Cold winds have already begun blowing across Chicagoland—early and often, like they always do. About this time each year, my thoughts start wandering off to warmer places. While Texas and Alabama typically get my nod, I currently have Florida on my mind. You should, too.

SMRP: Make it Personal And Prepare For The Future

SMRP, the Society for Maintenance & Reliability Professionals (“by professionals for professionals”) has been celebrating its 20th Anniversary throughout 2012. Held in Orlando, FL, last month, this year’s annual conference wasn’t just a nod to two great decades, it was among the best of the best SMRP events ever.

Dollars & Cents Vs. Dollars & Sense

Championing maintenance-improvement projects in tough economic times isn’t easy. Many will recall the infamous 1990s downsizing era, when countless maintenance departments suffered deep cuts in their capital and operating budgets, which, in turn, lead to a crippling deferred maintenance approach. 

A non-destructive form of positive material identification can be a shortcut to uncovering the root cause of bad welds, parts failure and more. It also can be an effective way to verify on-spec conditions in your equipment and systems.

Savvy energy staffers know that monitoring and tracking the performance of their pumping systems can be a very profitable undertaking. Just how profitable, though, often hinges on which key performance indicators are followed over time. A noted expert suggests a combined approach. 

Audio-replay capabilities have enhanced this author's vibration-analysis toolkit and could be doing the same for yours.

Faster Machinery Alignment

Ludeca’s sensALIGN tool combines PRUEFTECHNIK’s new, patented intelligent sensor technology with the ROTALIGN ULTRA iS platform. The result is instantaneous data acquisition and real-time displays, with guaranteed 100% accuracy, under even the roughest field conditions. The sensALIGN intelligence automatically considers the effects of ambient vibration, acceleration of rotation, backlash, speed of rotation and other factors in determining the Quality Factor (QF) of alignment. ROTALIGN ULTRA iS, with its user-friendly interface, is now faster than ever, even while collecting  thousands of measurement points with its patented Continuous IntelliSWEEP method.  

Ludeca, Inc.
Doral, FL

Handheld Multimeter Stands Up To Harsh Temperatures 

According to Agilent Technologies, its U1273AX OLED handheld digital multimetercan operate in temperatures from -40 to 131 F with no warm-up time required. This operating range is coupled with IP54 water and dust resistance, and a CAT IV/600 V safety rating. When paired with the U1583B AC current clamp, the device supports current measurements without breaking the circuit under test. Advanced capabilities include a low-impedance mode that reduces ghost voltages from capacitive coupling and a low-pass filter that eliminates switching noise from motor-drive measurements.

Agilent Technologies, Inc.
Santa Clara, CA

Calibration Services For All Industries  

Endress+Hauser offers a full range of calibration services, including providing regular checking, validation, calibration and clear, concise certificates. The company can help establish a metrology plan by fixing calibration specifications per parameter (maximum permissible errors, periodicities) or by defining the right reference tools according to their uncertainty. It also provides a full range of Standard Operating Procedures to support its on-site work. CompuCal™, a high-performance scheduling and electronic software tool, helps control the scheduling activity around your installed base, providing traceable and auditable records.

Endress+Hauser, Inc.
Greenwood, IN

Cost-Effective ‘Check-Engine Light’ Technology For Monitoring Semi-Critical Equipment 

SKF’s new CMSS 200 Machine Condition Indicator is a low-cost, battery-powered, stand-alone monitoring solution for semi-critical machines with constant operating conditions that usually aren’t evaluated on a regular basis. Independent and self-sufficient, it periodically measures vibration and velocity, and monitors for problems relating to misalignment, imbalance, etc. It also measures enveloped acceleration to detect bearing degradation and keeps a running check on operating temperatures. Built-in intelligence evaluates data and helps avoid false alarms. Performing like a car’s “check-engine light,” the device indicates alarm status on three LEDs. Individual units can be stud-mounted or epoxied to the monitored equipment. 

SKF
Lansdale, PA

Robust, Versatile, Handheld Data Collector 

SPM Instrument has launched the rugged Leonova Diamond®; its next-generation, handheld device for condition measurement in rough industrial surroundings. The first portable instrument offering the SPM HD® measuring technique for monitoring of rolling-element bearings, it enables simultaneous tri-axial vibration measurements with FFT up to 25,600 Lines at 40Khz. According to SPM, other features and capabilities, including a laser tachometer with IR temperature, voice recording, electronic stethoscope, single- and dual plane balancing, laser alignment, run up/coast down, bump-testing and RF measuring point identification, make it well suited for beginners and advanced vibration analysts. 

SPM Instrument, Inc.
Eugene, OR

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

Approaches to ensure the sustainability of an industry can come in many forms. This virtual-reality solution is a case in point. It's nowhelping the USDOE develop and train those clean-coal power-plant operators that we'll need in the future.

Not only were the plant’s legacy systems aging and out of compliance with the new owner’s corporate standards, they were no longer supported by the OEM or by company resources. The custom-batch system had no scheduling or historical batch record-keeping capabilities, making it difficult to manage production. Often, managers only became aware of wasted batches when shortages of raw materials for given recipes occurred—because needed ingredients had already been used. Moreover, the system’s inflexibility prevented the plant from making software-programming changes for routine enhancements. 

Bringing in the new
The new owner wanted a new solution—in the form of off-the-shelf batch software and an HMI system to deliver increased control and visibility. This solution needed to generate detailed records of batch and process data, as well as integrated enterprise resource planning (ERP) system data. It also needed to be flexible enough for repeat uses in other corporate operations. 

The company contracted the services of control and information-systems integrator Cybertrol Engineering (Minneapolis, MN), a member of the Rockwell Automation PartnerNetwork™ program. Cybertrol implemented a manufacturing-intelligence solution utilizing the Rockwell Automation FactoryTalk® software suite. 

The FactoryTalk suite includes FactoryTalk Batch software, which provides operators with electronic reports and access to real-time data through tighter integration with the plant’s ERP system. The enhanced integration allows the company to drive the batch schedule from—and store all recipes in—the ERP system. All procedures remain in the FactoryTalk Batch software, allowing for enhanced reliability for recipe execution and flexible product changeover, and less operator actions and probability for operator error.  

Cybertrol also implemented:

• FactoryTalk VantagePoint EMI software to provide data analysis to business network users, as well as to plant operators who can use it to gain access to historical production data throughout the facility: This software taps into information from systems across operations that have been automatically identified, gathered and stored by FactoryTalk Historian software. FactoryTalk VantagePoint EMI provides management reports to track and compare batch cycle times, so users can identify and correct maintenance and procedural problems that impact productivity. For example, if a transfer pump begins to wear, operators will see transfer times increase and have the ability to schedule a rebuild with minimal interruptions to production. 
• FactoryTalk View Site Edition software to provide production personnel the ability to set up unique parameters, like agitator and transfer pump speeds: Utilizing FactoryTalk Security not only helps protect critical machine settings, it also requires supervisor overrides for certain functions, reducing losses previously caused by incorrect operator actions. 

Counting on results*

As Ben Durbin, Cybertrol President, notes, “With plant floor and ERP system integration, plus access to real-time data, our client was able to immediately identify and correct production issues that had been causing lost batches all along.” 

Thanks to Cybertrol and Rockwell Automation, the plant estimates it now saves at least one batch per month. Based on this type of proven success, the corporate business has already rolled out similar manufacturing-intelligence solutions in its other facilities. MT

*Specific results may vary for other customers. 

Rockwell Automation
Milwaukee, WI

Allen-Bradley, FactoryTalk and PartnerNetwork are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are the properties of their respective companies.

For more info, enter 30 at www.MT-freeinfo.com

Multiprocess Welding Power Source

Miller Electric’s Multimatic 200 is an all-in-one, portable multiprocess welding power source capable of performing MIG, stick and TIG welding processes in one compact design. The Auto-Set Elite feature allows operators to quickly and easily set weld parameters based on material type and thickness, as well as fine-tune those parameters to match each specific application. The system weighs 29 pounds, and connects to common 120- and 230-volt power receptacles with the Miller-exclusive MVP multi-voltage plug. 

Miller Electric Mfg. Co.
Appleton, WI 

Pipe Inspection Software For Tablets

Designed for touchscreen data entry on a tablet PC, WinCan ProTouch from Pipeline Analytics allows operators to easily document pipe inspections made with a video crawler, push camera or zoom survey camera. ProTouch generates basic reports that include schematics and captured images, and can also export inspections to freely distributable viewer software. Data is fully compatible with the company’s WinCan v8, which means an operator can transfer the data to exploit v8’s enhanced reporting, querying, GIS features and standards support.

Pipeline Analytics
Pittsburgh, PA

VSD-Equipped Single-Stage Compressor Lineup 

Sullair has expanded its line of V250S Single-Stage Rotary Screw Air Compressors with models that include Variable Speed Drive (VSD) technology. Based on the same footprint and operating characteristics of the company’s comparable constant-speed designs, the new units incorporate Sullair’s WS Microprocessor Controller. Featuring an easy-to-read graphics display that highlights frequently used compressor information, this control system is programmed to monitor all necessary functions and provides a WSPC interface for service diagnostics and trending capabilities. Sullair’s VSD-equipped models range from 250 to 350 hp, with capacities of 1085 to 1580 cfm, and pressures of 100 to 125 psig.  

Sullair Corp.
Michigan City, IN

Water-Soluble Cutting Fluid 

Prolong® Super Lubricants notes that its Ultra Cut 1 Water Soluble Cutting Fluid can help eliminate uneven cuts, reduce power consumption and increase tool life. Designed to maximize results in sawing, grinding, boring, turning or milling processes that require coolants, it protects metals from corrosion and extends the life of cutting solutions and tools. It also can be used as a flood coolant and for making emulsions in machine shops. Ultra Cut 1 comes in gallon-size bottles, 5-gallon buckets and 55-gallon drums. 

Prolong Super Lubricants
Pomona, CA

Expanded Electronic Parts Catalog

Allied Electronics has released its 2013 Allied Catalog, which showcases 10,000 new products in addition to the 115,000 that were already featured in the book. New to this year’s catalog is an extensive product offering from Siemens. Other new suppliers include FLIR Commercial Systems, Interfan, Keithley Instruments/Tektronix, Spacecraft, wakefield-vette, WIKA Instrument Corporation and Yokogawa. This year’s catalog selection is complemented by over two million parts accessible online.  

Allied Electronics, Inc.
Fort Worth, TX

Industrial Diesel Engine With Notable Power Density

Caterpillar’s latest generation of its Cat® C9.3 ACERT™ industrial engine is designed to meet U.S. EPA Tier 4 Final/EU Stage IV emission standards. The engine is a six-cylinder, 9.3-liter platform that produces excellent power density, with ratings from 300-400 hp (224-298kW). It is equipped with a robust, fully-integrated Clean Emission Module (CEM), which includes a diesel oxidation catalyst (DOC), diesel particulate filter (DPF), and selective catalytic reduction (SCR) technology that reduces NOx. 

Caterpillar, Inc.
Peoria, IL

Fluid Storage With Spill Containment 

IFH Group’s Fluid Storage & Dispensing Systems incorporate spill containment systems that can prevent costly clean-ups, make fluid dispensing easier and provide compliance with EPA regulations such as 40 CFR 264.175. All 21 IFH standard centralized systems are equipped with a drip pan, making dispensing of fluids into containers from self-closing faucets quick and spill-free. For all two-, three- and four-container systems with outboard console mounting, a spill containment pan is provided at the base of the system to collect any accidental spills.  

The IFH Group, Inc.
Rock Falls, IL

High-Speed Gearbox Series

David Brown’s HX high-speed gearboxes are designed specifically for critical applications such as pumps, compressors and generators in the oil and gas and power industries. The line’s core platform is easily adaptable to suit all packaging requirements through a flexible case design and  multiple oil inlet/outlet positions, combined with optimized oil flow. The gearboxes are fully compliant with major international standards such as API and AGMA. Bearing choices are available to suit all application demands.  

David Brown Gear Systems Ltd.
Huddersfield, UK

Steam-System Component Literature 

Spirax Sarco has released the 14th edition of its Mechanical Product Manual. Subtitled “First for Steam Solutions,” it provides a complete range of information needed to evaluate and apply steam-system components. It includes technical information about Spirax Sarco’s regulators, steam traps, condensate recovery, strainers, high-purity, liquid drain traps, pipeline auxiliaries, humidification and engineered products. For a free copy, visit www.spiraxsarco.com/us or contact your local Spirax Sarco representative.

Spirax Sarco, Inc.
Blythewood, SC

DPM-Reading Technology Goes Wireless

Cognex Corp.’s DataMan® DPM-reading technology has gone mobile. The industrial-grade DataMan 9500 mobile computer can even the most challenging DPM (direct part mark) codes in applications where operators need to view the data on an integrated handheld device. Designed for the factory floor, the product features the 2DMax™ algorithm for decoding difficult-to-read codes, including dot peen and laser-etched, on any metal surface. Small and lightweight, the computer connects to factory networks via 802.11 a/b/g protocols  on the 2.4GHz and 5GHz bands for real-time wireless communication. 

Cognex Corp.
Natick, MA

MCC Combats Arc Flash Incidents

According to ABB, its new MNS-MCC Low Voltage Motor Control Center is the first product of its kind to address the causes of arc flash incidents while providing superior equipment and personnel protection. For flexibility and minimization of downtime, the product offers a plug-in type, withdrawable and full-height-unit technology, with up to 4000A horizontal bus and 1600A vertical bus. The design is available in a variety of unit types, including starters, softstarters, variable frequency drives and mains and feeder breakers. The company notes that no other MCC allows operators to remove a unit with the door closed, with no tools and without disconnecting wires.  

ABB Low Voltage Products 
New Berlin, WI

High-Performance Metalworking Fluid  

NuSoL® Alumax 89  from Chemtool is specifically formulated for all operations on non-ferrous alloys, exotic ferrous alloys (including titanium), Inconel and Monel, plastics and composites. According to the manufacturer, while NuSoL Alumax 89 provides the type of wetting, detergency and boundary lubrication that’s associated with other NuSoL metalworking fluids, this product incorporates a new performance-enhancing additive package that demonstrates lower foaming characteristics for typical use concentrations (5-15%). 

Chemtool, Inc.
Rockton, IL

Compressor Solutions For Large-Scale Oil & Gas Applications

York by Johnson Controls provides a single-source solution for large-scale process applications in the oil & gas industry. These compressors and controllers ensure facilities stay up and operational while lowering maintenance costs and increasing efficiency. The company’s Quantum™ HD controller offers secure networking features that enable remote control and systems monitoring from any Web-enabled device. The controller has been developed to operate as a single platform with custom programmed features, including compressor sequencing, condenser control, digital output control and real-time historical trending. The enhanced design features a high-definition display, as well as open access to all points for easy service and components that can be individually replaced.   

Johnson Controls
Milwaukee, WI

Heavy-Duty Slurry Pumps 

The ITT Goulds Pumps XHD Extra Heavy-Duty Lined Slurry Pump is designed for extreme slurry applications and can replace existing slurry pumps with minimal baseplate and piping changes. The pump can be maintained even while running with more accessible and adjustable parts than other slurry pumps. The XHD is intended for applications such as primary metals, mineral processing, non-metallic mining, power utilities and sand and aggregates. 

Goulds Pumps
A subsidiary of ITT Corp., Inc.
Seneca Falls, NY

Today’s operational leaders must navigate unprecedented levels of ambiguity and complexity. Rising customer expectations, relentless cost competition, capital constraints and rapid technological change are redefining performance requirements and forcing managers to quickly adapt and identify new ways to innovate within the production environment.