Technology is making it easier than ever for operations to document and organize critical technical information.

This respected maker of test and measurement instruments is operating in accordance with the purpose of its own products to keep its Washington-state headquarters on the cutting edge of energy efficiency.

Symptom:  
“Dear Dr. Lube, the automated grease-lubrication systems on our remote, continuously operating pump stations suffered intermittent failures last fall and spring. They seemed to shut down on their own accord, only to start up by themselves after many hours, whereupon they operated perfectly until the next incident (which could be hours or days later). Any suggestions?”

Diagnosis: 
The key to unlocking this problem is the specific time of year the failures occur. In spring and fall months, depending on geographical location, temperatures can be erratic—swinging from very cold to very warm in a matter of hours.

Due to its viscous nature, the state of a lubricant will change as ambient temperatures change. When the temperature heats up, a lubricant “thins out” and flows freely. As the temperature drops, the lubricant “thickens up” and becomes more resistant to flow. 

Heating systems in buildings are typically turned on in the fall and off in the spring. When this is scheduled for specific calendar dates, a facility could still experience extremely cold temperatures in the early to mid-morning hours. Such conditions are enough to thicken a lubricant’s viscosity to the point that it stalls a lube pump (especially with pneumatically operated systems). As the building warms, the lubricant thins to the point that the pump seems to “magically” start working. The common use of NLGI #2 grease only compounds the situation, since most automated lubrication systems are rated for less-viscous NLGI #1 grease.

Prescription: 
Check with your lube supplier to ensure that the correct viscosity of grease has been specified for your lubrication-system type and ambient temperatures at the site during those times when they’ve experienced intermittent failure. A lighter grade may be necessary during the winter or transition months.

Review maintenance records to determine the date of the last reservoir fill and ensure that grease was in the reservoir when the system failed. Perform a physical system check to make sure the correct lubricant is currently in use.

If a grade changeout is impractical, wrap the reservoir with a thermostat-controlled blanket wrap heater (similar to a car battery wrap heater) or drum heater, plug it in and use during times of transition between seasons.MT

Looking for advice from Dr. Lube? For specific lube questions and/or details about ICML lubrication-certification training (including in-house sessions and an upcoming workshop at MARTS 2013), email: doctorlube@atpnetwork.com. Or, go ahead and contact Ken Bannister directly. Telephone: (519) 469-9173; email: kbannister@engtechindustries.com. 

As this personal perspective notes, looking for the real causes of problems is a more effective approach than simply pointing a finger at others.

If you haven’t yet visited it, the DOE Website, http://www.eere.energy.gov/topics/manufacturing.html, contains information on all of the above, including software for steam; process heating; combined heat and power; compressed air; motors; pumps; fans; HVAC systems for data centers; solar panels; and refrigeration. These tools are free to download and use, as is the site’s other information. Training classes in a variety of tools are also available through the site, with some provided, for fee, by third parties.

The addition of PdM capabilities
One of the top DOE software programs, MotorMaster Plus, in its last version, received funding in 2000 from Dreisilker Electric Motors, Inc., Pruftechnik and ALL-TEST Pro for modifications that added predictive maintenance (PdM) capabilities. This allowed end-users to add vibration, motor-circuit analysis and similar testing to a motor database and search motors by condition, thus permitting repair versus replace decisions to be made in advance of equipment failure.  This version of MotorMaster Plus works on Windows through XP. Another version of the software, MotorMaster International, which does not have the PdM tool capability, works on versions of Windows through Windows 7. In addition to these software programs, DOE offers a separate belt-efficiency calculator that can be used online or downloaded for computer use. Users can enter a series of motors and the calculator will compare the efficiency of standard V-belts to cogged V-belts.

Tools for mature motor-system management programs  
The combination of motor-system-related materials, software and training offerings available via the DOE Website certainly can be utilized as the basis for an effective motor-systems management program. Still, there are other items that should be added to a mature/maturing program, as the primary emphasis of the tools referenced in this month’s column is energy, followed by reliability, maintenance and lifecycle costs. We’ll cover a number of those other items in future articles.MT

Dr. Howard Penrose is VP of Engineering and Reliability Services for Dreisilker, Webmaster of the IEEE Dielectrics and Electrical Insulation Society, and Director of Outreach of the Society for Maintenance & Reliability Professionals (SMRP).

Your air compressors won’t last forever. At some point in your career, you could be involved in specifying a compressor for a new application or deciding to repair or replace an old one that has failed. Let’s assume you had not thought about the subject for years. You would need to quickly bone up on the various makes, models and types that are available—and prepare for the blizzard of information that’s sure to come your way when you ask for sales quotes. 

But, how do you choose the best air compressor? That’s simple: If energy costs and efficiency are important to your operations, data sheets from the Compressed Air and Gas Institute (CAGI), along with resources from the Compressed Air Challenge (CAC), can be a big help in your decision-making process.

Many times the purchasing decision for an air compressor and related equipment comes down to the cheapest first price, without consideration of the ongoing operating cost. Often the price difference between various equipment quotes may differ by only a few hundred dollars, however the actual total lifecycle costs can quickly negate any purchase savings.

Based on 10 cents per kWh for a five-day, two-shift operation of about 4200 hours per year, a  typical 100 hp compressor will consume about $37,000 in annual electricity costs. Over a 10-year period, these electrical costs can make up about 76% of the total lifecycle cost of the air compressor, with the purchase price representing only 12%. This means, for example, if you select a compressor that’s 5% more efficient than the lowest cost choice, your decision could result in an $18,500 savings in operating costs over 10 years.

Much has changed over the years in the compressed air industry. Most customers are demanding energy efficiency—which, in turn, has encouraged manufacturers to develop better compressed-air equipment.  Because newer units often use less energy, hanging on to your old compressor may not always be in your best interest. Until recently, though, comparing a manufacturer’s efficiency claims for new equipment was confusing due to differing test standards and reporting methods and lack of verification of the numbers.  Fortunately, members of CAGI have all agreed to test, report and make their equipment-performance numbers available in standardized data sheets.

As a service to end-users of compressed-air-system equipment, members of the Rotary Positive Compressor and the Air Drying & Filtration sections of CAGI have developed standardized formats for reporting performance. All members of these sections have agreed to use the reporting forms—known as CAGI Datasheets—and to post the sheets on their respective Websites. Note that this data is subject to random third-party testing to verify accuracy. (For details, go to www.cagi.org.) The point is that plant engineers can use the CAGI Datasheets to calculate and compare various quoted options via standardized data that can justify the higher purchase price of more efficient equipment. 

Additional information on this topic can be found in the Library section of the CAC Website (www.compressedairchallenge.org), specifically in “Fact Sheet 5 - Packaged Compressor Efficiency Ratings.” MT

Even the smallest of details can provide plants with a competitive edge. A case in point is your choice of hydraulic fluids.

Ratchet For Limited-Access 

The 120XP™ Ratchet from GearWrench features 120 positions for every full rotation, allowing it to turn fasteners with a swing arc of as little as three degrees. Its design makes it easier for technicians to reach fasteners in severely limited-access applications. The 120XP has a 60-tooth gear that alternately engages its Double-Stacked Pawl™ Technology to produce the small swing arc. The ratchet’s teardrop-shaped head has a low profile, which also improves access in
tight spaces.

The ratchet design provides all the benefits of a fine-tooth ratchet without sacrificing strength or durability. The product exceeds the ASME (American Society of Mechanical Engineers) strength requirements, and its long handle is ergonomically designed to provide comfort and a good grip for users. It has an easy-to-clean, full-polish chrome finish and comes in three drive sizes: 1/4”, 3/8” and 1/2”.  The 120XP ratchets are sold separately and come in select SAE/Metric standard/deep socket sets. The ratchet and socket sets come in GearWrench branded blow-molded cases with removable lids for easy storage and distinguishing yellow latches. 

GearWrench
An Apex Tool Group Brand
Sparks, MD

Adjustable Spud-End Wrench

Martin Tool & Forge’s new 16-inch spud-end wrench features an adjustable 1 ½” jaw capacity and a 12” alignment spud. The ground-end spud allows for quick, easy alignment of holes and fasteners. The tool also offers a large knurl with lead-in that provides better access while adjusting. The wrench is well-suited for work in the oil and gas industry, military, government, factory maintenance, utilities, construction and iron work. A black oxide finish provides corrosion resistance for an extended life. 

Martin Tool & Forge
A division of Martin Sprocket & Gear, Inc.
Arlington, TX

Total Tool Management Made Simple

The makers of WinTool say their product is the only centralized, online tool database capable of seamlessly interfacing with many of the software programs that a manufacturing site already uses, including CAM, presetters, tool crib management, scheduling and ERP, purchasing, etc. According to the company, this single database not only provides users with online access to an up-to-date record of tool inventory, it helps them eliminate errors and uncertainty by not ordering tools that they already have on hand.  

According to the makers, the program allows for faster programming, reducing the amount of time needed to set up tool lists; faster simulation, saving the time spent gathering information to create an exact tool solid; and faster presetting, reducing the number of problematic or lost tools that need to be preset again each day.

WinTool software is modular. The base module is WinTool Professional, which is required to run all other modules except WinTool Compact. Other modules add functionality as needed for different manufacturing situations. WinTool is a Windows program (Windows 7, Vista, or XP required). The database server can be SQL Server or SQL Server Express, Access 2003, Oracle 10g XE (optional) — the server is not included.

WinTool USA
Arlington, TX

Telescoping Inspection Mirror

The Read Rite™ telescoping inspection mirror from Industrial Magnetics allows users to see a true, non-inverted image of numbers, letters, symbols and pictures in difficult viewing locations. The mirror measures 3.5” x 2”, is constructed of non-breakable, stainless steel and is mounted to a telescoping hex rod with a double-ball hinge for 360 degrees of rotation and stability. The Read Rite weighs .5 lbs., measures 15.5” while collapsed, extends to 28.5” long and features a non-slip, solvent-resistant gripped handle. 

Industrial Magnetics, Inc.
Boyne City, MI

This month's Technology Showcase is brought to you by:

Circuit protection protects electrical service personnel, physical assets and production schedules against shorts, faults and dangerous arcing conditions. In addition to protecting equipment from power surges and sags that result in immediate equipment failure, circuit breakers, interrupters and other protective devices also protect equipment from partial failures and faults that shorten the lifetime of electrical equipment. 

For circuit-protection applications with voltages in excess of 1kV, electricians and maintenance personnel traditionally have used circuit breakers with either air-magnetic or oil-based interrupters. More recently, vacuum interrupters (VIs) have supplanted many of these interrupters because of their ability to interrupt power faster—improving equipment and personnel safety—for more cycles than older interrupters. This translates to longer lifetimes for circuit protection equipment and less cost to the user for replacement interrupters. 

Vacuum interrupter manufacturers use three electrical tests to validate the operation of their products before sending them into the marketplace: 1) contact-resistance; 2) high-potential; and 3) leak-rate. Of these three, only leak-rate testing provides data for computerized maintenance management systems (CMMS) and enterprise asset management (EAM) systems. 

Until recently, leak-rate tests could not be conducted in the field because they required large, expensive magnetrons and bulky magnetic coils. Other hurdles for such field testing include calibration-sensitive magnetrons, a lack of compact magnetic coils, standard graphs for measuring ionization current against vacuum pressure and trending and prediction tools and algorithms. 

Solving the problem
New portable magnetron-based test equipment (shown above) and condition-based maintenance (CBM) algorithms developed by Vacuum Interrupters, Inc., recently proved the capability of leak-rate system while field testing 60 GE Power Vac Circuit Breakers at the Lower Colorado River Authority (LCRA) Fayette Power Project facility, in Fayette County, TX.

During field-testing, the VI is inserted into a flexible magnetic field coil (FMFC) developed by Vacuum Interrupters. The FMFCs significantly simplify the process compared to traditional shop-testing procedures. To determine the condition of the VI, the  system measures the relationship between the ionization current and pressure inside the device using the magnetron, coils and a vacuum pump. To create a vacuum-vs-current curve, a VI is opened and a vacuum pump connected to it so the pressure can be gradually decreased, while the magnetron measures the current effects on the magnetic field for each different pressure point. The test automatically enters the data into a CBM diagnostic and predictive algorithm. The algorithm evaluates the results and categorizes the device’s remaining lifetime based on changes between current and historic device measurements, similar to lab tests used to analyze dielectric oils, insulation and other electrical components.  

Of the 60 breakers field tested at LCRA, 10 interrupters were found to need of immediate attention or replacement. Out of those 10, only two would have been identified by traditional contact-wear field tests. MT 

Vacuum Interrupters, Inc.
A Group CBS Company
Carrollton, TX

According to Meltric Corporation, its switch-rated plugs/receptacles have been successfully applied as safe, reliable and rugged connecting devices across most major industrial applications, especially those involving motors or welding machines. These products combine the functionality of a disconnect switch with the convenience of a plug and receptacle. An integral switching mechanism allows users to safely make and break connections under full load. They are UL-approved as a “motor circuit disconnect switch” and as a “branch circuit disconnect switch” (UL Subject 2682). When the plug is removed from the receptacle, a safety shutter prevents worker exposure to live parts—only the correct mating plug can open the receptacle’s safety shutter. This design shields users from potential arc flash at all times and maintains a NFPA 70E-defined hazard risk category = ‘0’ while making and breaking electrical connections. In comparison, most competitive pin-and-sleeve or twist-type plugs and receptacles are not safe to connect or disconnect under load and may present an arc flash hazard that requires an electrician to properly deenergize the equipment.

Ease of application

Meltric’s plugs are built with a convenience feature that makes it easy to comply with OSHA lockout-tagout requirements. Incorporating a 5/16” lockout hole in the plug shroud, these switch-rated plugs/receptacles are easily locked out by simply inserting a user-provided lock through the hole in the male plug. The lock on the disconnected male plug prevents insertion into the female receptacle and provides visual verification of equipment deenergization. An optional lockout provision can be provided on the receptacle to prevent plug insertion or to lock the plug in the connected position. In comparison, most competitive
pin-and-sleeve-type plugs require an additional third-party lockout shield or plug cap, which not only can be expensive, but are often lost, broken or simply unavailable when needed.

Meltric switch-rated plugs/receptacles are available in three models:

• DSN Series: ratings up to 60A, 20HP, 600V (most compact, lowest cost design, NEMA 4X) 
• DS Series: ratings up to 200A, 25 HP, 600V (offering the highest amperage ratings, NEMA 4X optional)
• DB Series: ratings up to 100A, 60HP, 600V (highest horsepower ratings, heavy-duty applications, IP67)

These switch-rated plugs/receptacles are built to order in Franklin, WI, and are typically shipped on the next working day. MT

Meltric Corp.
Franklin, WI

More About Meltric

Meltric Corporation has built a strong reputation serving the needs of industrial operations seeking to improve their electrical connection safety and maintenance productivity. The company’s complete line of industrial plugs and receptacles, including UL/CSA switch-rated plugs and receptacles, is available through electrical distributors.

Capacity Controller For 

The AK-PC 781 Multifunctional Pack Controller by Danfoss makes it easy to set up energy-efficient capacity control of refrigeration compressors and condensers with modular hardware and flexible software that extends as system requirements grow or change. The controller allows users to configure inputs and outputs for sensors, switches and relays with a modular controller, and can also provide oil management, heat recovery and CO2 gas pressure control. Controller programming is easily accomplished with a PC using AK-Service Tool software.

Danfoss LLC
Baltimore, MD

Reliable Tapered Roller Bearings 

Baldor Electric Company’s Dodge Type EXL tapered roller bearing provides both misalignment and expansion capability, while maintaining industry-standard Type E mounting dimensions. Its design incorporates a cartridge-style inner unit into a split ductile iron housing. The split-housing design allows the inner unit to swivel freely in the housing, allowing up to +/- 4 degrees of static misalignment. The totally sealed inner unit incorporates the Dodge XTS triple-lip seal for increased protection in harsh environments.

Baldor Electric Co.
Fort Smith, AR

Portable, Easy-To-Use Borescopes

The VJ-Advance borescopes from RF System Lab offer four-way articulation, an easy-to-use joystick control and a medical-grade camera that takes video and still images. The portable, battery-powered units weigh only 23 ounces and have the rugged construction required for industrial remote visual inspection or commercial RVI work. The borescopes also feature a flip-up 3.5” monitor, removeable MicroSD memory and a hard-shell carrying case.

RF System Lab
Gaylord, MI

Inline Machine Tool Fluid Filtration And More

According to Eriez, its fully automated mobile SumpDoc™ provides inline coolant filtration and replenishment for machine tools while they run. The first phase of its three-phase process vacuums chips and sludge from dirty sump coolant at a rate of 85 GPM per minute (50 microns). Fine solid particulate is then filtered to 3-5 microns and tramp oils are removed to less than 0.5% at flow rates of 90-120 GPH.  Once clean, the fluid is analyzed and the SumpDoc is set to deliver a lean, medium or rich coolant mix back to the sump. Depending on the regularity of cleaning, a 200-gal. sump typically can be processed in about two hours. Mounted on a battery-powered pallet jack, the unit comes with onboard hookups and extensions for compressed air, plant water and 120V, single-phase electric. 

Eriez Manufacturing Co.
Erie, PA

Catalog Full Of RoHS-Compliant Components 

A revamped, 640-page hardware catalog from All Metric Small Parts features over 11,000 100% RoHS (Restriction of Hazardous Substances)-compliant components. The catalog, identified as M110, features an expanded 141-page section of quality industrial leveling foot mounts. Of special interest is a series of clamping adjustable levers offered in a wide variety of colors to complement specific applications. The catalog also offers a useful technical data section. 

All Metric Small Parts
New Hyde Park, NY

Torque Limiters For High-Torque Applications

According to R+W Coupling Technology, use of its ST torque limiters can help minimize machine downtime due to crashes, and increase the availability and productivity of a plant’s machines. The limiters are designed for high-torque applications, using individual torque modules evenly spaced around the circumference of the coupling. The limiters are based on a spring loaded, ball-detent design. The line is backlash-free and torsionally rigid with a compact, simple design.

R+W Coupling Technology
Bensenville, IL

Updated Software For Testo Thermal Imagers

Testo Thermal Imaging has released its next-generation thermal imaging software, IRSoft 3.1 sp3, the third such upgrade made available by the company in the past year. The software is free to all users of Testo Thermal Imaging Products, and it is backwards compatible with all of the company’s imagers. New reporting features include a Word-compatible file format, the addition of 12 user-customizable data fields and customizable reporting templates. Other benefits include upgrades to radiometric video capture and advanced memory management.

Testo, Inc.
Sparta, NJ

Bearing Protection For Harsh Environments

SKF’s three-barrier solution for harsh operating environments is a cost-effective, environmentally friendly bundle of products that can extend bearing service life without compli-cated sealing arrangements. The solution protects the bearing and can help eliminate contamination during both assembly and in service. Included in the kit are a housing, sealed spherical roller bearing, adaptor sleeve, spacer ring (if required), stabilizing ring, two PosiTrac Plus seals and mounting instructions. 

SKF
Lansdale, PA