In this economy, cutting back is common. But have you thought about cutting back on your operation’s energy bill? Cutting back on electricity consumption by boosting efficiency can lead to dramatic savings, reduced exposure to rising energy prices and improved process efficiency and control. Even better, there’s a large (and growing) number of energy-efficiency programs around the United States and Canada with financial and technical resources to help you identify and implement opportunities throughout your facility. In fact, the efficiency program industry [1] directed over $9 billion in 2011, according to the Annual Industry Report, published by the Consortium for Energy Efficiency (CEE). In the U.S., 39% of the total was dedicated to the commercial and industrial sectors—billions of dollars, some of which are ready to support qualifying energy-efficiency improvements in facilities like yours.

Where to start 
According to the U.S. Department of Energy (USDOE), motor-driven equipment consumes 64% of the total electricity used in the U.S. industrial sector.[2] As the largest single source running up an industrial plant’s electricity bill, zeroing in on your motors and motor-driven system such as pumps, fans and air compressors is a great first step toward cutting costs and increasing efficiency in your facility.  

Where get help
In addition to publishing the Annual Industry Report, CEE maintains a searchable spreadsheet of 94 efficiency programs that provide incentives for qualifying projects that improve motor system efficiency. This resource, Motors & Motor Systems Program Summary, includes the following types of program offerings:

Motors… Programs that provide incentives, typically rebates, to vendors, distributors, or directly to customers for motors that meet energy-efficiency specifications. 

Motor Management… Programs that work with customers and vendors to identify motors for replacement with energy-efficient models either upon failure or through early retirement programs. Other programs support best motor repair practices that maintain motor nameplate efficiency.

Motor Systems… Programs that provide incentives for efficiency improvements in specific motor-driven systems such as pumps, fans and air compressors, and for installing adjustable speed drives. 

To learn more about how you can cut costs and save energy with your motor-driven systems, visit the Motor Decisions Matter^SM (MDM) Campaign, www.motorsmatter.org, which provides free tools and resources that can help get your operations plugged into savings. These resources can also lead to partnerships with your local sales and service center, vendor, electric utility or other energy-efficiency representatives that are well positioned to offer added support. Plug into these programs and start saving today. MT

1. The efficiency program industry is comprised of electric and gas utilities, state energy agencies and other non-utility program administrators, municipal power providers and co-ops. 

2. USDOE, 2008. (http://www1.eere.energy.gov/industry/bestpractices/pdfs/motor.pdf)

As the industrial arena grows more sophisticated, it seems as though operations are confronting fewer and fewer broken machine shafts. When shafts DO break, however, there are almost always as many theories regarding the suspected culprits as there are people involved. ]]> Mon, 16 Jul 2012 18:15:47 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2127:electrical-safety-sense-understanding-your-options&catid=317:july2012&directory=90 Electrical safety boils down to a single objective: Reduce electrical risks. Consider, for example, the fact that a 120VAC outlet is riskier than 13.8KV power distribution equipment. The reason is because many more people are exposed to 120VAC. The Risk Control Hierarchy instructs us on the most effective ways to reduce the probability and severity of such risks.

• Elimination—Remove all voltage exposure
• Substitution—Replace high-risk tasks with lower-risk tasks
• Engineering Controls—Find ways to control electrical energy
• Awareness—Reveal all sources of electrical energy
• Administrative Controls—Ensure safe work practice procedures (NFPA 70E, CSA Z462)
• Personal Protection—Reduce risks of working on live voltage

Keeping people away from live voltage eliminates risk altogether and is the preferred option. Communication ports, mounted on the outside of control panels, allow workers thru-door access to necessary aspects of the panel without taking the sometimes-risky action of opening the panel door. Having the ability to customize communication ports is important because it means every panel can be dressed with this time-saving safety device and no one is left exposed.

Another way to keep people away from live voltages includes permanent electrical safety devices (PESDs). Keeping panel doors closed is vital to electrical safety. With PESDs, workers are able to perform lock-out/tag-out procedures from the safe side of electrical panels, and they do it in just seconds. This means not only are workers safer, but they are more productive with PESDs.   

Personal protective equipment (PPE) has its place and value, but, ironically, according to the Risk Control Hierarchy, it is the least effective at actually protecting workers. In fact, PPE’s sole purpose is keeping workers alive from the effects of an arc flash by minimizing, not eliminating, injuries. Furthermore, PPE does nothing to protect equipment or companies from the damaging aftermath of an arc flash. 

In the grand scheme of things, which option would you rather count on? MT

To learn more about specific recommendations and practices, email the author: philallen@grace-eng.com.

 

]]> Mon, 16 Jul 2012 18:11:32 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2126:green-gadget-save-time-a-money-troubleshooting-your-fluorescent-lighting-systems&catid=317:july2012&directory=90 According to Milwaukee Tool, its recently introduced Milwaukee® Fluorescent Lighting Tester lets electricians and facility maintenance technicians troubleshoot an entire building full of lights in half the time they’ve typically devoted to the task. Until now, the usual approach has been to “replace and hope” (i.e., change out a lamp or ballast and hope that fixes the problem). The innovative Fluorescent Lighting Tester, part of Milwaukee’s expanding Test and Measurement line, appears to be a real game-changer. With its 2-1/2 ft., fully retractable antenna, users can easily reach all lighting fixtures and, thus, change only those components that actual testing indicates are in need of replacement. Other features include a removable antenna adaptor to increase “flicker” response, audible and visual indicators for easy readings, a built-in LED work light to illuminate dark work spaces and a rugged, over-mold grip for increased durability. 

Milwaukee Tool Corp.
Brookfield, WI

For more info, enter 03 at www.MT-freeinfo.com

 

]]> Mon, 16 Jul 2012 18:09:15 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2125:on-the-road-to-sustainability-the-souths-sustainable-snack-maker&catid=317:july2012&directory=90

Frito-Lay’s award-winning facility in Fayetteville, TN, is turning out America’s favorite snacks with low environmental impact. ]]> Mon, 16 Jul 2012 17:56:01 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2124:automation-insider-university-research-can-pay-dividends-to-manufacturers-&catid=317:july2012&directory=90 The Center for Intelligent Maintenance Systems, a U.S. National Science Foundation consortium including the University of Cincinnati, the University of Michigan and the Missouri University of Science and Technology, held its latest meeting at the Chrysler Education Center in suburban Detroit May 16-18, 2012.]]> Mon, 16 Jul 2012 17:51:32 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2123:emphasis-on-innovation-rolling-bearings-in-mining-a-mineral-processing&catid=317:july2012&directory=90

Suppliers have made some great strikes in the design, heat treatment, sealing and lubrication of rolling bearings.]]> Mon, 16 Jul 2012 17:31:26 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2122:technology-showcase-safety-matters&catid=317:july2012&directory=90

Calibration & Testing Of Pressure-Switches ]]> Mon, 16 Jul 2012 17:03:53 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2121:permanent-magnet-couplings-a-adjustable-speed-drives&catid=317:july2012&directory=90

Perhaps it’s time to expand your motor-control horizons. ]]> Mon, 16 Jul 2012 16:58:31 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2120:capacity-assurance-marketplace&catid=317:july2012&directory=90

Permanent Magnet Motors

The PMSM (permanent magnet synchronous motors) series from Bauer Gear Motor is an environmentally friendly line with rotors that integrate embedded permanent magnets made from rare-earth material. According to the company, unlike induction motors with squirrel-cage rotors, this design reduces heat losses from the rotor by 100%, total losses by approximately 25% and increases total efficiency by 10% or more. Units in this PMSM series already fulfill the requirements of the soon-to-be-implemented IE4 (Super Premium Efficiency) classification.

Bauer Gear Motor
A member of the Altra Industrial Motion Group
Somerset, NJ

For more info, enter 31 at www.MT-freeinfo.com

Portable 1000V Megohmmeter 

AEMC’s Model 6527 Megohmmeter is a portable, multi-range unit capable of measuring insulation resistance from 1kW to 4000MW. It has three user-selectable test voltages of 250V, 500V and 1000V. Model 6527 is also a multimeter that features an AC/DC voltmeter function capable of measuring up to 600VAC and 1000VDC, a continuity test function with an audible beeper for resistances under 35W and an overload protection of 600Vrms. 

AEMC Instruments
Foxborough, MA

For more info, enter 32 at www.MT-freeinfo.com

Software For Easier Asset Management

RealVision notes that its Real Preventative Maintenance (RPM) system is easy to integrate and affordable for large and small businesses alike.  This CMMS tool can track all of a company’s equipment costs, service parts, inventory and maintenance schedules. The system features a powerful purchasing function that simplifies inventory control and provides the ability to order outside maintenance services.  The work order system not only facilitates the collection of scheduled maintenance information, labor and materials, it also handles all unplanned and emergency service. 

RealVision, Inc. 
Eagle, ID

For more info, enter 33 at www.MT-freeinfo.com

Geometric Measurement System For iPads

The ALiSENSOR™ LEVEL from Alignment Supplies allows users to obtain accurate geometric measurements using their iPad and other iOS devices. The system consists of a sensor unit and an iOS unit (not included). The sensor is a rugged data collector that contains MEMS gyros, accelerometers and a microprocessor. Data is provided via Bluetooth® to the iOS unit, which functions as a user-friendly environment to analyze the data. 

Alignment Supplies, Inc.
Maumee, OH

For more info, enter 34 at www.MT-freeinfo.com

Hand-Held Inspection Camera Diagnoses & Documents Problems

The new RIGID® micro CA-300 hand-held inspection camera offers an easy way to diagnose and document jobsite problems. The unit records still images and videos, and integrates audio with a built-in microphone and speaker to record insights and playback problems in hard-to-reach areas. The unit also features user-adjustable image rotation, digital zoom and an anodized aluminum camera head with four LEDs to provide improved lighting. 

RIDGID
An Emerson Business
Elyria, OH

For more info, enter 35 at www.MT-freeinfo.com

Remote Expert-Analysis Of Machinery & Processes

According Vibration Specialty Corp. (VSC), its new PROTECT Wireless tool cost-effectively merges predictive maintenance and energy monitoring with monitoring of every other process-related vital sign to provide a comprehensive picture of plant conditions in real time. Its  advanced hardware gives remote analysts a view of conditions through detailed phase analysis across couplings, motors and even separate machinery. VSC notes this is the type of data that has traditionally been available only via onsite analysts.

Vibration Specialy Corp. (VSC)
Philadelphia, PA

For more info, enter 36 at www.MT-freeinfo.com

Free App Converts Laser Shaft-Alignment Data

VibrAlign’s “Laser-Dials” app for iPhone and iPad converts rotating-shaft alignment data between dial indicator readings and laser shaft alignment system angles and offsets. The company notes that this app makes it easier to evaluate alignment results achieved through traditional analog methods that are often expressed in different terms than newer digital methods. It’s currently through the Apple App Store, with an Android version slated for future release.

VibrAlign Inc.
Richmond, VA

For more info, enter 37 at www.MT-freeinfo.com

Waste-Oil Recycling System

The Fuel Factory from Dieselcraft Fluid Engineering is a modular, drum-top centrifuge processing system intended for the recycling of waste motor oil, transmission fluid, hydraulic fluid and more. Driven by an industrial-duty gear pump that can run continuously for 24 hours, it cleans 216 gallons of waste oil per hour. The system is designed to fit inside a standard 55-gallon open-
top drum.

Dieselcraft Fluid Engineering
A division of The Magnum Group
Auburn, CA

For more info, enter 38 at www.MT-freeinfo.com

 

]]> Mon, 16 Jul 2012 16:46:16 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2119:are-most-maintenance-organizations-overstaffed&catid=317:july2012&directory=90 I’ll answer my question: Yes, I think most maintenance organizations are overstaffed—but not necessarily with their own personnel. Many of these organizations just seem to use more total maintenance hours than necessary. (Total maintenance hours include the organization’s internal hours, overtime hours and contractor hours.)]]> Mon, 16 Jul 2012 16:34:41 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=2133:times-arrow&catid=317:july2012&directory=90

This month's 25th Anniversary Article comes from our September 2004 issue.]]> Wed, 01 Sep 2004 15:59:28 +0100