromanage the process of increasing energy
efficiency, reducing greenhouse gas emissions, mandating
more stringent conservation measures, and driving greater
reliance on renewable energy resources.
38 NOVEMBER 2010 WWW.PLANTSERVICES.COM
PS1011_38_43_Electric.indd 38
An electrical energy survey can
provide guidance for reducing
utility bills and greening of industry
By Ross Ignall, Dranetz
FACILITY ENERGY PERFORMANCE
Whether the goal is to comply with government legisla-
tion, qualify for Energy Star, LEED, Green Globes, or other
ratings, or simply to save energy and cut costs, the tool most
often used to benchmark facility energy performance, the
starting point, is the energy audit. The purpose of such stud-
ies is a comprehensive evaluation of the actual performance
of a plant’s systems and equipment compared to its optimal,
designed performance level.
The difference between observed performance and best
practices is the twilight zone where potential energy and
cost savings reside. Plant performance audits are vital to
strong energy management programs, without which the
continuous improvements of energy efficiency and its resul-
tant cost savings are difficult to characterize. Energy audits
are an extremely useful way to:
• identify actions for improving energy performance
• prioritize projects
• track progress.
At the operations level, it’s not unusual for large industrial
and commercial power consumers to see electric bills car-
rying demand charges as high as 50% of the facility’s actual
consumption costs. As an offset, load shedding, peak shaving,
installing more efficient lighting, and other energy manage-
ment strategies go far toward helping plant professionals reduce
demand penalties. However, before any of these strategies can
be implemented, it’s necessary to gain an exact picture of how,
when, and where the energy is being used.
10/28/10 8:51 PM
 ConduCt Audits
right ConneCtions
As a cost-effective means for doing that, an energy audit
conducted at the front end of the process helps you under-
stand energy usage and identify areas where mitigation
strategies can be implemented to cut operating costs.
As part of a strategic corporate energy management
program, regular plant energy audits can be self-assessments
conducted by company staff, external audits conducted by
contracted energy service professionals, or a combination of
both. Regardless of the audit type, the audit team seems to be
most effective when represented by members offering varied
expertise, such as maintenance experts, systems managers,
and process engineers. Outside experts are especially useful for
providing specific technical expertise lacking in the company.

Know whAt to MeAsure

Energy audits come in many forms and can range from simple
applications that monitor a single device or machine to com-
plex monitoring of an entire campus. Most energy audits have
much in common. The most important variables to measure
when analyzing electrical energy are typically voltage (V), cur-
rent (I), Watts (W), Volt-Amperes (VA), Volt-Amperes reactive
(VAR) and power factor (PF). Over time, these can provide the
necessary information for a complete energy profile.
Voltage and current measurements are used to compute
the other variables. The variables can be viewed instanta-
neously using a variety of instruments, but the key benefit
of using an energy analyzer is its ability to record and trend
figure 1. The analyzer’s online help can show how to make the
connections properly.
variables over time. Energy analyzers also compute the
demand and energy that utilities use for billing. Low-cost
energy analyzers offer the functionality and flexibility to
perform simple-to-sophisticated energy audits that can be
exported into popular software programs.
whAt to LooK for in An energy AnALyzer
Today’s energy analyzers are more powerful and cost-
effective than ever before. Because even low-cost analyzers

www.PLANTSERVICES.Com NoVEmbER 2010 39

PS1011_38_43_Electric.indd 39 10/28/10 8:52 PM

 energy / POWER DISTRIBUTION

include the accessories and software needed to conduct a
complete and user-friendly energy audit, energy analyzers
are now within reach for any facilities that need to manage
ever-rising energy costs.
What an energy-measuring instrument measures and
computes is important, but how it measures can be critical.
For example, some inexpensive, low-resolution instruments
might measure the basic variables, but they can miss data
and thereby produce misleading measurements.
Effective energy-analyzing instruments provide a sam-
ing in more accurate data collection.
Look for an energy analyzer that can measure more than
just the basic power variables, because more advanced vari-
ables might be required to also help understand the quality
of the electrical supply, including voltage and current total
harmonic distortion (THD), transformer derating factor
(TDF) and crest factor (CF). Additionally, with the advent
of alternative-energy applications, variables such as forward
and reverse energy that record the flow of power to and from
the grid often are required.

monItor several CyCles of the load Instrument ConneCtIons

beIng audIted to obtaIn a Complete
pICture of Its energy profIle.
pling rate appropriate for the application while also captur-
ing continuous readings. Power analyzers typically define
sampling rate as the number of measurements taken per AC
(60/50Hz) cycle. Because the instrument produces a digital
representation of the analog voltage and current being
measured, it’s generally desirable to use an instrument that
provides a higher number of samples per cycle, thus result-
Connecting an energy analyzer properly is essential, espe-
cially considering the sometimes complex three-phase cir-
cuits. Proper voltage and current connections are necessary
for proper readings. It can’t be stressed enough to follow all
appropriate safety procedures and manufacturer’s instruc-
tions closely when making instrument connections. Such
circuit connections can pose a danger, and only qualified
personnel should make instrument connections.
Consider the three-phase wye circuit (Figure 1). To mea-
sure the circuit’s total power, the energy analyzer sums the
individual power in each phase. The instrument’s wattmeter

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PS1011_FPA.indd 41 10/28/10 9:11 PM

 righT ConneCTions
Time-of-use Billing
Site: Breaker32A-5
Measured from 07/14/2009 11:12:09.0 to 07/29/2009 02:37:01.0
BILLING DAY OF MONTH: 25
TIME-OF-USE COSTS
DeMAnD
ON-PEAK PARTIAL-PEAK OFF-PEAK
(USD) (USD) (USD)
Jul(*) 0.0 0.0 82.4
Aug(*) 0.0 0.0 0.0
enery ConsuMPTion
ON-PEAK PARTIAL-PEAK OFF-PEAK
(USD) (USD) (USD)

W
hen your plant’s compressed air system leaks,
Jul(*) 0.0 0.0 138.2
more than just air is getting out. You’re losing
money in the form of wasted energy, wear Aug(*) 0.0 0.0 0.0
and tear on your compressors and increased operating Total values 0.0 0.0 192.6
and maintenance costs. Duratec Airline, a unique time (*) Indicates partial month
and money-saving piping system, is designed to reduce
leaks and costs. Figure 2. Typical energy analyzer software enables the creation of printed
or electronic reports.
A tough piping system that meets Fast and Easy
ASME codes and OSHA safety Installation
requirements, Duratec Airline measures each phase, although the total number of wattmeters
requires less time, labor and money required varies by circuit type. A wattmeter requires both a voltage
to install and maintain than and current circuit connection and measurement. Voltage is always
traditional systems. Its long, measured between a “hot” wire and a reference, with the most com-
lightweight coils cut down on the 5 Sec. mon reference, when available, being a neutral wire. Voltage usually
number of potential leak points in
is connected directly to the circuit in low voltage systems instead
your system. Duratec fittings are
of through potential transformers or transducers. It’s important to
quick and easy to install and
feature double O-ring seals that
ensure the analyzer can measure the voltage levels in use safely.
ensure maximum joint integrity. Current usually is measured using current transformers. These
are available in many types ranging from rigid clamps to adaptable
Duratec requires no special tools or 25 Sec.
flexible units. Regardless of the type, it’s necessary that the current
installation training and eliminates
transformer be sized for the application and has a range appropri-
the need for soldering and
ate to the circuit.
threading. And because Duratec is
so quickly and easily installed,
If the current being measured falls outside this range, the
modified, and adapted to existing measurements might be inaccurate. Each current transformer will
metal systems, it can reduce your Total Time: 55 Sec.
have an arrow or other indicator showing the direction of current
plant’s downtime. So stop your flow. All current transformer connections must have the arrow in
compressed air system’s problems the same direction and pointing toward the load. Connecting the
before they become big news — Install Duratec. analyzer depends on the circuit type, so it’s important to make that
To find out more call us or visit: determination first.

U.S. Toll Free: 1-800-463-9572 The survey

www.ipexamerica.com
AirLine System
Products manufactured by IPEX Inc. and distributed in the United States
by IPEX USA LLC. Duratec® is a registered trademark of IPEX Branding Inc.
Details of the survey can vary greatly according to the application.
The usual energy audit goal is to determine the system’s energy pro-
file. Regardless of application, it helps to know some information
about what’s being monitored, such as the type of load, process,
or facility. These details are essential for determining the energy
survey’s duration.
Monitor several cycles of the load being audited to obtain a complete
picture of its energy profile. For example, an industrial process that

42 November 2010 www.PLANTServICeS.Com

PS1011_38_43_Electric.indd 42 10/28/10 8:52 PM


cycles (start to finish) every 15 minutes might need monitor-
ing only for an hour to capture multiple cycles and to find out
what is usual or typical for that load. An office building with a
24-hour cycle might require a longer survey, perhaps a week or
more, to determine a typical energy profile. A survey replicat-
ing a utility bill might require monitoring for multiple utility
billing cycles lasting several months.
reports and results
Most energy analyzer software provides printed or electronic
reports that summarize and report the result of an energy
survey, but the range of capabilities and flexibility vary widely
(Figure 2). Reporting requirements vary greatly by application,
with some requiring little detail while others might require
formal reports on a client’s company letterhead.
Many applications require advanced PC-based reporting
for e-mail or printing. To that end, some instruments enable
quick and easy reporting that includes a built-in energy
audit report along with the ability to export the information
to other software.
The good news for facility maintenance and engineering
personnel is that powerful, cost-effective handheld electrical
energy and power demand analyzers specifically designed
PS1011_38_43_Electric.indd 43
energy / POWER DISTRIBUTION
for conducting facility energy audits and power demand
studies are now on the market. These tools are a good way
to gather, record, and report where, when, and how much
electricity the facility uses. Applications in industrial,
commercial, and institutional facilities include energy/cost
MonItor several CyCles of the load
beIng audIted to obtaIn a CoMplete
pICture of Its energy profIle.
reduction programs, alternative energy monitoring, and
power/harmonic studies.
With the growing emphasis on green facilities, instruments
provide the ability to record both forward and reverse energy,
an essential measurement in grid-tied alternative energy sys-
tem analysis. Another important consideration in the LEED
process, these instruments also can be used for certifying a
facility’s energy consumption and carbon footprint.
ross Ignall is director of product management at dranetz
(www.dranetz.com). Contact him at rignall@dranetz.com and
(732) 248-4325.
www.PLANTSERVICES.Com NoVEmbER 2010 43
11/1/10 9:48 AM
 RELIABILITY / COMPRESSORS

DESIGN A
BETTER SYSTEM
VSDs and controllers can improve air
system efficiency BY HANK VAN ORMER, AIR POWER USA

In the industrial compressor market, most variable- These units have been available on the aftermarket
speed drives (VSDs) are found on rotary-screw and rotary- for decades. Like so many other products, when VSDs
vane compressors; however, VSDs can do well on recipro- were introduced as factory packages on rotary compres-
cating units and VSD centrifugal compressors running on sors, most manufacturers saw them as an instant fix for
magnetic bearings, which can be an excellent trim compres- numerous air system inefficiencies. Many plants bought
sor under the proper conditions. this configuration, even if no real need existed and even
if there were other options offering more efficiency for
COORDINATED ACTION less capital cost. Some thought that if one was good, two
were better. VSD units purchased as trim units installed
Typical Cascade Control Settings with a central control system couldn’t always maintain
proper alignment.
Compressor The VSD is the most power-efficient unloading control for
#1
110 Compressor lubricant-cooled rotary screw compressors operating from
#2
105 Compressor 75% to 80% load down to the lowest at which it can operate.
Pressure (psig)

#3
100 Compressor The most power-effective approach from 75% to 100% load
#4
95 is the variable-displacement concept, which usually unloads
90 the compressor in four steps of 12.5%, down to 50%, and
85 then defaults to base control below that.
Production minimum requirement With two-stage, oil-free, rotary screw compressors, the
80
VSD often isn’t significantly more efficient than the standard
5 psig
constant-speed two-step control. However, it’s easy to install
and avoids short cycling.
Figure 1. In cascade control, four compressors, each with a
10-psig operating band, are programmed slightly differently
As is the case with every important decision, pay atten-
to achieve smooth operation of the overall system. As system tion to detail when selecting a VSD. Know the demand
pressure deviates from the desired 85-psig minimum to 110-psig profi le. Know how each VSD unit on your compressors
maximum, on-board capacity controls load and unload the units. will match up with your profi le. A VSD of any design will

44 NOVEMBER 2010 WWW.PLANTSERVICES.COM

PS1011_44_46_Compress.indd 44 10/28/10 8:54 PM

 use from additional power draw compared to operating at
constant speed.
Consider rotary-screw compressors operating 8,000
hours/year and producing 490 acfm at 100 psig using 110
bhp on a 460 V/60 Hz/3 Ph circuit, where power costs
$0.06/kWh.
Constant-speed drive:
133 A
Power factor (pf) = 0.91
Mechanical efficiency = 0.923 x pf = 0.84
Efficiency = 3.684 cfm/A
Power draw = (133 x 460 x 1.732 x 0.84)/1,000 = 89.0 kW
Annual cost = 89 kW x $0.06/kWh x 8,000 hr = $42,720/yr
Variable-speed drive:
130 A
Power factor = 0.98
Mechanical efficiency = 0.958 x pf = 0.944
Efficiency = 3.769 cfm/A
Power draw = (130 x 460 x 1.732 x 0.944)/1,000 = 97.8 kW
Annual cost = 97.8 kW x $0.06/kWh x 8,000 hr = $46,931/yr
Variable-speed drive is 9% less efficient than a constant-
speed drive at full load for the same flow and pressure:
(46,931-42,720)/46,931 = 0.0897.
PS1011_44_46_Compress.indd 45
What is CaC?
The Compressed Air Challenge (CAC) is a national col-
laboration created to help industrial facilities achieve
greater reliability, quality control, and lower com-
pressed air system operating costs. The CAC encour-
ages facilities to take a systems approach to optimizing
compressed air operation, which means looking beyond
individual components to assess how well the com-
pressed air system meets actual needs. Matching supply
with demand also means identifying the root causes of
system problems, rather than treating the symptoms.
Compressor manufacturers use several types of VSD
units. These include:
• variable frequency drive (VFD)
• switched reluctance drive (SRD)
• permanent magnet.
All VSD compressors don’t exhibit the same performance.
Know what you’re reviewing. Get a complete performance
curve of scfm/input kW throughout the operating band.
This is standard manufacturer operating data. Most systems
need only one VSD trim unit. Some situations might be
able to use multiple drives more successfully, but be sure
to review the operating data in detail. Many factory VSD
packages limit the top speed to fit the discharge pressure you
select. The higher the pressure setting, the slower will be the
www.PLANTSERVICES.Com NoVEmbER 2010 45
10/28/10 8:54 PM
 Reliability / Compressors
full-load speed and the delivered air flow. If you find you can
run at a lower pressure, often the electronic controller can be
reset to a lower pressure, faster speed, and more air.
How does the VSD fit into this system control scenario?
The VSD can hold a discharge pressure within 1 psig to 2
psig, so you usually don’t need a flow controller and VSD
for trim to hold a steady discharge pressure on the same
system. Even with a VSD control, we recommend appro-
priate storage to smooth out the flows and give enough
time for proper reaction.
CentRal ContRol systems
There are few systems with three or more units that can’t
benefit from an effective central air management system.
Modern systems sense, or calculate, the coming change
before it occurs and quickly take appropriate action, some-
times even before evidence appears in the system.
To make it work, you’ve got to know what you’re doing
now that causes poor efficiency, what you want the central
air management to accomplish, the recoverable energy cost,
and how much you must invest to achieve the proper return
on investment. Many suppliers of central control systems
also are compressor manufacturers, independent, HVAC
control companies, and the like. Each offers an “intelligent”
microprocessor that minimizes energy cost and maximum
energy savings.
tHeRe aRe many DiFFeRent
PRotoCols WitH tHis tyPe oF system;
some aRe moRe ReaCtiVe tHan
otHeRs, bUt also moRe exPensiVe.
Early systems often were called alternators or sequenc-
ers. The basic protocol was pressure-based as typified by the
cascade-type control system (Figure 1).
Modern communication equipment eliminated this pres-
sure-based system in favor of a single target set point pressure
that is read from a stable source. Now, we can run the same
four units, but over only a 10-psig operating band (85 psig to 95
psig) most of the time. Because this system is pressure-based,
nothing happens until system pressure changes.
There are many different protocols with this type of
system; some are more reactive than others, but also more
expensive. You don’t need to purchase more than you need.
Some differences include:
• PID controller to include rate-of-change in the calculations
• uses fuzzy logic, as required to shorten reaction time
• either responds with a preset sequence alignment or
might be capable of analyzing available air and selecting
the proper unit by size and/or performance.
The most prevalent question for these types of central
control systems is: “Can you run all units at full load,
46 November 2010 www.PLANTServICeS.Com
PS1011_44_46_Compress.indd 46
more resources at www.plantservices.com
toPiC seaRCH
managing a compressor “When non-standard
maintenance project becomes
a project”
line sizes “the secret is in the pipe”
integrating Pdm “Controlling the compressors”
Rebate programs “invest it wisely”
audits “before you call for help”
For more, search www.Plantservices.com using the
keywords capacity, variable-displacement, and VsD.
except one at part load 85% to 95% of the time?” Many of
these systems have problems when a VSD unit isn’t con-
sidered in the calculated protocol. The high-performance
central air management systems are flow-based, meaning
they use a continuing stream of flow data combined with
pressure data to analyze what’s going on. These protocols
are proactive, often picking up data before the change
occurs. The flow values to drive the system are usually
obtained by several sources:
• measured flow determined by calibrated and properly
installed flow meters
• calculated flow from OEM test data (or field test data)
using input kW along with proper motor and capacity
control data
• other specific measured operating data points, such as
pressure below the inlet valve compared to ambient,
pressure to the inlet valve positioner, location of inlet
valve positioner, locations of blow-off air
• with mass flow units, particularly, detailed air-inlet con-
ditions are measured to allow full calculation to reflect
the inlet ambient condition’s effect on the performance
of the compressor.
Older types of software still use a pressure-actuated cas-
cade protocol with closer tolerance. Newer software:
• keeps all except one unit at full load
• measures percentage part load
• forces a unit to full load when possible
• reacts to rate of change, but also measures and reads
inlet conditions
• identifies and verifies compressor’s load points (kW
input, inlet vacuum)
• adjusts compressor choice as required for the most
power-efficient grouping
• targets the set points
• doesn’t require or use a preset sequence.
Hank van ormer owns air Power Usa. Contact him at hank@
airpowerusainc.com and (740) 862-4112.
10/28/10 8:55 PM
 Sullair Compressors with EES
Yield Quantum Cold Weather Savings

Did you know . . .

Today’s energy costs represent
82% of the expense of
compressor ownership.

Equipment
Maintenance
Energy

Save on Energy Costs
The Sullair compressors with
Energy Efficiency System (EES)
heat recovery were developed to
produce the most cost-effective
compressed air solution in the
marketplace. The Sullair EES
recovers the heat of compression
and re-circulates it for comfort
heating in plants for cold weather
operations during winter months,
use, the thermostatic controls
exhausts heated air to the outside.
This 100 hp compressor generates
1,649,000 BTUs per year. Annual
energy savings from the EES alone
may reach $10,993.00*, with a
payback period of 7 months as a
result of the energy savings.
Additional energy savings may be
achieved by combining the EES
provide flexibility to vary both
capacity and pressure to match
system demand, and result in
maximum effectiveness in
reducing total life cycle costs. Part
load capacity and efficiency
benefits can produce additional
energy savings up to 17 percent.
* Calculations are based on climate conditions for
Chicago, IL and natural gas at $0.50/therm
(subject to market fluctuations).

or provides pre-heated air for with Variable Capacity Control** ** Not available on all configurations.
boilers or processes. When not in and Variable Speed Drive**, which

Sullair Corporation, 3700 East Michigan Boulevard, Michigan City, IN 46360 • Telephone: 1-219-879-5451 • www.sullair.com
Sullair Corporation is a Hamilton Sundstrand Industrial business. Hamilton Sundstrand is a subsidiary of United Technologies Corp. (NYSE: UTX)

PS1011_FPA.indd 47 10/28/10 9:11 PM

CCOMP-430_Compression_rev.indd 1 4/28/10 4:38:56 PM
PS1011_FPA.indd 48 10/29/10 10:46 AM

MediCAl MArijuAnA in the WorkplACe
Acme considers an employee with a prescription for a pharmaceutical
Al Colloyd served in the military
overseas in the early 1980s. His role
was as technical specialist work-
ing with IT infrastructure, a job
he learned and performed well. He
continued doing that work for years
after his discharge.
While overseas, however, Al sus-
tained an injury, which had conse-
quences years later. He now suffers
from ever-worsening chronic back
pains and muscle spasms. When his
condition finally prevented him from
working, Al qualified as disabled
under the state’s Fair Employment
and Housing Act. He also qualified for
governmental disability benefits. This
arrangement allowed him to avoid
institutionalization and homelessness.
A physician had been treating Al
with a series of medical techniques
in search of anything that would
provide effective relief from the pain
and spasms. These efforts were largely unsuccessful. This situ-
ation effectively prevented Al from having a self-reliant and
functional life that included working at an IT job he enjoyed
and having a social life.
Al spent a lot of time apartment-bound, frustrated at what
life had done. With no other creative outlet, he spent a lot of
time online, learning the cutting-edge intricacies of source-
code programming that allowed him to develop a personal
website worthy of anyone’s admiration, if not awards.
At one of the office visits, Al’s physician recommended
medical marijuana because none of the standard pharma-
ceutical-based treatments had yet provided the desired out-
come. This remedy gave him relief sufficient to allow getting
back into life. He could now go shopping, cook real food,
and drive a car. Confident that the pain was under control
and would remain tolerable, Al began an intense job search.
At the last of his several interviews at Acme, he was
offered a job as lead system administrator, a position for
which, as a result of years of study and research, he had
become highly qualified, despite not having a formal degree.
After he accepted the position, Mary Harper, Acme’s HR
PS1011_49_51_Trenches.indd 49
in the trenChes
person, told Al he would need to
pass a pre-employment drug test.
Al gave the clinic that performed
the testing a copy of the physician’s
written recommendation and the
prescription for medical marijuana.
Three days later, he started the new
job and quickly became a contribut-
ing member of the Acme economy.
That same week, the clinic called
Al to say that the drug test was posi-
tive for THC, the active ingredient
in marijuana. The next day, Mary
informed Al that, according to
long-standing company procedures,
a positive drug-test result mandates
a suspension from work. Al handed
Mary another copy of the physician’s
recommendation and prescription,
explaining that medical marijuana
was the only remedy that alleviated
the chronic back pain and spasms.
Mary wasn’t sympathetic but
agreed to call the physician to verify the prescription. Mary said
that she’d let Al know Acme’s final decision regarding contin-
ued employment. Two days later, Acme’s CEO informed Al that
the corporate decision was immediate termination.
Al filed suit alleging that Acme violated the state’s Fair
Employment and Housing Act and terminated him in viola-
tion of public policy.
How could this situation have been prevented? Why should
a prescription for medical marijuana be the kiss of death when
job hunting? Is strict adherence to perhaps outmoded corporate
procedures a good policy in light of more recent medical research?
Is discrimination on the basis of medical condition justifiable?
An Attorney sAys:
Let’s get one thing straight. Acme didn’t terminate Al because
of his medical condition. He was terminated because he didn’t
pass a pre-employment drug test because of his use of marijua-
na for a medical condition. Whether that termination was legal
depends upon the state in which Acme is located. Under federal
law in the United States, the use of marijuana is illegal. Despite
that ban, some 13 states have passed laws addressing the medi-
www.PLANTSERVICES.Com NoVEmbER 2010 49
10/28/10 8:55 PM
 IN THE TRENCHES

cal use of marijuana. Each of those laws es and the physician who recommends employer from refusing to employ a
is unique to that state. the drug. Arizona, on the other hand, person who uses marijuana for medi-
For example, California immunizes requires employers to accommodate cal purposes.
from criminal prosecution both the the medical use of marijuana in the If Acme is located in a state that
user of marijuana for medical purpos- workplace. Rhode Island prohibits an doesn’t authorize the medical use of
marijuana or prohibit an employer
from discriminating against a mari-
juana user for medical purposes, Acme

The NeW
acted well within its rights in termi-
nating Al for failing the drug test. If,

INDUSTRIAL REVOLUTION: on the other hand, Acme is located in

Arizona, it might have violated that
it’s about MaXiMiZiNG PRoDuCtiVitY & saFEtY state’s law by not accommodating Al’s
medical use of marijuana.
tHRouGH 5s VisuaL MaNaGEMENt The gray area exists in a state that
permits the medical use of marijuana
sPRaYoN® sYstEM MaGNEtiC CaN HoLDERs
but has no law specifically addressing
whether an employer can refuse to hire
Available for single or multiple cans, Sprayon®
System Magnetic Can Holders can be located on a disabled applicant who uses mari-
or near your equipment ensuring the right product juana for medical reasons. But given the
is always used and improving productivity.
federal ban on marijuana use for any
for more info, visit sprayonsystem.com
purpose, an employer in that kind of
state likely would be within its rights in
terminating an employee such as Al.
Right or wrong? Arguments abound
on both sides of the question. While
there’s substantial evidence that
marijuana alleviates symptoms for
some cancer patients, opponents of
more of the sprayon® system elements the drug no doubt envision the likely
educational poster KAnbAn
nttAg consequences of a bunch of potheads
staffing the assembly line.
LU 201
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FLASH
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PRESSURE ºF/ºC PRESSURE ºF ºC F 4 HIGH
PRESSURE

47.4 D H2 550 288 205/96 -30 -34 R 0 450 232

ºF
KV ºF ºC ºC
S EASY TOUCH

A PLANT ENGINEER SAYS:

H 2
F 0
-20 -29 H2 0 -18 H 2
F 4
H2
R 0 R 0

PRODUCT TAGS LABELING & CATEGORIZATION

This situation could have been avoided if
LU 202 TM

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Al would have disclosed the fact that he
LIGHT
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PRESSURE
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RAY
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AN
YW
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H 2
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SILICONE
550 288
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-5 46
ºC

AN
RA
SP AY
YW
Y
H 2
F 4
R 0
EL CD MR was taking marijuana on the recom-
H2 H2 -40 -40

LU SP WL mendation of a physician and has a valid

prescription. This disclosure could have
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TM
TM

FLASH
taken place during the interviews that
LIGHT -47
10 D LIGHT
450 232 5% LIGHT
450 232 POINT
KV
KV ºF ºC ºF ºC
PRESSURE
S PRESSURE SILICONE PRESSURE ºF/ºC

Al had with Acme. If the information is

500 260 H2 -40 -40 H 2
F 4
-20 -28 H 2
F 0
200/93
ºF ºC
H 1 -20 -29 H1 RAY R 0 H1 R 0
SP AY

Using a product in the wrong application can damage your equipment

F 4 YW
AN
R 0

and endanger your workforce. known up front, the situation is avoided,

The NEW Sprayon® System integrates our proven products in our new
or at least out in the open.
packaging with simple, easy-to-use visual management tools to ensure A prescription for medical mari-
that the right product is used on every piece of equipment. juana is the “kiss of death” when job
Join the Revolution today at SprayonSystem.com. ™
hunting because the use of marijuana
is illegal in most states. The use of

50 NOVEMBER 2010 WWW.PLANTSERVICES.COM

PS1011_49_51_Trenches.indd 50 10/28/10 8:56 PM

 Document1.qxd 1/5/2006 7:44 AM Page 2

Clean, Dry Compressed Air Starts

with The Extractor/Dryer ®
Manufactured by
LA-MAN Corporation
marijuana for pain relief would seem to have the same effect on an • Point of Use Compressed Air Filter to
Improve and Extend Equipment Life
individual that recreational use would have. Much like drinking,
marijuana can dull one’s senses and cause one to be less responsive. • Removes Moisture and
Contaminates to a 5-Micron Rating;
If you can’t operate machinery or drive while using marijuana, why Lower Micron Ratings are Available
would a company want to take a chance of having someone on their • Models with Flow Ranges of 15
payroll that uses marijuana legally? Acme should not have to be SCFM to 2000 SCFM Rated Up To
250psi are Standard
exposed to that kind of liability.
• Differential Pressure Gauge
Built In to Indicate Required
DISCRIMINATION ON THE BASIS Maintenance

OF MEDICAL CONDITION IS JUSTIFIABLE, • Mounting Hardware

Included for Easy Installation
BUT MIGHT NOT BE LEGAL. • Weep Drain is Standard;
Float Drain or Electronic
Drain Valves Optional

It’s great that the medial use of marijuana helps Al with his pain
relief. Acme must protect its employees and stockholders and try
to keep the workplace clear of drugs that will hinder performance.
Discrimination on the basis of medical condition is justifiable, but
might not be legal. Should a company have to hire or keep a person
that requires strong drugs to allow one to function? People aren’t
allowed to drink or use drugs on the job for a reason. It promotes
safety for the whole facility.
To make exceptions could cause safety to suffer and place the patient
or others in danger. If Al got hurt on the job, could anyone prove that
his use of medical marijuana wasn’t somehow a factor in his injury?
Yet Acme would have worker compensation claims and expenses to
deal with anyway. Acme should have been told up front.
Jeffrey L. Strasser, Bacova Guild
(540) 863-2656, strasser.jeff@bacova.com

AN ACADEMICIAN SAYS:
I don’t see much hope for Al in this situation. Even though he’s using
marijuana for medical purposes, the company can legally terminate
him for using it. The argument is based on that assumption that the
use of this substance could impair the user’s judgment and could cause
serious accidents or errors. Companies usually take a hard line on this
(if it’s in your blood, you’re out) because companies don’t want to get
involved in attempting to decide how much marijuana needs to be
It’s a fact…an estimated 50% of your compressed air is lost
taken to impair judgment or which jobs or tasks might be affected by through leaky, wasteful or inefficient systems. Xcel Energy
the use of this substance. It’s doubtful that the company could sort this can help with a comprehensive study that shows where
out, so the best bet is to hold to the hard line. you can reduce compressed air-related operational costs.
Al should have checked with HR before he signed on. If he knew Funding is available for most or all of the study costs plus
that he had to pass a drug test, then he had a couple of options. One prescriptive and custom rebates are available up to $400
is not to take the job. Another is to go back to his medical people per kW saved. Visit ResponsibleByNature.com for details or
and keep exploring other substances that could give him relief and call our Business Solutions Center at 1-800-481-4700.
that are not illegal. It’s possible that the company would be willing
to make some accommodation for his disability, and this accom-
modation in combination with a reasonably effective medication
might have allowed Al to have a successful career with Acme.
Professor Homer H. Johnson, Ph.D., Loyola University Chicago
(312) 915-6682, hjohnso@luc.edu © 2010 XCEl ENERgy INC.

33481_XL_AIR_CO_BlowYouAway_PSM_3.25x4.875_4C_1101_FNL.indd
WWW.PLANTSERVICES.COM NOVEMBER 2010 1 51
10/5/10 9:50 AM

PS1011_49_51_Trenches.indd 51 10/28/10 8:57 PM

 PRODUCT FOCUS
GEARHEAD-MOTOR COMBO
The WX gearhead is paired with a
three-wire-reversible 34R frame AC
induction motor. The interior of the
high-torque gearhead features AGMA
9 steel helical gears and a synthetic
lubricant, allowing the unit to provide
50% more torque than previous
models. Gear ratios range from 4:1 to
312:1. The three-wire configuration simpli-
fies connection and makes reversing the direction simple. The
winding can operate at 50 Hz with a different value run capaci-
tor. Custom configurations are available.
Bodine Electric
(773) 478-3515 / www.bodine-electric.com
LIFT TRUCK HANDLES 4,000 LB
The ESC030-040AC se-
ries of electric stand-up
lift trucks are three-
wheel units featuring
precision control for
working on an incline.
The dual-steer tires
provide precise control.
Dual independent AC
drive motors and drive
controllers provide optimum maneuverability. The dash cov-
ers include a cup holder, clip holder, and two storage areas.
Service technicians can use the multifunction control handle
to perform diagnostics and set up the truck’s acceleration
rate, top travel speed, and hydraulic function speeds.
Yale Materials Handling
www.yale.com
FABRIC AIR DISPERSION
ChemSox duct air dispersion system
is designed for chemically harsh
environments. The recyclable, inert
HDPE fabric is designed to outlast
polyester-based fabric duct and acces-
sories, which are subject to brittleness.
It’s available as semi-translucent fabric
that use zippers to join sections to-
gether. Sections are available up to 50
ft long and in diameters from 6 to 56 in. The system is designed
to deliver air throws to 75 ft, and a uniform linear array of
orifices offers a more even air distribution.
DuctSox
(866) 382-8769 / www.ductsox.com
52 NOVEMBER 2010 WWW.PLANTSERVICES.COM
PS1011_52_53_Products.indd 52
SEMI-AUTOMATIC MIG GUNS
TGX semi-automatic MIG guns are engineered
for light fabrication and repairs. They feature
black polymer armored-style gooseneck, grey gun
handles, black triggers, and a rear handle. Available
in 10-, 12-, and 15-ft lengths, they are designed to keep
consumables running cooler and lasting longer.
Tregaskiss
(519) 737-3000 / www.tregaskiss.com
ON-THE-SPOT DIAGNOSIS
The Fluke 810 Vibration Tester is designed to enable main-
tenance teams to collect data, diagnose, and solve mechani-
cal problems quickly. The handheld unit is programmed
to diagnose common
mechanical problems of
unbalance, looseness,
misalignment, and bear-
ing failures in mechani-
cal equipment. It uses a
process to report machine
faults the first time mea-
surements are taken, without prior measurement history. It
is designed to identify faults by comparing data to a set of
rules developed over years of field experience and includes
soft ware compatible with Windows XP and Vista.
Fluke
(800) 760-4523 / www.fluke.com/vibration
TWO-WIRE TECHNOLOGY
Intrinsically safe drainable Micro Motion F-Series sensors
use two-wire technology and handle line sizes from ⁄ in.
(DN2) to 6 in. (DN150), with flow ranges of 0.075 lb/min to
20,000 lb/min. They have no constraints on temperature or
viscosity for use with long wiring runs and hazardous areas.
An optional stainless steel housing is available. They deliver
multivariable and diagnostic information via HART or IEC-
approved WirelessHART communications.
Emerson Process Management
www.emersonprocess.com
10/28/10 8:58 PM
 WIRELESS HUMIDITY /
TEMPERATURE SENSORS
Series WHP wireless
humidity/temperature
sensors use a 418-MHz
transmitter good for
100 ft without a repeat-
er. The unit can output
voltage, current, or
resistance values. Powered
by two AA batteries, it transmits
approximately one reading every 10 sec
for an estimated five to eight years. The
sensors have standard sintered fi lters to
protect against particulates. Set point
adjustment or manual override buttons
are available on wall-mount sensors.
PS1011_Chromalox.pdf 1 10/27/10
Dwyer Instruments
(800) 872-9141 / www.dwyer-inst.com
PS1011_52_53_Products.indd 53
MOTORS FOR SEVERE
CONDITIONS
Reliance Super-E Duty
Master motors are avail-
able in TEFC and WPII
foot-mounted configura-
tions for 2,300/4,000 V,
60 Hz. Stock motors are
available in 3,600, 1,800,
and 1,200 rpm and from
200 hp through 1,500 hp,
three phase, in NEMA 449T
through 05812 frame sizes. They
feature VPI construction, die-cast aluminum rotors, cast-
iron construction, NEMA Premium Efficiency, and three-
year warranties. Other features include winding RTDs,
space heaters, 1.15 SF, cast-iron conduit boxes.
4:20 PM
Baldor
(479) 646-4711 / www.baldor.com
READY FOR COLD WEATHER?
Chromalox heat trace system inspection service ensures proper
equipment operation before cold weather strikes. This added degree
of security provides confidence that your property and equipment
will be protected when you need it most.
Our expert service technicians will:
• Inspect all insulation, weatherproofing, junction boxes, connection
boxes and sensor connections
• Verify all circuits have been grounded and are properly connected
• Verify proper circuit breakers are in place (always use 30mA trip GFI
type breakers) and circuit lengths are within manufacturers’ specified limits
• Verify all proper safety warnings are in place
• Verify all end seal, splice/tee locations are marked on lagging
• Provide a full diagnostic report with recommendations for improvements
Call Chromalox today!
800.443.2640 or visit www.chromalox.com
WWW.PLANTSERVICES.COM NOVEMBER 2010 53
10/28/10 8:59 PM
 MRO MARKETplAcE
Oil sKiMMing ApplicATiOns sOuRcEbOOK
Abanaki’s 47-page handbook offers application
notes on 40 real-world implementations of oil
skimming, the lowest cost way to remove oil
from water. Newly expanded second edition is
indexed by industry and application so readers
quickly find case studies for their situation.
Sections include food processing, machin-
ing, manufacturing, grease/water separation,
groundwater remediation, oil/water separation and wastewater.
Call (800) 358-7546 (SKIM) or visit www.abanaki.com/008
Abanaki
nEW DAvis insTRuMEnTs v76 sOuRcEbOOK
Get the Davis Instruments V76 Sourcebook
for a comprehensive selection of test, mea-
surement, control, and calibration equipment;
including the latest technologies. Browse
1386 pages packed with products from
Fluke, Extech, Tektronix, and other lead-
ing brands. For a free catalog, call (800)
358-5525 or visit Davis.com/8096.
Davis instruments
TubE FiTTings
Swagelok® tube fittings remain leak-tight
around the clock. Featuring an advanced-
geometry, hinging-colleting back ferrule
design, Swagelok stainless steel tube
fittings provide consistent, leak-tight con-
nections. Fittings are available in tube
sizes from 1/16 to 2 in. and 2 to 50 mm
in a wide variety of configurations with excellent vibration resis-
tance and tube support. Download the catalog (MS-01-140) at
http://www.swagelok.com/downloads/webcatalogs/EN/MS-01-140.PDF
swagelok
liFT TRucK
The Hyster H50FT Fortis ® lift
truck is an industry leader suited
for a variety of hard-working ap-
plications, incorporating proven
processes and systems to ensure
the toughest, most durable design.
The advanced ergonomic fea-
tures significantly reduce opera-
tor fatigue and increase productivity through superior operator
comfort and precise, effortless handling. Visit www.hyster.com.
Hyster
54 November 2010 www.PLANTServICeS.Com
PS1011_54_55_AdLits.indd 54
cOxREEls cATAlOg
Coxreels full-color catalog showcases the
expanding line of Coxreels high-quality pro-
fessional grade hose, cord, and cable reels.
The catalog’s clean format navigates easily
and makes ordering options and accessories
for your reel a snap. Choose from a variety
of mounting brackets, roller guide options,
motor speed controllers, and so much more.
Visit www.coxreels.com.
coxreels
MiT400 sERiEs 1-Kv insulATiOn
AnD cOnTinuiTy TEsTERs
The Megger MIT400 Series meet the most
stringent requirements and are ideal for Cat-
egory IV 600V applications. The units feature
adjustable voltages providing 250V to 1000V
or 50V to 1000V. The top-of-the-range models
can store and download data. The instruments
are sealed to IP54, lessening the chance of
water ingress. Contact us at (866) 254-0962.
Megger
EnERgy EFFiciEncy
The EES multiplies energy savings of the
already efficient Sullair compressors. Heat
of compression is recovered for heating or
pre-heated air for various processes. When
not required, heat is rejected out-of-doors.
Annual energy savings for a 100 hp EES
compressor may reach $10,993. Payback in
as little as 7 months. Call (800) SULLAIR.
sullair corporation
puMps FOR inDusTRy
Gorman-Rupp’s products include self–prim-
ing centrifugal pumps, standard centrifugals
pumps, submersible pumps, trash pumps,
priming assisted pumps, and rotary gear
pumps. A complete line of packaged lift sta-
tions and booster stations that include pumps,
motors, controls, piping, accessories, and
enclosures are also available. Call (419) 755-
1011 or visit www.GRpumps.com.
The Gorman-Rupp Company
10/29/10 10:48 AM
 mro marketplace

eXpreSS YoUr HaNDHelD Dmm StYle DUraBle aND aDaptaBle INDUStrIal FaN
Agilent’s Award Winning U1240 and The 8 to 24-ft. diameter
U1250 series HH DMMs now come Powerfoil®X by Big Ass Fans® is
with FREE limited edition skins. the most advanced, durable and
Each DMM comes with 4 individu- adaptable industrial fan ever
ally themed skins – American Pride, built. Its materials, precision machining and functionality are based
Winner’s Stride, Go Green and The Next Frontier. Make a statement on years of unparalleled research and development, while employ-
with your handheld DMMs today! Visit http://ad.doubleclick.net/ ing innovative concepts never before seen in industrial fans such as
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02&cc=US&lc=eng&cmpid=36669 BigAssFans.com, call 877-BIG FANS, or email info@bigassfans.com.
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StaINleSS Steel pIcklING Gel 1/4 toN oF reFrIGeratIoN

Easy to use and store, Wonder Gel
safely cleans the toughest slag, weld
scale, black oxides and discolor-
ation from stainless steel surfaces
economically, without damaging
Before After sound metal surfaces. It restores the
protective chromium oxide layer to
resist new corrosion and leaves a silvery finish. Call (877) 899-5315
or visit www.derustit.com.
Bradford Derustit Corp.
EXAIR Vortex Tubes produce up to 10,200 Btu/
hr. with no moving parts. Stainless Steel Vortex
Tubes convert an ordinary supply of compressed
air into two streams; one hot and one cold.
Temperatures are adjustable from -50° to
+250°F. Applications include cooling hot melts,
cutting tools, welding horns, electronic controls,
soldered parts and gas samples. Call 800-903-
9247 or visit www.exair.com/85/130.htm.
eXaIr corporation

NeW WIreleSS commUNIcatIoNS BrocHUre color DISplaY VIBratIoN aNalYZer/BalaNcer

New brochure showcases our top-selling
wireless sensors, transmitters, receivers and
Ethernet- and web-based measurement and
control devices for monitoring and recording
data over the Internet. Wireless solutions
include temperature, pressure, pH,
humidity, flow, and process applications
for test and measurement, automation
and industrial manufacturing.
www.omega.com/literature/wireless26/
Omega
The new VIBXPERT II advanced analyzer
combines the advantages of a rapid pro-
cessor with a brilliant energy-efficient
full color VGA display. Enhanced with an
Fmax of 51KHz and up to 102,400 lines
of resolution, all machinery vibration and
balancing problems can be captured and
easily analyzed with VIBXPERT. Call (305)
591-8935 or visit www.ludeca.com/vibxpert.
ludeca Inc.

electrIc HeaterS, coNtrolS, aND SeNSorS
Tempco’s 864-page 35th Anniversary
catalog offers electric heaters, tempera-
ture sensors, TEC temperature controls,
turnkey process heating systems, and
related accessory Items. New products
include PPR-1800 video graphic data
recorders. Select from stock items or
have Tempco custom design and manu-
facture for your application. Visit www.tempco.com.
tempco electric Heater corp.
cUStom reprINtS StreNGtHeN BraND ValUe
Custom reprint products of articles and
features from Plant Services create power-
ful marketing tools that serve as instantly
credible endorsements. Reprints are a simple
way to put information directly into the
hands of your target audience. Having been
featured in a well-respected publication adds
the credibility of a third-party endorsement
to your message. Call 866.879.9144 x168
or e-mail sales@fosterprinting.com.
Foster Printing Service

www.PLANTSERVICES.Com NoVEmbER 2010 55

PS1011_54_55_AdLits.indd 55 10/29/10 11:12 AM

 Advertiser index
Advertiser index

CompAny pAGe CompAny pAGe

Allied Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
APC/Schneider Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Atlas Copco Compressors Inc . . . . . . . . . . . . . . . . . . . . . . . . 4
AutomationDirect .com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Baldor Electric Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cameron Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chesapeake Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Kaeser Compressors, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
La-Man Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ledtronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MacroAir Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Martin Sprocket & Gear Inc . . . . . . . . . . . . . . . . . . . . . . . . 12
Parker Hannifin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chromalox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Pentair Technical Products . . . . . . . . . . . . . . . . . . . . . . . . 40

Flir Commercial Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fluke Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,20,33
Goulds Pumps / ITT Industries . . . . . . . . . . . . . . . . . . . . . . 22
Hyster Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
IFS North America Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ingersoll Rand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inpro/Seal Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Ipex, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Sprayon Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sullair Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Swagelok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Testo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WD-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Xcel Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Yaskawa Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

United States Postal Service Statement of Ownership, Management, and Circulation (Requester Publications Only)

1. Publication Title: PLANT SERVICES 15. Extent and Nature of Circulation Average No. Copies No. Copies of Single
2. Publication Number: 0199- 8013 Each Issue During Issue Published Nearest
3. Filing Date: 09/30/10 Preceding 12 Months to Filing Data
4. Issue Frequency: Monthly a. Total Number of Copies (Net press run) 65,594 66,467
5. Number of Issues Published Annually: 12 b. Legitimate Paid and/or Requested Distribution (By Mail and Outside the Mail)
(1) Outside County Paid /Requested Mail Subscriptions Stated on PS Form 3541.
6. Annual Subscription Price: $96.00 (Include direct written request from recipient, telemarketing and Internet requests
7. Complete Mailing Address of Known Office of Publication: from recipient, paid subscriptions including nominal rate subscriptions, employer requests,
555 West Pierce Road, Itasca IL 60143 advertiser’s proof and exchange copies). 63,890 64,457
Contact Person: Jeremy Clark Telephone: 630-467-1300 (2) In-County Paid /Requested Mail Subscriptions Stated on PS Form 3541.
8. Complete Mailing Address of Headquarters (Include direct written request from recipient, telemarketing and Internet requests
from recipient, paid subscriptions including nominal rate subscriptions, employer
or General Business Office of Publisher: requests, advertiser’s proof and exchange copies).
555 West Pierce Road, Itasca IL 60143 (3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other
9. Full Name and Complete Mailing Address Paid or Requested Distribution Outside USPS 86 104
of Publisher, Editor, and Managing Editor: (4) Requested Copies Distributed by Other Mail Classes through the USPS
Publisher: Mike Brenner, 555 West Pierce Road, Itasca IL 60143 c. Total Paid and/or Requested Circulation[Sum of 15b. (1), (2), (3), and (4)] 63,976 64,561
d. Non-requested Distribution (By Mail and Outside the Mail)
Editor: Paul Studebaker, 555 West Pierce Road, Itasca IL 60143 (1) Outside-County Non-requested Copies Stated on Form 3541 (include Sample copies,
Managing Editor: Russ Kratowicz, 555 West Pierce Road, Itasca IL 60143 Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including
10. Owners Association Requests, Names obtained from Business Directories, Lists, and other sources) 825 822
Putman Media, Inc., 555 West Pierce Road, Itasca, IL 60143 (2) In-County Non-requested Copies Stated on Form 3541 (include Sample copies, Requests
John M. Cappelletti, 555 West Pierce Road, Itasca, IL 60143 Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including
Association Requests, Names obtained from Business Directories, Lists, and other sources
Julie A. Cappelletti - Lange, 555 West Pierce Road, Itasca, IL 60143 (3) Non-requested Copies distributed Through the USPS by Other classes of Mail (e.g. First-Class Mail,
Jenny G. Cappelletti, 555 West Pierce Road, Itasca, IL 60143 Non-requestor Copies mailed in excess of 10% Limit mailed at Standard Mail or Package Services Rates)
Nicholas G. Cappelletti, 555 West Pierce Road, Itasca, IL 60143 (4) Requested Copies Distributed Outside the Mail (Include Pickup stands,
Melody L. Cappelletti, 555 West Pierce Road, Itasca, IL 60143 Trade shows, Showrooms and Other Sources) 94 400
11. Known Bondholders, Mortagees, and Other Security Hold- e. Total Non-requested Distribution (Sum of 15d (1), (2), and (3)) 919 1,222
f. Total Distribution (Sum of 15c. and e.) 64,895 65,783
ers Owning or Holding 1 Percent or More of Total Amount g. Copies Not Distributed 699 684
of Bonds, Mortgagees, or Other Securities: None
12. Tax Status: The purpose, function, and nonprofit status of this h. Total (Sum of 15f and g) 65,594 66,467
organization and the exempt status for federal income tax purposes: i. Percent Paid and/or Requested Circulation (15c divided by f times 100) 98.58% 98.14%
• Has Not Changed During Preceding 12 Months 16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the November 2010
13. Publication Title: Plant Services issue of this publication.
14. Issue Date for Circulation Data Below: September 2010 17. Signature and Title of Editor, Publisher, Business Manager, or Owner: Jeremy L. Clark, VP of Circulation Date: 09/30/10
I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading
information on this formor who omits material or information requested on the form may be subject to criminal sanctions
(including fines and imprisonment) and/or civil sanctions (including civil penalties).

56 november 2010 www.PLAnTServICeS.Com

PS1011_56_57_Class.indd 56 11/1/10 11:47 AM

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PS1011_56_57_Class.indd 57 11/1/10 11:48 AM

 energy exPerT
peter garforth
The CosTs of Poor energy ManageMenT
Invest in energy improvements during good times to avoid the bad times
energy management in the United States is again in
danger of being neglected. A few months of relatively stable
prices calmed fears of runaway energy prices. Oil prices are still
relatively high when viewed historically, but well below recent
peaks. Natural gas, on the other hand, is approaching historic
lows following the dramatic run-ups after Hurricane Katrina.
With the probability of significant new domestic gas sources
coming online in the coming years, there’s a sense that prices
will stay low forever. Coal is down from its 2008 high, with a
relatively benign short-term pricing outlook..
an energy PLan ThaT faILs To address
energy reLIabILITy Is InCoMPLeTe and
under-resourCed.
In periods of economic stress, it’s easy to be lulled into put-
ting energy management on the back burner. Low prices being
caused by relatively soft demand might get overlooked. The
temptation to reduce energy focus can prove to be a false econ-
omy as it ignores many of the real costs. Most North American
companies manage energy with a degree of urgency only when
prices are high. This risks being on the wrong side of the real
costs of energy and is worthy of a little more examination.
The first area is the cost and availability of equipment and
expertise. Because most companies react to high prices at
the same time, the best experts are overstretched and costly,
and critical equipment might be both premium priced and
have long lead times. Ironically, global demand on a more
consistent basis from abroad in support of aggressive long-
term clean and renewable energy policies exacerbates this.
The conclusion is obvious — maintain a steady stream of
energy productivity investment and process improvements
while keeping an eye on the long-term quality of the busi-
ness and not the day-to-day fluctuations of energy pricing.
If energy prices move higher, the companies with consistent
energy management have an immediate competitive advan-
tage. They’re also able to focus on their core business instead of
scrambling to deal with the “emergency” of high energy prices.
The next area is reliability. The North American electrical
grid is experiencing many more incidents of outages and qual-
ity problems not caused by weather events. At a minimum, a
company should be thoroughly aware and up-to-date on the
58 November 2010 www.PLANTServICeS.Com
PS1011_58_Energy.indd 58
supply reliability risks and how these might affect the business.
A single event that causes a shutdown for even a few hours
might have major financial and customer satisfaction conse-
quences. In my experience, these costs often far exceed the
investments needed to prevent or mitigate them.
An energy plan that fails to address energy reliability is
incomplete and under-resourced. The energy manager ‘s key
role is to understand risks beyond the direct costs of energy
and to implement solutions that ensure business continuity
and value. Increasingly, this involves higher levels of effi-
ciency and more on-site clean and renewable energy genera-
tion than has been traditional. From time to time, teaming
with neighboring energy users can reinforce reliability
strategies. These combinations not only produce powerful
reliability solutions, they usually also manage day-to-day
costs relatively effectively.
The combination of business continuity and cash flow ad-
vantages when energy prices are rising usually is more than
enough reason to invest in energy management. The third
cost of poor energy management is environmental. This
is an area where the uncertainty of future energy-related
costs is the underlying concern. These uncertainties arise
predominantly from the future effects of greenhouse regula-
tion, costs that could be anywhere between negligible and
potentially threatening to the business. The easiest way to
reduce these risks is to invest in high levels of efficiency and
clean and renewable energy. These are the same strategies
needed to manage price volatility and supply reliability.
Before leaving the uncertain costs of climate change, it’s
important not to overlook possible costs on the business. Uni-
versities here are scrambling to reduce their carbon footprints
under pressure from well-organized initiatives that potential
students take seriously. Suppliers to major companies like
Walmart and Tesco are making sure their energy use and the
resulting greenhouse gases embedded in their products meet
increasingly stringent expectations. As regulations on climate
change tighten around the world, major global customers are
challenging their suppliers’ climate plans, which in most cases
are intimately linked to their energy plans. Again, a preemptive
approach, working with customers, will have a substantially
lower cost than reacting when the business is under the gun.
Peter garforth is principal of garforth International LLC, in Toledo,
ohio. he can be reached at peter@garforthint.com.
10/28/10 9:02 PM
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