Sie sind auf Seite 1von 64

Do more

Servers www Ethernet RS-232

TM

with

COMMUNICATIONS

SMTP Gateway

ViewMarq Industrial LED Message Displays RS-232

Sureservo Servo System

Barcode Scanner

Printer

2013
WINNER

RS-232 RS-232 RS-485 SOLO Temperature Controller SOLO Temperature Controller

RS-232 C-more HMI Ethernet RS-232

CLICK PLC Factory Network MODBUS TCP Server MODBUS TCP Server C-more Micro

DL205 PLC

Tons of communication options


The Do-more PLC oers connectivity right out of the box, and beyond. Whether you need serial communications to control devices, or high-speed Ethernet to connect to plant networks, you can do it easily and inexpensively with Do-more:
The first Ethernet port is a real bargain since it comes embedded on the H2-DM1E CPU ($399) All Do-more CPUs also have one serial port built in to communicate with other control devices For more serial ports, add H2-SERIO-4 modules, with three ports per module ($176 each) Need more Ethernet? Segregate Do-more connection to Ethernet networks for security or isolation by adding an H2-ECOM100 module ($301 each)

Each Do-more CPU comes with a coupon for a 30-day free trial of online video training. So visit www.do-moreplcs.com for the details, watch overview videos, and download the free programming software Do-more Designer to take it for a spin. Starter kits are available also.

Name your devices Give your communication ports logical names and refer to those names in your program for ease and clarity. Define a custom protocol with an instruction set that lets you define a non-standard data exchange (serial or Ethernet!)

Research, price, buy at: www.automationdirect.com/do-moreplcs

Order Today, Ships Today!


* See our Web site for details and restrictions. Copyright 2013 AutomationDirect, Cumming, GA USA. All rights reserved.

1-800-633-0405

the #1 value in automation

input #1 at www.plantengineering.com/information

2249
KNIT GLOVES

3709
SANDING HAND PADS

612 1990
STACK & HANG BINS

CONNECTORS

One less thing to worry about. Grainger KeepStock Inventory Management Solutions
Youve already got enough to do. You could use some ideas to handle the constant stream of parts and products that help keep your facility running. KeepStock solutions can help you organize, find, replenish, track and manage your MRO products. And thats just the tip of the iceberg. Find out more at grainger.com/keepstock.

Grainger KeepStock solutions are subject to customer eligibility and agreements. The Grainger shipping box design is a registered trademark of W.W. Grainger, Inc.

input #2 at www.plantengineering.com/information

ITS WHATS ON

THE INSIDE
No matter who made your dust collector, you can count on Donaldson Torit to have your next lter replacement. With more than 90,000 lters in stock, there is a Donaldson Torit lter to t most makes, models, sizes and styles of collectors. And, with our Ready2Ship program, your lters will be on their way within 24 hours. For the best lter selection and performance, Donaldson Torit has EXACTLY WHAT YOU NEED.

THAT COUNTS

input #3 at www.plantengineering.com/information

DonaldsonTorit.com 800.365.1331

Learn more about how pleated lters can solve baghouse collector problems:
www2.donaldson.com/pleatedbags

2013 Donaldson Company, Inc.

Whats INside
6 9 16 17 50 53 54 55 56

December 2013
Volume 67, No. 10

Interactive In Focus Apps for Engineers Media Showcase Innovations Product Mart Internet Connection Advertiser Contacts In Conclusion

37 2013 SI Giants
PLANT ENGINEERING (ISSN 0032-082X, Vol. 67, No. 10, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/ COO/Co-Founder. PLANT ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia. com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

18 Top Plant
Cover story

Lincoln Electric Co., Cleveland

Some manufacturers build for today. Some manufacturers plan for tomorrow. The truly successful companies can do both while growing their company and successfully empowering their workers. No better example of that philosophy exists today than the success Lincoln Electric has enjoyed over the past few years. Their reputation for leadership in the industry and their attention to manufacturing excellence makes them a worthy recipient of the Plant Engineering 2013 Top Plant award.
PLANT ENGINEERING

www.plantengineering.com

December 2013 3

Weld Smoke Collector

Paper Scrap Handling Systems

Abrasive Blast Dust Collectors

Laser Cutting Smoke

Looks Like a Safe Because Its


Bag-in Bag-out Filter Change
Large Agriculture Installations

TM

Food Processing Dust

Dust From Thermal Spraying

Dust From Chop Saw

Plasma Cutting Smoke Collector

is the most rugged, reliable, easy to maintain dust collector on the marketGUARANTEED!

Plant Engineers, the Camfil APC Farr Gold Series

The Farr Gold Series modular design allows for virtually unlimited customization and our exclusive stocking program assures that your Farr Gold Series is delivered when you need it.

Call us about NFPA and ATEX Explosive Dust compliance issues.

Toll Free:

International Calls:

866-354-8794
AIR POLLUTION CONTROL

1-870-933-8048

Follow. Connect. Watch. Learn.

www.camfilapc.com
input #4 at www.plantengineering.com/information

Virtual ride and fly through a Farr Gold Series

2013 B EST P RACTICES


PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph 630-571-4070, Fax 630-214-4504

CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager 630-571-4070 x2212, BVavra@CFEMedia.com AMANDA MCLEMAN, Project Manager 630-571-4070 x2209, AMcLeman@CFEMedia.com BEN TAYLOR, Project Manager 630-571-4070 x2219, BTaylor@CFEMedia.com CHRIS VAVRA, Content Specialist CVavra@CFEMedia.com

25 Building wildfire engagement in Lean

When introducing Lean manufacturing into a facilityand in order to maximize the velocity of the initiativeall parties involved must be engaged, and the engagement must be quick, decisive, and targeted.

PUBLICATION SERVICES
JIM LANGHENRY, LANGHENRY Co-Founder & Publisher 630-571-4070 x2203, JLanghenry@CFEMedia.com STEVE ROURKE, Co-Founder 630-571-4070 x2204, SRourke@CFEMedia.com TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com KRISTEN NIMMO, Marketing Coordinator 630-571-4070 x2215, KNimmo@CFEMedia.com MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com PAUL BROUCH, Director of Operations 630-571-4070 x2208, PBrouch@CFEMedia.com MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com MARIA BARTELL, Account Director, Director Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com RICK ELLIS, Audience Management nagement Director 303-246-1250, REllis@CFEMedia.com LETTERS TO THE EDITOR Please e-mail your opinions to BVavra@CFEMedia.com. Letters should include name, company, and address, and may be edited for space and clarity. INFORMATION For a 2013 Media Kit or Editorial Calendar, e-mail Trudy Kelly at TKelly@CFEMedia.com. REPRINTS For custom reprints or electronic usage, contact: Nick Iademarco, Wrights Media 877-652-5295 x102, niademarco@wrightsmedia.com

26 Four ways fabric curtain walls can improve energy efficiency


By enclosing open dock areas with fabric curtain walls, companies can have an easier time keeping the thermostat at a consistent temperature and reduce energy spending.

28 Use an FEB to ensure safe installation, operation of electrical equipment

The risk associated with not evaluating or not ensuring the compliance of electrical equipment is very high, which is why the role of third-party product safety testing organizations is so important.

PUBLICATION SALES
Tom Corcoran, West, TX, OK 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Karen Cira, Southeast 879 Autumn Rain Ln. Charlotte, NC 28209 Patrick Lynch, AL, FL 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523

TCorcoran@CFEMedia.com Tel. 215-275-6420 Fax 484-631-0598 KCira@CFEMedia.com Tel. 704-523-5466 Fax 630-214-4504 PLynch@CFEMedia.com Tel. 630-571-4070 x2210 Fax 630-214-4504

30 For a steam pressurereducing valve station, set up is crucial

Through proper system design, component selection, and installation of a steam pressure-reducing valve station, you may be able to greatly prolong the life of all the steam components.

Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com jwafalosky@cfemedia.com Tel. 216-409-8314 246 South Franklin St. Street Phone: Chagrin Falls, OH 44022 44022 Fax: Fax 440-348-1980 Richard A. Groth Jr., NJ/ E. PA 12 Pine St. Franklin, MA 02038 Stuart Smith, International SSM Global Media Ltd. RGroth@CFEMedia.com Tel. 774-277-7266 Fax 508-590-0432 stuart.smith@ssm.co.uk stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588

www.plantengineering.com

PLANT ENGINEERING

December 2013 5

DECEMBER

www.plantengineering.com

Trending

New Products

Maintenance

Electrical

Mechanical

Energy Management

Plant Automation

Safety

People and Training

3,000 strong and growing Finalists announced Nov. 15 Plant Engineering Professionals, the LinkedIn
The finalists for Engineering the 2013 Plant Engineering group for Plant magazine, just Product of the Year awards will be passed the 3,000-member mark inannounced December in the November issue rapidly. and online on Nov. has 15. and continues to grow This forum Its the plantmanufacturing managers source for the best new attracted professionals from products of the year, and theirthe chance tobuzz vote is on all over the world. See what all the the best of the best in manufacturing. about at Linkedin.com, and use the keyword, www.plantengineering.com/poy Plant Engineering Professionals.

LinkedIn members Product of the Year

Video: Control panel makeover: Before and after


Machinery original equipment manufacturers, panel builders, and others can more easily see the productivity, reliability, and economic advantages of using a smart-module-type device-level wiring system when compared to a conventionally wired control panel. In an interview with CFE Media, Richard Chung, Eaton product manager for Lean automation, explained how to streamline control panel design to produce overall savings of 35% and build time savings of 60% or more. Scan the QR code or go to www.plantengineering.com/videos.

Safety Workforce development Workforce development Energy management Energy management

On Plant Engineering Engineering conducts conducts On a a quarterly quarterly basis, basis, Plant research research studies studies on on various various industry industry topics. topics. Access the the following following full full reports reports at at Access www.plantengineering.com/research www.plantengineering.com/research:

Editorial Editorial research research

Let your voice be heard


This month, we invite our Plant Engineering readers to participate in the 2013 Salary Survey. This benchmark study takes a look at compensation trends by industry and by region, and looks at how plant managers are paid and 2013 SALARY SURVEY incented for leading U.S. manufacturing out of the Great Recession. Another part of our Salary Survey is the exclusive Manufacturing Pulse section, where we ask about the issues that affect your plant operation, your confidence in manufacturing as a whole and your outlook for the new year. Go to www.plantengineering.com and click on the Salary Survey button on the home page to complete the 2013 survey. You can look for the results in Plant Engineerings annual forecast issue in February and online at www.plantengineering.com on Feb. 10, 2014.

On-demand videos On-demand videos Upcoming and on-demand Webcasts Upcoming and on-demand Webcasts Online training center Online training center Case studies130+ all in one place on Case studies130+ dozens of topics all in one place on dozens of topics eGuides eGuides White papers White papers Site search engine: Search current and Site search engine: Search current and past articles at www.plantengineering.com by topic, past articles at www.plantengineering.com by topic, keyword, author or company name to find solutions keyword, author or company name to find solutions to your plant issues. to your plant issues. Channels, new products Channels, new products Visit our specialized microsites providing feature e-Newsletters e-Newsletters Keep current with the latest information
Visit our specialized microsites providing feature news, products, applications, tutorials and research news, products,professionals. applications, tutorials and research for engineering for engineering professionals. Keep current with latest information and news with ourthe weekly PlantMail and topicand news with our newsletters. weekly PlantMail and topicspecifi c electronic specific electronic newsletters.

People and training People and training

Services available Services available

In your opinion
Whats the biggest challenge facing your maintenance department?
Your responses at www.plantengineering.com:

System Integrator Guide System Integrator Consult our listing of more Guide than 2,300 automation Digital edition Digital edition Plant Engineering is delivered every month in a

56% 27% 15%

Lack of qualified people available to support and maintain my facility Pressure to increase production and productivity Complex, interconnected technologies that make downtime harder to resolve

Consult our listing of more automation system integrators. You canthan find 2,300 a specifi c company system can find a specifi c company or run aintegrators. seven-way You multi-parameter search. or run a seven-way multi-parameter search. Plant isenhanced delivered features every month in athe digitalEngineering format, with to bring digital format,alive withon enhanced features to bring the print product your screen. print product alive on your screen.
www.plantengineering.com

A new poll question is posted every two weeks at www.plantengineering.com.

6 December 2013

PLANT ENGINEERING

GE Power Conversion

The power to help you grow.

Our motors work well with your compressors, pumps, and many other applications to deliver a solid, reliable platform for owners and operators. GE has the value you know and the reliability you have learned to trust. Our machines fully comply to all applicable IEC and NEMA standards, are competitively priced, and are available in stock today. For the best AC and DC motors, there really is nowhere else to turn. Visit us at www.gemotors.com for more information.
input #5 at www.plantengineering.com/information

Give your next pneumatic conveyor the PNEUMATI-CON advantage:

The pneumatic conveying expertise you need for top efficiency, plus the broad process experience you need for seamless integration with your upstream and downstream equipment.
It takes more than a great pneumatic conveyor to deliver your bulk material with top efficiency. It also takes process engineering experts who know, in advance, how your process equipment, storage vessels, and material will affect your conveying results. Which is why you should rely on Flexicon. Under one roof you will find a comprehensive line of robust pneumatic conveyor components from filter receivers and rotary airlock valves to cyclone separators and blowers, and the in-depth pneumatic experience it takes to size and configure them to yield maximum efficiency, longevity and cost effectiveness. As importantly, you will find experienced process engineers who draw on Flexicons 15,000+ installations integrating conveyors, screeners, grinders, crushers, blenders, weigh hoppers, bulk bag unloaders/fillers, bag/drum dump stations, and/or storage vesselsexperts who understand how your upstream and downstream equipment can impact, and be impacted by, the operation of your pneumatic conveyor. Going the extra mile to outperform competitive pneumatic conveyors is what the PNEUMATI-CON advantage is all about. Its what enables Flexicon to guarantee top results, and you to make pivotal improvements to your process with absolute confidence.

When you convey with Flexicon, you convey with confidence

.com

See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

USA sales@flexicon.com 1 888 FLEXICON


input #6 at www.plantengineering.com/information

CHILE UK AUSTRALIA SOUTH AFRICA

+56 2 2415 1286 +44 (0)1227 374710 +61 (0)7 3879 4180 +27 (0)41 453 1871

BB-0721

2013 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

IN FOCUS
Use 4 key practices to enhance big datas value
By Dennis Brandl, BR&L Consulting

Big data is a big thing in information technology. Companies are collecting big data and analyzing it using sophisticated analytical tools to find hidden patterns and correlations. The shopping giant, Target, uses big data and analytics to determine when its customers have life changes, such as weddings, babies, and grandchildren, and then sends them individually targeted advertisements. Wouldnt it be great to be able to determine when your manufacturing systems have significant changes, such as failing equipment, changed raw material properties, or energy and labor costs, and to automatically determine the best operating conditions? That is the appeal of big data in manufacturing, and why manufacturing companies are starting big data projects for their production facilities. If you are starting a big data project, there are four important facts to remember.

A good practice is to use off-line copies or a data warehouse for analysis. Most plant data historians are optimized for writing data, and extracting the large amounts of data needed for big data analysis can take an extremely long time on a running system.

make sure that your sample size is large enough to determine correlations and causations. A small sample size may indicate invalid correlations and send you down the wrong path for corrections. It is also important to not confuse correlation with causation. Just because a correlation was discovered does not mean that the events are causally related. Data analysis can discover correlations, but there is still an engineering task required to determine if one is the cause of the other. It is important to have engineers or scientists involved in a big data analysis project so that real causations can be determined based on an engineering analysis and that data was not cherrypicked to find a correlation.

Operational staff members often have deep knowledge of the production systems and relationships, and discover hidden or nonobvious correlations.

1. Data needs context

The first is that data without context has limited value. In the manufacturing world, context is provided by either the job or recipe step being executed. Each piece of data must also be associated with the job being executed or product being produced and with all associated quality measures for the job. This context allows job-to-job comparisons to detect significant changes. The first step in using manufacturing big data is to collect context or event information and link it to your plant historian. Fortunately, all major suppliers of plant historians provide event or context addons that can link manufacturing execution system (MES) workflows or recipe execution systems to the historian data. The second fact is that online historians are great tools for saving data, but not necessarily analyzing data.

A better strategy is to perform periodic backups of the historian data to an offline system that is used for analysis or to consolidate the data into a data warehouse optimized for big data analysis.

2. Optimize for analysis

3. Consider sample size

The last fact to remember is that they can help detecting patterns is something that people do naturally but is difficult to automate. You can use this to your advantage by empowering your people to search and discover in the data warehouse. Operational staff members often have deep knowledge of the production systems and relationships, and they can help discover hidden or non-obvious correlations. Adding context to saved data, working in a data warehouse optimized for analysis, objective storytelling, adequate sample sizes, appropriate conclusions about correlation and causation, and empowered personnel are key elements of a manufacturing big data project. Ensure your projects use these practices to bring the value of big data E analysis to the production floor. P Dennis Brandl is president of BR&L Consulting in Cary, N.C. His firm focuses on manufacturing IT.
PLANT ENGINEERING

Empower people

4.

The third fact to remember is that you can prove anything with the right statistics. To prove the right thing,

www.plantengineering.com

December 2013 9

IN FOCUS
2014 AHR EXPO

New industry survey shows a warm forecast for 2014


By Bob Vavra, Content Manager

than 10%. The biggest growth markets are expected to be in the healthcare, commercial and data center marhile the weather forecast outside for the 2014 kets. A total of 58% of respondents ranked heavy comAHR Expo in New York City next month can be mercial business a promising growth market, while 53% unpredictable, the forecast for the industry that saw manufacturing as a strong growth market. will meet inside at the Javits Center is While reliability and installed decidedly more positive. 2014 AHR Expo costs are seen as key issues for all A poll of HVAC industry leaders segments of the industry, energy DATES: January 21-23, 2014 ahead of this years event, slated for management is a growing market LOCATION: Javits Center, New York City January 21-23, shows not just a growtrend. That is reflected in the exhibiEXHIBITORS: More than 1,800 HVAC ing optimism for the coming year, but tor offerings at this years Expo. companies are scheduled to exhibit at a decided lack of pessimism. More than two-thirds of attendees the 66th annual event The survey of the 1,000 induswill introduce new products at this WEBSITE: www.ahrexpo.com try leaders found 79% expected a years AHR Expo, and 54% expect good or excellent business climate to debut energy-efficient products. in the coming year. The remaining 21% rated the prosReducing energy usage for our customers is one pects fair. A year ago, only 70% were optimistic about of our most important goals, said Michael ONeil of the coming year, and 3% expected a decline in the Armstrong Fluid Technology, in an AHR press release. economy. We will be introducing some very innovative energyThat optimism is reflected in a bullish sales forecast saving products and solutions at AHR Expo that are as well. The survey found 90% of respondents expected designed to significantly reduce our customers carbon sales to increase in 2014, and 32% saw growth of more E footprint. P

Registered:
ality M Qu

ageme an

9001:2008

ISO

input #7 at www.plantengineering.com/information

S nt

ystem

10 December 2013

PLANT ENGINEERING

www.plantengineering.com

input #8 at www.plantengineering.com/information

IN FOCUS
Top 10 ways to streamline a live factory project
By Julian Quist, PE, SSOE Group

When it comes to design and construction projects, the conventional design process is relatively straightforward: the client hires the firm, the client shares expectations and requirements for the project, the firm develops and refines the design, and the design is constructed. Client expectations are confined to satisfaction with the final constructed state as it relates to functionality and aesthetics. The rules change when the facility is already built and operating and cannot be shut down for the sake of the project. While the objective of the project remains the same as in a conventional construction projecta functional, codecompliant designthe path to achieving a complete design and getting the project constructed under budget is far more complicated. Here are 10 great tips that can serve as a checklist of sorts to evaluate

whether you and your A/E supplier are employing best practices on your new design project: 1. Always be mindful that the A/E firm is a consultant accountable only to the project manager (PM). As the design is developed and the A/E interacts with stakeholders, new requirements and scope will be discovered, some more justified than the rest. The PM must decipher which of these elements should be incorporated into the project and determine the value of added design and construction costs. 2. Do not underestimate project impacts to pipelines, electrical panels or equipment. Necessary work-arounds may require engineered designs, bypass piping, or ductwork. Temporary facilities or HVAC and/or a plan for partial plant or equipment shutdowns may also need to be provided.

3. Keep the system owners in the loop. Generally, the purpose of projects is to upgrade or improve their systems. Being that they operate the systems, they can provide valuable insights for improvements or report system inadequacies. Sometimes projects can be oriented to be win-win by rectifying already existing issues at no incremental cost. 4. Field verification is crucial. Moving even small conduits, pipes or tubes in live factories can sometimes be impossible. Conflicts must be identified prior to releasing a design with foreknowledge that obstacles will be moved or the design will accommodate the obstacle in place. Diligence on the part of the A/E firm to identify conflicts between design elements and existing obstacles and decision making on the part of the facilitys stakeholders to decide how to accommodate these conflicts in the design in a timely fashion is crucial to project success.

input #9 at www.plantengineering.com/information

5. When new equipment is being placed on a factory floor, consider move-in paths. Can the equipment physically get from the loading dock to its installation location in one piece? Equipment may have to be designed or ordered in pieces or scope may need to be included to clear a path. 6. Interim conditions can be a crucial consideration. While the existing state works for the facility and the final constructed state also works, what about the state during construction? Is there room for the work-around and the new construction to exist simultaneously? Can the facility continue to operate during the he installation of new equipment? 7. Get buy-off from system and process owners during design development to shut down or modify systems. Sometimes the obvious Plan A is a no-go.

For instance, the nearest available tie-in that can be used might be hundreds of feet further away than expected, which adds significant project cost. System and process owner input is crucial with these considerations. 8. Analyze connections to piping and ductwork during design development. Some piping and ductwork materials or contents are not appropriate for hottapping either for engineering reasons, facility safety, or operational protocols. That said, if the design requires connecting to a system that doesnt have an available connection and cannot be shut down, the facility is going to have to consent to the use of an existing connection or coordinate a shut-down of that system to make a tie-in. 9. F ocus design review sessions around the issue of system interruptions and associated ramifications.

It is easy for an A/E to overestimate the effectiveness of communications within their clients organization. Try to get system owners and process owners engaged in the discussion of anticipated system interruptions. 10. Consider air quality requirements within the facility. Air quality can be an important concern to process owners at facilities that make food products, pharmaceuticals, microprocessors, etc. Concrete saw-cutting, welding, painting, gluing and roof work are just a few construction activities that produce dust or odors. Watch where outside air is taken in relative to these activities. Watch also for pressurization relationships between areas within the facility and E outdoors. P Julian Quist, PE, is a mechanical engineer with SSOE Group.

input #10 at www.plantengineering.com/information

IN FOCUS Make maintenance a dream for 2014


By Paul Lachance, Smartware Group

As 2014 approaches, business innovators are cooking up their heady goals: a new social network that mints billionaires; a Swiss Army smartphone that

makes your coffee; an affordable electric car with a 2,000 mile battery. Need some ideas for maintenance goals? Below are a few to get the process started. Most importantly, brainstorm with your team on areas you would like to improve or

enhance. If you dont have an automated computerized maintenance management system (CMMS), the goal is easy: find one! If CMMS is already part of the culture, consider adding these tactics:

Basic

RISK FREE
Providing the HIGHEST Air Purity Certied ISO 8573-1 CLASS ZERO & SILICONE FREE The ULTIMATE CHOICE for efcient 100% oil-free air

OIL-FREE D & DH SERIES

n Add/decrement spare parts in with your work orders. Now, when you track work orders (WOs), you can also track associate parts and decrement them to give you an accurate quantity on hand. n Automate your maintenance request process. If your team still gets request on paper or via email have them submit requests through your CMMS to end up as a WO, which you can track in a streamlined, automated flow.

D & DH Series
15 kW160 kW Oil-Free Rotary Screw Compressors Fixed & Variable Speed (RS)

n Prioritize WOs based on a traditional priority, criticality of asset, location, etc. Most WOs are tracked by priority classification, but if you match up the work with the importance of the asset and its location you can get a more accurate prioritization. n Set a goal to reduce your down-time by X%. X meaning a reasonable, achievable goal. Note, to hit this target you must be able to first measure your downtime! If you cant estimate machine downtime, head back to the basic section! n Associate your safety programs with your preventive maintenance (PM)/ WOsjob safety analysis, advanced lock out/tag out, etc. Ensuring your team has proper safety-related information, proper certifications, and emergency resources helps create a safe work environment, fewer accidents and regulatory fines. n Start using predictive analysis to better shape your frequency/timing of PMs for offending assets. Take the wealth of operational data, much of which comes from managing WOs and predict where and when to do your PMs. Whether you use a consultant or tackle it yourself, set some goals. It gives you something to chase and win. Make 2014 the year E you kick maintenance into high gear. P Paul Lachance is president and CTO for Smartware Group.

Intermediate

Advanced

input #11 at www.plantengineering.com/information

14 December 2013

PLANT ENGINEERING

GUARANTEED UPTIME
PROTECT ASSETS 24/7 WITH RELIABLE CONTINUOUS POWER
Your Cat Dealers are ready for all your power generation demands . . . permanent or temporary, large or small, urban or rural, simple to complex. From diesel and gas generator sets to uninterruptible power supplies, automatic transfer switches and electrical switchgear, our experienced worldwide network can deliver the power systems and support you need. We like to think of it as guaranteed uptime. Any size or shape, in any regulatory environment. When you need power, Cat is equal to the challenge. Visit us online today at www.NECatDealers.com/power
input #12 at www.plantengineering.com/information

SINCE 1927 Alban CAT


www.albancat.com Baltimore, MD 800-492-6994

SINCE 1948 Cleveland Brothers


www.clevelandbrothers.com Murrysville, PA 888-232-5948

SINCE 1923 H.O. Penn Machinery


www.hopenn.com Poughkeepsie, NY 845-437-4051

SINCE 1960 Milton CAT


www.miltoncat.com Milford, MA 866-385-8538

SINCE 1916 Giles & Ransome Inc.


www.ransome.com Bensalem, PA 877-RANSOME

2013 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com www.caterpillar.com

APPS FOR ENGINEERS

Featured apps
iQagent iOS 6.0+

CFE Medias Apps for Engineers is an interactive directory of more than 170 engineering-related applications for Android and iOS operating systems, created by various companies. The app helps users do their jobs better and save time, providing a pre-sort of relevant mobile engineering applications loaded with various calculators, catalogs, file viewers, measurement tools, and more. www.plantengineering.com/appsforengineers

Cost: Free Company: iQuest Inc. Company Website: http://iqagent.com


iQagent is a holistic data display and recorder for industrial and process environments. It will allow you to make your plant oor a data rich environment where you can access live process data, documentation, and resource links on specic machines, equipment, and processes on the plant oor. iQagent also works with Apple TV, so the display can be shown in real-time to management without having to disturb production.

Friction Calculator Android 2.1+, iOS 4.3+


Cost: Free Company: T2 Content Works Company Website: www.magnaplate.com
Based on General Magnaplates friction calculation tool, this application provides dynamic as well as static coefcients of friction for many pairings of regularly used materials and engineered coatings.

Mechanics Basics Android 1.5+, iOS 3.0+


Cost: Android $1.93, iOS $4.99 Company: FPC Ltd. Company Website: www.fpcapps.com/products
Mechanics Basics contains a large selection of laws, equations, tables and reference material that engineers may nd useful during their day-to-day operations. The application covers beams, measurements, gears, conversion formulas, and more.

ProductWhiz Android 2.2+


Cost: Free Company: Larsen & Toubro Ltd. Company Website: www.larsentoubro.com
ProductWhiz is an app that helps the user select switchgears faster and more accurately than previously. The app let the user to select Type 2 coordinated switchgear for IE1/IE2 motors, star-delta/direct-on-line starter, fuse/fuseless short circuit protection.

16 December 2013

PLANT ENGINEERING

www.plantengineering.com

MEDIA SHOWCASE FOR ENGINEERS


Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

Lighting Solutions
Explosion Proof High Bay Light Fixture Portable Explosion Proof LED Light Power Distribution Substation Solar Powered LED Strobing Beacon

Cart Mounted LED Work Area Light

High Intensity LED Light Bar

360 Degree Magnetic Mount Beacon

Mini Light Tower

www.magnalight.coml 1-800-369-6671lsales@magnalight.com
Input #100 at plantengineering.hotims.com

R. M g n You oved r App

Want to receive your Plant Engineering magazine as a

Plant Engineerings

electronic newsletters
Its time to get your plant ahead of the curve.

WELDER
RECEPTACLES
PROTECT FROM ARC FLASH
Safely breaks load UL Switch-Rated

digital publication?

OFF BUTTON

Update your subscription, and get our digital edition, on our NEW more interactive platform, in your e-mail in-box.
Update now at:

PlantMail HotWire Maintenance Connection Product Showcase Energy Management Safety & Security

Rated up to 200A 600V

EASY TO LOCKOUT/TAGOUT

Subscribe today. www.plantengineering.com/newsletters

www.plantengineering.com

meltric.com 800.433.7642
Input #101 at plantengineering.hotims.com

ple201310_digitlEditn_6th.indd 1

10/9/2013 8:48:01 AM ple201310_eNewsltr_6th.indd 1

10/8/2013 3:54:27 PM

PLANT ENGINEERING

December 2013 17

2 0 13

A spark of excellence
Many factors determine how well a manufacturing plant performs. Those that perform best are qualified to become a Top Plant.

xceptional manufacturing companies are more than just fabrication cells, assembly lines, or loading docksthey are departments working together in harmony. Successfully putting proven management philosophies into realworld action welds values and work ethic to form a cohesive culture at the Lincoln Electric Co. in Cleveland. The companys machine division is the recipient of the Plant Engineering 2013 Top Plant award. Lincoln Electric is the worlds largest manufacturer of arc welding equipment and consumables as well as a technological leader in the welding market. The companys machine division and the global headquarters are located in Euclid, a suburb of Cleveland, with a plant in nearby Mentor. The machine division occupies a little more than 800,000 sq ft of the 1.5 million-sq-ft main facility; the consumable division occupies the rest. The 14 departments within the machine division at Lincoln Electric are divided into supply, assembly, and support departments. The four supply departments provide work in progress (WIP) to the four assembly departments. The six support departments are the supply management, production planning, quality assurance, manufacturing engineering, material handling, and time study groups. The material handling group is also responsible for the storeroom, replenishing the manufacturing floor, and spare parts fulfillment. The group also includes a tool room responsible for die repair or buildup, fixtures or work holding devices, and plastic molded parts. The time study group performs the time-andmotion studies that become the benchmarks for completing every task in the facility.
PLANT ENGINEERING

Manufacturing and plant floor employees agree that the companys incentive management system and the entrepreneurial environment top the list of the many attributes that make Lincoln Electrics machine division an exceptional plant. Incentive management is the cornerstone of Lincoln Electric, said Geoff Lipnevicius, general manager of the machine division. It drives a culture that recognizes that our people are our greatest asset. It gives people an incentive to perform. Its a very big aspect of the company and its what really drives the machine division to be an exceptional plant. For many people, when the word piecework is mentioned, sweatshop comes to mind. At Lincoln Electric, these words are not synonymsand they never have been. Piecework, guaranteed employment, and the highly anticipated annual employee bonus are elements that marry the companys incentive management system and the entrepreneurial environment. In most cases, pieceworkers at Lincoln Electric are like entrepreneurs because they get paid only for the number of quality pieces they produce. Every job has standards that determine the average output from an average worker per unit of time. We go through time-and-motion studies on every task in our facility, Lipnevicius said. We ensure that when we say a task takes 30 seconds to complete, the assessment is fair and accurate. Lincoln Electric has not laid off any permanent employees who meet the companys performance standards due to lack of work or economic conditions since
www.plantengineering.com

18 December 2013

All images courtesy: Lincoln Electric Co.

By Jack Smith, CFE Media

Incentive management, entrepreneurial environment

1948. The Guaranteed Continuous Employment Plan was approved by the board in 1958. Regardless of the cyclical nature of the business, we dont lay off people, said Doug Lance, vice president of operations at Lincoln Electric. We only discharge people for poor performance just as any company would. When business is slow, we have the option to transfer people into jobs where there is work. By retaining our people, we keep the talent and knowledge within the company. Employee flexibility can translate into substantial rewards. We try to instill flexibility into our employees, said Lee Seufer, plant engineering manager for Lincoln Electrics machine division. We reward people with a substantial profit-sharing bonus at the end of each year. Part of this required flexibility involves cross-training. Employees who can run seven different machines are more valuable to us than those who can run only two, Seufer said. The size of the bonus depends on how an employees performance is rated in five equally weighted categories: output/productivity; quality; environmental, health, and safety (EHS); adaptability/flexibility; and teamwork/communication. The annual profit-sharing bonus has been in place at Lincoln Electric since 1934. For production workers, the merit basis is straightforward: make more, earn more. However, this model doesnt scale for maintenance employees.The best people typically tackle the toughest jobs, which usually take longer. Applying the productionoriented piecework model would work against them. The incentive management system in the maintenance department is managed differently, said Seth Mason, superintendent of maintenance. We rate people in 20 categories, such as safety behavior, completed training requirements, and project leadership. The incentive management system really ties everything together, said Dave Sterio, maintenance support engineer. It encourages the right kind of activities and behaviors. Its what makes us unique.
www.plantengineering.com

Figure 1: Every task in the facility is optimized for operator efficiency and analyzed to determine timing benchmarks.

Simplified workflow

Lincoln Electrics machine division makes three platforms of welding equipment. The newer, high-tech products are inverter-based welders. The traditional welders use the transformer/rectifier type design. Welders that are powered by engine-driven generators are included in the third platform. Workflow through the machine division facility is simple, although the same could not be said 20 years ago. Were laid out in bays from North to South, said Dave Perrin, chief plant engineer at Lincoln Electric. Raw materials come in at the north end of the building. Sheet metal comes right off the truck dock to its point of use where the operators use laser cutting machines, punch presses, and forming equipment to fabricate the parts that will become welding machines. After the fabricated parts are painted, they are assembled into finished products, tested, and then carted to shipping. Standard products are typically routed to the distribution center. The bulk of what we sell is make-to-stock, Seufer said. We have some made-to-order products. There are some specials that come through the operation as well. For example, somebody may need a special type of electrical connection for a special type of welding that theyre doing. Someone may need special or custom software that allows them to weld a special application. The machine division uses both assembly lines and cells to manufacture welders. Seufer said, Depending on the market were serving and the type of welder were building, we might be in a low-volume, high-mix module or we might be in a high-volume, low-mix module. The module were in at the time dictates how we make our products. I think Lincoln Electric is set up very well in how we develop our products and processes to allow us to be successful, Perrin said. The physical layout of our facility was designed intentionally to locate the engineering departments in the center of the plantright in the middle of the
PLANT ENGINEERING

December 2013 19

2 0 13

manufacturing area. By locating plant, manufacturing, and R&D engineering as well as new product marketing departments in the middle of the manufacturing area, theres a direct line of communication between engineers, supervisors, and shop personnel on the production floor. Our goal is to make welding the most cost-effective method to join materials together, said Lipnevicius. We have to constantly create increasingly more value in our products for lower cost, and we have a very good team that drives performance here. Quality has always been an emphasis at Lincoln Electric. However, manufacturing high-quality welding equipment has not always been as efficient as it is today. We recognized around 1999 that we were very busy, Seufer said. We decided to move from a push strategy to a pull strategy. We chose to stock some of every product in our finished goods warehouse, watch what customers bought, and replenish those items. In doing so, we dramatically reduced inventories. We started putting our efforts toward what the customers were buying, not what we hoped they would buy. Making this switch created some unique challenges for Lincoln Electric. Our evolution into Lean started around the year 2000, said Seufer. Going from a push system to a pull system was the spark that got the journey toward Lean started. But believe me, swapping more than 18 acres cant be done overnight. Its definitely a challenge. Lean is definitely an evolution. The pull system really works, said Lance. Our metrics measure on-time attainment: Our products are delivered to the

Journey toward Lean

warehouse when we say they will. Currently, our attainment numbers are running between 96% and 99% nearly every week. Thats an enormous increase from where they used to be. Lincoln Electric management has supported the journey toward Lean from its introduction into the company. Lean was driven from the very top of the organization, Seufer said. In the past, we were very focused on direct labor. Whatever we could do to reduce labor cost was always the issue. However, we came to realize that for every labor dollar, there are many dollars of overhead. In addtition to reducing labor, we started looking for ways to reduce overhead. Waste reduction is a very effective way to reduce overhead. Were continually looking for ways to eliminate non-value-added processes and activities, such as material handling and setup time, said Seufer. Setup reduction is a great example. The way we used to operate, we didnt focus on how much time it took us to set up as long as our piecework price was low. It may have taken 2- to 6-hour to set up a press just so that we could make parts rapidly. Then we realized that creating a setup reduction program could save us a lot of money. Today, our presses are optimized for quick changeovers. Long changeovers now might take 10 or 15 minutes. Lincoln Electric also optimized the molding presses and welding cells for quick setups. Not only did setup reduction save us a lot of money, it also freed up a lot of capacity, Seufer said. When you have a machine thats not producing for 2 to 6 hours, you might as well buy another machine. Focusing on scrap is a good way to identify processes that might not be in control. We do Pareto charts on everything we make said Seufer. If we get too much scrap out of a certain area, we may have to run more production through that area just to get the yield we need. We used this process to identify projects for waste reduction opportunities. And in the first 4 to 5 years of the waste reduction program, we reduced scrap by about 51%.

Working safely

Figure 2: Sheet metal is transported from the truck dock to its point of use.

WELD an acronym for Workplace, Education, Lifestyle, Disciplineis one of the companys horizontal safety teams. Lincoln Electric rolled out WELD in 2001 as a grassroots initiative to help improve the safety behaviors of the employees. WELD group members come from every production team. The education element is intended to ensure that employees have the training to do their jobs, said Bob Siktberg, EHS manager for North American operations at Lincoln Electric. Lifestyle means keeping fit for work, eating healthy, being well rested, and stretching before doing work. The discipline meaning self-disciplinemeans not taking shortcuts and risks, and not bypassing guards, for example. Lincoln Electric has a traditional safety committee, which is led by a machine division
www.plantengineering.com

20 December 2013

PLANT ENGINEERING

steering committee. While the two days of training to become safety committee focuses on an observer. Because SafeTrack issues such as dangerous workis an observation and feeding conditions, WELD is more back process, weve had very of a behavior-based safety progood response from it and the gram. For more than 10 years machine division embraces it. WELD has been one of the priAs of the end of October, the mary drivers in reducing our machine division has made injury numbers, Siktberg said. 3,617 observations to date. Weve crunched the numOur safety numbers are bers, said Lipnevicius. tracking well through SeptemEmployees are most likely ber, Lipnevicius said. Our to get injured in the first year OSHA incidence rate is 2.15 in the machine division. We and our days away, restrictions, ensure that the WELD group and transfers (DART) rate is puts a particular focus on new 0.72. employees. We rolled out a proOSHA recordables include gram last year that requires new lost work days (LWD) and employees to wear arm bands. DART, said Siktberg. DART Established employees are Figure 3: Lincoln Electric manufactures inverter-based includes LWD plus any restricencouraged to make observa- welders, traditional transformer/rectifier-based weldtions or transfers. tions to help those individuals ers, and units powered by engine-driven generators, The machine division is such as the one shown in the photo. with arm bands. seeing a 30% reduction in total New employees wear yelinjuries this year, said Lipnlow arm bands for the first few weeks, said Siktberg. The evicius. Thats a huge difference from last year. We know WELD representatives and employee WELD members wear our safety programs are really having an impact. Were red arm bands. The new employees can be seen by someone seeing good traction. driving a forklift or by supervisors. The WELD people wear the red ones because theyre the ones new employees can Maintenance As with many manufacturing facilities, the machine go to in particular. Lincoln Electrics machine division places significant divisions maintenance department balances its activities emphasis on near-miss reporting. We define the phrase among reactive, preventive, and predictive maintenance. We near miss injuries loosely, Siktberg said. Near misses are strive to employ preventive and predictive strategies, said based on observations of conditions or situations that, unless Mason. As the work load increases, the reactive level also they are dealt with, they will likely turn into accidents. For increases just because when the equipment runs harder, it example, a water leak might turn into a slippery surface, breaks more often. When business is slow, we can do more which might turn into a slip or fall accident. Near-miss report- preventive and predictive maintenance because we have ing is providing us with some really good chances to make enough hours to perform the work as well as more access to the equipment. corrections without there actually being a serious event. Mason and Sterio are also responsible for energy manNear-miss reporting is a proactive approach to preventing actual incidents and another way to look at continuous agement. Compressed air is one of our energy conservaimprovement. There should be many more near misses tion areas of focus, said Mason. Many engineers dont than there are actual injuries, said Siktberg. And near-miss understand how expensive compressed air is. Most of the reporting gives us a lot of data. We have had 549 near misses energy required to generate compressed air becomes heat in the equipment room or is lost through air leaks. Were to date through Sept. 30. Around 2009, Lincoln Electrics machine division pretty good at checking our leaks, doing our ultrasonic leak introduced another behavior-based observation method to detection, and replacing our hoses because compressed air enhance the WELD program. SafeTrack is a third-party is so expensive. People just dont realize the cost behind program that uses a checklist on a card that employees compressed air. General exhaust is another area where the machine divican carry with them easily. Each team is responsible for at least two observations per person per week. We chart sion was able to conserve energy. We have processes that the departments progress and we report on it quarterly, require dust and/or heat removal, said Mason. Instead Lipnevicius said. We really think there is a lot of value to of the upblast roof ventilators, we decided to use specific peer-to-peer observation. There is no discipline involved exhaust. Roof ventilators tend to pull too much heat out of the building in the winter. Specific exhaust is applied with the process and we gain a lot of good information. The questions on the card are more about behaviors than at the point source of the dust or heat. Sometimes a ring is about conditions, Siktberg said. Employees go through constructed around the point source to prevent too much
www.plantengineering.com

PLANT ENGINEERING

December 2013 21

2 0 13

heat from escaping. We didnt physically remove the upblast competencies in advanced welding system design, highfans. We still use them during the summer. quality weld fixtures, robotic integration, and process Using specific exhaust was very effective. On this cam- automation. We just started to put robots into our machining areas, pus, our heating load is about half of what it was 8 years ago, Mason said. Your exhaust can cost you a lot of money said Seufer. Were also putting robots into our printed circuit board manufacturing and you wont even realize it. areas. Weve had pick-and-place Mason and Sterio also installed Our goal is to make welding machines for many years. Howa wind turbine at the main Linever, many people dont think coln Electric campus. We started the most cost-effective method to of them as being automation. running the wind turbine in June Lincoln Electric is looking 2011, said Mason. We received join materials together. We have to into using RFID in its machinmoney from the American Reinconstantly create increasingly more ing areas. A machining center vestment and Recovery Act. have as many as 60 tools in The 2.5 MW machine has value in our products for lower cost, can it, Seufer said. We want to use accelerometers so we can perform vibration analysis throughout the and we have a very good team that RFID to ensure that we have the right tool married to the right drivetrain and monitor bearing drives good performance here. machining center position, so that wear. The turbine is not part of if the machine grabs tool No. 17, the electrical transmission grid. Geoff Lipnevicius, General Manager, its not really grabbing tool No. We feed power from it directly Machine Division, Lincoln Electric Co. 23. RFID will enable the machine into our plant. Our quiescent load to read each tool as it grabs it. is about 3 MW. There is never a time that the output of the wind turbine is not being used by this campus. In a years time, weve generated about 6 Training, workforce development CNC, Lean, lift truck, safety, and basic print reading are million kWh. This campus uses a total of about 55 million kWh, so the wind turbine enabled us to shave about 10% just a few of the many training opportunities that Lincoln Electric provides. We offer a lot of training, said Lipnof our energy purchase. evicius. Weve authorized more than 40 different training Automation opportunities this year. We attach deliverables to all the trainLincoln Electric recently acquired two large automation ing we do because we want to ensure employees apply that companies: Wayne Trail and Tennessee Rand. Wayne Trail knowledge; otherwise, theyll lose it. Entry-level employees designs flexible automated systems used in a variety of receive instruction that includes job hazard analysis training metal forming, fabricating, and joining industries. Tennes- and basic skills classes. Weve been doing this for 20 years, see Rand provides engineering, machining, and integrated but we revamped it pretty significantly in the last year. robotic systems, and is an automation integrator with core The maintenance department appears to be a training ground for technical people. Were recruiting constantly, said Mason. Other departments at the Cleveland campus tend to raid us for technical peopleand thats a good thing. Our department is large enough to teach employees about safety and skilled trades. After we get them trained, they migrate to other groups. The maintenance department is becoming a pipeline into this business. Although Lincoln Electric has had no problem hiring good employees, Mason predicts a hiring shortfall ahead. Unfortunately, manufacturing in general and maintenance specifically is not viewed as a glamorous job. We are working hard with the local colleges to put recruiting programs together and were trying to bring a little glamour to the industry, Mason said. We are working with HR to come up with recruitment programs, said Mason. Were visiting universities to find out what they need from us. Weve talked with students and discovered that these kinds of jobs really arent even on their radar. Young people are not being told that these E Figure 4: Lincoln Electric expanded the clean room area where it opportunities exist. P manufactures electronic printed circuit boards. The company added View more photos and read the longer version of this automated component placement and inspection equipment. article online at www.plantengineering.com/top-plant .

22 December 2013

PLANT ENGINEERING

www.plantengineering.com

THE GREATEST SUPPLY CHAIN SHOW ON EARTH.


MODEX 2014. Discover solutions and learn from the brightest thinkers in the supply chain, including three industrial-strength keynotes:
Lee Scott, former Walmart President and CEO will speak on global business and supply chain innovation. Edward H. Bastian, President of Delta Airlines will deliver Shipping Trends for Global Supply Chains. George W. Prest, CEO, MHI and Scott Sopher, Principal, Deloitte Consulting LLP will preview the MHI Industry Report on industry trends and issues. MODEX is where efciency meets productivity and insight has no bounds. Its where manufacturing and supply chain professionals gather to meet 800 of the leading equipment and system providers. See them all. In person, in action. And gain insight from the top minds in the industry at the MODEX Supply Chain Conference including more than 150 education sessions. Streamline your operations. Improve visibility. Maximize efciency. Get started at the greatest supply chain show on Earth.

Collocated with MODEX 2014

Georgia World Congress Center Atlanta, Georgia March 17-20, 2014


input #13 at www.plantengineering.com/information

Register to attend for FREE at modexshow.com

Lubriplate Gear Lubricants


100% Synthetic, Extended Life Gear Oils

Advanced Technology, Extended Life Synthetic Gear Oils...


Designed To Meet All Of Your Gearbox Requirements.

PGO & PGO-FGL Series (PAG)-Based


Advanced, Polyalkylene Glycol (PAG)-Based, Gear Lubricants. ECO-Friendly - Extended Service Life, Energy Conserving. Ultra High-Performance - Unsurpassed Anti-Wear Protection. PGO-FGL Series are NSF H-1 Regisered, Food Machinery Grade.

Syn Lube Series (PAO)-Based


100% Synthetic, Polyalphaolefin (PAO)-Based Gear Lubricants. Compatible with Petroleum-Based Oils for Easy Conversion. Available in ISO Grades 150 through 1000.

Syn Lube HD Series EP Type (PAO)-Based


Extra Heavy-Duty, Polyalphaolefin (PAO)-Based Gear Lubricants. Meets AGMA EP (Extreme Pressure) Requirements. For Heavy-Duty Applications.

Synthetic Worm Gear Lubricant (PAO)-Based


100% Synthetic, Polyalphaolefin (PAO)-Based, ISO 460 Grade. Formulated Especially for Worm Gear Applications. Provides Excellent Oxidation Resistance.

SFGO Ultra Series NSF H-1 Registered Food Grade


100% Synthetic, PAO-Based, Food Machinery Grade Gear Oils. For Food Processing and Bottling Operations. Available in ISO Grades 150 through 1000.
Backed By:

Extra Services Package

ESP

Lubriplate

Plant Surveys Tech Support Lubrication Software Machinery Tags Training Follow-Up Oil Analysis

Lubriplate Lubricants
Newark, NJ 07105 / Toledo, OH 43605 1-800-733-4755 / E-Mail: LubeXpert@lubriplate.com To visit us on Facebook, Twitter or LinkedIn, go to www.lubriplate.com and click on the desired icon.
input #14 at www.plantengineering.com/information

BEST PRACTICES

Heres what clicks with you

he 2013 Plant Engineering Best Practices summary listed on page 35. You can find these articles online at is a look at fresh ideas in the areas of Lean www.plantengineering.com/archives, or view the digital management, panel wiring, energy management edition at www.plantengineering.com/magazine . in material handling, and steam system design. Taken as a whole, these solutions offer a chance to But a review of what you thought get a fresh perspective on some were our best articles in 2013 common plant issues, and to IN THE PRINT ISSUE offers a chance for you to review review your practices against 25 Building wildfire engagement in Lean even more good ideas. these best practices in the 26 Four ways fabric curtain walls can improve So beyond the new coverage industry. Based on the reaction energy efficiency weve provided on these four of our online readers, it also 28 Use an FEB to ensure safe installation, operation important areas, we wanted to will keep you in step with what of electrical equipment offer you a chance to review others have learned from Plant 30 For a steam pressure-reducing valve station, the 15 most widely-read online Engineerings articles in 2013. set up is crucial articles of this past year,

Building wildfire engagement in Lean


By Shawn Casemore

ngagement is communication. Thats the message I brought forward during my session on Why skinny is he new Lean, at the AME conference in Toronto in October. To obtain a culture that is committed to Lean, its imperative that employees are engaged; that is, they must understand three fundamental questions: Why are we introducing Lean? How is Lean different than other improvement initiatives weve tried? How will I benefit from this? Each of these questions is equally important when introducing Lean, and in order to maximize the velocity of the initiative, we must engage all of those involved, from employees to suppliers, leaders to contractors. The engagement must be quick, decisive, and targeted. I call this Wildfire Engagement, as we build from a small ember that must not only support its own flame, but also spread organically and rapidly without our direct influence.

3. How will the new strategy help employees achieve their objectives? 4. The role each employee and each work group plays in delivering the strategy. 5. How employee feedback will be incorporated into delivering the strategy. The list goes on, but these are the fundamental questions to be considered. Point No. 3 is the most critical. You must understand what is important to employees generally, and what is important to each of them specifically. I recently helped a great client of mine formulate a strategy. When we were considering the points above (prior to introducing the new strategy to the employees), we brainstormed around Point No. 3. What emerged was the realization that the year before, employees had been selected to meet with the company president to provide feedback on the business and their perceptions of it. Nearly all of the employees who were interviewed identified that working at the company was important to them as it allowed them to live and work in a beautiful rural community. This became the basis of what mattered to employees generally. We then set about determining what was important to each group of employees (i.e., skilled trades enjoyed the ability to cross train in other disciplines; production employees enjoyed the shift flexibility). By the end of this session what arose were some very clear points that had come directly from employees. We were in turn able to use these to communicate how the new strategy will help employees achieve E their objectives. P
PLANT ENGINEERING

How can you build wildfire engagement?

Engagement has always been built upon strategically targeted communication, meaning messages are designed to achieve their intent, and are distinctly different for each specific group involved. Take, for example, an engagement plan to introduce the business strategy, which would entail the following considerations: 1. Why does the business need a strategy? How has it helped/ hindered business in the past? 2. Why is a change in strategy necessary now? Why not last week or next year?

www.plantengineering.com

December 2013 25

BESTPRACTICES

Four ways fabric curtain walls can improve energy efficiency


By Kyle Justice, Zoneworks

abric curtain walls basis. have many uses to Another area where fabric separate environments curtain walls improve energy within and around efficiency is at large gradethe perimeter of industrial level door openings or rail buildings, while also offering dock openings. Many of a simple, quick, inexpensive these larger door openings means of improving energy are too big for fast-acting, efficiency. high-speed doors, and the Many buildings, especially cost for giant telescoping older ones, have open dock doors (think airplane hangar areas that are inside or size) isnt in the budget. outside the footprint of the Keeping traditional building envelope. doors at these locations is Not everyone uses the a maintenance headache modern dock design of and a nightmare for the individual dock positions By enclosing open dock areas with fabric curtain walls, maintenance budget. By with individual dock doors, temperature settings can remain constant, reducing energy utilizing a sliding fabric etc. These open areas spending. Courtesy: Zoneworks curtain wall, simple in introduce cold air or hot air design, the opening can be into the building, causing the temperature within to rise blocked off to keep wind and elements from entering the or drop. This can be tough on the climate control systems building and lowering or raising the temperature. in use, if any. Controlling air infiltration (wind) is the larger part of the By enclosing these open dock areas with fabric curtain battle in controlling temperature. These simple curtains seal walls, companies have an easier time keeping the thermostat off the openings nicely, and the original existing door unit at a consistent temperature to reduce energy spending. As can be kept for security or as an off-hours door as needed. the seasons change, these types of walls can be designed to Lastly, controlling dust and debris, which can migrate open up when weather is more agreeable for full weather into and through a building, shouldnt be overlooked. This and energy control. Additionally, keeping the facility at type of contaminant in a building can wreak havoc on the proper temperatures usually makes for happier, more HVAC or refrigeration equipment or process equipment productive employees. that is overly sensitive to foreign matter. By controlling Along the same lines, we see many customers introduce the migration and/or collection points of dust within your HVAC cooling into large areas of their buildings and, in building, you allow your HVAC and process equipment to some cases, condition the whole footprint. The reasons for work at a higher efficiency. This saves energy dollars and this vary from employee comfort and safety, raw material, could prolong the life of the units. or ingredient requirements, or for specific processes in When it comes to saving energy, everyones been told to production areas. turn off the lights if theyre closing up the shop or to turn With fabric curtain walls, you can effectively set up off the computer if theyre done using it for the day. While HVAC te mpe ra t ure z one s every little bit helps, for real so that a specific space is cost and energy savings, Four ways curtain walls receiving the treated air and theres a big opportunity help reduce energy energy dollars arent floating for your plant with fabric E throughout the entire building. curtain walls. P 1. Thermostat can remain constant By compartmentalizing the 2. Creating HVAC temperature zones Kyle Justice is vice square footage, you can be 3. Blocking in dock and loading areas p re s i d e n t o f s a l e s f o r more strategic with HVAC 4. Controlling dust and debris Zoneworks. expenditures on an annual
PLANT ENGINEERING
www.plantengineering.com

26 December 2013

input #15 at www.plantengineering.com/information

BESTPRACTICES

Use an FEB to ensure safe installation, operation of electrical equipment


By Wally Vahlstrom, eti Conformity Services

here are two types of issued under the accreditation organizations that perform of the American National product safety testinga Standards Institute (ANSI). In field evaluation body fact, both testing organizations (FEB) and perhaps the more can determine if an equipment well-known nationally recognized installation is acceptable as testing laboratory (NRTL). While defined by CFR 1910.399. similar in their purpose, there are An NRTL would perform significant differences. Without the service stipulated in CFR qualified organizations like FEBs 1910.399 (1), which states that and NRTLs, there would be no an installation of equipment way of ensuring that a particular is acceptable to the Assistant product or installation meets the Secretary of Labor if it is necessary safety requirements. accepted, or certified, or listed, or National Fire Protection labeled, or otherwise determined Association (NFPA) Standard 790 to be safe by a nationally is the U.S. standard applicable to recognized testing laboratory FEBs. The most credible method pursuant to 1910.7. for certification of FEBs involves When authorities having jurisdiction rely on listed or labeled S i m i l a r l y, a n F E B c a n accreditation to NFPA 790 by a products, it can make the job easier since the inspector determine acceptability by qualified third-party certifier does not need to evaluate all the parts as required by NEC providing the test data called like International Accreditation 110.3(A). Courtesy: eti Conformity Services for CFR 1910.399 (3) which Services (IAS). FEBs can perform reads as follows: With respect field evaluation services and equipment labeling. NRTLs to custom-made equipment or related installations that are must comply with the Code of Federal Regulations (CFR) designed, fabricated for, and intended for use by a particular 1910.7 and are certified by the Occupational Safety and Health customer, if it is determined to be safe for its intended use by Administration (OSHA) to perform product listing services. its manufacturer on the basis of test data which the employer OSHA does not certify FEBs, nor does it certify NRTLs to keeps and makes available for inspection to the Assistant provide FEB services. Secretary and his authorized representatives. Another important difference between these two organizations is that NRTLs provide product safety testing How to help inspectors Occasionally, a listed or labeled product doesnt look and certification at the point of manufacture. Their listing process involves rigorous testing of representative samples quite right or has obvious violations. This is when electrical of a product and the periodic factory follow-up verification inspectors will notify the NRTL or FEB. The testing and inspection (usually two to four times per year) to ensure organization can determine if it is a counterfeit label, if the equipment was modified, or if a manufacturer is incorrectly new production exactly mirrors the tested samples. On the other hand, FEBs have the capability to provide manufacturing the product. In any case, the NRTL or FEB has product safety testing and labeling primarily in the field for a process to review, evaluate, and stop problems in the future. In those cases, where an item with violations is holding a wide range of products found in the workplace, while still up the opening of a business, working with an FEB that has adhering to stringent national standards from the NFPA: NFPA 790: Standard for Competency of Third-Party the ability to nondestructively test in the field can provide significant time savings, especially with equipment that Evaluations Bodies (FEBs) NFPA 791: Recommended Practice and Procedures for has been modified, refurbished, or relocated. Such changes normally void the NRTLs approval of that product, and an Unlabeled Equipment Evaluation. employers use of it in the workplace violates the OSHA The listings performed by NRTLs and evaluations performed standard requiring the approval. The FEB provides field label services paid for by one of the by FEBs are based on product safety standards developed by U.S.-based, standards-developing organizations and often parties involvedtypically the manufacturer or the installerto
PLANT ENGINEERING
www.plantengineering.com

28 December 2013

Evaluating a projects conformity


determine facilitates if the greater equipment equipment is compliant efficiency. in the specific This reduces installation. time is essential. Choosing the possibility the right FEB of asset during failure, this critical making certain that Youll an organization that a geographically assets want are running correctly and nothas utilizing excess dispersed network highlymore trained, safety-certified energy to cost the of company money than nectechnicians, essary. along with engineers who know the applicable safetyFurthermore, standards for effective your class of equipment and the reasons safety management safebehind the standards. Working engineers who are regular guards manufacturers fromwith potential litigation suits participants codes and standards-making processes as a resultin ofthe employee injury, or in the case of conoffers added benefits. sumer-targeted products, customer injury as a result Aof good placeflaws. to start in the management search for an FEB is IAS, which product Safety applications is a help nonprofit corporation that hasthey been providing accreditation organizations prove that are ensuring safety services since 1975. IAS makesprevent sure that an FEBs on their property, helping lawsuits asexperience, well practices, equipment, and processes meet thestandards. stringent NFPA as enabling compliance with government 790 and 791 standards, as well as other IAS Safety management technology isrequirements. applicable The accreditation objective that an FEB operates for every provides company that hasevidence assets, from food and at the highest level of ethical, legal, and technical standards. drug manufacturers to manufacturers of automotive The importance ensuring proper installation and operation and electronicof components. Organizations should of electrical equipment cannotflexible, be overstated. all, many take advantage of todays easily After auditable organizations already embrace safety compliance and invest applications as an integral part of their asset manageconsiderable resources in order to protect employees, ment program to generate company savings through the P E litigation environment, and the company a whole. reduced equipment downtime,as lower odds of Wally Vahlstrom has more than 40 years electrical expenses, increased asset efficiency, and easierof proven P E engineering experience and Emerson Network Powers compliance with government standards. Kevin Price is the Senior Product Manager Infor. Electrical Reliability Services groups directorat of technical services.
Factors that should be considered when evaluating an FEB for a potential conformity project:

1. Objective and unbiased


- Independent, professional, third-party testing organization focused on conformity assessment services

2. Quality

- Certified by a recognized accreditation body BE TAKEN BEFORE A DIAMOND -WILL Qualified and trained staff CHAIN THINKS ABOUT ITS FIRST ONE. - Appropriate quality system in place - Financial stability - Qualified technical supervision and management

3,840 COFFEE BREAKS

3. Methodology
- Documented reference to applicable ANSI or other product safety standards - Proper sample control/integrity requirements - Testing/evaluation procedures comply with NFPA 790 Scan the QR code for additional and about 791 information the Performance
of Diamond Chain Products

4. Responsiveness
- Complete record keeping system with test data availability - Professional systems in place to deliver prompt service
www.diamondchain.com

2013 The Diamond Chain Company. DCCPE-0613

input #26 at www.plantengineering.com/information

Eliminate bolting problems


The Nord-Lock Group is a world leader in bolt securing systems. We offer a unique combination of bolting expertise and a wide product range, including wedge-locking solutions and Superbolt tensioners. Discover safe and easy bolting for your critical applications today!
ABOUT OPTIMISING A MAGAZINE BOLT SECURING W W W.BOLTED.COM # 2 2013

FREE SUBSCRIPTION: www.bolted.com/subscribe


BIG LIFT

HOLDING TOGETHER THE WORLDS LARGEST CRANE

MINING

WANT WHY YOU DONT TO COMPROMISE BOLT SECURITY


EXPERT ADVICE

SAFETY AND QUALITY ARE KEY IN THE NUCLEAR INDUSTRY

HOW TO DEAL WITH GALLING, SEIZING AND SLACKENING

Bolting tips and case studies from the bolting experts, released twice a year.

www.nord-lock.com 1-877-799-1097 input #27 at www.plantengineering.com/information input #16 at www.plantengineering.com/information

BESTPRACTICES

For a steam pressure-reducing valve station, set up is crucial


By Kelly Paffel, Swagelok Energy Advisors Inc.

steam pressure-reducing valve (PRV) station is an indispensable part of many steam systems. It plays a critical role by providing the correct steam pressure to process applications in a process plant. Steam enters the PRV station at a higher pressure than what is required for downstream applications, and the station reduces the pressure to the desired level before delivering steam to those applications. Within a steam PRV station (see Figure 1), the controlling valvewhich reduces the steam pressureis typically a pneumatic control valve. However, a regulating valve (also called a PRV) may sometimes be used instead. In either case, youll want the controlling device to have a long operational life so you can reduce maintenance needs, downtime, and total cost of ownership for the PRV station. Thanks to current available technology and better materials, PRV station components should last at least six years.

But you can likely do better than that. Through proper system design, component selection, and installation of your steam PRV station, you may be able to greatly prolong the life of all the steam components. Lets review several best practices that can help you achieve this goal.

1. Match the valve to the application

To select the correct PRV for a given application, you need to know the maximum and minimum steam flow rates, as well as understand the turndown capabilities of the pneumatic control valve and/or regulating valve. Although maximum steam flow rates are seldom, or never, reached in the operation of the steam PRV station, be certain the PRV meets or exceeds this rate. Just as important, the PRV needs to accommodate the minimum flow rate, as it will be a frequent and important control point. To summarize: the steam PRV must be able to operate successfully at the minimum and maximum steam flow rates.

Figure 1: A typical pressure-reducing valve (PRV) station, noting the following:


The option to increase the pipe size to reduce the dBA level and outlet velocities A steam line drip pocket to remove condensate from the line A horizontally mounted strainer to prevent condensate from passing through the PRV Proper valve placement, placing straight piping measuring at least 10 pipe diameters in length after the PRV Use of a warm-up valve arrangement, including a bypass valve, to minimize condensation in the steam line.

30 December 2013

PLANT ENGINEERING

All graphics courtesy: Swagelok Energy Advisors Inc.

For Control Room Spaces


Self-contained no piping needed Fast, convenient installation Minimal water presence No costly clean up or equipment replacement 100% Green design Quick system recharge, minimal downtime No need for assurance of tight room integrity

Visit victaulic.com/vortex500 to learn more about the Victaulic Vortex 500 system.
2013 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

input #17 at www.plantengineering.com/information

BESTPRACTICES
Figure 2: A two-stage steam pressure-reducing valve station.

Knowing the turndown capabilities of the pneumatic control valve and/or regulating valve will help you make an appropriate selection. As a general rule of thumb, typical turndown ratios for select valve types include: Regulator: 20 to 1 Globe valve: 30 to 1 Cage valve: 40 to 1 In addition to meeting the requirements for a given application, all valves in a steam PRV stationincluding control and isolation valvesalso need to meet permissible internal leak rate standards as designated by FCI/ANSI or API. The standards denote the tolerance level for steam leaking across the valve seat to pass downstream or to the atmosphere. FCI/ ANSI designates six permissible leak rates, or classes, numbered I through VI. The higher the leak rate number, the lower the permissible internal leak rate. Therefore, a Class I valve will have the highest internal leak rate and usually the lowest cost, while a Class VI valve will have the lowest rate and typically the highest cost. In a steam PRV station, all the isolation and PRV valves should be Class IV or higher.

high dBA levels will also have high outlet velocities and reduced operational life. A PRV with low dBA levels, or lower velocities, will have a much longer reliable operational life. There are many ways to lower the dBA level in a PRV application, including increasing the valve outlet pipe size, muffling the orifice, or adding special trim. The valve manufacturer will provide the appropriate pipe size required after the PRV to achieve the desired dBA level. One can also use a muffling orifice plate to reduce a high-pressure drop across the steam valve to reduce velocities. In addition, special trim can be used to minimize velocity and noise.

3. Include a steam line drip pocket

2. Specify a noise level of 85 dBA or lower

All steam PRVs must have a condensate removal drip pocket piped upstream of the valve. The drip pocket removes condensate from the steam line, preventing condensate from passing through the valve. This is essential because condensate that enters the steam valve will cause erosion and shorten the life of the valve. Even during those times when the steam PRV shuts off during low or nonproduction periods, the condensate drip pocket will continue to remove accumulating condensate from the inlet of the valve. A strainer is also a requirement upstream of a steam PRV to protect the valve from materials that may corrode the system.

Setting an upper noise limit of 85 dBA for a PRV is more a function of managing outlet velocity and extending valve life, with the added benefit of reducing noise. PRVs that have
PLANT ENGINEERING

4. Include a strainer with a blow-off valve

32 December 2013

The drip pocket removes condensate from the steam line, preventing condensate from passing through the valve. This is essential because condensate that enters the steam valve will cause erosion and shorten the life of the valve.
Steam lines frequently contain residual solid materials from corrosion in the steam line. The strainer will filter the steam stream and prevent this material from lodging within the valve, which could otherwise cause premature failure. The strainer should be rated for 20 perforated stainless steel mesh. Never mount the strainer with the strainer segment in a down position; instead, install the strainer segment in a horizontal position. This will prevent condensate from accumulating in the strainer pocket and eventually passing through the PRV, thereby reducing the likelihood of internal erosion and premature valve failure. Finally, install a blow-off valve on the strainer to allow plant personnel to periodically clean out the strainer.

The regulating valve should be at least 20 pipe diameters ahead of a direction change as well.

6. Position the pressure-reducing valve

To extend the life of PRVs, always install them on horizontal steam lines, never vertically. A PRV in a vertical installation has no ability to eliminate the build-up of condensate prior to the valves inlet. Condensate passing through a steam PRV always negatively affects the valves life.

5. Locate the pressure reducing valve

Placing the steam PRV correctly in the station helps to ensure proper system operation. Make sure the distance after the steam PRV is at least 10 pipe diameters before any change in steam flow direction or before the steam line takes offline.

Bypass valves and warm-up valves should be used in all PRV installations. The warm-up valve warms the steam line within recommended time frames for the steam line. The warm-up is modulated and controlled during the start-up procedure. A steam PRV should not be used for warming up a steam distribution line. The bypass valve must have a lower flow coefficient (Cv) than the PRV. When using the same diameter bypass valve as the PRV, the safety valve will have to be sized for the bypass valve, which always will have a higher Cv. Sizing the safety valve for the bypass valve will usually require the safety valve to be extremely large in size and capacity.

7. Use bypass valves and warm-up valves

8. Check if you need a safety valve

Safety valves are an important consideration in a steam PRV station. But they may not be required in every case. If

FILTRATION TRENDS

New Filtration Technology Keeps Cooling Tower Water Clean


Typical Full Flow filtration using existing pump. Typical Side Stream filtration using a booster pump.
ORIVAL
Cooling Tower Cooling Tower

ORIVAL

Typical Side Stream filtration of basin using a recirculating pump. Typical Side Stream filtration using existing pump.

O RI VA L

Cooling Tower

Cooling Tower

www.orival.com filters@orival.com
specific gravity, even lighter than water. Typical examples include: airborne particles, microbiological growth, bugs, sand, scale, algae, rust, etc. Line pressure powered, they permit use of the existing cooling tower pump, lowering initial system cost. The fully automatic self cleaning cycle takes
input #18 at www.plantengineering.com/information

very cooling tower has its unique dirt conditions, space constraints and other special characteristics. Filtration systems must take these into account in order to maintain particle free water. Orival filters are versatile enough to meet these criteria. They remove a wide range of dirt down to micron size, of any

seconds and does not interrupt flow. Reclaim units recirculate rinse water making filtration a zero discharge operation. For more information and system design assistance, contact: Orival, Automatic SelfCleaning Filters, 213 S. Van Brunt St., Englewood, NJ 07631. (201) 568-3311, (800) 567-9767 , Fax: (201) 568-1916.

O RI VA L

BESTPRACTICES
any steam component or the steam line downstream of the steam PRV is not rated for the maximum inlet steam pressure to the PRV station, then a safety valve must be installed to protect the system. The safety valve needs to be sized for the maximum steam flow with the highest steam pressure that could be provided to the PRV. In addition, to ensure the proper safety valve size, perform calculations with the largest Cv trim available for the PRV. When installing a safety valve, be sure the discharge is piped to a location where it will not pose a safety risk for plant personnel. system. Therefore, if the isolation valve is closed and the PRV opens, the piping could experience the inlet steam pressure.

10. Install before and after pressure gauges

It is always good practice to install pressure gauges before and after the steam PRV as diagnostic tools. Be sure to include a siphon pipe and isolation valve for maintenance purposes. Every PRV station requires a SOP to ensure that plant personnel are starting, operating, and shutting down the valve station correctly and safety. Valve manufacturers should provide a SOP as part of the documentation with the equipment. By paying careful attention to proper system design, component selection, and installation practices, you can prolong the life of components in your steam PRV station. Be sure to match the PRV to the application, minimize velocities, include drip pockets and strainers, and position components properly. Following the guidelines above, you can reduce maintenance headaches and total cost of ownership for your E PRV station. P Kelly Paffel is technical manager for Swagelok Energy Advisors, Inc.

11. Establish a Standard Operating Procedure

9. Determine when more than one valve is required

There will be times when a steam PRV station requires more than one PRV (Figure 2). For example, when the steam flow varies greatly and one valve does not have the required turndown capabilities, an additional valve or valveswill be required to achieve the desired outlet pressure. In systems with more than one PRV, the safety valve must be sized based on all valves failed in the open position and have the largest trim available from the manufacturer. Note that the piping from the PRV to the downstream isolation valve should be designed and installed to meet the highest steam pressure at the inlet to the PRV. The downstream isolation valve is located before the safety valve that protects the

DEMANDING ENVIRONMENTS DEMAND

Rig-A-Lite has been the leader in rugged and innovative lighting solutions for nearly 75 years. Engineered specically for the worlds most demanding environments, RigA-Lite provides illumination plus protection from high-pressure hose down, corrosives, temperature extremes, severe vibration, explosive elements, and other severe and hazardous location challenges.

The worlds most demanding environments demand RIG-A-LITE.

input #19 at www.plantengineering.com/information

TEL 713.943.0340 FAX 713.943.8354 www.rigalite.com

Plant Engineering in 2013: The top 15 online stories


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Calculating proper rolling resistance a safer move for material handling 2012 Product of the Year award winners Nine reasons why hydraulic hoses fail Oil-fired boiler users converting to natural gas Electrical safety from the ground up Avoid over-specifying inverter duty motors A close look at wet stacking Motor repair and replace by the numbers Best practices for steam trap installation Considerations when deciding to NEMA Premium motors Selecting proximity sensors for diverse applications 2012 Plant Engineering Salary Survey The 14 elements of OSHA inspections: How they affect maintenance processes Debunking the myth around arc flash safety prevention Study identifies 10 ways to improve supply chain efficiency Read these articles online at www.plantengineering.com/archives.

Together, we can move clean air, guaranteed. From the compressor outlets to the machines with optimal ow, minimal downtime and increased plant productivity.

Transair: Compressed Air Pipe Systems 1/2 to 6


When you partner with the global leader in compressed air pipe systems, expect to move your business and the world forward. From various ttings to highly integrated pipe systems, Transairs aluminum pipe ensures higher longevity of equipment and avoids frequent changes of ltration elements. Not to mention, Transairs energy savings element is critical to lowering your overall cost of ownership. So partner with Parker, and get ready to move clean air, guaranteed.

Scan to see a Transair video.

www.parkertransair.com ph 480 830 7764


input #20 at www.plantengineering.com/information

No matter what your social networking preference is, theres a way for you to connect with Plant Engineering!

www.plantengineering.com/connect/social-media.html

Make the connection now...

socialMed_fillePG_ple.indd 1

10/8/2013 3:34:30 PM

Top 100 System Integrators | More than $7 billion in revenue represented inside

Image courtesy of Beckhoff Automation, Saugatuck Brewing

Vance VanDoren, PhD, PE

System Integrator Giants of 2013


The 100 largest system integrators in the industrial automation businesswho they are and what they do.
n its second year of production, the 2013 System Integrator Giants (SI Giants) program has assembled the 100 largest system integrators based on system integration revenue for the most recently completed scal year. Compared to last years data, the 2013 metrics have signicantly increased in response to the number of participating rms, making the group even more giant in many ways. For 2013, all 2,387 system integrators listed in the CFE Media Automation Integrator Guide (AIG) were asked to provide details about annual revenues, head count, client base, industries and areas served, technical skills, professional afliations, and product experience. They also were asked about the educational opportunities available to employees and

the biggest challenges they face as a company. Respondents reporting the largest system integration-related revenue are shown in the accompanying table (see pages 53 to 56). In the early days of the computer industry, it was said that no one ever got red for buying IBM, meaning that the largest vendor in the business was never a bad choice. Some would say the same is true in todays industrial automation industry when it comes to system integrators. Bigger integrators with more personnel and a broader geographic presence are arguably more adept than smaller competitors at implementing largescale automation systems spread over multiple locations. In practice, the advantages of hiring a larger integrator versus a smaller one probably depend on the particulars of each project, so the question of whether or not bigger is always better can never be denitively answered. Even the question of which integrators are the largest in the automation industry was a topic of debate before the 2013 System Integrator Giants survey. The biggest change from last year is the addition of M+W Automationthe No. 1 system integrator for 2013moving

System Integrator Giants: 2013 to 2012 revenue comparisons


Total gross revenue for fiscal year ($ U.S.) Total system integration revenue ($ U.S.) $1,238,430,068 $875,824,751 Change in total SI revenue among those ranked 41% % of revenue from system integration 17% 39% Median (50th ranked firm) total revenue $8,500,000 $5,000,000 Change in median (50th ranked firm) total revenue 70% Median (50th ranked firm): SI revenue $7,600,000 $4,400,000 Change in median (50th ranked firm) total SI revenue 73% % revenue from system integration 89% 88%

2013 2012 2012 vs. 2013

$7,097,250,184 $2,251,284,436 Change in total revenue among those ranked 215%

More firms with larger total revenue and larger system integration revenue replied to the SI Giants survey for 2013 than in 2012. Yearto-year total revenue increased 215% to $7.1 billion, and system integration revenue increased 41% to $1.2 billion. As a percent of total revenue, the revenue for system integration is less in 2013 at 17% compared to 39% in 2012. However, just excluding M+W alone (among new respondents with an unusually disproportionate amount of non-system integration revenue) increases the percentage of system integration income for 2013 to more than 30%.

38

Image above is from ABB Robotics 2013 Technology Day.

All charts, graphs, and data courtesy of CFE Media.

Staff Information
Total number of employees 25,580
Engineers (number, % of total) Automation and control engineers assigned primarily to system integration projects Technical staff other than engineers, managers, and executives Technical staff assigned primarily to system integration projects Managers and executives Managers and executives assigned primarily to system integration projects

Did your company acquire another company in 2011?


8,761, 34%

No

Yes
9%

91%

5,038, 20% 3,908, 15% 1,966, 8% 1,417, 6% 631, 2%

Was your company acquired by another company in 2011?

No

Yes
4%

96%

Engineers represent about 34% of staff totals for the 2013 SI Giants, down from about 38% in 2012. This years 100 list includes a higher proportion of larger firms.

More integrators reported acquiring other companies than were acquired, suggesting a net gain of capital and resources for the industry.

last years leader, Wood Group Mustang, to No. 2. Everything about M+W Automation is, well, giant. Its 800 automation and control engineers outnumber the entire staff at 96 of the other SI Giants, and its $150 million integration-related revenue accounts for more than 12% of the $1.2 billion system integration revenue reported by all 100 SI Giants combined. M+W Automations parent company, M+W Group, is even larger, with 2,000 engineers, 7,500 employees overall, and $3.5 billion in overall corporate revenue, nearly equal to the $3.6 billion overall revenue reported by the other 99 SI Giants. The average size of the SI Giants also grew between 2012 and 2013, though mostly from the addition of several larger companies to the mix more than the growth of those returning this year. The average integration-related revenue gure rose from $876,000 to $1.2 million, the average engineering staff rose from 52 to 88 (with 50 automation engineers on average versus 36 in 2012), and the average revenue per employee rose from $187,000 to $280,000. The median income for automation system integrators in general (as represented by the other 2,287 integrators listed in the AIG) remained in the $5 million to $10 million range. See the stafng information chart (top-left) for employee counts in other categories, all of which are higher for 2013.

On the other hand, survey results do show some evidence of actual growth in the automation system integration industry, at least in the sense of larger companies forming from mergers and acquisitions. More integrators reported acquiring other companies (9%) than were acquired (4%), suggesting a net gain of capital and resources for the industry. As the professional afliations chart on page 48 shows, this years SI Giants have also demonstrated a signicant increase in involvement with the various professional and trade organizations that focus on automation-related skills and industries that use automation. And like last year, the survey results show that SI Giants tend to join these organizations more readily than other automation system integrators do. For example, in 2013 more than half of the SI Giants (57%) reported being members of the Control System Integrators Association (CSIA), up from 43% in 2012. CSIA membership also grew among automation system integrators in general, but not nearly as much. This year, 18.5% of other integrators cited the CSIA as a professional afliation, up from 17% last year. It comes as no surprise that an association dedicated to control system integrators would have a signicant following

Professional affiliations

39

Professional and Third-party Affiliations


Control System Integrators Association Underwriters Laboratories International Society of Automation National Fire Protection Association Project Management t Institute National Society of f Professional Engineers Control Systems Society (IEEE) International Society of f Pharmaceutical Engineers Institute of Electrical & Electronics Engineers American Society of f Mechanical Engineers Instrumentation and Measurement Society (IEEE) Industry Applications Society (IEEE) American Institute of f Chemical Engineers Society of Manufacturing Engineers OPC Foundation Fieldbus Foundation American Water r Works Association American Petroleum Institute Robotic Industries Association

57% 39% 34% 25% 24% 24% 20% 18% 17% 17% 13% 13% 13% 7% 6% 6% 5% 5% 3%

The 2013 SI Giants are more involved in professional and trade organizations focusing on automation-related skills and industries that use automation. Majority of respondents belong to CSIA; RIA has the largest growth opportunity among the 2013 SI Giants.

among both SI Giants and automation system integrators in general, but exactly why the CSIA should appeal so much more to larger rms is not altogether obvious. There was a time that the CSIA required a minimum annual revenue before a prospective member could join, but that requirement has been lifted. Perhaps smaller integrators still think of the CSIA as an organization just for the big guys. The organization for robotic system integrators, the Robotics Industry Association (RIA), was cited by 3% of both

SI Giants and other integrators. At the 2013 Automate Show, the vast majority of system integrators exhibiting were RIA members (the event was sponsored in part by the RIA), yet only one belonged to the CSIA. Control system integration and robotic system integration industries seem to have little overlap, even though both cover industrial automation. This divide is also evident in engineering specialties performed by the 2013 SI Giants (see table on page 52). Robotics (32%), vision systems (33%), and automated assemblies (33%) are the three least-common specialties performed, while automation and control engineering (95%), installation and start-up (93%), and HMI and operator interfaces (92%) round out the top three. Among automation system integrators in general, automation and programmable logic controller (PLC) skills were not so dominant (56% and 63%, respectively), but still well ahead of robotics and vision systems (32% and 30%, respectively). Other professional organizations that gained popularity among the SI Giants included Underwriters Laboratories (UL), the Project Management Institute (PMI), and the National Society of Professional Engineers (NSPE). Comparing the 2012 and 2013 SI Giants data, UL increased from 19% to 39%; PMI increased from 11% to 24%; and NSPE increased from 10% to 24%. The International Society of Automation (ISA) remained in the top ve as the third most-cited professional afliation, with 34% in 2013 vs. 38% in 2012. Rounding out the top 10 afliations were the National Fire Protection Association (NFPA, 25%), the Control Systems Society (CSS, 20%), the International Society of Pharmaceutical Engineers (ISPE, 18%), the Institute of Electrical & Electronics Engineers (IEEE, 17%), and the American Society of Mechanical Engineers (ASME, 17%). Most of these professional/third-party organizations are dedicated to the practice of various technical disciplines, which makes sense considering what automation system integrators do for a living. The list of most-cited professional afliations among other integrators was similar: ISA, IEEE, CSIA, UL, CSS, NFPA, ASME, NSPE, and PMI. ISPE was the 2013 SI Giants only top 10 professional afliation associated with a specic industry. It did not make the top 10 list for automation system integrators in general, but even for that group, ISPE was still the most popular of all professional organizations that focus on an industry rather than a technology. Ironically, pharmaceuticals as an industry

Industries served

Robotics vs. controls

40

VS

There is Power in Numbers


Partner Ecosystem = More Choices + Accelerated Success
As a global or regional manufacturer you need choice who you work with and where. Invensys and the Partner Ecosystem community opens you to thousands of delivery and solutions experts with in-depth knowledge of your business.

wonderware.com/partnerecosystem
input #21 at www.plantengineering.com/information
Copyright 2013. All rights reserved. Invensys, the Invensys logo and Wonderware are trademarks of Invensys plc, its subsidiaries or afliates. All other brands and product names may be trademarks of their respective owners.

Industries Served - Big 6


Food, beverage, and allied industries (including baking, confections, and snack foods) ....... 10% Oil and gas (including exploration, production, transportation, and distribution)........................ 8% Chemicals and petrochemicals (products and processing) .............................................. 6% Automotive (components and manufacturing)................................................................... 6% Water and wastewater .............................................................................................. 6% Pharmaceuticals manufacturing................................................................................ 5%

Business from Existing Clients


What percentage of business in 2012 was from existing clients? (not first-time clients)
44%

Food and beverage, oil and gas, chemicals and petrochemicals, automotive, and water and wastewater are the top five industries for the 2013 SI Giants.

30% 9% 3% 3%

12%

was not as popular with the 2013 SI Giants or the other integrators listed in the AIG. Only 5% of the 2013 SI Giants serve the pharmaceutical manufacturing industry (see the chart on page 50), up 2% from 2012. Despite the industrys increased popularity, pharmaceuticals still only accounted for half as much revenue as the most-served industry on the list: food and beverage (10%). The formerly most-served industry, oil and gas, dropped from 11% in 2012 to 8% in 2013. Rounding out the top ve were chemicals and petrochemicals (6%), automotive (6%), and water/wastewater (6%), about the same as last year. It is interesting to note that only one of these top ve industries served, automotive, is discrete, and of the top 10, theres only one more, material handling (4%). The remaining industries are process or hybrid industries: metals (4%), consumer products (4%), and processing (3%). Perhaps the simplest explanation is that the reneries, foundries, and processing plants of process industries generally operate on a much larger scale, with the exception of automotive plants of discrete industries, requiring the largest system integrators. The divide between the SI Giants and robotic system integrators came up again when the SI Giants were asked about vendors products they have integrated in the past 12 months. The most-cited robotics vendors were ABB with 55% popularity and Mitsubishi Electric Automation with 32%. But even those results are probably overestimates of the SI Giants involvement in robotics since ABB and Mitsubishi offer other automation products, and the product experience question did not specify divisions. Which brands proved popular with the SI Giants? The Product Experience table (only online at www.controleng. com/giants) shows that Rockwell Automations Allen-Bradley brand from 71% in 2012 to 92% this year. The Rockwell

0-10%

11-30%

31-50%

51-75%

76-90%

91-100%

More than half (56%) of 2013 SI Giants derive 76% to 100% of current business from existing clients.

Automation brand itself increased to 89%, and Rockwell Software completed the Rockwell hat trick at 86%, up from 55% in 2012. While the defending champion, Siemens Industry, fell to beneath the three Rockwell Automation brands with 79% this year, that popularity score improved from 71% in 2012. Invensys Wonderware also increased to 80%, up from 68% last year. The biggest gainers in this years product experience list were Microsoft (82%) and Dell (81%). Last year, they were 53% and 42%, respectively. These results would suggest that the SI Giants have become even more partial to product vendors offering PLCs, HMI software, and the personal computers (PCs) required to program PLCs and host HMI software. The Engineering Specialties table on page 52 indicates that HMIs (92%) as a speciality are only slightly more selected by the 2013 SI Giants than PLCs (91%). Only the more generic skills of automation and control engineering (95%) and installation/start-up (93%) placed higher. Ironically, the SI Giants did not identify PCs as a particularly popular engineering specialty, in spite of their afnity for Dell and Microsoft. In 2013, only 58% of rms listed PCs as an engineering specialty, up 30% from 2012. Keeping consistent with the 2013 SI Giants top ve ranking of PMI, project management is an engineering speciality offered by 90% of the rms, up from 52% in 2012.

Product experience

Engineering specialties

42

A DV E R T I S E M E N T

Prime Controls: Total Solutions, Total Responsibility, Total Excellence

Complete responsibility for total industrial automation and control solutions Prime Controls is a Systems Integration and I&C Construction rm specically structured to meet all of a clients industrial automation and control needs. They have the size, expertise, and experience to take complete responsibility for total industrial automation and control solutions.
Structured as a Main Automation Contractor, Prime Controls provides customers a sole source solution for Industrial Automation challenges.

Along with all of these services, we are focused on safety, quality, and improving our customers efciencies and protability, giving them the competitive advantage. Why choose Prime Controls?
>> Established 1991 >> Licensed Engineering & Contracting Firm >> Professional Staff >> Project Team Concept >> State-Of-The Art Facilities & Equipment >> Manufacturer Independent Not A Rep Firm >> Quality & Safety Conscious >> Service Oriented >> Bondable >> Customer-focused

Our experience and focus: Oil and Gas Production and Distribution Water and Wastewater Semiconductor Fabrication Critical Infrastructure and Utilities Food and Beverage General Manufacturing applications Services include: System Design Application Engineering DCS / PLC Programming Equipment Installation 24/7 Maintenance Services

As a dedicated systems integrator, Prime Controls is professionally staffed with over 250 employees to supply the customer with all aspects of their Instrumentation and Control needs. Headquartered in Dallas, TX with ofces throughout the South Central US, Prime Controls successfully executes projects throughout the United States. Want to learn more? Visit www.prime-controls.com
input #22 at www.plantengineering.com/information

Tel: 972.221.4849 | Fax: 972.420.4842 | sales@prime-controls.com | www.prime-controls.com

Engineering Specialties
95% 93% 92% 91% 90% 90% 87% 85% 85% 85% 82% 82% 81% 81% 80% 79% 79% 79% 79% 77% 75% 74% 74% 72% 70% 59% 59% 59% 58% 49% 42% 33% 33% 32% Automation and control engineering (including designs and implementation) Installation and start-up Human-machine interfaces and operator interfaces Programmable logic controllers (including installation and programming) Process control and automation Project management Data collection and reporting (including historians) Control panels (including fabrication, installation, and UL listing) Networking and communications (including fieldbus, Ethernet, and telemetry) Systems engineering (including design and integration) Computer engineering - software and programming SCADA (supervisory control and data acquisition) Instrumentation and data acquisition Training and education Turnkey systems Discrete and sequential control Factory automation Field service Motors, drives, and motion control (including ac, dc, and variable frequency drives) Batch control (including recipe management) Project planning and consulting CAD/CAM, drafting, and documentation Data processing and database management (including SQL programming) Supervisory control Designs and specifications (including P&ID development) Distributed control systems (DCSs) Electrical/electronics engineering (including electrical contracting) Product tracking and identification (including bar codes and radio frequency tags) Personal computers (PCs) Machine design and controls Water, wastewater, and groundwater systems Automated assembly Vision systems (including image processing and OCR) Robotics

Automation and controls, PLCs, installation and start-up, HMIs and operator interfaces (OIs) are among leading engineering specialties for the 2013 SI Giants.

The 2012 SI Giants top 10 engineering specialties were virtually identical as were the 2013 top 10 engineering specialties cited by other integrators in the AIG, though this years popularity scores for SI Giants were considerably higher than both. These results also were consistent with the SI Giants afnity for the CSIA and Rockwell Automation. All of the top 10 engineering specialties are integral to the practice of automation system integration, Rockwell Automation has signicant market share for the products involved (at least in North America), and the CSIA is the control system integrators most popular association, just as its name implies. In a open-ended response, by far the challenges most often cited by the surveys respondents focused on nding, training,

and compensating the skilled labor they need. Last years top issue, the economy, came in a distant second for 2013. This result seems to reect the overall optimism about the economy in general and the automation industry in particular as reported by the CSIA in its own recent survey. (See System integrators worldwide expect revenue growth in 2013 at www.controleng.com.) Business seems to be so good that business-growth issues barely registered in respondents comments this year. Perhaps the 2013 SI Giants already have their hands full, but theres a hidden danger in complacency. In response to a separate survey question, the SI Giants estimated their business percentage from existing clients, which showed that a whopping 86% of all respondents rely on existing clients for at least half of their revenue, and 12% rely on existing clients almost exclusively. Repeat business is desirable, but what happens when projects run out? Presumably, there must come a time when even the most loyal client nds that everything that can be automated has been. But only three of the 2013 SI Giants cited nding new customers as a current challenge. Apparently, the rest of the SI Giants plan to cross that bridge when they come to it. Another challenge was geographical expansion. One SI Giant expressed interest in offering more services in more places, compared to 21 in 2012. It could be argued that trying to cover additional territory without opening new ofces could be futile since clients would rather hire an integrator that can be on site within a matter of hours rather than days. (See the Areas Served charts online at www.controleng.com/giants.) In conclusion, after two years worth of data collection from the System Integrator Giants, it remains apparent that system integrators continue to be a key component in the everevolving industrial manufacturing landscape. ce - Vance VanDoren, PhD, PE, edits the CFE Media Automation Integrator Guide. Patrick Lynch, project manager, provided data collection/analysis. Edited by Mark T. Hoske, content manager, CFE Media, mhoske@cfemedia.com; and Amanda McLeman, project manager. This article rst appeared in the June 2013 issue of Control Engineering, sister publication of Plant Engineering.

Challenges and opportunities

At www.controleng.com/archive: See more tables, read more from system integrators about challenges See the SI Giants for 2012 at www.controleng.com/giants A no-cost listing in www.controleng.com/integrators is the first step for any automation, controls, instrumentation system integrator to be considered for SI Giants in 2014.

Go online

44

In the second year of CFE Media SI Giants, 65 companies that didnt respond last year are ranked in the 2013 list of 100 largest by automation system integration revenue, providing a much larger set of companies, overall. Until the 94th ranking, all the 2013 firms have greater system integration revenue than those in the 2012 list. Only those ranked 96-100 had less system integration revenue than those 2012 rankings.

2013 SI Giants (by system integration revenue)


ra nk Ow * ne rs hi p ty pe To ta l fis gr ca os ly sr ea ev r ( en $ ue US fo To ) r ta l re sy ve st nu em e i ( $ nt Pe US egr rc ) ati fro en on m tag sy e o st f em re in ven te ue Co gr rp at io or n at e ad dr es s 20 13 Co ran m k pa ny na m e ad dr es s W eb
www.mwgroup.net www.mustangeng.com www.mavtechglobal.com www.prime-controls.com www.optimation.us www.manganinc.com www.ekb.nl www.callistointegration.com www.avanceon.com www.averna.com www.intechww.com www.matrixti.com www.avtron-ia.com www.premier-system.com www.enengineering.com www.etech-group.com www.saic.com/engineering www.Testengeer.com www.conceptsystemsinc.com www.ace-net.com www.masmec.com www.thermosystems.com www.bwdesigngroup.com www.indicon.com www.interstates.com

1. 2. 3. 4. 5. 6. 7. 8.

M+W Automation Wood Group Mustang ** Maverick Technologies ** Prime Controls L.P. Optimation Technology Inc. Mangan Inc. ** EKB Callisto Integration (Aseco **, PS2 merged) Avanceon Averna 6 4 11 1 3

20 12

Private Public Private Private Private Employee Public

$3,500,000,000 $102,000,000 $80,000,000 $65,235,302 $61,208,000 $52,000,000 $36,976,989

$150,000,000 $95,000,000 $64,800,000 $45,956,701 $45,500,000 $41,600,000 $36,976,989

4% 93% 81% 70% 74% 80% 100%

Lotterbergstr. 30, 70499 Stuttgart, Germany 16001 Park Ten Pl., Houston, TX, 77084, USA 265 Admiral Trost Dr., Columbia, IL, 62236, USA 815 Office Park Cir., Lewisville, TX, 75057, USA 50 High Tech Dr., Rush, NY, 14543, USA 1500 W. Carson St., Ste. 100, Long Beach, CA, 90810, USA Wijkermeerweg 31, 1948 NT, Beverwijk, The Netherlands

Private Private Private Private 10 22 Private Public Private 14 Private Private

$32,000,000 $32,000,000 $37,000,000 $38,124,319 $29,006,654 $35,000,000 $29,500,000 $62,300,540 $17,000,000

$30,000,000 $24,000,000 $24,000,000 $23,447,318 $23,205,323 $20,000,000 $19,800,000 $17,078,045 $17,000,000

94% 75% 65% 62% 80% 57% 67% 27% 100%

635 Fourth Line, Unit 16, Oakville, Ontario, L6L 5B3, Canada 180 Sheree Blvd., Ste. 1400, Exton, PA, 19341, USA 87 Prince, Montreal, Quebec, H3C 2M7, Canada 4903 W. Sam Houston Pkwy., North, Ste. A-100, Houston, TX, 77041, USA 1760 Indian Wood Cir., Maumee, OH, 43537, USA 7555 E. Pleasant Valley Rd., Bldg. 100, Independence, OH, 44131, USA 140 Weakly Lane, Smyrna, TN, 37167, USA 28100 Torch Pkwy., Ste. 400, Warrenville, IL, 60555, USA 5530 Union Centre Dr., West Chester, OH, 45069, USA

9. 9.

11. Intech Process Automation 12. Matrix Technologies Inc. ** 13. Nidec Avtron Automation Inc. 14. Premier System Integrators 15. EN Engineering LLC 16. E-Technologies Group 16. SAIC Energy, Environment & Infrastructure LLC ** 16. Testengeer Inc. 19. Concept Systems Inc. ** 20. Applied Control Engineering Inc. 21. Masmec SpA 21. Thermo Systems LLC 23. Barry-Wehmiller Design Group 24. Indicon Corp. 25. Interstates Control Systems Inc. **

48 13

Private Employee Private

$659,075,000 $26,000,000 $16,700,000

$17,000,000 $17,000,000 $16,700,000

3% 65% 100%

9400 N. Broadway, Oklahoma City, OK, 73114, USA 3777 Hwy. 35 South, Port Lavaca, TX, 77979, USA 1957 Fescue St. SE, Albany, OR, 97322, USA

16

Private Private Private

$15,900,000 $15,700,000 $25,500,000

$15,900,000 $15,700,000 $15,700,000

100% 100% 62%

700 Creek View Rd., Newark, DE, 19711, USA Via dei Gigli, 21, Modugno, 70026, Bari, Italy 84 Twin Rivers Dr., East Windsor, NJ, 08520, USA

Private Private

$196,544,057 $38,000,000

$14,163,937 $14,000,000

7% 37%

8020 Forsyth Blvd., St. Louis, MO, 63105, USA 6125 Center Dr., Sterling Heights, MI, 48312, USA

19

Private

$18,500,000

$14,000,000

76%

444 12th St. NE, Sioux Center, IA, 51250, USA

2012 rank notes 1 - as Mustang Automation & Control 22 - as Avtron Industrial Automation

45

2013 SI Giants (by system integration revenue)


ra nk Ow * ne rs hi p ty pe To ta l fis gr ca os ly sr ea ev r ( en $ ue US fo To ) r ta l re sy ve st nu em e i ( $ nt Pe US egr rc ) ati fro en on m tag sy e o st f em re in ven te ue Co gr rp at io or n at e ad dr es s 20 13 Co ran m k pa ny na m e ad dr es s W eb
www.vfd.com www.champtechnology.com www.industrialsystems.ru www.hollandertechniek.nl www.icshealyruff.com www.i2r.com www.kahlerautomation.com www.jmpeng.com www.getmatrixed.com www.mlr.de www.faithtechnologies.com www.spiratec-solutions.com www.avidsolutionsinc.com www.innovativecontrols.com www.tricore.com www.ausenco.com www.aesolns.com www.SuperiorControls.com www.atcss.com www.a-cc.com www.theescogroup.com www.calbay.com www.direct-automation.com www.zarpac.com www.malisko.com www.cotmacelectronics.com

26. Five Star Electric 27. Champion Technology Services Inc. 28. Insist Avtomatika 29. Hollander Techniek 29. ICS Healy-Ruff 29. Integrity Integration Resources (I2R) ** 29. Kahler Automation Corp. 33. JMP Engineering ** 34. Matrix Design Inc. 35. MLR System GmbH 36. Faith Technologies 37. SpiraTec 28 8

20 12

Private

$68,000,000

$13,600,000

20%

4729 Shavano Oak, San Antonio, TX, 78249, USA

20 17

Private Private Private Private

$22,720,000 $14,837,000 $85,241,278 $15,000,000

$12,950,000 $12,218,741 $12,000,000 $12,000,000

57% 82% 14% 80%

11824 Market Place Ave., Baton Rouge, LA, 70816, USA 18-1A Marx St., Omsk, 644042, Russia Boogschutterstraat 30, Apeldoorn, 7324 AG GLD, The Netherlands 13005 16th Avenue North, Ste. 100, Plymouth, MN, 55441, USA

Private Private Private Private Employee Private Private/ Employee Private Employee Private Public Private Private Private

$29,500,000 $14,000,000 $19,245,000 $11,200,000 $15,641,333 $261,000,000

$12,000,000 $12,000,000 $11,850,000 $10,990,000 $10,948,933 $10,535,000

41% 86% 62% 98% 70% 4%

4001 E. Plano Pkwy., Ste. 500, Plano, TX, 75074, USA 808 Timberlake Rd., Fairmont, MN, 56031, USA 4026 Meadowbrook Dr., Unit 143, London, Ontario, N6L 1C9, Canada 1627 Louise Dr., South Elgin, IL, 60177, USA Voithstrasse 15, Ludwigsburg, 71640, Germany 225 Main St., Menasha, WI, 54952, USA

$12,185,000 $15,236,000 $104,000,000 $10,173,595 $633,500,000 $29,000,000 $9,400,000 n/a

$10,525,000 $10,281,000 $10,200,000 $10,173,595 $10,120,544 $9,396,000 $9,000,000 $8,800,000

86% 67% 10% 100% 2% 32% 96% n/a

1839 Ygnacio Valley Road, #390, Walnut Creek, CA, 94598, USA 2875 Ridgewood Park Dr., Winston-Salem, NC, 27107, USA 624 Reliability Cir., Knoxville, TN, 37932, USA 6921 Mariner Dr., Racine, WI, 53406, USA 1320 Willow Pass Rd., Ste. 300, Concord, CA, 94520, USA 250 Commonwealth Dr., Ste. 200, Greenville, SC, 29615, USA 135 Folly Mill Rd., Seabrook, NH, 03874, USA 2080 Nelson Miller Pkwy., Louisville, KY, 40223, USA

38. Avid Solutions 39. Innovative Controls 40. TriCore Inc. 41. Ausenco 42. aeSolutions 43. Superior Controls Inc. ** 44. Alliant Technologies 45. Automation & Control Concepts Inc. 46. ESCO Automation 47. Cal-Bay Systems 47. Direct Automation LLC 47. Zarpac Inc. 50. Malisko Engineering Inc. 51. Cotmac Electronics Pvt Ltd. 40

37 18

Private Private Private Private Public Private Private

$8,353,000 $38,100,000 $8,000,000 $10,000,000 $11,000,000 $8,500,000 $37,735,849

$8,353,000 $8,100,000 $8,000,000 $8,000,000 $8,000,000 $7,600,000 $7,547,169

100% 21% 100% 80% 73% 89% 20%

1310 Papin St., St. Louis, MO, 63129, USA 3450 3rd St., Marion, IA, 52302, USA 3070 Kerner Blvd., Ste. B, San Rafael, CA, 94901, USA 408 N. Hwy. 77, Dell Rapids, SD, 57022, USA 1185 North Service Rd. East, Oakville, Ontario, L6H 1A7, Canada 707 N. 2nd St., Ste. 650, St. Louis, MO, 63102, USA S-168, MIDC, Bhosari, Pune, Maharashtra, 411026, India

46

2013 SI Giants (by system integration revenue)


ra nk Ow * ne rs hi p ty pe To ta l fis gr ca os ly sr ea ev r ( en $ ue US fo To ) r ta l re sy ve st nu em e i ( $ nt Pe US egr rc ) ati fro en on m tag sy e o st f em re in ven te ue Co gr rp at io or n at e ad dr es s 20 13 Co ran m k pa ny na m e ad dr es s W eb
www.rdcustomautomation.com www.cougar-automation.com www.dynamicdesignsolutionsinc.com www.pattieng.com www.stratusauto.com www.iastech.com.br www.automationgroup.com www.integro-tech.com www.advancedintegrationgroup.net www.itac.us.com www.nexjen.com www.cogentind.com www.PhantomTechnical.com www.customcontrol.net www.mikrokontrol.rs www.ecn.com.mx www.merteknc.com www.optimacs.com www.trimaxsystems.com www.machinevc.com www.lomancsi.com www.aaronct.com www.indpg.com www.pro-at.nl

52. R+D Custom Automation 53. Cougar Automation Ltd. 54. Dynamic Design Solutions Inc. 55. Patti Engineering Inc. ** 56. Stratus Automation 57. IASTech Automacao de Sistemas Ltda. 58. Industrial Automation Group 59. Integro Technologies Corp. 60. Booth Welsh 61. Advanced Integration Group Inc. 62. Industrial TurnAround Corp. (ITAC) 63. Nexjen Systems LLC 64. Cogent Industrial Technologies Ltd. 65. Phantom Technical Services Inc. 66. Custom Controls Technology Inc. 84 67. Mikro Kontrol Doo. 68. Electro Controles del Noroeste, S.A. de C.V. 69. Mertek Solutions Inc. 70. Optima Control Solutions Ltd. 71. Trimax Systems Inc. 72. Machine Vision Consulting Inc. 64 73. Loman Control Systems Inc. 74. Aaron Associates of Connecticut Inc. 75. Industrial Process Group LLC 76. Pro-AT BV 68 76 53 55 38 41

20 12

Employee Private Private Private Private

$8,200,000 $8,253,968 $6,150,000 $6,700,000 $7,260,000

$6,970,000 $6,603,174 $6,150,000 $5,900,000 $5,780,000

85% 80% 100% 88% 80%

23411 W. Wall St., Lake Villa, IL, 60046, USA Birch House, Forest Rd., Waterlooville, Hampshire, PO7 6XP, U.K. 3565 Centre Cir., Fort Mill, SC, 29715, USA 2110 E. Walton Blvd., Auburn Hills, MI, 48326, USA 22613 68th Ave S., Kent, WA, 98032, USA Rua Sansao Alves dos Santos, 76 - 4 andar - Brooklin Novo, Sao Paulo, SP, 04571-090, Brazil 1340 Coldwell Ave., Modesto, CA, 95350, USA 305 N. Lee St., Salisbury, NC, 28144, USA

Private Private Private Private

$7,500,000 $7,400,000 $5,500,000 $22,700,000

$5,625,000 $5,600,000 $5,500,000 $5,150,000

75% 76% 100% 23%

First Ave., Stevenston Industrial Estate, Ayrshire, KA20 3LR, Scotland www.boothwelsh.co.uk

Private

$7,082,560

$5,052,000

71%

1 McCormick Rd., McKees Rocks, PA, 15136, USA

Private Private

$42,000,000 $5,500,000

$4,600,000 $4,500,000

11% 82%

13141 N. Enon Church Rd., Chester, VA, 23836, USA 5933 Brookshire Blvd., Charlotte, NC, 28216, USA Unit 180 - 13091 Vanier Pl.,

Private Private Private Private

$4,400,000 $3,896,536 $4,275,250 $7,800,000

$4,400,000 $3,896,536 $3,785,900 $3,600,000

100% 100% 89% 46%

Richmond, British Columbia, V6V 2J1, Canada 111 Outerbelt St., Columbus, OH, 43213, USA 705 W. 20th St., Hialeah, FL, 33010, USA Vase Pelagica 30, Belgrade, 11040, Serbia Boulevard Paseo Rio Sonora Sur No. 69, Hermosillo, Sonora, 83270, Mexico 3913 Hawkins Ave., Sanford, NC, 27330, USA Blakewater Rd., Blackburn, Lancashire, BB1 5QR, U.K. 565 Explorer St., Brea, CA, 92821, USA 69 Milk St., Ste. 217, Westborough, MA, 01581, USA 143 E. 28th Division Hwy., Lititz, PA, 17543, USA

Private Employee Private Private Private Private

$19,400,000 $4,000,000 $3,336,000 $5,199,518 $3,200,000 $3,900,000

$3,560,000 $3,500,000 $3,336,000 $3,328,239 $3,200,000 $3,128,000

18% 88% 100% 64% 100% 80%

74

Private Private Private

$3,330,000 $3,738,644 $3,200,000

$3,000,000 $2,845,185 $2,800,000

90% 76% 88%

478 W. Main St., Waterbury, CT, 06723, USA 111 E. Mildred St., Logansport, IN, 46947, USA Kubus 70, Sliedrecht, Zuid-Holland, 3364 DG, Netherlands

47

2013 SI Giants (by system integration revenue)


ra nk Ow * ne rs hi p ty pe To ta l fis gr ca os ly sr ea ev r ( en $ ue US fo To ) r ta l re sy ve st nu em e i ( $ nt Pe US egr rc ) ati fro en on m tag sy e o st f em re in ven te ue Co gr rp at io or n at e ad dr es s 20 13 Co ran m k pa ny na m e ad dr es s W eb
www.processplus.com www.riverconsulting.com www.adaptiveresources.com www.synsysinc.com www.control-associates.com www.jordansynergist.com www.kaier.net www.nextautomation.com.br www.fitchcompany.com www.smithcontrols.net www.georgethall.com www.apexmfgsolutions.com www.cqsinnovation.com www.genesyscontrols.com www.auto-eng.net www.northwindts.com www.agatos.com www.projectweb.it www.plantwerx.com.sg www.synergetech.com www.flowdynamics.net www.esr-systemtechnik.de www.kccsoftware.com www.avisonelectrical.com

20 12

Private/ 77. Process Plus LLC 78. River Consulting LLC 79. Adaptive Resources Inc. 79. Synergy Systems Inc. 81. Control Associates Inc. 82. Jordan Engineering Inc. 83. Kaier Engineering 84. Next Automation Focus Solution Group 84. The Fitch Company 86. Smith Controls 87. George T. Hall Co. Inc. 88. Apex Manufacturing Solutions 89. CQS Innovation Inc. 90. Genesys Controls Corp. 91. Automation Engineering 92. NorthWind Technical Services 93. Agatos Software Engineering Pte. Ltd. 94. Project S.R.L. 95. Plant Werx Pte. Ltd. 96. Synergetech Co. Ltd. 97. Flow Dynamics and Automation 98. ESR-Systemtechnik GmbH 99. KCC Software 100. Avison Electrical Private Private Private Private Private Private Private Private $2,500,000 $1,300,000 $1,200,000 $2,000,000 $8,000,000 $1,950,000 $225,000 $850,000 $1,300,000 $1,000,000 $960,000 $500,000 $400,000 $300,000 $225,000 $90,000 52% 77% 80% 25% 5% 15% 100% 11% 91 81 63 Employee Private Private Private Private Private Private Private Private $3,600,000 $4,100,000 $2,900,000 $15,500,000 $1,963,747 $2,300,000 $3,500,000 $6,294,586 $2,600,000 $2,200,000 $2,200,000 $1,980,000 $1,900,000 $1,842,730 $1,650,000 $1,500,000 $1,434,820 $1,350,000 61% 54% 68% 12% 94% 72% 43% 23% 52% Av Angelica 2223, So Paulo, 01227-20, Brazil 631 Hammond St., Bangor, ME, 04401, USA 1839 Route 9H, Hudson, NY, 12534, USA 1605 Gene Autry Way, Anaheim, CA, 92805, USA 408 E. Parkcenter Blvd., Ste. 200, Boise, ID, 83706, USA 2390 Pipestone Rd., Benton Harbor, MI, 49022, USA 1917 Olde Homestead Ln., Lancaster, PA, 17601, USA 100 North Main, Hackett, AR, 72937, USA 2751 Antelope Rd., Sabetha, KS, 66534, USA Blk 67, Ayer Rajah Crescent, #07-18, Singapore, 139950, Singapore Via Don Lorenzo Perosi, 50, Firenze, 50127, Italy 51 Bukit Batok Crescent, #09-02, Singapore, 658077, Singapore 31/65 Moo 6 Pracharaj Rd., Taladkwan, Muang, Nonthaburi, 11000, Thailand 1024 11th Court West, Birmingham, AL, 35204, USA Waiblinger Strasse 56, Fellbach, 70734, Germany 830 Eldorado Ave. SE, Huntsville, AL, 35802, USA 592 Collins Dr., North Bay, Ontario, P1B 8G3, Canada 67 87 97 Employee Private Private Private Employee Private Private $16,100,000 $27,392,098 $3,500,000 $3,100,000 n/a $2,316,361 $3,000,000 $2,660,757 $2,591,479 $2,500,000 $2,500,000 $2,400,000 $2,316,361 $2,250,000 17% 9% 71% 81% n/a 100% 75% 1340 Kemper Meadow Dr., Cincinnati, OH, 45240, USA 445 Hutchinson Ave., Ste. 740, Columbus, OH, 43235, USA 104 Broadway St., Carnegie, PA, 15106, USA 1982 Ohio St., Lisle, IL, 60532, USA 20 Commerce Dr., Allendale, NJ, 07401, USA 4516 Mountainview Rd., Beamsville, Ontario, L0R 1B3, Canada 106 Commerce Blvd., P.O. Box 503, Lawrence, PA, 15055, USA

Notes * 2013 rank could be lower and system integration revenue higher: 65 names are new to the ranking in 2013. See the 2012 SI Giants listing at www.controleng.com/giants. ** CFE Media named three firms System Integrator of the Year annually since 2007 in three revenue classes; 12 are included here.

After deadline, two firms asked that their total revenue not be reported. Firms not allowing requested data points will not be included in the 2014 ranking.

ONLINE: More graphics, links to related content at June 2013, www.controleng.com/archive Not here? Process starts with a listing at www.controleng.com/integrators. System Integrator of the Year deadline is Aug. 1: www.controleng.com/SIY

48

DIGITALEXCLUSIVES

Check out the Digital Edition exclusive article


Plant Engineering Digital Edition Exclusives provide additional information not included in the print edition. As with all Digital Edition content, click on any highlighted headline to read a longer version online.

Lean manufacturing processes: Look for waste in time and space

How do you get started making a manufacturing process Lean, so you can then apply automation, and where does it makes sense? Start by asking operators how to eliminate waste and think visually around your facility.

Go to www.plantengineering.com/digitaledition today!

www.plantengineering.com

PLANT ENGINEERING

December 2013 49

DIGITALEXCLUSIVE

Lean manufacturing processes: Look for waste in time and space


Ask operators how to eliminate waste and think visually.
By Jack Rubinger Graphic Products

KEYPOINTS

As a first step toward Lean, look for wasted movements, time and effort, wasted space, and disorganized work areas. Ask operators how to eliminate waste. Think visually about how and where things should go.

ow do you get started making a manufacturing process Lean, so you can then apply automation, where it makes sense? Just take a look around. Look for wasted movements, time and effort, wasted space, and disorganized work areas. The next step is to ask operators how to eliminate waste and think visually about how and where things should go. Often, a simple instructional or operational sign can help an operator remember and prioritize all the steps in a particular process. Color-coded shadow boards are great for helping users and tool crib managers track tool usage, minimizing theft and keeping track of whos hogging the hammer. Manufacturers typically deal with seven forms of waste: inventory, overproduction, transport, defects, overprocessing, motion, and waiting, said Melissa Topp, the director

of global marketing for enterprise software provider, Iconics. Lean manufacturing is an iterative approach that encourages manufacturers to eliminate those sources of waste. Technology solutions accompanying each phase concentrate on manufacturing intelligence reporting, alarm management, and downtime reduction. The manufacturing automation industry is huge, encompassing technologies such as computer controlled machines for processing and handling products, process automation systems, general motion control systems, automation related software, and conditionmonitoring equipment and systems. Business benefits of automation include global competition, meeting orders more quickly, faster deliveries, increasing shift productivity, lowering operating costs, increasing yields, reducing load/unload times, reducing damage or breakage during handling, less material waste, and labor savings. In Australia, theres no such thing as cheap labor, explained James Abbot, Challenge Engineering. Abbot relies on computer numeric control (CNC) machining, which offers multiple manufacturing processes in one machine. Setup is streamlined, with most tools already in a carousel that can hold up to 72 tools, but all turning, milling, and drilling operations can be carried out in one setup. This type of automation machinery maximizes staffing and helps the company maintain a competitive edge over imported rivals, particularly with a strong Australian dollar.

Return on investment (ROI)


Figure 1: Labeling personal protective equipment and tools can eliminate wasted time and augment a manufacturers safety culture. All images courtesy: DuraLabel

When faced with production requirements that exceeded current operational capabilities, PGT Industries applied Iconics software
www.plantengineering.com

DE-1 December 2013

PLANT ENGINEERING

to the 12 most critical production assets to analyze the overall equipment effectiveness (OEE) of the current plant. The software was used to zero in on sources of loss of OEE, focusing on availability, quality, and performance. PGT Industries realized enough savings and cut enough waste that it postponed its plans to build a third production facility, resulting in major savings for the company, and discovered that it could run at 1.5 times its previous production capacity with the same capital assets. With these findings, PGT Industries decreased labor and energy costs by 20%. Portable analytical instruments help automate processes in the pharmaceutical and scrap metal industries, according to Larry Zeltner, director of operational excellence, portable analytical instruments, Thermo Fisher Scientific. Monitoring and controlling raw material and quality regulatory compliance is critical with pharma companies, he said. A relatively low-cost handheld device generates instantaneous, real time, and accurate results, avoiding costly and time-consuming quality control analysis typically done by offsite labs, which charge by the hour or project. This approach puts quality control into the hands of the operator. On the industrial side, were working closely with customers who deal with sorting through scrap metal from trailer loads. XRF screening tools help them make accurate and quick estimates of the value of these loads, leading to profitable decisions in a business that operates on thin margins. Automation played an important role in the recipe for Barbers Farmhouse Cheesemakers success. The challenge there is to ensure accurate size and weights for cheeses (required by U.K. law), while minimizing oversized portions. Barbers engineers implemented an automated weighing and cutting system and reduced give away from between 4% and 5% to less than 1%. Another hands-on approach to Lean manufacturing and automation was delivered by Lois Quinn, rapid operational improvement, for a furniture manufacturer, eliminating the need for an outside Lean consultant. With the patience of a good parent, the encouragement of a high school basketball coach, and the precise calculations of an engineer, Quinn and her team addressed several key challenges and engineered the changes.
www.plantengineering.com

Figure 2: Labeling supplies Identify power tools by bar code, individual, or by the section in which theyre stored so time is not wasted looking for toolsone of the key principles of Lean manufacturing.

One obvious challenge was an awkward framing table used to square and assemble office desk divider panels commonly used in offices. Before launching into the Lean program, measureable goals were established: n Improve the table, decrease frame assembly time, and eliminate defects. n Reduce change-over time from one panel size to the next and improve ergonomics by eliminating reaching over to get to smaller panels in the middle of the table. n Identify and eliminate major safety hazards. A Kaizen workshop lead by two operators resolved related issues. The new table rides on linear bearings to adjust to the width of the panel. Two clamps (one at each corner) can be quickly moved to adjust panel height. This allows two operators to work on opposite sides of the panel at the same time without reaching out over the table. In the past they would be required to carry the panel to another table. Now all the work can be completed at one table, eliminating safety and ergonomic issues of lifting and moving panels, and saving time.

Figure 3: Bin labeling helps speed workflow and eliminate efforts for manual (shown) or robotic part picking.

PLANT ENGINEERING

December 2013 DE-2

DIGITALEXCLUSIVE
Automation plays an important role in Lean manufacturing because it frees up time for humans to actually think about their processes and it speeds tasks and jobs that machines can ably do.
simplify, shine, standardize, and sustain). From both a managerial and an operational perspective, automation plays an important role in Lean manufacturing because it frees up time for humans to actually think about their processes and it speeds tasks and jobs that machines can ably do. But some experts believe automated processes should be phased in systematically. Automation typically isnt a solution that can be tried, fixed, and changed easily, and should occur in the latter stages of a Lean implementation to eliminate worker ergonomic overburden as well as mitigate potential safety concerns, said Paola Castaldo, Oregon Manufacturing Extension Partnership. Castaldo added, But designing automated systems before going through the rigors of Lean could potentially fix the wrong problem because you could be automating a broken system. However, when human constraints get in the way of continuous flow and quality, automation could be the only way to deliver the next incremental improvement and be an appropriate solution. Eliminating opportunities for injuries goes hand in hand with increasing business productivity. While some view injuries as an unavoidable consequence in many operations and industries, these impact the bottom line, the lives of employees and their families, and even the morale of the other employees. The wave of the future is balancing the ROI of implementing automation processes and achieving job/work satisfaction. The tools and coaches are out there. Dont hesitate to start eliminating the waste from your E operation. P

Figure 4: DuraLabel labeling systems and supplies, manufactured by Graphic Products, are used globally by companies that rely on visual communications to aid in Lean manufacturing processes. This is a magnetic label on a shelf.

Safety and Lean

Figure 5: Adhesive labels provide visual communication for Lean manufacturing, and can help with error-proofing efforts, improving quality.

Benefits include: n Minimal work in progress (WIP) n Minimal part travel distances n Safe and ergonomically designed production cell n Production readiness for the table, handling 800 panels daily n Quantified the allocated portion of labor costs and time to achieve 25% cost reduction n Reduced safety and ergonomic issues by 100% n Improved 5S level by 25% (5S = sort,

Jack Rubinger, public relations, Graphic Products.


www.plantengineering.com

DE-3 December 2013

PLANT ENGINEERING

Engineering is personal. So is the way you use information. CFE Media delivers a world of knowledge to you. Personally.
You take pride in your profession one of
acquiring and applying design and build structures, machines, devices, systems, materials and processes that safely realize a solution to the needs of society. And, to do your job better each day, you need a trusted source of information: CFE Media Content For Engineers.

Other opportunities to connect


While our print magazines remain the touchpoint for more than 200,000 qualied subscribers each month, we also recognize that there are so many other opportunities each day to reach busy end users. Thats why weve developed a wide range of ways to connect with our audience:

CFE Media strives to...



Inspire engineers to interact, respond to peers, and contribute to content that will assist other engineers with similar challenges. Develop an infrastructure that aligns, organizes and maps content to audiences specialized needs and business opportunities. Fully understand our audience and its changing needs for targeted information and delivery channels through the use of industry experts and leaders.

CFE Media is home to three of the most trusted names in the business:
Consulting-Specifying Engineer provides the latest knowledge on commercial and institutional facility construction and management. Visit www.csemag.com Control Engineering delivers a wide array of strategies and solutions to help control system designers create a more efcient process. Visit www.controleng.com Plant Engineering delivers plant-oor knowledge and expertise to help manufacturers operate smarter, safer and more efciently. Visit www.plantengineering.com

Webcasts Videos Newsletters Websites RSS feeds An expanding global video library iPhone and Droid apps Social networks

Our goal?
To give you the knowledge you need, when you need it, in the format you want it, delivered to the device youre using, with the ability to utilize that knowledge to do your job better.

CFE Media 1111 W. 22nd Street Oak Brook, IL 60523 630-571-4070

www.cfemedia.com

IN NOVATIONS
Modules for harsh industrial environments
The CLXT Modules are designed for use with Rockwell ControlLogix XT PLCs in harsh and corrosive industrial environments. The CLXT Modules are available in three versions: the SSTESR2-CLXT Module for Ethernet and serial connections, the SST-ER4-CLXTserial communication module with four Modbus serial ports and the SST-PB3-CLXT-RLL for Profibus Master/ Slave applications. All versions feature wider temperature ranges, conformal-coated boards and harsh-duty components.
Molex www.molex.com
Input #200 at www.plantengineering.com/information

Advanced module for welding


The Power Wave Advanced Module increases flexibility for manufacturers by expanding their welding capabilities. The module has ac welding capability to run aluminum processes. The welding system module performs several welding processesshielded metal arc, metal inert gas (MIG), pulsed MIG, tungsten-electrode inert gas (TIG) and surface tension transfer (STT). With STT welding capability, the module can also help welding open root gaps with high frequency inverter technology.
Lincoln Electric Co. www.lincolnelectric.com
Input #201 at www.plantengineering.com/information

Elevator pulley line


The Dodge elevator pulley line is available in drum or single disc design with HE, XT, QD or Taper-Lock hubs and bushings. Heavy duty elevator pulleys meet CEMA standards, but these pulleys are also available with Mine Duty Extra construction that features the Dodge integral hub design for ultimate strength and durability. The Dodge elevator pulleys are available in diameters from 6 to 72 in., with face widths up to 120 in.
Baldor Electric Co. www.baldor.com
Input #202 at www.plantengineering.com/information

Mobile app program


The new Altivar 212 mobile programming application and drive-to-iPad converter cable allows users to perform all Altivar 212 and S-Flex drives programming through iPads. The application contains simple menu-driven parameter sets that walk users through the drive configuration process. Digitizing the start-up and programming of a drive streamlines the process, allowing customers to store pertinent drive information in a single location, and facilitates a standard drive configuration throughout a facility. The app enables an iPad to function as a drive keypad using pre-loaded common default parameters for HVAC fan and pump applications, significantly streamlining the configuration process.
Schneider Electric www.schneider-electric.com
Input #203 at www.plantengineering.com/information

50 December 2013

PLANT ENGINEERING

www.plantengineering.com

Send new product releases to: peproducts@cfemedia.com

is for

Photoelectric sensor series


The OPT series of short and long range distance photoelectric sensors are available with either Class 1 or Class 2 laser options and are constructed with rectangular plastic housings and fitted with an M12 quick-disconnect. OPT short-range diffuse distance sensors utilize high-resolution CMOS line array technology, eliminating material, color and brightness-related measurement differences. Analog and switch output models are available with sensing ranges from 30 to 660 mm, at up to 1,500 scans per second. Diffuse styles have a sensing range up to 10 m; retro-reflective styles sense up to 100 m. Analog and switch output models are available.
AutomationDirect www.automationdirect.com
Input #204 at www.plantengineering.com/information

YOUR DOWNTIME SOLUTION


2013 The Diamond Chain Company. DCPE-1113 www.diamondchain.com | 1-800-872-4246
Diamond, the Diamond chain logo, and Nothing Outlasts a Diamond are trademarks of Diamond Chain Company, Inc.

input #23 at www.plantengineering.com/information

nothing outlasts a diamond

Robotic MIG gun series


The Tough Gun ThruArm G1 Series Robotic MIG Guns offer durable features that help prevent production downtime and shield components from harsh welding environments. The guns also provide 500 A of welding capability. Featuring the durable Low-Stress Robotic (LSR) Unicable, Tough Gun ThruArm G1 Series Robotic MIG Guns are designed specifically for todays through-arm style robots. The LSR Unicable incorporates a rotating power connection that allows for stress-free rotation, as well as a protective conduit to better shield the cable components from abuse. These features limit the influence of torsion and extend the usable life of the unicable.
Tregaskiss www.tregaskiss.com
Input #205 at www.plantengineering.com/information

Can This Man Push 250,000 lbs? She can.

Effortlessly and safely push, pull or maneuver rolling loads up to 250,000 pounds.
Dramatically increase employee productivity and safety. Alternative to expensive fork lifts and ride-on equipment. Four models from 500 to 250,000 lb. capacities. Comply with Health & Safety Guidelines limiting pushing/pulling by a single person.

Visit www.powerpusher.comfor free instructional DVD


If it rolls... we can move it. Division of NuStar, Inc. www.PowerPusher.com 800-800-9274
input #24 at www.plantengineering.com/information

PowerPusher

PLANT ENGINEERING

December 2013 51

IN NOVATIONS

Send new product releases to: peproducts@cfemedia.com

Programmable PC
The Automation PC 910 is available with five slots and the housing can now be selected to allow installation of up to five PCI or PCI Express cards. By selecting the right processor, memory and housing, customers can program the PC to meet the needs of their automation solution. Customers with computationally intensive control or image processing tasks and few peripheral hardware devices can select a quadcore processor with lots of memory and a one-slot housing. For other tasks, a singlecore processor and multiple insert cards may be more effective.
B&R Automation www.br-automation.com
Input #206 at www.plantengineering.com/information

Portable heat pump


The PACSlim-5 heat pump delivers 57,100 BTU/hr cooling capacity and 55,700 BTU/ hr heating capacity. It is less than 30 in. wide, allowing it to roll into narrow spaces where other units cant go. It may be used for outdoor spot cooling and heating or for indoor areas. The PACSlim-5 offers year-round duty and may be used as a portable cooling unit or as a conventional cooler or heat pump. It also features a powder coated, heavy duty steel cabinet on lockable casters for ease of transport, and removable 16-in. supply and return duct collars.
Atlas Sales & Rentals Inc. www.atlassales.com
Input #207 at www.plantengineering.com/information

Mechanic gloves
The MG-9850 Deerskin Leather Mechanics Gloves and the MG-9855 Dupont Kevlar-Lined Deerskin Leather Mechanics Gloves are constructed using soft gold deerskin leather palms and include breathable gold and black polyester/spandex knit backs to offer the ideal balance of ergonomics, dexterity and durability. Both gloves feature black rubber protection on the backs of the hands and fingers as well as padded palms to enhance impact protection and better absorb shocks and vibrations.
Saf-T-Gard International Inc. www.saftgard.com
Input #208 at www.plantengineering.com/information

Semiautomatic unit for oil and gas industry


The High-Volume Swaging Unit (HVSU) aimed to increase safety and productivity for the oil and gas, alternative fuel, and general industries. The HVSU enables installers to easily preswage nut-ferrule sets onto stainless steel tubing. The pneumatically driven and electronically controlled semiautomatic unit uses sensors to start and stop the process for consistent preswaging results. This process provides several reliability and convenience features including an automatic start when tubing is inserted and properly bottomed and prevention of over swaging with stroke-limiting tooling. No tools are need to switch from one tube fitting size to another, either.
Swagelok www.swagelok.com
Input #209 at www.plantengineering.com/information

52 December 2013

PLANT ENGINEERING

www.plantengineering.com

PRODUCTMART
Why Should You Filter Your Water?

Scale formation reduces the heat transfer rate and


Input #100 at plantengineering.hotims.com

increases the water pressure drop through the heat exchanger and pipes. In fact, one study has shown that .002" fouling will increase pumping needs by 20%.

OIL MIST & SMOKE IN YOUR SHOP?


www.mistcollectors.com Tel: 1-800-645-4174
Input #102 at plantengineering.hotims.com

The Best Engineered Water Filtering Solution Always Costs Less


2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A ( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8 w w w. t e k l e e n . c o m info@tekleen.com

Please visit us at the AHR Expo, Jan. 21st-23rd, New York, NY Booth 8015
Input #103 at plantengineering.hotims.com

3.5" wide x 4.5" high Pantone 382c

Dayton Soft Start Motor


More than just a soft starter, the Dayton energy-saving, soft start motor controller combines traditional soft start and Class 10 motor protection with patented energy saving technology. Conserving energy while maintaining normal motor speed, the motor controller detects when the motor is not fully loaded and reduces the voltage and current fed to the motor, lowering the total power consumption by up to 40%! Helps reduce energy usage without changing the speed of the motor and provides the necessary torque for the application. Starters are available in 4 models to suit a variety of environments. grainger.com/daytonps07
Input #105 at plantengineering.hotims.com

Get More Coverage with FabEnCos XL Safety Gate


Another Fall Protection Solution from FabEnCo
For extended coverage at unprotected openings on ladderways, platforms, stairways, catwalks, mezzanines and machine guarding, get the FabEnCo Self-Closing XL Safety Gate.
Carbon Steel, Aluminum and Stainless Steel
Easy To Install Available in Variety of FabEnCoat Finishes 22 Vertical Coverage

Made in the USA

www.safetygate.com/ple3 Toll Free: 1-800-962-6111


Input #106 at plantengineering.hotims.com

Reach your Audience!


Place your Ad in PLANT ENGINEERINGS Product Mart or Classifieds section, call today and get results! 630-571-4070
PLANT ENGINEERING

December 2013 53

For more information on how to advertise in PLANT ENGINEERINGS Internet Connection, call Jim Langhenry at 630-571-4070 x2203
aitkenproducts.com
Aitken Products manufacturers and distributes highquality industrial heaters. Aitkens products are for a variety of industrial applications and are available when needed. Aitken Products Inc.

gardnerdenver.com
Gardner Denver is a global manufacturer of industrial compressors, blowers, pumps, loading arms, and fuel systems. Gardner Denver Inc.

orival.com
Orival is a leading manufacturer of self-cleaning water filters, automatic water filters and strainers, for use as industrial water filters, irrigation filters, cooling tower filters, and more. Orival Inc.

automationdirect.com
AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including PLCs, operator interfaces, sensors, and more. AutomationDirect

ge-energy.com
GE Energy is one of the worlds leading suppliers of power generation and energy delivery technologies. GE Energy provides integrated products, services, and solutions in all areas of the energy industry. General Electric Co.

parker.com
Parker Hannifin is the worlds leading diversified manufacturer of motion and control technologies and systems, providing precision-engineered solutions for a wide variety of commercial, mobile, industrial and aerospace markets. Parker Hannifin Corp.

baldor.com
Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.

grainger.com
Grainger is a leading distributor of industrial supplies, MRO equipment, tools, and materials. MRO, manufacturing, supply chain, tools, and morefor the ones who get it done. Grainger Inc.

prime-controls.com
Prime Controls is a systems integration and I&C construction firm specifically structured to meet all industrial automation and control needs. Prime Controls

calpipe.com
Calpipe Manufacturing offers stainless-steel protective auto vehicle safety security bollards, electrical conduit fittings, and pipe tube bending, rolling, threading and finishing. Calpipe Industries

hochikiamerica.com
Hochiki America Corp. manufactures life safety, fire detection and emergency devices. Hochiki America Corp.

rigalite.com
Rig-A-Lite leads the industry in innovative solutions and ruggedly designed products for marine lighting, industrial lighting, specialty lighting, petroleum lighting and food processing lighting. Rig-A-Lite Industrial Lighting

camfilfarr.com
Camfil Farr is the worlds largest and leading manufacturer of filters and clean air solutions. Camfil Farr

iom.invensys.com
Invensys is a provider of automation and information technologies, systems, software solutions, services and consulting to manufacturing and infrastructure industries. Invensys

saferack.com
SafeRack.com offers truck loading racks, railcar loading platforms, gangways, loading arms, swivel joints, and fall protection equipment. Six Axis LLC

cat.com
Caterpillar is a manufacturer of construction and mining equipment, diesel and natural gas engines, industrial turbines and diesel-electric locomotives. Caterpillar

lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.

victaulic.com
The grooved piping method dramatically reduces the amount of installation time and reduces total installed costs as compared to welding, threading or flanging. Victaulic Co.

diamondchain.com
Diamond Chain provides expertise in drive systems and design, wear and fatigue performance, and superior ROI with the consistent performance of its products. Diamond Chain Co.

mhia.org
MHIA is the leading non-profit trade association representing the U.S. material handling and logistics industry. Material Handling Industry of America

yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.

donaldson.com
Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.

nord-lock.com
The Nord-Lock Group manufacturers patented Superbolt multi-jacket tensioners designed to eliminate unsafe and time-consuming bolting methods. Nord-Lock

flexicon.com
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.

nustarinc.com
NuStar offers PowerPusher, Automatic Car Wash, Wet Noses Clean Paws and SkyPro products. NuStar Inc.

54 December 2013

PLANT ENGINEERING

Place next to your computer or go online to plantengineering.com for hot links to these companies.

Remove at Line

3 er 201 b m e Dec

CONTACTS
Advertiser
Aitken Products, Inc 800-569-9341 AutomationDirect 800-633-0405 Baldor Electric Company 800-828-4920 Calpipe Inustries, Inc 800-225-7473 Camfil Air Pollution Control 800-479-6801 Caterpillar - Northeast
Page Number RSC Number

Advertiser Contacts for plant engineers

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Plant Engineering.
Send Info

Advertiser
Invensys 713-329-1600

Page Number

RSC Number

Send Info

13

10 www.aitkenproducts.com 1 www.automationdirect.com 26 www.baldor.com www.calpipe.com www.camfilapc.com

41 21 www.wonderware.com/partnerecosystem

C-2

C-4

Lets Connect Socially, Plant Engineering Social Media 36 630-571-4070 www.plantengineering.com/connect/social-media.html Lubriplate Lubricants Co 800-733-4755 MODEX 2014 704-676-1190 Nord-Lock, Inc 877-799-1097 NuStar, Inc 800-800-9274 Orival, Inc 800-567-9767 Parker 480-830-7764 Prime Controls 972-221-4849 RIG-A-LITE 713-943-0340 Victaulic Company 610-559-3300 Yaskawa America, Inc 800-927-5292 24 14 www.lubriplate.com 23 13 www.MODEXShow.com www.nord-lock.com www.powerpusher.com www.orival.com www.parkertransair.com

12

29

16

15

12 www.NECatDealers.com/power 11 www.CompAir.com

51

24

CompAir 800-372-2222 DIAMOND CHAIN COMPANY 800-872-4246 Donaldson Co., Inc 800-365-1331 ErectAStep 888-878-1839 Flexicon Corp 888-353-9426 GE Energy 203-373-2211 Grainger 847-535-1000 Hochiki America Corp 714-522-2246

14

33

18

51

23 www.diamondchain.com 3, 7 www.DonaldsonTorit.com 8 www.ErectAStep.com www.flexicon.com www.gemotors.com

35

20

2, 10

43

C-1, 11

22 www.prime-controls.com 19 www.rigalite.com www.victaulic.com www.yaskawa.com

34

31

17

C-3

25

2 www.grainger.com/keepstock 15 www.hochiki.com

27

or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523

Need More Info? FAX this page to: 630-214-4504


Title Address State e-mail

Name Company City Telephone

Zip

Fax

PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.

www.plantengineering.com

PLANT ENGINEERING

December 2013 55

INCONCLUSION
Take a risk: challenge conventional wisdom

Bob Vavra
Content Manager

Conventional wisdomis the safest route, the path of least resistance. It is vanilla. There is nothing wrong with any of that, except that it isnt a path to greater success. It is just an avoidance of possible failure.

hanksgiving is fellowship, and a pause in our year to reflect on the bounty of our blessings. Thanksgiving is a repast complete with turkey, stuffing, cranberries and leftover turkey, which is used to make MY favorite holiday treat, a cold turkey sandwich the next day. And Thanksgiving is football, wherein I eat my cold turkey sandwich while planted in front of the TV watching the endless parade of football instead of standing in line for the Thanksgiving weekend store bargains. And this particular Thanksgiving football weekend, there were three notable football events, each remarkable in their own way: Michigan losing 42-41 to Ohio State when the Wolverines decided to go for a two-point conversion with 31 seconds to play and fail ed to convert. Alabama losing to Auburn 34-28 when Alabama tried a game-winning 57 yd field goal. The kick came up short, and Auburns Chris Davis returned the kick 109 yds out of the end zone for a touchdown as time expired. The Chicago Bears losing 23-20 to Minnesota in overtime after kicker Robbie Gould missed what would have been a record-shattering 66 yd field goal as time expired in regulation, and then missed a 47 yd kick in overtime because his coach decided against trying to get closer for a shorter kick. The winners here each get a tally mark under the Win column, but Id rather focus on the losers here. Each of them tried something remarkable and failed, and that failure cost them the victory. The question, however, is whether there is more to be celebrated by the attempt than by the outcome. It is clear that we are an outcome-based society. We keep score of everything, and our psyche is buoyed or crushed by the outcome. From weekend box office results to the sales figures, from Black Friday (another Thanksgiving tradition) to the monthly ISM manufacturing numbers, we just cant help but rank ourselves based on the numbers game. Yet sometimes it is trial and error that we find the way to greater success. We have common practices in our manufacturing plants. We have tried-and-true methods of operating our facilities. In an effort not to disrupt what already seems to be working just

fine, we dont try to get better. This is called conventional wisdom. It is the safest route, the path of least resistance. It is vanilla. There is nothing wrong with any of that, except that it isnt a path to greater success. It is just an avoidance of possible failure. So do we risk failure or avoid greater success? Lets look at the results: Michigan lost a chance to beat Ohio State its greatest rival, and ruin the Buckeyes hopes for a national championship; Alabama certainly lost its chance for a national championship; and The Bears almost certainly cost themselves a chance at the NFC playoffs. It doesnt sound like a ringing endorsement for challenging conventional wisdom. But the problem wasnt in the attempt. The failure was in the execution. So what we can learn most from that weekend of football? Its that challenging conventional wisdom takes two parts: the attempt and the execution. We often stop ourselves at the attempt. We arent willing to change the way we do things because were afraid to fail, and in a world that prizes victory above almost all else, failure is not an acceptable outcome. I would argue a more dangerous trend is to fail to try. In trying there will be failure, but there also can be greater success than anyone might expect. In order to succeed, though, its not just about the attempt, but also the execution. If you can prepare yourself and your team for both, you tip the scales away for a 50/50 proposition and in your favor. We are at the point in our manufacturing resurgence that we need to get better at what we do. This will require changing things that have helped the resurgence in the first place. And change is hard. Our annual Top Plant issue shows that excellence is not about being content with yesterday or today, but having a clear vision on what is possible tomorrow. It is important to take risks to get better, and it is important to have a plan to mitigate those risks with extraordinary execution. Regardless of the outcome of any single event, I believe that taking calculated risk gets you further in the long run than just by E standing pat. P
www.plantengineering.com

56 December 2013

PLANT ENGINEERING

SPELL RELIABLE

We dont like to brag, but we are proud of our ability to offer the highest quality drives and servos in the industry. We also work very hard at providing quick response to customer orders and questions. And, we boast some of the best meantime between failure rates in the industry. Is that because of our quality products and innovative manufacturing processes? Sure. But its also because of the Yaskawa associates that come to work every day looking to maintain a standard of excellence in serving you that wed match against anybodys. Our people and our products are held to this standard every day. Thats why we spell reliable Y-A-S-K-A-W-A.

YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M


input #25 at www.plantengineering.com/information
Follow us:
http://Ez.com/yai567

For More Info:

2013 Yaskawa America Inc.

Easy Call. Big Payoff.

Save Energy. Save Money.


Motor-driven equipment accounts for 63% of your plants electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow or call in Baldors Installed Base Evaluation Team to identify improvements you can start making today. The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors, drives and mechanical power transmission products, both in operation and from spares inventory. The IBE Team will produce a comprehensive report and plan, targeting inefficient motors and mechanical drives as well as identifying systems where adjustable speed drives could be added to save even more energy. This report will provide recommendations for immediate action along with long term strategies all positively affecting your bottom line. If youre ready to do something about your growing electricity consumption, email the Baldor IBE specialists at IBETeam@Baldor.com or call (864) 281-2100 to receive case studies with realworld savings. Its an easy call with a big payoff. baldor.com
input #26 at www.plantengineering.com/information

2012 Baldor Electric Company

Das könnte Ihnen auch gefallen