Equipped with quality tools and personnel to manage them, these mobile units continue to deliver for Alstom Powerin planned outages across North America.

With the right condition-monitoring program and the right tools, you can reduce the costs of your equipment maintenance and fully utilize your personnel. ]]> Wed, 01 Jul 2009 06:00:00 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=1309:motor-docs-hot-topics-the-use-and-misuse-of-standards-in-sales-and-marketing&catid=245:july2009&directory=90 In my work, I often ask companies about the standard(s) they follow. Most will cite IEEE, ASTM, EASA, IEC, UL, CSA, etc. Generally, the language and standard(s) are correct and the companies appear to be complying. Sometimes, however, they aren't—either accidentally or, in enough cases to be annoying, deliberately.

What is the impact when a standard isn't followed? For the buyer, the price of products/services can be lower than those from companies that perform to actual standards. Conversely, not following standards can result in a very costly product or service—something that may put people in danger, damage equipment, lead to lost production, expose the buyer's organization to litigation and/or the denial of insurance coverage.

How do you avoid these problems? Remember this: any company that truly follows standards or certification processes will be proud of the fact. Compliance with standards is not just something to protect you, the buyer; it's also a sales and marketing tool for the vendor. If you run into a supplier who objects to showing you its applicable standard(s) or certification(s)—or acts insulted because you're asking—your next step should be to dig deeper. A legitimate company would be able to show either a referenced standard or certificate on the spot (or at least obtain it for you in short order). Company representatives also should be familiar with the parts of the standard or certification that involve their product or service.

Industry standards and certifications reflect agreed-to Best Practices. The most effective way to protect yourself and your organization is to become familiar with any standards and certifications that specifically affect you. Many standard-writing and certifying bodies maintain libraries and definitions that are available to you; some will also have standards collections that can be used. Understanding an appropriate standard and its intent will help you quickly identify questionable sales and marketing approaches. MT

---

Howard Penrose is VP of Repair Services (Operations) for Dreisilker Electric Motors, Inc. (http://www.dreisilker.com) and editor-in-chief of the IEEE DEIS Web. He is author of the Axiom Business Book Award-Winning Physical Asset Management for the Executive and the ForeWord Book of the Year Finalist, Electrical Motor Diagnostics: 2nd Edition.

For more info, enter 3 at www.MT-freeinfo.com

]]> Wed, 01 Jul 2009 06:00:00 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=1310:my-take-looking-at-the-bright-side-of-new-energy-regulations&catid=245:july2009&directory=90 As July is heating up, so is the national debate on energy and how we're going to be using and paying for it in the future. I've asked myself why I feel compelled to wander into this minefield and risk being accused of politicizing our magazine. That's not my intent; I'm just making observations—and continuing to gently pester you about one of the most critical issues of our times. ]]> Wed, 01 Jul 2009 06:00:00 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=1311:big-money-talks-power-plant-efficiency&catid=245:july2009&directory=90

William C. Livoti

I am sure almost everybody has received some notification from their local utility regarding energy conservation. Many of the larger utilities offer incentive programs for premium efficient motors, energy efficient windows, etc. I believe we all understand the purpose and the necessity of the power generator promoting energy efficiency on the demand side. On the other hand, have you ever wondered how efficient a power plant truly is? Let's examine a typical fossil fuel power plant.

The average fossil plant is roughly 33% efficient (at design point). What does this mean? Simply stated only about a third of the fuel (oil, gas, coal) entering the plant actually generates electricity. Even less-around 30%-is actually transmitted to the consumer. So, where does the remaining 70% go?

Thirty-three percent of that remaining 70% goes out the stack; 33% is used to cool the process and ultimately winds up back in the cooling source (lake, river or ocean) and the other 4% is lost in transmission/distribution. This is the same level of efficiency that has existed for the last 60+ years. To get a better understanding of how the power industry determines efficiency, we can break it down by the numbers.

Power plants live and die by the Heat Rate number expressed in Btu (British Thermal Units). Heat Rate is defined as a ratio between fuel energy and generated electricity. The smaller the Heat Rate number, the less fuel is needed to generate one unit of electricity. Although there are several factors that figure into Heat Rate, in the interest of keeping this article brief, let's break it down to the basics:

• Thermal Efficiency:
  This is the inverse value of the Heat Rate of the power plant.
  
• Load Factor:
  For a power plant, Load Factor is the ratio between Average Load and Peak Load.
• Economic Efficiency:
  This is the ratio between production costs, including fuel, labor, materials and services, and energy output from the power plant for a period of time.
  
• Operational Efficiency:
  This is the ratio of the total electricity produced by the plant during a period of time compared to the total potential electricity that could have been produced if the plant operated at 100% in the period.
  
• Capacity Factor:
  For a power plant, this is the ratio between Average Load and Rated Load for a period of time.

The utility calculates your rate in the following manner:

The power company assumes the Heat Rate as a fixed cost. This is not the case, as the plant efficiency can be improved dramatically by simply improving process control. Why would one believe power generation technology hasn't changed over the last 60 years? Europe has improved the efficiency of its fossil plants to roughly 40 to 45%. What are we waiting for?

The bottom line is the resistance to change and the paralyzing fear associated with change. That being said, how long can we—as a country—operate in such an inefficient manner? At the end of the day, we all pay the price. UM

References
The Engineering Toolbox, Peter Garforth of Garforth International, LLC

---

Bill Livoti is a fluid power and power industry engineer with Baldor Electric Company. He also is vice chair of the Pump Systems Matter (PSM) initiative. Telephone: (864) 281-2118

]]> Wed, 01 Jul 2009 06:00:00 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=1312:utilities-manager-energy-showcase&catid=245:july2009&directory=90 Energy-Saving Motors

Baldor's Super-E Motors are designed to conserve energy over extended time periods. Payback can occur in less than a year depending on motor size. The right combination of these motors and adjustable-speed drives can yield energy-cost savings up to 50%, according to the company. Baldor Save+ software can compare operating costs, summarize annual savings and calculate payback time based on individual operation. Premium Super-E motors are available in Totally Enclosed Fan-Cooled and Open Drip-Proof construction. All three-phase motors are Inverter Ready per NEMA Standard MG1, Part 31.4.4.2., meaning the motors in 230 and 460 volts meet NEMA's corona inception voltage requirements and can withstand peak voltages of up to 1600 volts. Premium efficiency motors also are available in single-phase designs.

Baldor Electric Co.
Ft. Smith, AR

For more info, enter 261 at www.UMfreeinfo.com

AC Drives

Motors controlled by AC drives enable users to control motor speed, which can afford various energy-saving benefits. Fans and pumps are the most common energy-saving applications for AC drives, with savings typically 20-50%. When a fan is driven by a fixed-speed motor, for example, airflow can be higher than needed. Airflow can be regulated by using a damper to restrict flow, but it is more efficient to regulate the airflow by regulating the speed of the motor. AC drives also reduce start-up current, which allows for use of smaller fuses and supply connections, and reduces peak loads on the electrical network. In addition to energy-savings, AC drives allow for smoother overall operation, acceleration control, use of different operating speed for each process and the ability to compensate for process variables.

Vacon, Inc.
Chambersburg, PA

For more info, enter 262 at www.UMfreeinfo.com

Cylinder/Valve Units for Pneumatics

Of the many ways in which compressed air systems can lose energy, one is the use of centralized systems, which are cumbersome and wasteful due to the need for long lines. Small, decentralized units at the site of the application are more efficient. The concentration of pneumatic functions prevents pressure losses through long lines from the control cabinet to the pneumatic drive. By using cylinder/valve units, hose connections can almost completely be spared, providing an average energy-saving potential of 35%, according to the company. Additional advantages include simple installation and maintenance, faster response times and higher cycle frequencies.

Bosch Rexroth Corp.
Lexington, KY

For more info, enter 263 at www.UMfreeinfo.com

Gas-Fired Water Heaters

Armstrong Flo-Direct® Complete Thermal Exchange Gas-Fired Water Heaters can deliver fuel savings as high as 60% when compared with steam/water heating systems, according to the company. These units produce potable hot water instantaneously, meaning no fuel consumed for warm-up or idle time. No energy is lost through steam conversion or within a heat exchanger. Virtually all fuel energy is transferred to the water. Use of Armstrong Flo-Direct Complete Thermal Exchange Gas-Fired Water Heaters can help companies achieve Energy Conservation Measure (ECM) and Reduced Carbon Footprint objectives. The company's line of heaters includes a range of high efficiency, compact, all-stainless steel models suitable for many industrial applications.

Armstrong International
Three Rivers, MI

For more info, enter 264 at www.UMfreeinfo.com

Clamp-On Flow Meters

TFX Ultra ultrasonic flow meters clamp onto the outside of pipes and do not contact internal liquid. Two versions are available: a stand-alone flow meter and an energy flow meter that's used in conjunction with dual clamp-on RTDs. The energy flow meter measures energy usage in BTU or tons and is ideal for retrofit, chilled-water and other HVAC applications. The TFX Ultra units' clamp-on design reduces installation time and material costs because there is no need to shut down a process for installation or maintenance. A TFX Ultra can be installed and fully operational in minutes. With no moving parts, there is no mechanical wear; no repair kits or replacement parts are ever needed. The units feature bi-directional flow measurement, a totalizer featuring forward, reverse and net total, and Modbus communications.

Dynasonics
Racine, WI

For more info, enter 265 at www.UMfreeinfo.com

Software Identifies Savings Opportunities

Eaton's Power Xpert® Reporting software helps facility, information technology and energy managers benchmark existing energy usage and power consumption in their power distribution systems, allowing energy and cost-saving opportunities to be identified and implemented. The software can aggregate data from multiple databases to provide a complete enterprise-level view of power consumption and energy usage. When combined with the company's Power Xpert Software or Foreseer, Power Xpert Reporting is designed to enable energy-cost allocation, compare power consumption, monitor branch circuits and summarize overall power quality. It can also play a key role in helping users adopt green strategies and qualify for Leadership in Energy and Environmental Design (LEED) credits through the U.S. Green Building Council (USGBC).

Eaton Electrical Group
Raleigh, NC

For more info, enter 266 at www.UMfreeinfo.com

Integrated Automation System

ABB's IndustrialIT Extended Automation System 800xA integrates process and power systems on one unified platform, offering advantages such as improved energy efficiency, process reliability and overall productivity. By integrating power and process systems on the common 800xA platform, users can optimize the design and performance of their electrical and automation systems, and see additional benefits in reduced maintenance, engineering and overall lifecycle costs. Typical savings can result in a 20% reduction in capital and operating expenses. According to ABB, the 800xA system has been sold to more than 5000 new and existing ABB customers in virtually every industry, from process industries and mining to electric and water utilities.

The ABB Group
Norwalk, CT

For more info, enter 267 at www.UMfreeinfo.com

"The human mind is prone to suppose
the existence of more order and
regularity in the world than it finds."

…Sir Francis Bacon, 1620 ]]> Wed, 01 Jul 2009 06:00:00 +0100 http://www.mt-online.com//index.php?option=com_content&view=article&id=1314:the-green-edge&catid=245:july2009&directory=90 Energy-Efficient Hydraulic Fluid

Shell Lubricants has added a new lubricant to its Shell Tellus hydraulic oil range that can help increase the energy efficiency of hydraulic systems. Based on customer-reported and Shell-managed evaluations, the Shell Tellus EE has been shown to help companies reduce the energy consumption of their hydraulic machinery by an average of 8%, while also providing equipment protection and the capability of extending oil maintenance intervals.

Shell Tellus EE is the company's first synthetic hydraulic fluid that has been specifically designed to help improve the energy efficiency of the machinery in which it is used. The fluid contains a unique and patented additive technology, and has undergone extensive laboratory tests and field trials that have demonstrated its ability to help improve a machine's energy efficiency. With hydraulics being at the core of many production processes, Shell Tellus EE has the potential to contribute to the goal of reducing an organization's energy costs.

"Energy costs will continue to represent a significant part of an industrial organization's operating overhead for the foreseeable future," said Dennis Woodley, Shell Hydraulics Product Application Specialist. "As a result, investing in a hydraulic lubricant designed to both help improve the energy efficiency of the machinery in which it is used and reduce the maintenance costs makes good sense from a commercial perspective."

Shell Lubricants
Houston, TX

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

Single-Source Services For Mixers

It's a matter of sustainability. Although capital budgets aren't what they used to be, plant operators are still expected to deliver peak performance and maximum output while lowering energy and operational costs. That's where the Philadelphia Mixing Solutions "Service All Mixers (SAM)" program comes in. SAM lets operators do more with less by helping them leverage their investment in existing equipment, solve their most complex mixing challenges and increase the overall financial health of their plants. According to Philadelphia Mixing Solutions, its SAM offering is the only service that allows plant operators to work with a single company for scheduled mixer upkeep, planned upgrades or emergency repairs, regardless of who manufactured the mixer. Among other things, within the scope of the program, complete evaluations of mixer conditions, such as age, service history, oil analysis, etc., are conducted. Based on results, a detailed report of recommended actions to improve the performance and extend the life of the equipment is generated. Additionally, three-year warranties are provided for all repair work. True root-cause failure analyses—a veritable "CSI" for mixer performance—identify mechanical failures in the context of process conditions to help customers eliminate downtime and promote higher levels of performance
and repeat.

Philadelphia Mixing Solutions
Palmyra, PA

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

Lower Operating Costs In Drying & Blow-Off Operations

A new White Paper published by Spraying Systems Co. takes an in-depth look at how to reduce or eliminate compressed air use in drying and blow-off applications and achieve dramatic savings. Among other things, How to Reduce Compressed Air Consumption in Drying and Blow-Off Applications reviews various air nozzle options that use compressed air, provides application guidelines and estimates the savings each option offers over open pipe. The White Paper is available at no cost upon request from the company or at its Website

Spraying Systems Co.
Wheaton, IL

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

GE Plans $100M R&D Facility

GE recently announced plans to build a $100 million research center in Michigan, about 25 miles from Detroit. The new Advanced Manufacturing and Software Technology Center will include a research and development component that will be part of GE's Global Research network (which is headquartered in Niskayuna, NY). The state of Michigan is providing $60 million in incentives over 12 years for the project. The center is set to open later this year and is expected to employ more than 1100 people within the next few years. They'll work there to help develop new manufacturing technologies for GE's renewable energy, aircraft engine, gas turbine and other products. Work on smart grid technologies, software development, networking and program management are some of the other fields to be targeted. "Michigan is well positioned to be a leader in advanced manufacturing and development of green technologies," said U.S. Senator Carl Levin. "This facility will take advantage of our state's strengths and keep us on the forefront of these critical emerging industries."

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

EGSA Establishes Green Committee

The Electrical Generating Systems Association (EGSA) has announced the formation of its new Green Committee. Michael Pope of Süd-Chemie will serve as the inaugural committee chairperson. Initially, the Committee will gather, monitor, communicate and distribute Green business opportunity information to the EGSA membership. Additionally, it will teach best practices in conducting Green Conferences as well as instruct techniques to move to a Green strategy. Any EGSA members are welcome to join the Green Committee It will hold its first meeting at the association's Fall Conference.

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

Bird-X has been producing humane pest and bird deterrents for 45 years. Established in 1964, its first product was an ultrasonic repellent engineered to affect pest birds using audio signals undetectable to human ears. Since that time, the company has continued to develop unique and effective products and now offers a full arsenal of bird repelling devices and other pest and critter deterrents. In fact, according to company literature, today Bird-X offers the most comprehensive line of eco-friendly (i.e. "green"), environmentally safe, non-toxic and non-harmful pest and bird-control products available. They range from state-of-the-art laser technology to ultrasonic/sonic bird control, goose and pigeon repellents, bird spikes, bird netting, animal sound repellers and taste aversion gels and solutions.

Bird XPeller

• Physical Barriers: Bird Spikes, Sticky Gels, Bird Netting
  

  Gator Guard
• Sound Repellers: Bird XPeller, Critter Blaster, Goose Buster
• Ultrasonic Sound Deterrents: QuadBlaster QB 4, Ultrason X
• Taste Aversions: Bird Repellent Sprays, Bird Repellent Solutions
• 

  Terror Eyes
  Visual Deterrents: Bird BLazer, Terror Eyes, 3D Coyote

Bird-X notes that while each of its products is an effective deterrent on its own, using them in combination (i.e. a sound device plus a visual device plus a physical roost inhibitor) can yield significantly greater results than any one product alone. This is especially true in situations where pest birds are particularly stubborn, where they have nested in one place for extended periods, or where an area provides food, warmth or shelter. In spite of your best efforts, does this sound like your plant or facility? If so, a combination of Bird-X products will work synergistically to create an aurally, visually and physically undesirable environment for bird and animal pests. MT

Bird-X, Inc.
Chicago, IL

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

Dreisilker Electric Motors is re-introducing its trademark Motor-Safe Repair System for rewinding electric motors as an alternative to other destructive methods using burnout ovens. The company points out that this process results in finished motors that are more efficient, reliable and longer-lived than those subjected to burnout-oven rewinding methods.

How it works
Using the Motor-Safe process, a technician carefully removes the original windings using a controlled "warming" method and hydraulic device. This technique pulls the softened windings from the stator without damaging the stator and thus avoids the extreme, uneven temperatures of burnout ovens that distort the core and laminations. In addition to maintaining the structural integrity of the motor frame and components, the Motor-Safe process allows for a faster turnaround—typically a 1- to 2-hour process, compared to 8 to 10 hours using burnout ovens and other destructive stripping methods.

The vast majority of motor repair shops use burnout ovens to remove original windings by baking the motor to exceed 680 F. Those types of high, uneven temperatures compromise the integrity of the motor core with frame damage and iron distortion. High heat also damages the insulation of motor laminations, causing circulating currents, hot spots and uneven amperage draw. A motor coming out of such a process runs hotter, is less efficient and has a shortened half-life.

A nationwide reach
Dreisilker Electric Motors, Inc. is a leading provider of commercial and industrial motors, drives, controls and repair and field service expertise to a wide range of industries, including: machine tools, utilities, municipalities, water reclamation, heating-ventilation-air-conditioning (HVAC) and material processors. Founded in 1955, the company specializes in non-burnout motor rewind, field service and motor repair, engineered solutions and reliability-based solutions for rotating machine assets. Its corporate headquarters, located in Glen Ellyn, IL, is supported by an auxiliary sales and repair facility in McHenry, IL, as well as five other branch locations in the greater Chicago area and an additional location near Atlanta, GA.

Dreisilker Electric Motors, Inc.
Glen Ellyn, IL

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

EXAIR's new Adjustable E-Vac® is a series of low-cost, compressed-air-powered vacuum generators in which vacuum and flow rates can be easily adjusted to suit the application requirements. Engineered for high efficiency, these products minimize compressed air use by allowing it to be tuned to the application. With a simple turn of the unit, the vacuum and flow levels can be changed to overcome porosity and increase or decrease the lifting power. The straight-through, single-stage aluminum construction requires no vacuum filter and simply passes contaminants from dirty environments through the unit so there is no clogging or loss of suction. According to EXAIR, these units are ideal for a wide variety of "pick and place," box-opening, clamping, lifting, chucking and surface-mounting applications. Maintenance-free, they have no moving parts to wear out.

EXAIR Corporation
Cincinnati, OH

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

Fluid Storage & Dispensing System For Corrosive Chemicals

A Special Product Package version of the IFH Fluid Storage and Dispensing System provides an easier, safer, cleaner and more cost-effective way to deal with corrosive chemicals and other abrasive fluids that require special handling. The standard PVC sight gauge on the front of the steel containers is replaced with a glass sight gauge equipped with ball check fittings at both ends. Underneath the containers are 3/4" NPT fittings and flex steel hose for resistance to fluids that may damage the PVC hose on standard IFH systems. The Special Product Package can be supplied with new IFH fluid storage and dispensing systems or as a retrofit to existing systems.

IFH Group
Rock Falls, IL

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

Water & Particulate Removal Process

Schroeder's Triton Dehydration Station (TDS) is designed to eliminate 100% of free and up to 90% of dissolved water from small reservoirs, barrels and gear boxes. Using a patent pending transfer process, it efficiently removes water and particulate contamination quickly in all environments. A proprietary design reduces aeration of free and entrained gases of returned fluid. It is extremely portable via either a central lifting point or an optional cart to access tight areas.

Schroeder Industries
Leetsdale, PA

For more info, enter 39 at www.MT-freeinfo.com

A New Wireless Multimeter/Datalogger

Extech's new EX540 Wireless Multimeter/Datalogger features real-time wireless data transmission directly to a user's PC up to 30' away, and true RMS measurements for accurate AC Voltage and Current measurements. It's built for heavy-duty use with a double-molded housing, waterproof (IP67) protection and a CAT IV-600V safety rating and 1000V input protection. It comes standard with a large, backlit, triple LCD display that includes two sub-displays for simultaneous indication of primary readings and related minimum and maximum values. The unit incorporates a diode open circuit voltage of 2.8V DC and auto power-off with disable feature.

Extech Instruments
Waltham, MA

For more info, enter 40 at www.MT-freeinfo.com

Self-Adjusting Locking Pliers

New Crescent RapidVise pliers from Cooper Tools automatically lock onto objects of different thicknesses at a preset pressure without any user adjustment. The strength of the jaws stands up to any standard locking pliers, and the angled tooth pattern provides a superior grip over traditional models. Plus, the nickel-plated finish protects against damaging rust and corrosion. The RapidVise product line currently includes a 10-inch "curved jaw with wire cutter" model and an 11-inch ‘C' clamp in swivel pad and regular tip versions. By late 2009, the line will expand to include 5-inch and 7-inch curved jaw styles and 6-inch and 9-inch ‘C' clamps with swivel pads or regular tips.

Cooper Tools
Apex, NC

For more info, enter 41 at www.MT-freeinfo.com

Current Diversion Ring Protects VFD-Controlled Motors

VFD-controlled motors inherently produce destructive shaft currents that must be redirected around the bearings. Otherwise, unmitigated electrical currents initiated by the VFD and induced by the motor shaft destroy the bearings. Inpro/Seal's Current Diversion Ring (CDR^TM, patent pending) safely diverts these currents and saves the motor bearings. Available through all major motor manufacturers around the world, as well as EASA repair facilities, the new device can be furnished either as a "press-in," a "Clip-on," a "split" configuration or an "MGS" design, which prevents contamination from entering the motor bearing enclosure while diverting destructive shaft currents.

Inpro/Seal Company
Rock Island, IL

For more info, enter 42 at www.MT-freeinfo.com

Pneumatic Wrenches Deliver In Heavy Use

TorcUP's Raptor pneumatic wrench with patented gear technology delivers continuous and repeatable torque and an accuracy of +/- 5%. Light and fast, it can accommodate torque needs from 120 ft./lbs. to 6000 ft./lbs. A sealed housing and ergonomic grip enhance safety and user comfort. The manufacturer points out that this product has been specifically designed for industrial torque applications. Unlike pneumatic wrenches with typical air motors, the Raptor has heavy use in mind and will continue to run when others can't. It also comes with a 13-month warranty.

TorcUP
Easton, PA

For more info, enter 43 at www.MT-freeinfo.com

Metering Pumps For Cooling Tower Applications

All variations of Neptune^TM Series 500 hydraulic metering pumps are designed to handle the demanding operating conditions present in all water cooling tower applications. The company notes that these pumps feature a Variable Oil By-pass^TM stroke adjustment, which results in better valve performance than variable-linkage designs. Their valve checks have extra time to seat, even in heavy liquids, since they are idle during the by-pass portion of the suction and discharge strokes. Series 500 also feature EZE-CLEAN^TM valves, whose cartridges can be removed for cleaning without disturbing the piping to the pump. Additionally, these units are available as electric-stroke-control, pneumatic-stroke-control, variable-speed-control or sodium-hypochlorite-gas-bleed models.

Neptune Chemical Pump Co., Inc.
A Member of Dover Corporation's
Pump Solutions Group (PSG)
Lansdale, PA

For more info, enter 44 at www.MT-freeinfo.com

Adhesives For Installation, Maintenance & Repairs

Sanford Distributing introduces new, smaller quantity packaging for its Double/Bubble® epoxy, urethane and silicone adhesives. In addition to the traditional 100-pack, these adhesives now are available in Variety-Pak cartons of 25 or 50. The color-coded, dual-pouch adhesive formulations include 8 epoxies, 3 urethanes and a silicone to handle virtually any installation, maintenance or repair requirement. Users can purchase cartons of a single Double/Bubble epoxy, urethane or silicone formulation, or they can specify a combination of adhesives to meet their needs. According to the manufacturer, the patented, single-use packaging concept solves the time-consuming and costly problems of having to preserve unused portions of adhesives in conventional containers, which typically hold more material than necessary for most applications.

Sanford Distributing
West End, NC

For more info, enter 45 at www.MT-freeinfo.com

Parts: In a "cash is king" environment, deferring expenditures is always an option. When it comes to maintaining production equipment, allowing on-site spare parts to dwindle may be an outcome. However, before taking actions that further jeopardize the productivity of remaining assets, consider a vendor-managed parts repair and replenishment program. Such programs start with a detailed analysis of existing assets, and prescribe a formula for distributing stock of critical spares among manufacturer, distributor and user. This may actually free up cash. Consolidation of repair vendors can reduce transactional costs and relieve purchasing departments already stretched by prior cuts.

For example, when Pepsi Bottling Group became overwhelmed by the many sensors in its inventory, we set up a services agreement that included parts management. Today, Pepsi pays a fixed monthly cost for spare parts that are owned and managed by us—yet stocked on-site at Pepsi facilities. This lets Pepsi reduce up-front expenses, have immediate access to spares, reduce carrying costs and economically update its control technology. Also, parts don't go out of warranty before they're used.

Labor: Maintenance staffs everywhere are worn thin. With fewer hands to do the work, those who remain are often cast into new roles. Structured needs assessments provide the basis for customized training to build the skills workers need now. Access to sources of a contingent technical workforce can help bridge gaps when training is not enough. Finally, remote technical support offers a low-cost way to leverage the accumulated knowledge of equipment manufacturers.

Remote Support: Remote support encompasses a range of services, from self-help access to knowledge databases, to live support via phone and chat, to continuous Web-enabled process monitoring from a command center. Users tailor their desired approach, based on factors like number of sites and hours of coverage and the required degree of familiarity with specific applications.

CENTRIA, a leading supplier of architectural wall and roofing systems, knows the value of remote services firsthand. It has a services package with round-the-clock access to a team of specialists who have intimate knowledge of the company's processes and control system components. Engineers at our command center continuously assess production status using proprietary software applications that compare real-time and historical process data to a predetermined optimal range. If a parameter deviates outside the range, we notify production personnel at CENTRIA—often before they realize there is a problem—and begin troubleshooting. We then collaborate with plant maintenance to execute corrections and restore normal operations.

Consulting: Manufacturers finding themselves in unfamiliar waters may need outside help to better define new challenges. Consulting services can prescribe steps to optimize availability, safety, performance and compliance of assets. Resulting recommendations will likely include a mix of the services previously described.

For the remainder of the recession and as the economy recovers, manufacturers will place strong emphasis on the value of collaborative partnerships. Suppliers should be able to help define the typical ROI from a comprehensive support program. They should take time up front to identify those KPIs with a proven impact on financial performance, then create a winning strategy for increasing operational efficiency without depleting scarce resources. MT

The opinions expressed in this Viewpoint section are those of the author, and don't necessarily reflect those of the staff and management of Maintenance Technology magazine.