PERFORMANCE RELIABILITY EFFICIENCY ASSET MANAGEMENT … · 2013-08-21 · 9 THE PS FILES Pressed...

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PERFORMANCE | RELIABILIT Y | EFFICIENCY | ASSE T MANAGEMENT

PERFORMANCE RELIABILIT Y EFFICIENCY ASSE T MANAGEMENTPERFORMANCE | RELIABILIT Y | EFFICIENCY | ASSE T MANAGEMENT

teamer

PS0712_01_CVR.indd 2 12/6/07 12:15:36 PM

Just a few pushes of a button and you’re ready for small targets, shiny surfaces, and distances up to 60 feet. It’s that easy to be accurate.

The NEW Fluke 568 IR and contact thermometer makes any measurement easier and more accurate with features you won’t fi nd on any other tool.

• Simple 3-button interface,just scroll, select, and shoot

• Built-in emissivity table of common materials for higher IR accuracy

• 2-color fl ashing alarm,alerts you visually when measurements exceed limits

• Hands-free data loggingwith USB interface and included software.

• Soft rubber boot for increased ruggedness

• Includes FlukeView® Formsfor trending and creating reports from downloaded data

• 2 levels of backlight, let you read the display in any environment

• Choice of 6 languages makes setup a snap

Fluke. Keeping your world up and running.®

The fi rst thermometer that speaks

your language.

©2007 Fluke Corporation.Specifi cations subject to change without notice. Ad 02188

See your local distributor to buy now. To choose the product that fi ts your work, or for more details, go to www.fl uke.com/temperature

Choose your language. Select the surface. Measure.

RoundL/C 1 2 3 4 5 6

ICS# 071416 • Fluke568 ad • EC&M • CC 6524 GL611017.875 x 10.75 • 150 ls • PDF/X1A

Color_____Layout____

G A R L O C K

Mill Saves Millions with Garlock Sealing SolutionsOne U.S. mill needed to increase its plant’s efficiency—significantly reducing water consumptionand tramp water, and increasing the mean time between repairs (MTBR). Garlock and a localdistributor performed a complete rotating equipment audit of over 1,000 pumps and agitators, anddetermined which sealing techniques and products would be the most cost-effective and offer thebest return on investment.

We identified and eliminated 100 GPM of tramp water—approximately 50 million gallons of waterper year—which has saved the mill $750,000 annually. This elimination and several operationalimprovements helped increase the concentration of black liquor to the recovery boiler byapproximately 1 Baume point, which translates into an additional $1,000,000 in estimated annualcost reductions.

For more on FLUSH-GARD®, visit www.garlock.com

World Headquarters: 1666 Division Street, Palmyra, NY 14522 USA1.800.448.6688 www.garlock.com

H I G H - P E R F O R M A N C E D Y N A M I C S E A L S

Isn’t it time you take a closer look...Does your isolator carry the Garlock® name? Only Garlock Bearing Isolators are designed with a unitizing element and patented Cam-Lock design for long lasting bearing protection.

Unlike other isolators that use a simple o-ring, our unitizing element eliminates metal-to-metal contact that can create bearing contaminants such as o-ring fragments and bronze shavings that can lead to premature bearing failure. Our patented Cam-Lock design provides twice the retaining power. GUARDIAN™ Bearing Isolators can be easily installed by hand without the need for tools. They also won’t score the bore which can result in metal shards being released into the housing, damaging costly bearings. The GUARDIAN is also API 610 compliant.

For more information go to www.klozure.com

FLUSH-GARD®

G A R L O C K

Garlock MULTI-SWELL™ Delivers on Utility Company’s“Zero Leak Tolerance” PolicyOne major utility company had chronic leak problems in its turbine’s lube oil and seal oil systems.Flanges and gear pump casing covers were constant sources of leaks, resulting in oil loss andunsightly residue. The company tried various types of expanded PTFE (like engineered ring gaskets,sealants, and sheet forms), but nothing worked. Enter Garlock MULTI-SWELL—self-loading, self-sealing gaskets activated by contact with water or oil.

Twice as compressible as standard fiber gaskets, the MULTI-SWELL gaskets were cut and installedeasily—and they swelled immediately to ensure a tight, no-drip seal. MULTI-SWELL helped thisutility deliver on its “Zero Leak Tolerance” program: the lube oil and seal oil systems have been leakfree since the gaskets were installed more than two years ago.

For more information, go to www.garlock.com

Garlock_PlantServices_Aug07.qxd 7/13/07 9:56 AM Page 1

PS0712_Ads.indd 2 12/4/07 1:38:26 PM

Just a few pushes of a button and you’re ready for small targets, shiny surfaces, and distances up to 60 feet. It’s that easy to be accurate.

The NEW Fluke 568 IR and contact thermometer makes any measurement easier and more accurate with features you won’t fi nd on any other tool.

• Simple 3-button interface,just scroll, select, and shoot

• Built-in emissivity table of common materials for higher IR accuracy

• 2-color fl ashing alarm,alerts you visually when measurements exceed limits

• Hands-free data loggingwith USB interface and included software.

• Soft rubber boot for increased ruggedness

• Includes FlukeView® Formsfor trending and creating reports from downloaded data

• 2 levels of backlight, let you read the display in any environment

• Choice of 6 languages makes setup a snap

Fluke. Keeping your world up and running.®

The fi rst thermometer that speaks

your language.

©2007 Fluke Corporation.Specifi cations subject to change without notice. Ad 02188

See your local distributor to buy now. To choose the product that fi ts your work, or for more details, go to www.fl uke.com/temperature

Choose your language. Select the surface. Measure.

RoundL/C 1 2 3 4 5 6

ICS# 071416 • Fluke568 ad • EC&M • CC 6524 GL611017.875 x 10.75 • 150 ls • PDF/X1A

Color_____Layout____

G A R L O C K

Mill Saves Millions with Garlock Sealing SolutionsOne U.S. mill needed to increase its plant’s efficiency—significantly reducing water consumptionand tramp water, and increasing the mean time between repairs (MTBR). Garlock and a localdistributor performed a complete rotating equipment audit of over 1,000 pumps and agitators, anddetermined which sealing techniques and products would be the most cost-effective and offer thebest return on investment.

We identified and eliminated 100 GPM of tramp water—approximately 50 million gallons of waterper year—which has saved the mill $750,000 annually. This elimination and several operationalimprovements helped increase the concentration of black liquor to the recovery boiler byapproximately 1 Baume point, which translates into an additional $1,000,000 in estimated annualcost reductions.

For more on FLUSH-GARD®, visit www.garlock.com

World Headquarters: 1666 Division Street, Palmyra, NY 14522 USA1.800.448.6688 www.garlock.com

H I G H - P E R F O R M A N C E D Y N A M I C S E A L S

Isn’t it time you take a closer look...Does your isolator carry the Garlock® name? Only Garlock Bearing Isolators are designed with a unitizing element and patented Cam-Lock design for long lasting bearing protection.

Unlike other isolators that use a simple o-ring, our unitizing element eliminates metal-to-metal contact that can create bearing contaminants such as o-ring fragments and bronze shavings that can lead to premature bearing failure. Our patented Cam-Lock design provides twice the retaining power. GUARDIAN™ Bearing Isolators can be easily installed by hand without the need for tools. They also won’t score the bore which can result in metal shards being released into the housing, damaging costly bearings. The GUARDIAN is also API 610 compliant.

For more information go to www.klozure.com

FLUSH-GARD®

G A R L O C K

Garlock MULTI-SWELL™ Delivers on Utility Company’s“Zero Leak Tolerance” PolicyOne major utility company had chronic leak problems in its turbine’s lube oil and seal oil systems.Flanges and gear pump casing covers were constant sources of leaks, resulting in oil loss andunsightly residue. The company tried various types of expanded PTFE (like engineered ring gaskets,sealants, and sheet forms), but nothing worked. Enter Garlock MULTI-SWELL—self-loading, self-sealing gaskets activated by contact with water or oil.

Twice as compressible as standard fiber gaskets, the MULTI-SWELL gaskets were cut and installedeasily—and they swelled immediately to ensure a tight, no-drip seal. MULTI-SWELL helped thisutility deliver on its “Zero Leak Tolerance” program: the lube oil and seal oil systems have been leakfree since the gaskets were installed more than two years ago.

For more information, go to www.garlock.com

Garlock_PlantServices_Aug07.qxd 7/13/07 9:56 AM Page 1

PS0712_Ads.indd 3 12/4/07 1:39:39 PM

At Sherwin-Williams we’ve found the best way to improve the quality of coating applications is to

shorten the curing time. Which is exactly what we did with ExpressTech coatings. Sherwin-

Williams’ ExpressTech introduces new technologies to speed up the curing

time, reduce vulnerabilities and improve overall quality. Using ExpressTech

coatings means you’ll need fewer coats, which reduces labor costs, improves productivity and

gives you faster return to service. It’s perfect for bridges, tanks, power generation, industrial

floors, steel fabrication and more. To learn more about the quality advantages of our

ExpressTech coatings, contact your Sherwin-Williams sales rep, or call 800-524-5979 to have a

representative contact you.

©2005 The Sherwin-Williams Company www.sherwin-williams.com/im

SHERW876 7.875x10.5 2/21/06 11:14 AM Page 1

PS0712_Ads.indd 4 12/4/07 1:40:08 PM

December 2007 www.PLANTSERVICES.com �

15 ENERGY EXPERT

Energy’s “perfect storm”By Peter Garforth, Contributing Editor

17 TECHNOLOGY TOOLBOX

Know your positionBy Sheila Kennedy, Contributing Editor

33 WEB HUNTER

Potpourri XBy Russ Kratowicz, P.E., CMRP, Executive Editor

42 BOILER ROOM

Getting educatedBy Ricky Smith, CMRP, Contributing Editor

columns and departments

specialists

7 FROM THE EDITOR

Orange alertBy Paul Studebaker, CMRP, Editor in Chief

9 THE PS FILES

Pressed into innovationBy Ken Schnepf, Managing Editor

11 UP AND RUNNING• CPMM courses offered • Greenhouse gas data released• Automation Fair draws 13,000 from 65 nations

13 WHAT WORKS

Samuel Adams facility refreshed in CincinnatiFloor-to-ceiling coating cuts filter room maintenance

36 IN THE TRENCHES

Making a big stink

USINGSIGNATUREANALYSISONDCMOTORS Little research has been performed using Current Signature Analysis on DC motors. This paper is a brief introduction to online fault diagnosis of DC motors using CSA.www.PlantServices.com/motor_faults

WhITEPAPERONUSINGMODbUSA senior application engineer at Moore Industries describes how Modbus works and how it can be used. www.PlantServices.com/modbus

WEbCAST:ENhANCEDEAMANDRELIAbILITYSAP and its partners describe how Perfect Plant Solutions improve asset performance.www.PlantServices.com/webcasts/as set_management/sap_webcast.html

ExPERIENCEAPOWERfULNEWPRODUCTSECTIONAdvanced search options include specific drill-down capabilities that lead you to the exact type of item you're seeking. www.PlantServices.com/products

PlantServices.com

18 COVER STORY

Get a grip on the SteamerReduce energy consumption, save money and improve safetyBy Steve Connor

28 PIPING

Inside, looking outMaintain your pipeline infrastructure with video inspectionBy Richard Lindner

Volume 28, Number 12

18

Illus

trat

ion

by S

teph

en H

erne

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PS0712_05_TOC.indd 5 12/6/07 12:02:29 PM

Our world-class warranty is a real . In a clinch,

other manufacturers can’t stand up to Quincy Compressor’s

Royal Blue Warranty®. It offers the industry’s only 10-year

airend coverage* without a blow to your budget.

When it comes to high quality backed by an unmatched warranty,

Quincy Compressor is the undisputed champ.

* Available on select models** Our Warranty Policies and Procedures Handbook, which is incorporated

herein by reference, contains additional terms and conditions applicable to this warranty and is available at www.quincycompressor.com.

Our comprehensive, 10-year warranty** includes:

• 10-year Airend Warranty

• 5-year Variable Speed Drive

Warranty

• 5-year Drive Motor Warranty

• 5-year Air/Fluid Receiver Warranty

• 5-year Drive Coupling Warranty

• 5-year Cooler Warranty

.

quincycompressor.com/knockout

© 2007 Quincy Compressor an EnPro Industries company

For more informationabout the Royal Blue Warranty visit

PS0712_Ads.indd 6 12/4/07 1:40:26 PM

December 2007 www.PLANTSERVICES.com �

As the latest in a series of events that includes flood-ing New Orleans, neglecting

Walter Reed Army Medical Center and collapsing the I-35W bridge over the Mississippi in Minneapolis, the November 28 explosion on a ma-jor Canadian-U.S. crude-oil pipe-line showed once again that terror-ists would be hard-pressed to match the damage we can do to ourselves with engineering, maintenance and management mistakes.

The explosion killed two maintenance workers. Then it spooked specula-tors into raising oil prices by more than $3 a barrel to $95 on November 29. Those of us in the rapidly-freezing Midwest were terrorized by loose talk of fuel oil and gasoline shortages, and only some-what reassured when U.S. Department of Energy spokesperson Megan Barnett promised to consider tapping the U.S. Strategic Petroleum Reserve.

Later that day, oil futures investors discovered that the incident would have no appreciable effect on U.S. supplies be-cause the pipeline was already shut down for maintenance and would be back in service in three days.

The two human casualties, Enbridge Energy Partners maintenance workers Dave Mussati Jr. and Steve Arnovich, were performing scheduled maintenance on the underground pipeline. Workers had successfully replaced a segment of pipe that had a pinhole leak when the explosion occurred.

As I write, the cause of the explosion hasn’t been determined. If it follows the usual root-cause analysis pattern, it will turn out to be a breach of procedure blamed at least in part on a system that doesn’t adequately prevent such a breach – in layman’s terms, someone made a mistake and no one caught it in time.

Maybe what the United States needs is a Department of Homeland Integrity to match our Department of Homeland Security. We could invest a few of the billions of dollars we spend trying to

fend off external threats on educating people about the costs and value of sound infrastructure, the payback on intelligent maintenance and the in-dispensable roles of reli-ability-enforcement per-sonnel including facility managers, engineers and technicians.

The Corps of Engineers could become the core of a national effort to recruit, train and employ an army of experts to search out, identify and exorcise the structural and procedural deficiencies that daily threaten our citizens.

We’d save lives, improve our envi-ronment, and increase the efficiency of our infrastructure. If we did it right, we ought to be able to make a profit.

Who’s with me?

Orange alertWith maintenance like this, who needs terrorism?

Maybe what the United

States needs is a Department of Homeland

Integrity.

PAUL STUDEBAKER, CMRPEDITOR IN [email protected](630) 467-1300 ext. 433

FROM THE EDITOR

editorial staff

paul studebaker, cmrp editor in [email protected]

russell l. kratowicz, p.e. cmrp executive [email protected]

ken schnepf managing [email protected]

michael ermitage senior web [email protected]

dan hebert, p.e., senior technical [email protected]

stephen c. herner group art [email protected]

jennifer dakas art [email protected]

david berger, p.eng. contributing editor

peter garforth contributing editor

sheila kennedy contributing editor

joel leonard contributing editor

r. keith mobley, cmrp contributing editor

ricky smith, cmrp contributing editor

publication services

carmela kappel assistant to the [email protected]

jerry clark v.p., [email protected]

jack jones circulation [email protected]

rita fitzgerald production [email protected]

claudia stachowiak reprints marketing managerFoster Reprints (866) 879-9144 ext. [email protected]

administrative staff

john m. cappelletti president/ceo

julie cappelletti-lange vice president

keith larson v.p., content

rose southard it director

mike brenner, group publisher

[email protected]

PLANT SERVICES (ISSN 0199-8013) is published Junely by Putman Media, Inc., 555 West Pierce Road, 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. 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 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 apply for qualified-reader subscriptions, please go to www.plantservices.com. To non-qualified subscribers in the U.S., subscriptions are $96 per year. Single copies are $15, except the August and October issues which are $36. Canadian and foreign annual subscriptions are accepted at $145 (Foreign airmail $200/yr). Single copies are $81. © 2007 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 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 apply to our growing marketplace. Putman Media, Inc. also publishes THE JOURNAL, CHEMICAL PROCESSING, CONTROL, CONTROL DESIGN, FOOD PROCESSING, INDUSTRIAL NETWORKING and PHARMACEUTICAL MANUFACTURING. PLANT SERVICES assumes no responsibility for validity of claims in items published.

PS0712_07_MastheadFTE.indd 7 12/5/07 2:32:50 PM

U N I T E D W E G R O W .

You may already know Unicco as a powerhouse in integrated facilities services. Now we’re UGL Unicco and we’re stronger than ever. We’ve joined forces with United Group Limited (UGL), a $2.5 billion global company with more than 30,000 employees and a proven track record in engineering,maintenance, and operational services. What does that mean to you? That you can look to us for a superior range of services covering all your plant needs. And there’s more to come. UGL Unicco and you. Let’s grow together. I N T E G R AT E D FA C I L I T I E S S E R V I C E S UGL-Unicco.com

PS0712_Ads.indd 8 12/4/07 1:40:48 PM

www.vibralign.com800-379-2250

Flash is a registered trademark of Adobe Systems Incorporated.

Now, when you add the patented “OL2R” (offline-to-running) hardware+software expansion kit to the revolutionary XA alignment system, you can measure the dynamic movement of critical machines as they reach operating conditions from a cold start. The resulting data is stored in the XA and is readily accessible to automatically adjust future alignments.

Onscreen animated graphics make accurate alignments of critical machines

fast and easy.

New! Measure and correct for dynamic growth in a Flash.

Shaft alignment in a Flash®

D .PLANTSERVICES. 9

Internationally, manufacturers are optimistic about the future, however they’re losing confi dence in the U.S.

economy, according to a recent survey. Respondents are confi dent about value chain improvements, but concerned about cost pressures, say the results of the fi fth annual Multinational Manu-facturing Pulse, a survey by the TBM LeanSigma Institute (www.tbmcg.com) in Durham, N.C.

“To compete in the global economy, leaders in these countries are under increased pres-sure to fi nd innovative ways to manage the cost of doing business. By con-centrating on value chain improvements, companies can sustain profi tability and become nimble at re-sponding to changes and opportunities in the marketplace,” says Anand Sharma, CEO of TBM Con-sulting Group.

� e TBM survey polled 3,082 execu-tives from mid-sized to large fi rms in six major manufacturing countries in the western hemisphere – the United States, U.K., Germany, Spain, Mexico and Brazil. � e majority (91%) of manu-facturers surveyed reported productivity gains during the past year and identify continuous process improvement (Lean) as the leading source of improved pro-ductivity (United States, 52.5%; U.K., 50%; Germany, 47.4%; Spain, 75%; Bra-zil, 36.8%; and Mexico, 36.3%). When asked to specify the productivity/qual-ity improvement programs being used, nearly three-quarters (72%) identify kaizen as their primary method. Lean

(63%) and ISO certifi cation (84%) also ranked among the top three methods.

Manufacturers say the plant fl oor is one of the top three areas where innova-tion is most active. When asked where innovation is most active in their value chain, 39% of them say new product de-velopment, 25% identify the plant fl oor and 11% name new technology.

Recognizing that innovation occurs on the factory fl oor refl ects a benefi t of Lean that manufacturers hope to ex-

tend throughout their value chains, says TBM. In a Lean culture, where everyone continuously strives to improve, em-ployees must be innova-tive in their day-to-day activities and in getting closer to their customers to understand and meet

their needs, develop new products and services faster, and deliver solutions.

“� e value of human capital to an organization should not be underesti-mated or overlooked, there should be continuous awareness of the state of the workforce and its level of engagement, empowerment and integration,” says Mike Serena, managing director, TBM LeanSigma Institute. “Today there is a toolbox full of techniques in the lean factory to activate and compel workers. By encouraging all workers to think, eliminate waste and fi nd ways to con-tribute and add value, companies will be able to create a compliant, fully engaged workforce.”

E-mail Managing Editor Ken Schnepf [email protected].

Pressed into innovationProductivity improvements are being led by Lean

The plant fl oor is one of the

top three most active areas of

innovation.

K E N S C H N E P F

THE PS FILES

PS0712_09_PSFiles.indd 9 12/4/07 2:11:12 PM

Get the airflow you need.From slow to fast, it’s all about results.

The right airflow means optimum production efficiency and

constant energy savings. Engineered with precision, the

Gardner Denver VS & VST Series of rotary screw compressors

are true energy conservationists – minimizing power

consumption while maximizing productivity. Variable speed.

Airflow as needed. Proven bottom-line results.

Phone: 217.222.5400 • Fax: 217.228.8243 • Email: [email protected] • www.GardnerDenverProducts.com

PS0712_Ads.indd 10 12/4/07 1:41:11 PM

D .PLANTSERVICES. 11

UP AND RUNNINGCPMM courses off ered

Enrollment is open for the 2008 Certifi ed Plant Maintenance Manager (CPMM) program off ered by the Association for Facilities Engineering (AFE).

� e CPMM program, soon entering its second decade, is designed for people who have hands-on or technical, but not managerial, expertise in the in-creasingly complex maintenance arena. � ose who complete this program – as proven by passing an examination – have up-to-date, useful knowledge of concepts such as maintenance management, preventive maintenance, inventory and procure-ment, work orders, work fl ow, planning and scheduling, computerized maintenance management, total productive maintenance, maintenance fi nancials and return on investment.

� ere are three ways to pursue the program:• Online. AFE will conduct the program from noon to 4 p.m. ET on January 8,

11, 15, 18, 22, 25, 29 and February 1. Participants must have access to a tele-phone and computer.

• On site. AFE will conduct the course in a traditional classroom setting March 10-14 in Indianapolis, and June 9-13 and September 22-26 at locations to be determined.

• On ones own. Participants can study independently and be tested at their workplaces with proctors. Advance registration is required. Eligibility requirements are current employment as a maintenance professional and two years of experience. As a study aid, AFE off ers the “CPMM Review Pak” containing the topics the exam covers.

Download CPMM program applications at www.AFE.org.

Greenhouse gas data released

Comparable data on greenhouse gas emissions among Midwestern states was recently released, giving the region a tool to set priorities and policies on climate change.

� e comprehensive breakdown of Midwestern greenhouse gas (GHG) emis-sions (www.wri.org/publication/charting-the-midwest) is found in “Charting the Midwest: An Inventory and Analysis of Greenhouse Gas Emissions in America’s Heartland,” a report by the World Resources Institute (WRI) in cooperation with the Lake Michigan Air Director’s Consortium (LADCO).

“Charting the Midwest” breaks down key regional fi ndings, important economic sector fi ndings and GHG details particular to each state, including:

• If the Midwest were its own country, it would rank 5th in GHG emissions, be-hind the U.S., Russia, China and India.

• � e Midwest accounts for nearly 25% of the U.S. emissions and 5% of world emis-sions.

• Among the sector fi ndings, the report isolates electricity, transportation, industry and agriculture as the largest contributors to the Midwest’s total emissions.

• In sections for each state, data on total emissions, emissions trends, per capita emis-sions, and emissions as a percentage of the total U.S. contribution are included.

� e report, and the cooperation of several state agencies in producing it, comple-ments a recent paper issued by WRI that identifi ed characteristics of state policies that have historically infl uenced federal policies.

www.vibralign.com800-379-2250

Flash is a registered trademark of Adobe Systems Incorporated.

New! Offset shaft alignment in a Flash.

Shaft alignment in a Flash®

A new hardware+software expansion kit is now available for the XA that allows quick and easy alignments of offset (cardan) machine shafts. The system incorporates on-screen Flash®

animations that actually walk the user through the offset shaft alignment

process! Quickly align your offset shafts to reduce wear

on gearboxes, bearings and offset joints.

PS0712_11_12_UpAndRunning.indd 11 12/6/07 9:46:37 AM

UP AND RUNNING

December 2007www.PLANTSERVICES.com12

Automation Fair draws 13,000 from 65 nations

FLOWS TO 3,000 SCFM • ENERGY SAVING emm™ CONTROLLERS COLDWAVE™ 316SS HEAT EXCHANGERS • DEMAND-OPERATED DRAINSINTEGRAL OIL REMOVAL FILTRATION • WORLDWIDE DISTRIBUTION

ColdWaveTM Refrigerated Dryers wring the nasty oily water out of compressed air systems to deliver pure, clean, dry compressed air to your air-powered operations. Equipment lasts longer and you will keep productivity high and energy use low - all year round. Specify ColdWaveTM Refrigerated Dryers and weather those hot, humid dog days of summer.

®®

The 16th Annual Automation Fair held No-vember 14-15 attracted more than 13,000 attendees from 65 nations to McCormick

Place in Chicago, according to Rockwell Automa-tion, sponsor of the free, educational forum on man-ufacturing technology and one of the largest private trade fairs in the United States.

“Each year at the Automation Fair event, we have the opportunity to bring together customers and manufacturing professionals from around the globe,” says Keith Nosbusch, Rockwell Automation chairman and chief executive officer.

The event showcased some of the latest automa-tion and technology solutions available through Rockwell Automation and its partners — aimed to help manufacturers improve product time to market, increase profitability, develop asset management and

Resources

UE Systems presents a live electrical inspection WebcastVisit www.uesoundadvice.com to register or view the December 19 webcast.

JETS and Motorola champion the innovation generationVisit www.engineeryourlife.com to learn about an initiative to inspire female scientists and engineers of tomorrow.

Integrate failure analysis with maintenance systemsThis benchmark study investigates the ways top performing com-panies develop corporate cultures of reliability and leverage invest-ments. Download it at www.aberdeen.com/summary/report/bench mark/4159-RA-ground-up-strategies.asp.

optimization strategies, and manage business risks.For more information about the Automation Fair visit www.

automationfair.com .

PS0712_11_12_UpAndRunning.indd 12 12/5/07 2:35:52 PM

December 2007 www.PLANTSERVICES.com 13

WHAT WORKS

Using urethane floor coating to resurface a beer fil-tration room’s ceiling has significantly reduced maintenance costs at one of America’s favorite mi-

crobreweries. But the task, which included a 35-ft.-high ceiling amid a maze of tanks and pipes, was declared “our toughest job ever” by installer Greg Hardig of E.B. Miller Contracting, Inc., Cincinnati.

The Boston Beer Company is the seventh largest brewery in the nation, producing 1.2 million barrels annually at fa-cilities in Boston and Cincinnati. Its flagship beer, Samuel Adams Boston Lager, has won more awards than any beer in history.

Purchased in 1997, the Cincinnati brewery underwent a $6.5 million expansion project in 2005. It added new lager-ing and aging tanks, a storage cellar and two custom-made copper brew kettles. About two-thirds of all Samuel Adams beer is now brewed at the Cincinnati plant.

At the time of the expansion, E.B. Miller Contracting installed Flowfresh RT on thousands of square feet of fresh (or “green”) concrete poured for the new facility’s walkways and base floor. Developed by Flowcrete PLC and offered in North and Central America by Valspar Flooring (www.valspar.com), Flowfresh RT is a non-slip, heavy-duty, rake and trowel urethane concrete that resists chemicals and includes Polygiene, an antimicrobial that inhibits growth of bacterial odors and guards against biological degradation.

Assistant Brewing Manager Todd Roseman was impressed with Flowfresh’s performance, so when it came time to re-finish the original brewery’s aging filtration room, he again turned to E.B. Miller Contracting and Valspar Flooring. “The older section of our brewery has the unique heritage, pride and tradition that characterize Samuel Adams beer,” Roseman says. “However, we wanted it to share in all the state-of-the-art production capabilities found in the expan-sion. Resurfacing the floors, walls and ceiling of the filtration room was an important part of achieving that goal.”

As a rule, filtration rooms are hot and steamy, making them perfect environments for mildew and mold growth. The Samuel Adams filtration room is between several others kept cold for production, which caused so much condensa-tion it appeared to be raining indoors.

“The filtration room only measures 60 ft. by 60 ft., so

it sounded as if it was a small job at first,” explains Adam Jordan, technical sales representative, Valspar. “However, when I visited and saw the volume of coating removal that would be required, plus the brewing equipment the crews needed to work around, I quickly changed my mind.”

During the six-day, around-the-clock installation, the room’s tanks, pumps, piping and other equipment remained in place. E.B. Miller’s team set up “an amazing rigging job” that reached up the 35-ft. high walls, providing 100% fall protection, along with a makeshift tunnel to give control engineers ongoing access to computers on the perimeter walkway, says Hardig.

“We had to remove the failing coatings from the floor, walls and ceiling,” Hardig says.

On the floor pit area and walkway, E.B. Miller Contract-ing applied blue Flowfresh SR for its heavy-duty durability, heat resistance to 210°F, and superior slip resistance. For the ceiling, Jordan made the unusual specification of Flowfresh FC floor resurfacer rather than a conventional coating.

“As great as these high-performance, long-lasting coat-ings look in the filtration room, the real bottom-line benefit is the reduced maintenance requirements that are yielding immediate savings,” says Roseman. “Washdowns are much easier to perform, especially for the ceiling, and because the floors resist abrasion, chemicals and impact, we aren’t inter-rupting production for repairs or recoating.”

Samuel Adams facility refreshed in CincinnatiFloor-to-ceiling coating cuts filter room maintenance

Washdowns are much easier to perform, especially for the ceiling, and because the floors resist abrasion, chemicals and impact, production is not being interrupted for repairs or recoating.

PS0712_13_WhatWorks.indd 13 12/5/07 4:51:38 PM

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Last month’s column about how hard it is to share en-ergy productivity best practices inspired some inter-esting reactions.

Predictably, one was from a company offering a technical solution for efficient steam management, intensely frustrat-ed that they couldn’t sell a $360,000 investment that would save the client more than $1 million per year. The customer’s strangely common rationale for not moving forward was that the results seemed too good to be true.

My advice is that they stop trying to get the customer to accept the benefits of such an investment, and change the conversation to one of management accountability.

It would sound something like this: “Can you explain why it’s good business to leave $1 million of cost reduction on the table when your industry faces some of the toughest global competition in history? It seems an odd way of fulfilling your duty as a company officer. Further, this cost reduction would be based on proven ap-proaches and paid back in four months. What other investments yield a risk-free 300% re-turn? As part of an integrated energy management plan, the value of energy productivity would likely enhance operating profit by at least 30% within three to five years. In the inter-ests of shareholders, how can you ignore it?”

This might not be the best approach for our reader to get an order, but it’s increasingly the nature of questioning from shareholders, directors and customers. Senior officers will need better answers than they have had in the past.

The second reaction came from a Danish engineer, recall-ing his youth in the 1960s at the height of the cold war. He was told, in case of a missile attack from the U.S.S.R. and east bloc countries, to just lie down – there wouldn’t be enough time to seek shelter. Western Europe’s economy was rapidly growing and desperately needed more energy. The only convenient place to get it was from the U.S.S.R. and its allies. This was a key factor in Europe’s early focus on energy efficiency and supply security. At the same time, acid rain, largely from power generation, was devastating the rivers and forests of northern Europe, further underlining the ur-gent need for more rational energy use.

Yet another reaction came from a process engineer work-

ing in a major global U.S. manufacturing company. He em-phasized the need for a holistic approach and added, “New technology is great and will always be welcome, but why do we (politicians/decision-makers/engineers) have to procras-tinate and why would we not do what’s appropriate in the present time?” When we are on a burning platform, a read-ily available, proven solution would seem a far better option than a perfect solution that might develop in the future.

Crude oil prices have moved close to $100 per barrel, caused by changes in the dollar exchange rate and oil market fundamentals. The conventional wisdom is that high prices and volatility are here to stay. Recent Intergovernmental Panel on Climate Change reports raise the political likeli-

hood of significant action to more aggressively mitigate greenhouse gas emissions.

A new government was recently elected in Australia professing plans to formalize its na-tional commitment to mandatory greenhouse gas targets. This is an interesting comment on the power of a climate debate that was a non-issue only a few years ago.

Three key factors that need to come together to produce the perfect energy storm are coalescing rapidly in North America: high energy prices and fears they’ll head higher; politically challenging energy supply sources; and fear of major environmental impacts. In a recent survey of U.S. State Electricity Regulators, the most important issue was environmental concerns, followed by electricity costs and availability of generating capacity. Just two years ago, envi-ronmental concerns weren’t among their top five issues.

As each month passes, the role of corporate energy man-agers becomes clearer. They must urgently develop workable strategies to simultaneously manage energy cost, price vola-tility, rapidly changing technology, environmental impact and reliability in an uncertain regulatory framework, and with many colleagues and even bosses who remain skeptical of the need for such an integrated approach. Not the easi-est task in the world, but one that is becoming increasingly important and in demand.

Peter Garforth is principal of Garforth International LLC, Toledo, Ohio. He can be reached at [email protected].

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Encoders are being engineered to meet increasingly specific needs. Space considerations, environmental factors and applications come into play when deter-

mining which encoder is best suited for a given job. When properly matched, plants can achieve their operational ob-jectives while avoiding unnecessary and costly downtime.

Physical environment: Encoders can withstand dust, dirt and explosion hazards. For instance, magnetic encod-ers and digital tachometers by Dynapar are more rugged than optical rotary encoders and resistant to dust, moisture, shock and vibration. They use magneto-resistive (MR) tech-nology to track machine speed and provide digital shaft velocity feedback. A magnetic pulse wheel, imprinted with small magnetic poles and an integrated MR sensor produce magnetic fields that penetrate dust, dirt, oil and contaminants. The wheel rotates with the shaft, and the sensor’s resistors change value with the magnetic field.

In harsh areas, where caustic chemicals and corrosive agents threaten equipment re-liability, stainless steel encoders offer a rug-ged alternative to aluminum or plastic. Encoder Products’ Model 865T, designed to mount on NEMA C-face motors, has a housing milled from solid piece of 316 stainless steel. An optional stainless steel cover protects internal bearings and electronics from dust and machine wash-downs.

Another example is BEI’s H25 and H20 incremental ro-tary encoders, available with optional stainless steel hous-ing, encoder body and bearing housing. Applications are chemical or petrochemical, food packaging, medical and similarly harsh industrial environments.

Space constraints: Industrial machinery and equipment is getting smaller, and so are the electronic components. For space-constrained applications, an array of small encoders is available. An example is the surface-mounted encoder series by Avago Technologies. Measuring 6.5 mm by 4.2 mm by 1.69 mm, the AEDR-8320 is useful in robotic equipment, pick-and-place machines and other applications. The reflec-

tive analog optical encoder offers precise, real-time position-ing and directional sensing. It uses a reflective code wheel or linear code strip to sense position and velocity. Two-channel analog signal output offers 180 lines per inch resolution that can be increased through interpolation. The lead-free pack-age is compliant with the European Union’s Restriction of Hazardous Substances (RoHS) directive.

Targeted applications: Dynapar’s Hengstler Acuro AX71 absolute encoder was designed with the help of a drilling services firm to withstand downhole conditions. Its stain-less steel construction, IP67 sealing and bearings withstand

shock loads to 100 g. An ATEX-certified housing allows it to be used in explosive en-vironments without electrical barriers. The unit’s electronics use heat-stable substrates and diodes that ensure reliable operation to 140°F. In addition, the encoder is self-grounding to prevent shorting.

Heidenhain’s LS 688C linear encoder is for manually operated machine tools with digital readout. It’s scanning carriage rides on ball bearings, providing rigidity and

tight backlash and mounting tolerances. By comparison, in machine tools without linear encoders rely on the pitch of the ball screw, which is subject to thermal expansion, re-sulting in inaccurate output. Linear encoders compensate for thermal expansion, thereby keeping machine tools ther-mally stable and producing tight manufacturing tolerances.

Built-in encoders are available for applications such as conveyor belts and door openers that require low-resolu-tion speed and position feedback. Bodine’s custom-made Incodermotors with built-in magnetic encoders are avail-able as permanent magnet DC, brushless DC or gear-motors. The encoder is pre-wired and dropped into the OEM’s design, reducing assembly time and protecting it from the environment.

E-mail Contributing Editor Sheila Kennedy, managing director of Additive Communications, at [email protected].

Know your positionEncoders can handle the environment, the application and size limitations

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teamer

Reduce

energy

consumption,

save money

and improve

safety By Steve Connor

PS0712_CoverSteam.indd 18 12/6/07 11:46:02 AM


ndustrial fuel bills can amount to between $1 million and $3 mil-lion per year, eating up a large percentage of operating budgets. Surging energy costs have facility engineers, managers and mainte-nance supervisors looking for ways to make plants more efficient. In many cases, the most logical place to start is with the boiler system. You might think of it as getting control of the Steamer, one of three

archetype energy-wasting villains – the D-Energizers – originally introduced in our May cover story (www.PlantServices.com/articles/2007/105.html).

The reason? Eight out of 10 boilers are more than 30 years old. They run less efficiently, often are unreliable and might even be in violation of U.S. federal pollution standards. There are still 400 counties in the United States that are considered U.S. EPA non-attainment zones, meaning they don’t achieve cur-rent air quality standards. And while the EPA is the highest-ranking regula-tor of boiler emissions, many state and local governments are enforcing even stricter regulations.

One way to find out whether the boiler in your facility is efficient is to perform a steam audit: a comprehensive analysis of energy used within a facility, process or equipment, including recommendations for energy conservation measures. A steam auditor can work much like a superhero to apprehend the Steamer and eliminate his wasteful effects on your boiler and steam system.

Scope, cost and deliverablesThere are two types of steam audits: a simple boiler system audit and a complete facility audit. In a simple audit, a professional evaluates the boiler room, boiler and accessory support equipment, possibly extend-ing the evaluation somewhat into the facility. With a complete site audit, auditors evaluate the boiler system as well as components throughout a fa-cility, including steam traps, piping, valves and steam users.

A simple boiler system audit costs approximately $1,000, whereas a complete site audit, depending on the number of steam traps, other equip-ment and the size of the plant, could cost a few thousand dollars. The essen-tial steps of an audit are:

• Data acquisition: Identify where and how a facility, process or equipment uses energy, along with costs and utility issues affecting the energy consumption.

• Data analysis: Identify energy conservation measures to make energy use more efficient, less expensive and more environmentally friendly.

• Recommendations: A final report details what was found, a list of areas that need improvement, and recommended actions, usually accompanied by some type of economic justification.

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About the auditing processIf your facility recently replaced the boiler system, more than likely a steam audit isn’t needed. However, if the boiler system is more than five years old, the Steamer may have been doing his dirty work for quite a while and a steam audit is highly recommended.

A steam audit can take several days to complete, depending on the type of audit and the size of the facility. A fa-cility need not shut down for the pro-cedure; it’s actually better that it con-tinue as usual so the auditor can easily spot steam leaks and other anomalies during daily operations.

During a boiler room audit, your mild-mannered auditor will check the boiler controls, the boiler, blowdown and feedwater conditioning to identify inefficiency issues. Auditors use their uncanny abilities to do an inventory of key equipment, looking for:

• Energy-saving methods• Areas to implement better engi-

neering practices• Health and safety concernsIn a complete facility audit, an in-

spector not only checks the inventory of key equipment in the boiler room, but also focuses on potential improve-ments throughout the energy-using facility, effectively putting the cuffs on the Steamer to bring him under con-trol. The evaluator inspects the boiler, steam flow, pressures, temperatures, air handling, steam trapping, piping ancillaries including valving and insu-lation, condensate handling and heat recovery. Energy savings are sought through:

• Locating steam leaks• Heat recovery• Conservation of flash steam• Return of condensate

Start at the boilerOne of the first things an auditor needs to determine is the condition of the boiler system (Figure 1). The decision to replace a boiler shouldn’t be based solely on the boiler’s age. Some boilers, even 70-years-old, re-main in good condition. However, if

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the boiler is leaking, heavily scaled, or has outdated burners and controls, Steamer has made it his home and it’s probably time for replacement.

If the boiler is in good shape, it might only need efficiency retrofits such as an updated burner or combus-tion control system, which can save 50% on capital costs compared to a new boiler unit and provide significant fuel savings at least equal to the retro-fit cost during the first year.

Auditors also investigate whether the boiler has been overheating. If the boiler overheats, there might be prob-lems with either the boiler’s insula-tion or gasketing, which could lead to damaged and unsafe equipment. The cost of repairs to correct these types of problems are relatively nominal when compared to the serious safety or me-chanical repair issues that can result if you let the Steamer flex his energy-sapping muscles unchecked.

The auditor will perform a combus-tion test using stack gas analysis equip-ment to quantify boiler efficiency. This could lead to the recommendation of an oxygen sensor/transmitter in the exhaust gas.

The sensor/transmitter continuously senses oxygen content and provides a signal to the controller, which adjusts the air damper and gas valve to main-tain a consistent oxygen concentration in the flue. This minimizes excess air while optimizing the air-to-fuel ratio and puts the Steamer on the run.

Oxygen trim systems typically in-crease efficiency by 1% to 2%, which, if you’re looking at energy bills in the millions, means saving $10,000 or more each year.

How is steam applied?The next step in the audit process is to determine what the steam is used for, how it’s applied and if it’s possible to reduce the operating pressure to re-duce the sensible heat required to pro-duce a pound of steam.

To determine this, the heating process is reviewed along with the existing piping layout to see whether

the diameters of the piping, controls, steam traps and control valves allow operation at lower pressure, knowing velocities and pressure differentials will be changing.

If it’s concluded the pressure can be reduced, fewer BTUs will be used per hour in the process, saving the facility those energy dollars.

Minimize stack temperatureStack temperature also is something to consider when looking for ways to be more efficient. A well-tuned boiler should operate between 50° to 100° above saturated steam temperature. If it operates at higher levels, fixing the problem begins with maintenance and cleaning.

From an efficiency standpoint, ev-ery 40°F in temperature reduction re-sults in a 1% fuel savings and provides much frustration for the Steamer.

Sometimes, the stack temperature

is higher because there’s soot on the fireside surfaces caused by improper air/fuel ratio control. This means the burner was operating with excess fuel (rich), causing fine black particles,

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chiefly composed of carbon, to form on the heat transfer surfaces. This slows heat transfer, causing consider-able energy loss.

Soot can be mechanically removed with a flue brush. Once the soot is gone, a professional will be needed to reca-librate the burner. The payback on your investment to reduce stack temperature is quick, usually less than one year.

Another cause of elevated stack temperature is scale formation on the waterside surfaces of the boiler caused by improper water treatment. The remedy might be either acid cleaning or tube replacement, depending upon the severity of the scaling condition. In either case, the fix, though more expensive than cleaning the fireside, is often paid back through energy savings in a year or less, depending upon boiler size.

Survey pipingIn complete facility site audits, auditors survey the steam piping for energy loss-es through radiation and steam leaks. These manifestations of the Steamer are identifiable by the naked eye.

Cutting down on steam loss through radiation is as simple as insulating the distribution system. More than half of process plants lack pipe insulation or the insulation has deteriorated to the point of useless-ness. The larger the pipe diameter and greater the length, the more in-sulation can help in saving energy.

Reducing steam leaks caused by piping corrosion and compromised flanging can be another significant energy saver. The leaks appear as wisps of condensed steam, and, once secured, result in considerable dollars saved (Table 1).

Other opportunities to reduce energy costs with piping include ensuring steam mains are laid out, sized, drained and vented properly,

according to the U.S. Department of Energy (DOE). An auditor can en-sure that distribution system piping is sized to produce the appropriate system pressure drops; that it’s ad-equately supported, guided and an-chored; and that appropriate allow-ances are made for pipe expansion at operating temperatures.

Water in, water outDuring a complete facility audit, the auditor also will investigate how the feedwater supply and condensate re-turns are being handled. They check to see if the water sent directly into the boiler is free of dissolved gases such as oxygen and carbon dioxide, which can cause destructive corrosion to the boiler and condensate lines.

To avoid these conditions, one thing an auditor may recommend is install-

ing a deaerator (Figure 2) for remov-ing dissolved oxygen and carbon diox-ide from the feedwater.

Auditors also will check to ensure the facility is using a water softener and that it’s working properly. With-out a water softener, scale builds up in the heat exchanger, and it doesn’t take much scale to cause fuel usage to skyrocket: a quarter-inch of scale in-creases fuel use as much as 15%.

They also will examine conden-sate return. For many years, conden-sate was dumped down the drain. In the past few years, cost pressures and environmental concerns have forced facility engineers, managers and supervisors to rethink how they handle condensate.

Because condensate has already been through the steam system, it takes far less heat and fuel to turn it back into steam than it would to pro-duce steam from an equal quantity of cold water. That’s why steam users should return the condensate back to

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The payback on your investment to reduce stack temperature is quick, usually less than one year.


the boiler, where the whole process starts over again. This reuse can lead to hundreds of thousands of dollars in savings, depending on the size of the boiler and its operating hours.

Raise feedwater temperatureFacilities also can reduce their energy bills by taking a look at how much they spend on heating feedwater (Fig-ure 3). An auditor will probably sug-gest an economizer if your facility hasn’t already invested in one, because an economizer can reduce the steam boiler’s fuel requirements, frustrating the Steamer by transferring heat from the flue gas to incoming feedwater.

By recovering waste heat, an econo-mizer can often reduce fuel require-ments by 5% to 10%, and if you’re looking at $1 million to $3 million in annual energy costs, this retrofit can save $50,000 to $300,000 a year.

To determine if an economizer should be used, the auditor consid-ers the boiler size (200 hp or larger is a likely candidate), the operating pressure of the boiler, the degree of burner modulation, and the feedwa-ter temperature. A payback analysis can then be made based on the size, pressure, modulation and tempera-ture conditions combined with hours of operation and fuel costs.

Alternative fuel?Fuel alternatives are assessed dur-ing an audit, as adding the capability to burn a second fuel may result in a lower primary fuel burning cost.

For example, by retrofitting a boil-er’s burner to handle No. 2 oil, facility management can then negotiate with the local gas utility for a better rate be-cause it can burn oil during the times of the year when gas usage paks and proces are high.

Beware the hammerSteam traps are typically part of a complete facility site audit. Audi-tors look for traps that pressurize the condensate line (“blowing through”), causing waterlogging and inefficient

process performance. Traps are nor-mally checked using heat-sensitive or ultrasonic instrumentation.

The other critical issue the auditor is looking for is evidence of the Steamer swinging his water hammer. In steam systems, water hammer most often oc-curs when some of the steam condenses into water in a horizontal section of the

steam piping, usually caused by poor condensation drainage. Subsequently, steam picks up the water, forms a slug and hurls it at high velocity into a pipe elbow or other restrictive device, creat-ing a loud hammering noise and greatly stressing the pipe.

Imagine a filled 8-in. pipe, 8 in. long. It weighs about 15 pounds, or

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D I S C O V E R

17639_2 07 CTGNL GENRL American.indd 1 9/19/07 7:53:52 AM

Equivalent orifice

diameter

Steam loss (lbs/yr)

Steam cost per 1,000 lbs

$5.00 $7.50 $10.00

1/16 in.1/8 in.1/4 in.1/2 in.

115,630462,5451,848,3897,393,432

$578 $867 $1,156$2,313 $3,469 $4,625$9,242 $13,863 $18,484$36,967 $55,451 $73,934

* Dollars per year at 100 psig. Cost multipliers for other steam pressures:

16 psig: 0.26 50 psig: 0.56 150 psig: 1.43200 psig: 1.87 300 psig: 2.74 600 psig: 5.35

Table 1: The high price of escape*




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the same as a bowling ball. Now put 100 psi of pressure behind the ball and roll it at 60 mph: that’s the level of force when water hammer is oc-curring. It can cause pipes to break or even disintegrate if the pressure is high enough, potentially scalding or severely injuring employees in the vicinity. Clearly, this is a problem that needs to be f ixed.

A steam trap auditor will gather information on the number of steam traps in the facility, test and tag the steam traps, record f indings, and calculate energy saving measures and potential ROI.

Maintain a boiler logTo maximize the audit process and help keep boilers running optimally at all times, all facilities should keep a boiler room log. The log serves as a guide to a comprehensive mainte-nance program. By helping to evalu-ate performance and spot trends that may affect operating pressure (steam boiler), operating temperature (hot water boiler) and stack tempera-ture, boiler logs help to determine when to clean the boiler, adjust the combustion, repair or maintain the refractory or insulation and adjust water treatment. It also helps with timing on replacing safety devices, fuel f ilters or gaskets, stopping the Steamer in his tracks. Because the log keeps track of issues with the boiler, the auditor will know what to look for up front.

For everyday safety, the log should also include standard operating pro-cedures, which allow it to serve as a “how to” reference book for employ-ees. Not knowing the proper proce-dures when an issue arises can lead to boiler outages and accidents.

Calculate ROIFacilities that invest in steam audits learn a lot about their boiler systems and why the energy bills may be going through the roof. They also learn a lot about how they might proceed to conserve energy, reduce

cost, increase reliability and im-prove safety.

The last key component of a steam audit is what you can expect of ROI for the suggested improvements and maintenance. Opportunities vary from simple cleaning procedures to replacing equipment, and have pay-backs that begin immediately, one of the most important being keeping employees safe. Incorporate your su-per-auditor’s energy efficiency sugges-tions to save hundreds of thousands of dollars over the next few years, and force the Steamer to take his D-Ener-gizing bag of tricks elsewhere.

Steve Connor, director of marketing/com-munications, Cleaver-Brooks Co., has more than 40 years of experience in the steam generating field including engineering, service training, and field application sales. He can be reached at (414) 359-0600 or [email protected].

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17640_2 07 CTGNL GENRL Wrap Up.indd 1 9/19/07 8:02:37 AM




It’s no secret that the slightest disruption in plant systems can cause challenges ranging from

scheduling and delivery problems to lost profits and unwanted downtime. Increasingly, plant mangers are avoid-ing emergencies by using a variety of technologies and methods that not only solve problems, but help to iden-tify them before they occur. This is especially true with inspection of the pipelines that supply the life’s blood for many manufacturing, processing and power facilities.

In recent years, the need for pipe-line inspection has spawned many innovations, allowing maintenance personnel to capture crisp video imag-

ery from pipe of any condition, size, material and layout.

Among these innovations are push cameras and inspection crawlers, as well as zoom survey tools and side-wall scanning technologies. Each technology offers a combination of benefits that’s sure to address unique facility needs, as well as budgetary

and manpower constraints. The trick is understanding each technology and making an informed investment deci-sion based on in-depth field tests and on-site demonstrations.

The traveling cameraOver the years, delivery mechanisms have emerged that carry cameras deeper into pipelines, while capturing increasingly better images. At the low-er end of the market are push cameras, which televise pipelines using a self-leveling camera head and shadowless

LED illumination, both mounted to the end of a semi-rigid push pole.

Push cameras (Figure 1) can tele-vise as much as 200 ft. of pipe, and are optimized (and often are the only suit-able alternative) for lines smaller than 4 in. In recent years, push cameras have evolved to incorporate text writ-ers, which allow an operator to make onscreen annotations, as well as digi-tal storage media such as DVD writers and flash card bays. Higher-end push cameras offer the option of panning and tilting the camera, a feature that proves useful when a pipe dead-ends into a tank, vessel or mainline.

On the more sophisticated end is the video inspection crawler, a re-motely-operated vehicle designed to carry a robotically articulated camera hundreds — even thousands — of feet into pipelines to identify corrosion,

Seeing from afar

Figure 1. Push cameras can maneuver to overcome common pipeline obstacles.

Customized eyes

Figure 2. Crawlers with interchangeable parts adapt to perform in a broad range of pipe sizes, materials and conditions.

Maintaining your pipeline infrastructure with video inspection By Richard Lindner

Real-time convenience

Figure 3. Scan segments to be unfolded and stitched together as they’re captured. The operator can view the scan as it is generated, and immediately transmit it to an analysis team.


PS0712_28_31_piping.indd 28 12/5/07 4:45:43 PM

deposits, foreign matter, cracks, de-formations, offsets and erosion.

However, even with the most ad-vanced crawlers, you need to deter-mine the right tool for the job. For instance, the crawler size must be consistent with the size of the pipeline and the flow rate in the line. Specific applications require specialized crawl-ers. Fortunately, most inspection work involves line sizes between 8 in. and 24 in., and most crawlers target these applications.

But, questions still arise as to size when choosing the appropriate crawl-er. As a result, many plant engineers have chosen more compact designs that have the flexibility to tackle a larger range of applications. Many crawlers are fully modular (Figure 2), and can be easily reconfigured to various line sizes via interchangeable wheels, lamps, cameras and camera elevators. Another benefit a compact crawler provides — especially those with a short wheelbase and six-wheel drive — is an ability to maneuver around protruding pipe taps, over thick patches of sediment, up offsets and in tight spaces.

Furthermore, while bulk is often associated with sturdiness, size and weight can work against a crawler. In contrast to their larger counter-parts, compact crawlers use less ten-

sion to pull their lightweight cables, and steerable crawlers require no pe-riodic yanking to get them back into alignment. Reducing such sources of cable strain reduces the frequency of cable maintenance, the most common service procedure. Moreover, when

service needs arise, smaller crawler systems are less expensive to ship, maintain and repair.

Pipeline zoomingA pipeline inspection technique called zooming delivers quick, comprehen-

Flexible viewing

Figure 4. Software allows quick scan navigation, analysis and annotation.

ASSET MANAGEMENT Piping


PS0712_28_31_piping.indd 29 12/6/07 10:53:09 AM

sive information about pipe conditions using inexpensive equipment and few personnel. Zooming’s goal is a rapid classification of infrastructure as either satisfactory or in need of maintenance, repair/replacement, or additional CCTV inspection. These classifications allow you to confi-dently prioritize maintenance activities, committing main-tenance resources — inspection crawlers, cleaning trucks, cutters/rodders, GPS surveyors, and grouting and relining crews — exactly where they’re needed most.

Inspection crawlers can’t be matched for their detailed, 360° pipe inspection, but they move slowly, require substan-tial investment and demand considerable manpower and overhead. By contrast, zooming allows a single operator to make a rapid visual pipe assessment using an inexpensive, ultra-portable zoom inspection camera.

Zooming’s simplicity is its power. A typical zoom inspec-tion system consists of a camera, lamps, a positioning pole and a video display. Grasping the pole, an operator orients the camera to look down a section of pipe. Starting with a wide-angle view, the operator slowly increases zoom so the camera’s view advances down the pipe. In this manner, an operator inspects the entire length of the pipe for anomalies, and then classifies its condition accordingly. Zoom inspec-tion cameras also are ideal for inspecting tanks and vessels that provide limited access, helping avoid the hazards of confined space entry.

Another benefit accrues to cleaning crews, which often work more efficiently with zoom inspection cameras. With a quick glance down a line before cleaning, and then again af-terward, an operator can judge the effectiveness of cleaning, or even monitor the efficacy of a specific cutter or nozzle, in real time.

Manhole inspection is an integral part of infrastructure assessment, and some zoom cameras can be adapted for wide-angle viewing. A wide field of view allows a camera to see larger regions of a manhole wall or other up-close target. It also allows an operator to capture the entire circumfer-ence of a manhole wall from a downward-looking vantage point. Commonly, use of a wide-angle lens for pipeline zooming requires a lamp diffuser to produce more uniform illumination.



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Figure 5. The high-resolution digital scan captures the entirety of a pipe wall interior.

PS0712_28_31_piping.indd 30 12/5/07 4:46:07 PM


Sidewall scanningDigital visual sidewall scanning (DVSS) relies on the proven inspection crawler platform to gather visual data from within a pipe (Figure 3). Howev-er, unlike traditional video inspection, DVSS uses digital image processing to deliver information about pipeline condition in a format that’s easy to an-alyze. DVSS uses signal processing to convert video frames into a flat digital scan. This scan resembles a long mural or scroll, and it bears an image whose length corresponds to the length of the pipe, and whose height represents the pipe’s inside circumference. These scans capture a level of detail greater than conventional video, while pre-senting it in a format that’s easier to review and analyze.

Rather than sitting through hours of inspection video, an analyst can re-view an entire length of pipe at a time, quickly pinpointing problem areas and

making notations and measurements directly on the scan itself. Special cli-ent software further aids this review. It provides a thumbnail version of the entire scan (resembling a film strip) allowing quick navigation to specific regions of the scan (Figure 4 and Fig-ure 5). Drawing and annotation tools also allow analysts to mark up the scan, while identifying pipe features and highlighting regions of concern.

The empirical approachUltimately, there are many innovative alternatives for improving a facility’s pipe inspection capabilities. Fortu-nately, the decision doesn’t have to be entirely academic. Explore the options firsthand by requesting field demon-strations on your most challenging pipelines.

This will allow you to throw all the curve balls you want — partial collapses, protruding taps, curved

inverts, offsets, debris, roots, grease, flow — and let the best technologies for the job reveal themselves. In this way, the true winner in the end will be the facility itself.

Richard Lindner is president of Envirosight, LLC, Randolph, N.J. Contact him through www.envirosight.com.


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WEB HUNTER


The 11 months of diligent, intense Web research that produces this column often uncovers quite a few totally irrelevant Web sites. These online resources

are in keeping with the basic philosophy we’ve followed for more than 10 years – zero-cost, noncommercial, registra-tion-free Web sites only. I hope you find something useful in this exploration of the off-the-beaten-path “sights” that don’t necessarily have a rational relationship to the business life of the plant professional.

The visual treatsMaybe you’ve heard about the phenomenon sometimes called Web 2.0, or social networking. These Web sites feature content that is provided by the users, not those who own or host the site. A typical exam-ple is YouTube, which offers users the chance to upload their homebrew videos for the world to see. Most of them have video and audio quality that really isn’t ready for prime time. But, I di-gress. Even if you have no interest in worldwide fame, you might need to use video for train-ing purposes. If so, remember a reference video called “How to Make a Video” that can help make your cine-matographic exploits more professional. Aim your eyeballs at www.askthebuilder.com/How_to_Make_a_Video.shtml for the full story.

Then again, you might prefer still photography. Inexpen-sive digital photo media offer many advantages. The cost is near zero, so rookies can waste unlimited exposures in search of that one good keeper image. Suppose you’re at-tending some one-time event and think you got that great shot, only to discover that it’s a little blurry, everyone has redeye, the background is bad or some irrelevant bystand-er got into the frame. The software that came with your camera allows you to edit and manipulate the images, but I’ll bet the online photo editing capability you’ll find at www.picnik.com is better. After you upload an image, use the “Edit” tab at the top to rotate, crop and otherwise make basic tweaks. The real power, however, is found under the “Create” tab. Apply any of 24 effects, add text and shapes, whiten teeth - supercharge the image. Warning: the soft-ware’s response to your commands will appear to be sluggish

because a computer somewhere is sequentially processing individual pixels from your megapixel camera.

Speaking of megapixel cameras, most of them have a telephoto feature. Even though the image clarity remains outstanding when you zoom in, you lose overall perspec-tive. You might be able to frame a distant window in your viewfinder, but it’s out of context if you can’t see the rest of that building. How would you like the best of both worlds – a wide-angle photo that allows you to zoom in anywhere to see incredible detail? That’s what you can find at www.gigapan.org. Start with a high-quality digital camera. Set the lens to max zoom. Mount the unit on an ultra-steady

tripod. Shoot thousands of overlapping im-ages. Alternatively, you can use a robotic mount that automates the entire process. Then, use software to stitch those images into a single large-scale panorama image that has, perhaps, billions of pixels. Check the examples on the site. You can find sourc-es for free software by searching the Web for “stitching software.” Include the parentheses in the search box entry. The overall effect is

similar to the map feature in Google, where you start with a map of the entire United States and zoom down to the rooftops of individual houses.

Speaking of mapsYou can’t get there from here unless you have a map. So, take advantage of the Maptech Charts Application at www.sailmag.com/charts. It offers online access to nation-wide set of USGS topographic maps, NOAA nautical charts and aeronautical charts. The site doesn’t appear to have many of the navigational photos it promises. Select a location, pick the type of map you want and zoom in for whatever level of detail you need. In the lower right you’ll see the latitude and longitude of the cursor position in any of several formats.

Pick up a quick $25 millionAll you need to do is come up with a commercially viable way to produce a worldwide net removal of manmade atmospheric greenhouse gases each year for at least 10 years without pro-ducing any negative unintended consequences. The contest

Potpourri XIt’s time again for the annual collection of cyberspatial oddities

Now, we’ve dispensed with

screws and nails. We simply glue things together.

PS0712_33_35_WebHunter.indd 33 12/4/07 2:38:51 PM

was launched by Sir Richard Branson (of Virgin Airline fame) and Al Gore. � e rules and entry forms for the Vir-gin Earth Challenge are available at

www.virginearth.com. If you’re go-ing to get in the game, you’d best do it quickly because the deadline for sub-mitting your entry is February 8, 2010.

Forming long-term attachmentsIn the bad old days, when a maintenance guy needed to connect item A to item B, it was likely that some mechanical fastener was involved. Fast forward to better living through chemistry. Now, we’ve dispensed with screws and nails. We simply glue things together. But, with so many materials and surface textures, with so many tubes, bottles and cans of chemical goo available, se-lecting an appropriate adhesive is more diffi cult than it used to be. As you’d ex-pect, the Web comes to the rescue with www.thistothat.com, a relatively un-pretentious site dedicated to the propo-sition that one can glue anything to anything else. Use the two drop-down menus to specify the type of material to be bonded, click “Let’s Glue!” and follow the advice it reveals. Before you leave the site, check out the material listed under “Trivia” and under “News” for a quick, interesting read.

Pushing backwardBruce Simpson, a resident of New Zealand, has a hobby that should be of interest to anyone with a technical bent and access to some tools. Work-ing with a vertical mill, lathe, drill press, MIG welder, gas welder and air compressor, Simpson builds jet en-gines that he uses to power go-karts. His Web site has photos that lend cre-dence to his claims of possessing a lot of knowledge about gas turbines, tur-boshaft engines, pulsejets and valveless pulsejets. � e latter class of hardware represents the simplest engine you can imagine – it has no moving parts. It’s basically a large U-tube device into which he dumps relatively large quan-tities of liquid propane fuel. Simpson gets something on the order of 100 lbs. of thrust out of his models, which is suffi cient to push a go-kart along at a pretty good clip, and he’s posted vid-eos to prove it. Check it out at http://aardvark.co.nz/pjet/valveless.htm and

WEB HUNTER

D .PLANTSERVICES.34


commandeer the maintenance shop to build one in your spare time.

No chair and whipIt’s said that music can soothe the sav-age beast, even a beast old enough to re-member music from half a century ago. The next Web resource is aimed at that cohort, who will find the Playa Cofi Jukebox at www.tropicalglen.com. This is a free, online music-streaming ser-vice developed by some retirees living in Puerto Rico. The bulk of the mate-rial consists of hits that were popular in the years 1950 to 1984. Although it has content for just about any genre, the de-fault is popular music. The tunes play in random order continuously throughout the day. Instead of dropping a quarter in the jukebox, simply click on the icon corresponding to a year. This offers you 10 song titles on which you can click to enter the random stream that lasts three to five hours. When you start hearing too many repeats, go back and select a different year. Alternatively, you can pick your genre and go through a simi-lar exercise. The site’s licensing agree-ment prohibits downloads to portable digital devices and users don’t get to determine the playlist. These are minor restrictions that won’t affect your abil-ity to achieve a musically-induced inner calm during the work day.

Poetic licenseMy favorite poet is Les Barker. Many of his topics are a bit on the absurd side and his timing and delivery are that of a standup comedian. His wordplay is delightful and he plays the English language to its limit. Merely telling you about the poems wouldn’t do them justice. You really should hear them yourself to get the full effect. Fortu-nately, that’s possible at http://cdbaby.com/cd/lbarker6. Tune in and you’ll be able to hear some of his shorter poems and perhaps 90 seconds or so of some of his longer ones. Scroll down, the poem

titles are on the left of the page. If you’re pressed for time, take a shortcut and listen to “Go, Stay and Fetch” and “I don’t like my boomerang” to get the es-

sence of what Barker does with words.

E-mail Executive Editor Russ Kratowicz, P.E., CMRP, at [email protected].

WEB HUNTER



Through luck and persistence, Chris Mazguze was landed a clerical position at Acme’s corporate head-quarters. It was about time he found a job that was a

cut above flipping burgers and stocking shelves.One week after he was hired, Chris informed Flo Snurrey,

his supervisor, about his allergic reaction to perfumes and the fragrances in many common household products. The allergic symptoms he experienced included clogged sinuses, watery eyes, a sore throat and, occasionally, migraine-like headaches. The symptoms might be temporary or they might last two or three days. A particularly severe exposure would leave him lethargic, groggy and unable to con-centrate on his work. He asked Flo to arrange for Acme to accommodate his condition by prohibiting employees from wearing perfume.

Flo, a lady’s lady herself, said she can’t do anything of the sort because Acme has no right dictating employee hygiene. Besides, the idea that she herself would no longer wear per-fume was unthinkable. Secretly, she harbored second thoughts about her new employee.

So, on his own, Chris told anyone with whom he came into perceptible olfactory contact that he had this extreme allergy and described his potentially severe re-action to the scent the person is wearing. Several coworkers

were sympathetic; some cut back on their morning splash of scent, others completely stopped. But most of Acme couldn’t care less and continued with their routine a.m. ablutions.

Chris also regularly visited the HR depart-ment to lobby for a company-wide ban on wearing perfume and cologne while on the

premises. He likened his reaction to the one that justifies the ban on second-

hand smoke in the workplace. All that Chris managed to get was a change to a different type of air freshener in the men’s rooms.

Even though Chris’ symp-toms arose often during the next two years, he didn’t miss many days of work. He just

grouchily trudged on, toughing it out, feeling as miserable as he looked. But, coworkers felt he spent a lot of time on his anti-aroma crusade. This wasn’t lost on Flo, who mentioned it at the last three performance reviews she gave Chris.

It was during an office upgrade and rearrangement that Flo thought she had an opportunity to accommodate Chris’ original request. She specified that his workspace be sur-rounded by empty workstations and file cabinets to help minimize the potential for continuing allergy attacks.

With the new seating arrangements, his symptoms eased a bit, continuing along at a lower intensity. Chris continued

to lobby the HR department and got several additional accommodations. Acme told Chris that he could wear a mask while in the office. HR also had private discussions with employ-ees who walked through the office leaving a cloud of aroma in their wake. HR even went as far as sending a company-wide e-mail asking employees to be circumspect in the amount of odor they bring into the workplace.

Now, with three full years at Acme, Chris was still struggling with his allergy and try-

ing to extract comprehensive changes. Topping his list was getting a ban on scents inside the building. But Acme’s HR department was weary of rehashing the same material with the same employee. Finally, HR asked Chris to submit a medical certification form, to be completed by his physician. The company wanted the benefit of a third-party opinion.

A week later, Chris submitted the form. The doctor re-ported that Chris was extremely sensitive to odors, but it wasn’t a serious health condition. He added that Chris was theoretically able to perform any work that Acme needed.

During the following year, Chris continued to file his monthly complaints about scents and perfumes. Each time he did, Acme asked for an updated medical certification form. Chris never submitted any.

Last October, Flo sent Chris a memo telling him that his performance wasn’t up to par. She put him on probation pending a performance review scheduled two weeks out. Flo cited certain behaviors and unresolved performance is-sues He failed to meet the provisions of the action plans to resolve these problems that were highlighted during previ-

IN THE TRENCHES

Making a big stinkAcme learns to deal with an allergic crusader

December 2007www.PLANTSERVICES.com

The ADA doesn’t require that a company redesign its

workplace for an employee.

36

The scenario presented here is based on a true story;only the names have been changed to protect the innocent.

PS0712_36_39_InTheTrenches.indd 36 12/4/07 1:53:41 PM


ous performance reviews.It was at this review that Chris submitted a follow-up

medical form. The doctor now told Acme that Chris has a serious health condition, which is a result of the allergy and that he can’t work when the symptoms arise. Acme felt jus-tified in terminating Chris and thought the matter closed.

But, Chris sued, claiming that Acme had discriminated against him by refusing to accommodate his disability.

How could this situation have been prevented? Can Acme dic-tate hygiene matters? How would the situation differ if a non-allergic Chris never bathed? Does an allergy require workplace accommodation? Is there a practical way to do it? Should pre-employment physicals be mandatory? If Acme wasn’t willing to accommodate Chris, shouldn’t they have terminated him within the first 90 days after they learned about the allergies?

An academician says:My favorite smell story is an office guy who went online to buy a special cologne that was guaranteed to attract women. However, those in his office found it putrid and nauseous,

and said it made them sick. Romeo was told to get rid of the stink or find himself another job. So, if someone’s aroma makes coworkers ill, either the person or the smell goes. However, even this could get complicated if the odor is caused by a health-related problem.

Chris’ problem is a different. A lot of things at Acme make him ill. So, the question is whether Acme should or can get rid of all smells, or can move Chris to an environ-ment devoid of odors, or gets rid of Chris.

Chris sued under the ADA, which states that companies must make “reasonable accommodations” for people with disabilities. Chris has argued that Acme didn’t do that. However, the complication is that the law seems to have avoided the question of whether a perfume allergy is a dis-ability. I’m not sure if Chris even has a valid complaint.

Acme has the right to ask workers to avoid wearing per-fume, if it wanted to push this. But I’m not sure doing so would help because Chris seems to be allergic to a variety of odors. Acme attempted “reasonable accommodation” by asking employees to avoid the use of perfume, allowing

IN THE TRENCHES

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ous performance reviews.It was at this review that Chris submitted a follow-up

medical form. The doctor now told Acme that Chris has a serious health condition, which is a result of the allergy and that he can’t work when the symptoms arise. Acme felt jus-tified in terminating Chris and thought the matter closed.

But, Chris sued, claiming that Acme had discriminated against him by refusing to accommodate his disability.

How could this situation have been prevented? Can Acme dic-tate hygiene matters? How would the situation differ if a non-allergic Chris never bathed? Does an allergy require workplace accommodation? Is there a practical way to do it? Should pre-employment physicals be mandatory? If Acme wasn’t willing to accommodate Chris, shouldn’t they have terminated him within the first 90 days after they learned about the allergies?

An academician says:My favorite smell story is an office guy who went online to buy a special cologne that was guaranteed to attract women. However, those in his office found it putrid and nauseous,

and said it made them sick. Romeo was told to get rid of the stink or find himself another job. So, if someone’s aroma makes coworkers ill, either the person or the smell goes. However, even this could get complicated if the odor is caused by a health-related problem.

Chris’ problem is a different. A lot of things at Acme make him ill. So, the question is whether Acme should or can get rid of all smells, or can move Chris to an environ-ment devoid of odors, or gets rid of Chris.

Chris sued under the ADA, which states that companies must make “reasonable accommodations” for people with disabilities. Chris has argued that Acme didn’t do that. However, the complication is that the law seems to have avoided the question of whether a perfume allergy is a dis-ability. I’m not sure if Chris even has a valid complaint.

Acme has the right to ask workers to avoid wearing per-fume, if it wanted to push this. But I’m not sure doing so would help because Chris seems to be allergic to a variety of odors. Acme attempted “reasonable accommodation” by asking employees to avoid the use of perfume, allowing

IN THE TRENCHES

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Falk Complete Solution - 3.27 x 4.89.qxp 7/25/2007 11:58 AM Page 1

PS0712_36_39_InTheTrenches.indd 37 12/6/07 9:20:08 AM

Chris to wear a mask, and changing the air freshener in the men’s room. The ADA doesn’t require that Acme redesign its workplace, but rather make a reasonable attempt to ac-commodate Chris. My guess is that Acme complied with the “reasonable accommodation” clause and is in the clear. Moreover, Acme dismissed Chris because of poor perfor-mance, not allergy issues (although he could claim they were related), so this might not be an ADA case at all.

Would a pre-employment physical have helped? Maybe, but it’s rare that we ask office workers to undergo such ex-aminations, although this is becoming more common given the escalating cost of medical benefits. At the very least, it’s reasonable to require that the employee complete a health questionnaire, which would include questions about aller-gies (and additionally have the employee certify to the accu-racy of that information). Any problems that show up on the questionnaire should be further explored before hiring.

Professor Homer H. Johnson, Ph.D.Loyola University Chicago(312) [email protected]

An attorney says:Whether a court would determine that Chris’ allergic reac-tion to scents was a disability protected by the ADA is open to debate. If a court made that determination, Acme would have to make reasonable accommodation unless doing so posed an undue hardship. It’s difficult to envision that a ban on wearing perfume and scented lotions would cause an un-due hardship. Alternatively, Acme could have allowed Chris to take leave when he was symptomatic. Under the Family and Medical Leave Act, he could have taken as much as 12 weeks of leave a year intermittently, and Acme could have provided additional leave beyond that. Terminating him for requesting accommodation for a condition protected under the ADA, however, would leave Acme in legal hot water.

But apart from the legal issue, the allergic employee issue is one easily resolved. Acme got part of the solution right. An employer can relocate the employee’s work area away from other employees, and nearby employees can be prohib-ited from wearing scent. Allowing Chris to wear a mask also was a good idea. Did Acme ever think of adding an air filter to his work area? Or allowing him to use sick days or paid days off on days he was especially symptomatic?

Of course, an employer can dictate an employee’s hy-giene. Even Acme has had trouble in the past with em-ployees who sport an offensive odor from poor hygiene. Just as an employer can send an aromatic waitress home until she cleans up her act, Acme could discipline and even discharge employees who violated the perfume ban,

IN THE TRENCHES


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0

1890_07ALE330AS_2_PS.indd 1 5/15/07 9:25:55 AM


IN THE TRENCHES


assuming the company adhered to its normal progressive disciplinary steps and warned the employees first. These employees, after all, are employees at will.

Julie Badel, partnerEpstein Becker & Green, P.C.(312) [email protected]

A corporate consultant says:It seems unrealistic, and unreasonable, to expect every per-son in any group to accommodate one member. Even ADA’s requirements that structural changes accommodate the physically disabled, and that work processes be modified to accommodate certain mental and physical challenges, don’t necessitate acts of accommodation by each and every em-ployee. Chris is seeking to dictate that “the masses” change their to ease a condition he knew he had when he took the job. It’s his responsibility to find work that minimizes his discomfort, rather than the responsibility employees to cus-tomize the workplace to Chris.

Chris is allergic to almost every scent. It’s unlikely he would be comfortable in anywhere. However, the need for clerical work is omnipresent, and Chris could find a job where scents are less common, such as allergy clinics, medi-cal/laboratory facilities, food processing or high-tech clean-room facilities. He doesn’t have an ordinary condition, and shouldn’t have sought work in an ordinary environment.

It’s outrageous to suggest that Acme refused to ac-commodate him. Indeed, they took many initiatives to make him comfortable, including an all-employee e-mail asking for courtesy regarding the use of scent, and reconfiguring workspace to insulate him. These actions surpassed what the original medical form suggested was necessary. Many individuals altered their routine to suit him. All this - for an employee whose intellectual capi-tal isn’t essential to the competitive differentiation, and whose skills are replaceable. I’d have sought legal ways to terminate Chris during his f irst 90 days. Failing this, I’d get a cost/benefit analysis of litigating/settling ver-sus implementing a telecommuting policy to allow Chris and others to work from home.

Clearly, Chris’ discomfort is perpetual, and there’s no degree of on-site accommodation by Acme that would eliminate his discomfort. This fact isn’t Acme’s fault nor is it Chris’ fault. But the time spent attempting to tailor the work environment to Chris doesn’t make good business sense.

Francie DaltonDalton Alliances Inc.(410) [email protected]


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To many organizations, maintenance is a word that provides little value when, in fact, it provides great value if developed and managed properly. I’ve

worked in more than 600 plants and observed that a com-pany can be its own worst enemy. It faces equipment prob-lems every day because people don’t understand the basics of maintenance and reliability.

What’s most misunderstood about maintenance is that its true objective is to maintain the assets so they meet reli-ability needs at an optimal cost. Many people don’t seem to understand the word reliability, either. Webster’s dictionary says it’s the quality or state of being reliable, the extent to which an experiment, test or measuring procedure yields the same results on repeated trials.

In other words, reliability is what your as-sets must have to meet customers’ needs with repeatable results. If you’re in a production environment, you want the equipment to per-form to the standard required to meet produc-tion and quality goals. Maintenance sustains reliability. In any environment, assets must provide the reliability their users require and must be maintained (thus the term “mainte-nance” was born) so that reliability doesn’t degrade to the point that an asset can’t meet its intended function.

Begin with an education in maintenance and reliability for every stakeholder. This isn’t optional. I’ve found throughout the years that the more someone says they know, the more you discover they don’t know.

Few companies understand what it takes to achieve the threshold of optimal reliability at optimal cost. It’s a jour-ney, not a short sprint. Changing a plant culture from re-active to proactive can require more time than you think. Moving from a reactive state requires measuring the mean time between failures (MTBF) of your critical assets. That allows you to focus on what’s destroying reliability, not the fire of the day. This is the first step in the journey to pro-active maintenance and optimized reliability. (Contact me about the MTBF Users Guide if you need help.)

Once you’ve optimized your mean time between failures, you can retire the MTBF metric and use “number of poten-

tial failures” as the operative metric of choice. Companies with high reliability at optimal cost focus on the number of potential failures because they’re focusing proactively, not reactively. By measuring MTBF and making decisions based on this data, you’ll have some exciting quick wins.

Even though you get some quick wins, always stay fo-cused on the main objective – optimal reliability at optimal cost. It might be wise to hire a professional who can pro-vide customized maintenance and reliability training that meets your needs. Check references and don’t hire the least expensive or your local college. Hire the best you can af-

ford. If you’re losing money everyday because of reliability issues, then this is money well spent. Ensure the instructor visits your op-eration a day early to understand your culture and problems. Investigate the training agenda and look for topics such as the PF curve or PF interval, leading and lagging indicators, quick wins, best practices and the like. Remember, you get what you pay for. If you need some ideas send me an e-mail.

Everyone in your organization must have the same vision and understanding of main-tenance and reliability. Two tables are posted

at www.PlantServices.com/plant_culture that outline the education requirements. Table 1 shows the typical number of hours required and what must be taught if the position is to support and manage maintenance properly. Ensure what’s being taught meets the needs of the position. Those needs are listed in Table 2.

The class content should be matched to the person’s posi-tion. For example, training an operator in function and func-tional failure requires only a brief overview of about eight-minute duration, whereas a maintenance manager would need to learn more about the topic during a 30-minute class.

Following the training prescribed will clarify the vision for the future and the correct path forward. It’s time to stop the losses and begin making money. The journey isn’t easy, but it’s navigable. Focus on the basics and the reliability will follow. Let me know if you need a push to get rolling.

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