A Gathering Of Innovative Eagles

I had the joy of sailing around the post-holiday doldrums last month by spending a couple of days at the 2013 Shell Innovation Summit. As an invited media guest, to say that I felt like an odd duck among a gathering of eagles would be quite the understatement. But you know me: I do love “innovation”  and will travel far and wide to learn about the concept—then write about it as it applies to your jobs, your suppliers and our magazine. 

Don’t Believe Everything You Read: 

“I just got through reading a report that said something about the ‘worries of a skills gap crisis are overblown.’ From where I sit and from the people I talk to in manufacturing, this report can’t be right. We have a skills gap in our plants now and it’s probably only going to get worse. What’s going on? Help me understand this skills gap crisis, please. It is real?”

What’s Your Site’s 

Industrial professionals have always lived closer to the potential for disaster than average citizens. But the frequency and scope of catastrophic events today (from natural disasters to armed, disgruntled workers to fires and explosions) seem to defy conventional ability to prepare for them. We asked our Reader Panelists about the disaster preparedness of their own operations.

The plant manager can’t succeed without a well-defined maintenance program.
Here’s how to make things happen.

What's your next move when things don't make sense? 

Expanding asset management through expert services can add to savings, as well as improve work practices.

Symptom:

Diagnosis: The life of a compressor lubricant is not easy! A regular mineral-based oil can deteriorate quickly. Deterioration leads to oxidation-caused carbon, gum and varnish buildups that result in excessive wear of all mechanical moving parts, increased energy costs and reduced compressor efficiency and availability.

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Prescription: A variety of synthetic compressor fluids for large commercial ammonia refrigeration systems have been formulated to relieve many of the problems associated with volatile solvent-refined paraffinic and naphthenic mineral oils, including:

• Wax deposit problems at very low temperatures
• Excessive oil consumption resulting from oil carry over into the refrigerant low-temperature side 
• Premature oxidation causing oil thickening, deposits and sludge formation

In large commercial refrigeration operations, temperatures can be lower than -60 F (-51 C). Synthetics provide the viscosity stability required for dealing with the extreme hot and cold temperatures. They’re also less soluble in ammonia refrigerant than their mineral counterparts and can significantly reduce oil consumption and subsequent refrigerant contamination effects. 

Compared to typical mineral-based lubricants with a recommended maximum life of 3000 hours, synthetics are often rated for up to 8000 hours, thus reducing downtime, maintenance and environmental impact. Synthetic-oil manufacturers also claim energy savings of up to 4%. Your choice of synthetic type will usually vary among polyalphaolefins, alkyl benzines, polyol esters and polyalkylene glycols. Selection is based on compressor type, operating conditions, oil-separator efficiency and system design.

To learn if a synthetic is right for your application, discuss the refrigeration-system design with your lubricant supplier. Based on that information, the vendor can develop a business case with a return-on-investment statement that will allow you to determine if the change meets the needs of your sustainability program. MT

Lube questions? Ask Dr. Lube, aka Ken Bannister, author of the book Lubrication for Industry and the Lubrication section of the 28th edition Machinery’s Handbook. He’s also a contributing editor for Maintenance Technology and Lubrication Management & Technology. E-mail: doctorlube@atpnetwork.com.

Split Roller Bearings Handle Greater Loads

Cooper Roller Bearings has increased load capacities of many of its split roller bearings to levels higher than any split roller bearings of similar size, with L10 life that is 23% to 135% longer (depending on size). These new 01E (medium-duty) and 02E (heavy-duty) bearings are fully interchangeable with Cooper’s 01 and 02 Series bearings, yet provide up to 29% more radial capacity and 16% to 90% more axial load capacity. The increased life and capacities are due primarily to changes in internal geometry. Featuring the same superior sealing and energy-efficiency as their counterparts in the 01 and 02 Series, they also share the same exterior dimensions, giving users more capacity in the same space.  Rugged brass cages make the 01E and 02E bearings suitable for service underground and in other challenging environments. Typical applications include mining equipment, industrial fans, conveyors and power generation.

The Cooper Split Roller Bearing Corp.
Norfolk, VA

Packing Solution Reduces Flush Rates

Chesterton’s SuperSet has been specifically designed to increase packing and equipment service life while dramatically reducing flush rates. It combines the sealing capabilities of the company’s Mechanical Packing products (including enhanced performance, sealibility, leak prevention, chemical compatibility, strength, toughness and thermal characteristics) with the patented design of the EnviroSeal SpiralTrac™ Version P Environmental Controller for Packed Stuffing Boxes. The SpiralTrac Version P enhances the utilization of the flow and centrifugal effects around the shaft by performing like a centrifugal separator. The built-in tangential lantern ring and helical grooving system impart motion to the flush, and the resulting centrifugal force throws the particulates in the fluid to the outside of the bushing. The SpiralTrac grooving system then hydrodynamically pumps the solids to the bottom of the stuffing box and back into the pump casing.

A.W. Chesterton Co.
Woburn, MA

AODD Accessories Boost Pump Efficiency  

Warren Rupp’s SANDPIPER brand has launched a new, improved line of Air Filter/Regulators and Lubricators for air-operated double-diaphragm (AODD) pumps. Features include a liquid-filled pressure gauge, as well as accessories such as lockout valves and mounting bracket kits. These point-of-use Air Filter/Regulators have been specifically developed to reduce maintenance and lower operating costs. The addition of a Filter/Regulator will help prevent dirty, wet and contaminated compressed air from decreasing the performance of an AODD unit, and SANDPIPER recommends the use of these items with all of their pumps. Although the company’s AODD pumping equipment is designed to operate without lubrication, in applications with poor-quality air supplies or where nitrogen runs the pump, lubrication of the compressed air is required. For these situations, SANDPIPER offers a full-line of Lubricators that easily connect to its Filter/Regulators.

Warren Rupp, Inc. 
A Unit of IDEX Corp.
Mansfield, OH

Analyze Power And Quantify Energy Losses

According to Fluke, its 430 Series II Three-Phase Power Quality and Energy Analyzers not only offer exceptional power-quality analysis capabilities, they introduce, for the first time, the ability to monetarily quantify energy losses. The models in the Series II (the 434, 435 and 437) help locate, predict, prevent and troubleshoot power-quality problems in three-phase and single-phase power-distribution systems. Incorporating what the company calls revolutionary functions, they can help a facility reduce electrical-power consumption and improve the performance and lifespan of its electro-mechanical equipment. Capabilities include: 

• Frontline troubleshooting: Quickly diagnose problems on-screen. 
• Energy loss management: Measure and quantify causes of energy losses to enablesimple ROI, calculation of harmonics and unbalance mitigation. 
• Power inverter efficiency: Simultaneously measure AC inputand DC output forpower electronics systems.
• Dynamic load testing: Capture instantaneous values to see the effect of load switch on generators and UPS systems.
• Capture fast RMS data: Show halfcycle and waveforms to characterize electrical system dynamics.
• Predictive maintenance: Detect and prevent power-quality issues before they cause downtime.
• Quality of service compliance: Validate incoming power quality at the service entrance.
• Long-term analysis: Uncover hard-to-find or intermittentissues.
• Load studies: Verify electrical system capacity before adding loads.

Fluke Corp.
Everette, WA

Wireless Pump Control Goes Mobile

Grundfos North America has launched the Grundfos GO, a combination of a mobile interface and free app that provides intuitive wireless pump control. To manage pumps by remote control, users need only to download the app from the App Store or Google Play and connect the mobile interface to an iPhone, iPad, iPod Touch or Android smartphone. They can then copy profiles to new pumps, generate installation reports, request status data, adjust pump settings and receive alarms and warnings, as well as monitor a live data feed from the pumps that includes duty points, historical data, power consumption, pump speed and temperature. The app also provides round-the-clock access to exhaustive product information via Grundfos GO CAPS, a mobile version of the company’s product database that, among other things, allows users to select replacement pumps on site at any time. 

Grundfos Pumps Corp.
Olathe, KS

Flexible, Extended-Height Gauging System

Renishaw’s Equator 300 Extended Height comparative gauge doubles the space below the measuring volume of the company’s original model, providing a 300-mm height to accept tall parts or those attached to machining fixtures. The additional space also facilitates automated part handling with robots and conveyors. The system can inspect features on parts up to 300 mm tall, with rapid changeover to smaller parts using an extended fixture plate spacer. Equator is a lightweight, highly repeatable gauge that can switch between parts in seconds, making it suited for flexible manufacturing processes or for accepting parts from multiple machines. An Equator-specific stylus changing rack, included with the system, allows automated in-cycle changing of SH25 stylus holders. Up to six stylus combinations can be loaded into the rack at any time.

Renishaw, Inc.
Hoffman Estates, IL

Extended-Rating Drives

Rockwell Automation has extended the ratings of its Allen-Bradley PowerFlex 755 AC drives to 1500 kW/2000 Hp. The high-power drives are suited for applications from simple variable speed and variable torque control to those requiring constant torque control. The latest frame extension delivers the same control capabilities of earlier high-power models, such as 400/480/600/690 volt ratings and N-1 technology. With N-1 technology, users can configure the PowerFlex 755 high-power drive to use one, two or three power structures. This gives the redundancy and advanced control needed to manage load changes, protect equipment and keep the drive running in the event of a power failure. Like all PowerFlex 755 drives, the latest includes an embedded Ethernet port and multiple option slots. 

Rockwell Automation
Milwaukee, WI

Adaptable, Modular I/O System

The XI/ONTM modular input/output (I/O) system from Eaton is designed for decentralized signal processing and provides adaptable I/O options. It includes XN and the XNE series of I/O modules. The XN Series provides modularity with hot-swappable plug-in modules, while the XNE series provides integrated I/O modules and bases in higher density configurations. The XI/ON system also includes a host of digital, analog and technology modules. A programmable CANopen gateway delivers PLC power to the fieldbus terminal. Engineered to handle decentralized automation tasks, the gateway relieves the load of higher-level PLCs. A configuration and diagnostics tool, I/O assistant, provides interactive support and can be used to plan and implement installation.

Eaton Corp.
Pittsburgh, PA

 Visual inspections are more important than most people realize. They’re more effective than instrument tests because the human eye can detect broken parts, overheated insulation and missing grounds; other senses, such as touch and smell, can detect a number of different problems. In fact, several standards call out visual inspections, including IEEE 1068-2006 (motor repair) and IEEE 432-1992 (insulation testing and maintenance).

When making decisions related to the condition, reliability or troubleshooting of your machines, it’s crucial to remember that visual inspection findings are more important than electrical or mechanical tests, not the other way around. This is one reason why a machine-experienced technician should take data or make inspections when evaluating electric motors. 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).

Housing With Multiple Connection Options For Timers And Monitors

A new housing for ABB’s CT-S range of time relays and CM range of measuring and monitoring relays features two connection options: Double-Chamber Cage Connection terminals and Push-in terminals. Double-Cage Connection terminals use screw technology and can be connected with two wires of different diameters up to 14 AWG, solid or stranded, with or without wire-end ferrules. Push-in terminals feature spring-clamp, Easy-Connect technology, which allows timers and monitors to be wired without tools. They are suitable for solid or stranded wires up to 20-16 AWG. The industrial housings complement other ABB din rail products, and all models meet UL standards for voltages up to 690V.

ABB Low Voltage Products
New Berlin, WI

Channel Grinder With Increased Flow Through 

The Moyno® Annihilator™ C3A channel grinder is now available in 40” and 60” models. According to the company, the new versions produce an average of 30% more flow through due to high-flow side rails and a lower-profile bottom housing. The revamped models offer the same design and features as the company’s smaller units, and have an added intermediate bearing for greater service life. 

Moyno, Inc.
A unit of Robbins & Myers, Inc.
Springfield, OH

Fuel-Efficient Air Compressor

Atlas Copco’s XAS 1800 JD7 air compressor is designed for applications requiring a high volume of air at medium pressure. Compliant with Tier 4 EPA emission regulations, the compressor produces 1800 cfm at 100 psi (7 bar) and 1600 cfm at 150 psi (10 bar). A large display and intuitive design provide ease of use. With the optional FuelXpert fuel-saving system, engine speed and air-inlet valve can be electronically regulated to optimize fuel consumption. 

Atlas Copco
Rock Hill, SC

Thermoplastic Basket Strainers For Piping System Components

Platinum GF-PP (Glass Filled Polypropylene) SB Series Basket Strainers are designed to protect critical piping-system components such as pumps, filters and flow meters from particulate and debris. The series is available in sizes up to 4”, with true union-threaded or flanged-end connections. Vessels feature a maximum pressure rating of 150 psi at 70 F non-shock, with a maximum service temperature of 240 F. Other features include FPM or EPDM O-Rings and Seals, and an ergonomic hand-removable cover.

Hayward Flow Control
Clemmons, NC

Portable Four-Gas Detector

Honeywell’s IQ Force™ multi-gas detector is available as part of the company’s IQ Management System for portable gas detection. The detector can function as a base-model four-gas detector for meeting compliance requirements, or as an extension of the IQ Management docking station for automated bump test, calibration and recharging. It monitors O2, LEL, CO and H2S gas hazards, and can remotely send email notifications of an alarm.

Honeywell Analytics Distribution, Inc.
Lincolnshire, IL

Cart-Mounted Temporary Power System

The MGL25-8C-480-120V-GFI Temporary Power Distribution System converts three-phase 480V current to usable single-phase 240V AC and 120V AC for applications where operators must tap into high voltages independently of the local grid. Safeguarded by fused and integrated GFI breakers, the portable substation provides multiple outlets and includes 50’ of line power cord fitted with a 480V 60amp 3ph/4 wire plug. An optional glass door allows for quick visual inspection. 

Larson Electronics, LLC
Kemp, TX

USB Port Hub For Harsh Environments

StarTech.com’s 7-port USB 3.0 hub (ST7300USBM) enables users to add multiple external USB 3.0 connection ports to a PC, server or thin client located in industrial operating environments. The hub features a solid metal chassis for harsh conditions, 350W surge protection on each port and can be mounted to a wall or DIN rail.  

Startech.com USA LLP
Lockbourne, OH

Multi-Point Lubrication Delivery System

Oil-Rite’s Hydracision multi-point lubrication system can distribute to as few as 12 or up to hundreds of separate points. It combines efficient hydraulic movement of fluid with the precision of positive displacement injection. The reservoir housing contains a gear pump motor which pressurizes the outlet for uniform fluid distribution. A PLC with programmable display allows selection of lube cycles, while a low-level switch prevents operation when oil supply is depleted.  

Oil-Rite Corp.
Manitowoc, WI

Compact High-Viscosity Filter Cart 

The OilMiser 15V456 High Viscosity Filter Cart features a low center of gravity,  compact design and high-efficiency TEFC motor. Its color-coded Filter Condition Indicator signals a needed filter change. Quick-disconnects comply with ISO-7241-1B Interchange Standards, and are supplied with dust caps on suction and discharge ports. The cart’s low flow rate of 1.9 gpm (7 L/m) minimizes filter media stress and maximizes contamination retention on the oil filter. 

JLM Systems Ltd.
Richmond, BC, Canada

High-Efficiency Geared Motors

The Simogear geared motor series from Siemens features helical, parallel shaft and helical bevel gear unit types with integral high-efficient and NEMA Premium® efficient motors. The line’s two-stage helical bevel unit features a mechanical efficiency of up to 96% and a wide range of ratios that make it suitable for replacing worm and spiroid units in conveying applications. Designed for automation engineering, Simogear integrates smoothly with all Siemens drives and automation products. 

Siemens Industry, Inc.
Atlanta, GA

Crimp Tool For Tight Spaces

RIDGID® Close Quarters ASTM F1807 PEX crimp tools feature handle openings up to 70 percent smaller than standard PEX crimp tools, allowing for easy maneuvering in tight spaces. Available in ½” and ¾” sizes, they have glass-filled polycarbonate E3™ handles and a built-in Go/No-Go Gauge that folds into a handle for easy access and storage. An adjustable lock screw for easy calibration is also included.

RIDGID
An Emerson Business
Elyria, OH

To Innovate,

I believe that innovation can’t be taught. It must come naturally, as part of a lifestyle. This became clear to me recently when I was given an opportunity to experience a work process outside of my day-to-day routine. Not that my job as a lubrication scientist on Shell’s Aviation Technology team in Houston is boring. I’m involved in a range of interesting activities, from working on aircraft engine oils and hydraulic fluids for high-tech jets to researching what makes the whitest, brightest smoke for stunt aircraft.