Plant Engineering - April 2016 Issue

17 Honoring manufacturing excellence: The 2015 Product of the Year Winners
PlantEngineering.com
Hannover Messe 2016
Taking hold
of the future
Partner Country status spotlights
U.S. manufacturing 25
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KAESER SUCCESS STORY
COMPRESSORS
Seize the Savings!

A fresh approach yields sweeping savings for a quick ROI
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central controlscausing excessively high energy costs. When a new
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efficiency. Having attended a Kaeser Compressed Air Seminar, he knew
a systems approach could unlock significant savings.
SOLUTION:
Kaeser ran a KESS (Kaeser Energy Saving Simulation) using supply
side audit data and designed a complete system solution that would
dramatically reduce the specific power from 62.0 kW/100 cfm to 17.5
kW/100 cfm. New energy efficient compressors, an air receiver, as well
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2016 Donaldson Company, Inc.
April 2016
Volume 70, No.3
Cover image courtesy: Hannover Messe
25
Hannover Messe 2016
26 American manufacturing in the spotlight

The United States leads the world in manufacturing output and helped lead the U.S. economy
out of recessionso it is a well-earned celebration of U.S. manufacturing that will begin April 24
when President Barack Obama delivers the keynote at Hannover Messes opening ceremony. The
designation of the United States as the 2016 Partner Country at Hannover Messe will bring the
largest-ever U.S. contingent to the worlds largest industrial trade show.
27 Manufacturer builds for a global future

The worlds largest industrial trade fair is just 45 minutes from Blocks home in Verden, Germany.
Block also has a growing presence in the United States, making this years Hannover Messe a
chance for the company to celebrate its past and its future.
30 Universities bring knowledge, curiosity to Hannover

More than 20 of the United States top universities and industrial technology institutes will take
center stage in the U.S. Pavilion at Hannover Messe 2016. In the Research and Technology trade
fair in Hall 2, exhibitors will showcase groundbreaking research, business startups and global
partnerships that line up with the fairs emphasis on the Industrial Internet of Things (IIoT) and
the German initiative, Industrie 4.0.
34 Products
Hannover Messe is known as the place where manufacturing innovation is debuted. Here are
some of the top new products that will be seen at Hannover Messe 2016.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 70, No. 3, 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.
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PLANT ENGINEERING
April 2016 3
Reliable Detection
For Your Application
You cant afford not to know. See it all at thinkallied.com/sensors
1.800.433.5700
Allied Electronics, Inc 2015. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
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Honoring manufacturings future
It was a night to recognize the future in manufacturing in people and products as

Plant Engineering presented the 2015 Product of the Year grand award to Infor, recognized Phoenix Contact USA as the 2015 Top Plant Award winner, and celebrated
the achievements of the 2015 Engineering Leaders Under 40.
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Mechanical Solutions
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Preventive maintenance: How one company did it
Companies with well-planned preventive maintenance (PM) programs enjoy

minimal unplanned downtime, minimal spare-parts costs, minimal manufacturing interruptions from breakdowns, maximum manufacturing times, maximum
product quality, and longer machine lifespans. These companies have done their
homework upfront. Heres how one such company succeeded.
Define maintenance data value to gain IIoT benefits
Maintenance offers great potential value in the Industrial Internet of Things (IIoT).
Getting the right data to the right worker at the right time can head off potential
problems and point the way to more uptime. Chris LeBeau, global IT director at
Advanced Technology Services (ATS), talks with Plant Engineering about how
manufacturers can leverage IIoT to greater benefit.
Automation Solutions
59
Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com

246 South Franklin St.
Tel. 216-409-8314
Chagrin Falls, OH 44022
Fax 440-348-1980
Richard A. Groth Jr., NJ/ E. PA
12 Pine St.
Franklin, MA 02038
The three leading technologies used to measure liquid volumetric flow are differential pressure (dP), vortex, and magnetic flowmeters. Selecting among these three
measurement methods for a particular application is often based on which technologies have been successfully used before under similar circumstances. Measurement challenges with dP, vortex, and magnetic flow measurement can be overcome
by employing new technologies.
Maintenance Solutions
RICK ELLIS, Audience Management Director

303-246-1250, REllis@CFEMedia.com
INFORMATION
For a Media Kit or Editorial Calendar,
e-mail Trudy Kelly at TKelly@CFEMedia.com
Match the flowmeter to the application
IIoTs power found in controllers, HMIs
The first step when implementing the IIoT is generating data from sensors and
actuators connected to components and equipment, the things in the IIoT, often
referred to as edge devices. Once collected, this data can be shared with local and
remote users via the Internet and company intranets in a variety of ways.
Whats Inside:
6
9
65
72
INsight
IN Focus
INnovations
IN Conclusion
PLANT ENGINEERING
April 2016 5
INSIGHT
A sense of anticipation, and a sense of home
Bob Vavra
Content Manager
This month, Bob was in

Houstons Minute Maid
Park for the Siemens Oil
& Gas Conference, where
his beloved White Sox won
the 2005 World Series.
Bob also moderated a
panel discussion and took
batting practice. Send
your plant floor selfie to
bvavra@cfemedia.com.
The bustle of Monday mornings commuter

rush means that this could be any train station
anywhere in the world. But this is Hannover, Germany, on the opening day of Hannover Messe, and
theres a different feel in the air.
You walk through the wide doors into the Hannover hauptbahnhof and proceed past the regional
trains taking in and sending out workers across
Lower Saxony, and then down to the local commuter line. Get on the No. 8 or No. 18 train; either
one will take you right to the front door of the
Hannover Messe fairgrounds in about 15 minutes.
The womens voice in German intones Messe
Nord and then a voice in an English accent
helps those who dont quite understand the
translation that youre at the north entrance to
the fairgrounds, and that you should depart the
train and Enjoy your day at the fair.
Ive been fortunate to attend a decades worth
of Hannover Messe events. It always is the most
valuable week of my schedule, but its also a
lot of information and a LOT of walking. I tell
people all the time that the three most important words at Hannover Messe each spring are
wear comfortable shoes. The sheer size and
scope of the fairgrounds, and of the booths,
presentations and events, are unparalleled in
the manufacturing sector.
Yet, over time, Hannover Messe has become
an intimate show for me. There are people I have
met over the years who welcome me back with
a warm handshake. It is a comfortable place to
visit now. From the time I land to the time I
depart, there is a sense ofwell, if not home,
then at least a sense of belonging.
INTERACTIVE
Read this on your tablet
17 Honoring manufacturing excellence: The 2015 Product of the Year Winners
The tablet and digital

editions of this
publication are greatly
Hannover Messe 2016
enhanced for digital
subscribers. They also Taking hold
of the future
include interactive
tools such as videos,
Web links, and other
items. Update your
subscription, and
receive the digital edition in your e-mail
in-box:
Partner Country status spotlights
U.S. manufacturing 25
www.plantengineering.com/subscribe
6 April 2016
PLANT ENGINEERING
In this particular year, however, there is a sense

of anticipation greater than any before; and this
year, there is a real sense of home. My country, my
manufacturing sector, will be front and center at
Hannover Messe, and its about time.
President Obama will deliver the keynote at the
opening ceremonies April 24, and I wont need the
translation headphones this time. The U.S. Pavilion in Hall 3 will showcase the excellence of U.S.
manufacturing. U.S. business leaders are coming
in unprecedented numbers to shake hands, ask
questions, create relationships and build bridges
for manufacturing.
We dont need walls and barriers; we need
bridges and understanding. We need to get away
from our comfort zone, from our safe sense of
doing what we always do, and venture out to see
what else might be out there. While I believe the
return on the investment to come to Hannover
Messe is as enormous as the fairgrounds, this is not
something you can measure in traditional ways.
Hannover Messe, for me, is something you need
to feel. We hope to convey some of those feelings
with our live coverage of Hannover Messe online
starting April 24 from the opening ceremony. For
those of you who are coming, I remind you that
I will be at the U.S. Pavilion at Hall 3 at 5 p.m.
Wednesday evening. The first round is on me.
For those of you who do not plan to come, it is
worth considering. The best manufacturing operations I know are collaborative, involving all corners
of the plant. Manufacturing as a whole gets better
when we collaborate, involving all corners of the
planet. This week in Germany is our time to come
together. I hope to see you there. PE
2016 Upcoming webcasts
Register for educational webcasts at
www.plantengineering.com/webcasts
Join the discussion

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THANK
YOU,
Plant Engineering readers,
for your continued support of our
1/4 NPT Back Blow Air Nozzle

Compressed Air Category
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Environmental Health Category
For over 30 years, EXAIR has worked to create Intelligent Compressed Air products that increase production
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IN FOCUS
ONE MONTH DEFERMENT
Asset
Current
State
Conveyor
System
Visual
inspection
identified
worn liners
in transfer
chute
TWO MONTH DEFERMENT
Maintenance
Activity
Effect to
Mitigate
(C) $
Consequence
(P)
Probability
(ID) Incurred
Damage
(PxC)+ID
Monetized Risk
Potential
Benefit
(P)
Probability
(ID) Incurred
Damage
(PxC) + ID
Monetized
Risk
Potential
Benefit
Replace
liners in
transfer
chute
Damage
to chute
structure,
belt damage,
material
spillage,
fugitive dust
$50,000
20%
$-
$10,000
$12,000
50%
$5,000
$30,000
$24,000
Figure 1: The cost analysis of a deferred repair shows that while one months deferral is a manageable risk, waiting two months
increases the risk beyond any benefit. Graphic courtesy: Life Cycle Engineering
Deferred maintenance and risk assessment:

Technical analysis is critical to the process
By Will McNett, CMRP
Life Cycle Engineering
With constant pressure to reduce maintenance costs as well as short-term budget constraints, asset managers are often
compelled to continue operating aging
assets while deferring maintenance and
investment. As the consequences of such
decisions are rarely immediate, it can seem
relatively harmless to skip preventive maintenance or eliminate repairs/upgrades from
an outage schedule. In fact, deferring maintenance and investment will often result in
the desired outcome (cost reduction) in the
short term, further reinforcing the practice.
However, problems can arise when
these decisions are made in the absence
of a technical evaluation or risk analysis.
Without a robust analysis, it is impossible
to understand all of the implications of the
decision. An organization can be exposed to
a level of risk that offsets any cost savings.
Additionally, value can be lost if funds are
not allocated to the activities that maximize
return on investment.
The objective of this article is to summarize a framework for deferred-maintenance
decision analysis and outline additional
considerations beyond the quantitative
analysis.
Deferred maintenance defined
For the purposes of this discussion and

to maintain consistent communication,
the definition for deferred maintenance

outlined in the FASAB (U.S. Federal
Accounting Standards Advisory Board)
accounting standard is referenced. The
standard states:
7. Deferred maintenance and repairs
(DM&R) are maintenance and repairs that
were not performed when they should have
been or were scheduled to be and which are
put off or delayed for a future period.
8. Maintenance and repairs are activities
directed toward keeping fixed assets in an
acceptable condition. Activities include preventive maintenance; replacement of parts,
systems or components; and other activities
needed to preserve or maintain the asset.
Maintenance and repairs, as distinguished
from capital improvements, exclude activities directed toward expanding the capacity
of an asset or otherwise upgrading it to serve
needs different from, or significantly greater
than, its current use.
Analysis framework
Analyzing the risks associated with deferring maintenance is not entirely different
from performing a technical risk analysis
such as failure modes and effects analysis
(FMEA). The difference is that, instead
of analyzing the risk associated with each
potential failure mode of the equipment
(under FMEA), the objective is to analyze
the risk associated with adjusting the timing
or the scope of the maintenance task that is
under scrutiny. The assumption is that the

maintenance task already exists as part of
the maintenance strategy, so the starting
point of the analysis is at the task itself.
Similar to any traditional risk analysis,
there are several parameters that must be
considered. If the organization has a formal set of risk criteria, these can be used
to quantify the analysis. However, it is
favorable to report in dollars as opposed
to an arbitrary value such as a risk priority
number. This is simply because it provides
a more meaningful and precise illustration
of the impact to the operation.
Outlined below are the data requirements
and steps to complete a deferred-maintenance risk analysis.
Asset to be analyzed
Clearly, the asset to be analyzed must be
selected. The maintenance activity in question may be at the component level, but the
analysis can be done at the equipment level
for simplicity and efficiency.
Condition assessment
The next step is to assess the condition
of the equipment, where possible. This will
provide a more accurate representation of
the probability of failure of the equipment or
the probability over time that it will degrade
to a state in which it will begin to negatively
impact the operation. The assessment can
be as simple as a documentation of performance from a control system or as complex
as a detailed structural assessment.
Continued on page 12
PLANT ENGINEERING
April 2016 9
IN fOCUS
Weighing the costs and benefits of TPM implementation

World-class organizations by and large are
implementing programs for total productive
maintenance (TPM). With effective leadership, high-performing infrastructure and
specialized experts on staff to address any
and all needs, a business can do more than
just fix problems. You can prevent them and
add efficiency to your operations.
Before your organization dives into TPM
implementation, however, its crucial to
understand the costs and benefits associated
with such an undertaking. There are costs in
the beginning, no doubt. But its also a move
that should ultimately prove productive for
any manufacturer thats willing to stick with
it and see it through.
Weighing the costs of TPM implementation
Marshall Institute, an asset management

consulting and training company, has
found that while TPM implementation has
its benefits, there are financial drawbacks
at first. Companies can expect an increase
in training costs of 10 or 20%, plus 15% for
additional maintenance costs.
Understanding the major variables in play
Its not uncommon for these costs to lead

to budget overruns in the immediate aftermath of a new implementation. Typically,
though, these blips last for only a year, and
certainly no longer than three. During this
time, its advisable for companies to aim for
85% to 90% overall equipment effectivenessif they can reach this level within
a year of a new TPM implementation, it
means theyre back on track.
What separates a successful TPM implementation project from an unsuccessful one? According to Marshall Institute,
there are a few factors to monitor to keep
tabs on how things are processing. They
include:
Hows your equipment? What is its
current condition, and how well is it
being maintained it over the long haul?
What about your people? How skilled
and experienced are they? What sort of
knowledge do they bring to the table?
Is there backing from leadership? Are
your CEO, CFO and other executives
committed to making TPM implementation work?
Not all implementation projects are
created equal, but if an organization goes
about it the right way, they should be seeing benefits before long. PE
Uncovering benefits in the long run
While TPM implementation has its initial

costs, there are also tremendous benefits
that should start to become apparent immediately. Companies that implement TPM
should expect to see cost-saving opportunities that include longer equipment life
cycles, simpler maintenance challenges and
fewer logistical headaches for employees.
One common metric that companies
use to measure their progress is mean time
between failure (MTBF). Put simply, MTBF
serves as tangible proof that your maintenance is getting better.
This article originally appeared on the

Smartware Group blog. Smartware Group
is a CFE Media content partner.
Legendary Brand.
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The next generation of superior reliability is coming.
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Spring 2016
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IN fOCUS
Continued from page 9
Criticality assessment
Many of the data requirements for the
risk analysis are shared with a criticality
assessment. If a criticality assessment has
been completed for the asset, the effects of
failure, such as safety, quality and production impact, can be used. This data will
provide the majority of the consequence
input to the risk calculation.
Technical basis
To evaluate the maintenance task, the
purpose or basis for it must be understood.
For which failure mode(s) is the maintenance task in place to manage or mitigate?
Identification of the failure mode(s) will
further clarify the consequence input to
the risk calculation for both deferring and
performing the maintenance.
Consequences of the failure mode
As previously stated, the effect of the
failure mode on safety, quality and production impact will provide much of the
consequence input to the risk calculation.
If the asset is already in a failed state, the
current impact should be documented.
Even if a formal set of risk criteria exists,

the total impact on the operation should
be monetized.
Incurred damage
If the asset will incur incremental damage
or accelerated wear as a result of deferred
maintenance, the cost should be documented on an interval basis over time. An
example would be extending lubrication
intervals, which would result in reduced
life of the asset. The impact of the deferred
maintenance is not just the consequence
of failure, but also the increased cost of the
asset due to premature replacement.
Probability of occurrence
Risk is defined as probability multiplied
by consequence, so it is necessary to determine the probability that the failure will
occur once the maintenance is deferred. The
probability of failure should be determined
on an interval basis to project the impact
over time. The interval serves to illustrate
the increasing probability of failure over
time and help determine how long to defer
the maintenance. It can be in months, years,
turnaround cycles, etc. The probability
should be calculated through data analysis, but it is acceptable to determine from

experiential information.
If the asset is already in a failed state,
the probability will be one. Or, if it is more
suitable, the probability can be calculated
for secondary damage due to the loss of
function of the asset (for example, a caustic
or acid leak that is damaging nearby equipment). If the latter is the case, adjust the
consequences accordingly.
Alternative activities
If there are alternative activities (i.e.,
bandages) that may be cheaper and less
effective, these can also be analyzed as a
lower cost option to reduce risk versus a
total deferment of maintenance.
Assess the risk and make the decision
Once all of the aforementioned information is gathered, calculated and documented, the monetized risk of the deferment can
be calculated as:
(Probability x Consequence)
+ Incurred Damage
= Monetized Risk
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Comparing the expected value of the

deferment (increased production output,
on-time delivery, budget performance,
etc.) to the monetized risk will enable
management to make an informed decision on whether, and how long, to defer
the maintenance activity.
A simple example to illustrate the
analysis is outlined in Figure 1. In the
example, a visual inspection identified
worn/thin wear liners in a conveyorsystem transfer chute. To correct the
issue, a replacement of the wear liners
is required.
The operations manager asks the asset
manager to defer the maintenance to
meet the production schedule, which is
valued at $12,000/month. Deferring the
maintenance by one month increases the
probability of failure by 20% at a cost
of $10,000. Deferring by two months
increases it to 50% and incurs $5,000
worth of damage to the chute structure
for a total cost of $30,000. Based on the
analysis, the asset manager decides to
defer the maintenance by one month,
as the increased risk of deferring by two

months outweighs any potential benefits.
required based on the availability of cash

for the expense.
Financial considerations
Strategic considerations
The risk analysis outlined above is primarily focused on the acute operational risks to
the organization as a result of maintenance
deferments.
The first is the type of expense. Operating expenses have been considered the
scope of this analysis; however, if the maintenance activity is substantial enough that
the life of the asset is extended, or the asset
is upgraded to a point where it could be
repurposed, it may be a capital expense. If
so, the asset is required to be recapitalized
and the expense deducted over a period of
time. As a result, the timing and scope of
the activity should be reviewed to ensure
alignment to the organizations capital plan.
The next is cash flow. Although the risk
assessment may determine the optimum
timing for the maintenance activity, the
cash position of the organization may not
support the investment. Adjusting the
timing of the maintenance activity may be
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Maintenance-deferment decisions must

also include strategic implications. The
strategic plan for the asset may change
the availability requirements, or even the
future configuration of the asset, which
will ultimately affect the cost of risk.
Additionally, future market conditions
will affect the cost of risk. If the asset utilization is expected to increase or decrease,
maintenance-deferment decisions should
be aligned accordingly.
Analyzing maintenance-deferment decisions for risk obviously requires resources
and time. Therefore, it should be reserved
for critical assets and cost-intensive activities. It can be done on an ad hoc basis or
systematically to form the foundation of
the outage or turnaround plan. PE
Will McNett is a senior reliability engineering subject matter expert at Life Cycle Engineering. His email is wmcnett@LCE.com.
IN fOCUS
Five reasons why manufacturers embrace IoT
By Doug Drinkwater
Internet of Business
The Internet of Things (IoT) is

enabling manufacturers to be more
efficient, productive, and profitable in

the face of increased competition worldwide. There are five major reasons why
manufacturers are betting big on these
new technologies.
STATE-OF-THE-ART SOLUTIONS FOR DEMANDING APPLICATIONS
1. Productivity
Productivity is arguably the main
driver of IoT in manufacturing, as
companies recognize that the sensors and collected data enable them
to be more efficient, minimize loss
and waste, and make their workers
more effective.
Trumpf is one of the manufacturers to have taken the plunge with
IoT, harnessing C-Labs IoT software
to connect equipment on the manufacturing floor at multiple locations
with enter prise applications and
systems running on corporate IT
networks.
Ultimately, manufacturers are convinced IoT can reduce downtime,
boost savings, and produce more
goods, more accurately and with
less waste.
2. New revenue streams
The IoT offers manufacturers the

chance to drive bigger revenues, not
only by being more efficient and saving costs, but also by making intelligent and expensive products.
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3. Operational savings
The one thing that is going to get

your C-level executives on board
with any IoT strategy is the ability to
save or make money, and this is certainly the case with manufacturing.
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NYLON
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Konecranes is a go o d example
of this. The Finnish firm has been
selling intelligent cranes and reinventing itself as a services company.
These intelligent cranes are more
expensive, but have more features
too. Theyre able to let the operator
know (via sensors) their last known
condition, how often theyre used, if
theyre overused, improperly used,
and when they are likely to break
down.
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14 April 2016
plant engineering
The one thing that is
going to get your C-level

executives on board with any
IoT strategy is the ability to
save or make money, and
this is certainly the case with
manufacturing.
predictive maintenance, theres less waste (you make
exactly what you need), and staff are working on the
things you want them to work on.
4. Reduced downtime
Predictive maintenance is about knowing when
machinery is going to break down and fixing it before
it does. And this is already a huge boost on reducing
downtime, ensuring that operations are smooth and
that repairs are done before equipment goes wrong.
5. Keeping up with the competition
European manufacturers face a battle against their

low-cost Asian competitors, but with IoT helping
on all of the above matters, the war can still be won
through leaner and meaner operations.
The German government has recognized this, and
through Industrie 4.0 is trying to help German industrial manufacturingthe backbone of Europes largest
economyto keep its competitive edge against laborcost advantages of developing countries and a resurgence in U.S. manufacturing.
During the next five to 10 years, Industrie 4.0 is expected to boost productivity across all German manufacturing sectors from $102.5 to $171 billion. Productivity
improvements on conversion costs will range from 15% to
25%. When the materials costs are factored in, productivity gains of 5% to 8% will be achieved. Cost benefits like
these can only help European manufacturers compete
with global competitors. PE
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is hosting the Internet of Manufacturing Conference
November 1-2, 2016, in Chicago. Internet of Business is
a CFE Media content partner.
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April 2016 15
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Honoring
manufacturings future
Infor received Product of the Year Grand Award; Phoenix Contact
accepts Top Plant; Leaders Under 40 Honored
By Bob Vavra
Content Manager, Plant Engineering
t was a night to recognize the future in manufacturing as well as in its people and products as Plant Engineering presented the 2015
Product of the Year Grand Award to Infor,
recognized Phoenix Contact USA as the 2015
Top Plant Award winner, and celebrated the
achievements of the 2015 Engineering Leaders
Under 40.
The annual CFE Media Engineering Awards in
Manufacturing banquet, co-sponsored by Hannover Fairs USA, also honored Control Engineerings 2016 Engineers Choice Award recipients.
More than 150 people attended the awards dinner in Chicago on March 21, wrapping up a day
of knowledge and information that included the
popular Marketing to Engineers seminar series.
Infors CloudSuite Facilities Management was
the winner of the 28th annual Grand Award,
presented to the product that receives the most
individual votes from among the
products voted on by Plant
Engineering readers. There
were 111 product finalists
in 15 categories this year,
Kevin Price (left) and Mike Stone of Infor accept the 2015 Product of the Year Grand Award
for Infors CloudSuite Facilities Management software. All images courtesy: CFE Media.
PLANT ENGINEERING
April 2016 17
HonoringExcellence
Plant Engineering and Control Engineering honored the 2015 Engineering Leaders Under 40 recipients with plaques at the annual CFE
Media Engineering Awards in Manufacturing banquet March 21 in
Chicago.
and 48 trophies
were presented.
The Infor Cloud Suite is designed to help customers reduce inefficiencies, costly maintenance
requirements and missed business opportunities by
delivering greater asset visibility to help streamline
core processes. Infor also received a Gold Award in
the energy management category (see the full list of
winners on page 22).
These award wins are very exciting for our team
and only solidify the great work we are doing with
our products at Infor, said Kevin Price, director of
product management and product strategy, Infor.
We would like to thank everyone who voted for
Infor CloudSuite Facilities Management and Infor
EAM Energy Performance Management. We are very
excited to carry this momentum as we move into the
next fiscal year and beyond.
Phoenix Contact was recognized as the 2015 Top
Plant Award winner. A German-based company,
Phoenix Contact built its business in Harrisburg, Pa.,
from a distribution center in the 1980s to a progressive manufacturing center that now exports some
of its work back to Germany for global distribution.
As demand for Phoenix Contacts locally designed
and manufactured products has grown, so has the
company. In 2014, Phoenix Contact completed construction of a 125,000 square-foot addition to its U.S.
facility. The expansion included 50,000 sq. ft. of pro-
18 April 2016
PLANT ENGINEERING
duction and support space and 50,000 sq. ft. of office

and lab space.
The company went from no exports a decade ago
to exporting around 30% of its manufacturing dollar
volume in 2015.
The development and manufacturing investments
were founded on the principle that being close to our
customers would bring significant benefits in speed
and flexibility. Our growth is recognition that these
high-quality facilities and people are delivering that
value, said Dave Skelton, vice president and general
manager, Phoenix Contact D&M, who accepted the
award on behalf of the company at the awards dinner.
At Phoenix Contact, we believe we have proven
that with the right strategy and the right focus on our
people, we can successfully manufacture in the U.S.
and compete globally, said Jack Nehlig, president of
Phoenix Contact USA. It was decisive investment,
a focus on the long term, the pursuit of excellence
while you do it and really treating our people right
that made the difference. We are honored to receive
the 2015 Top Plant Award, which is a testimony to
the success of those decisions.
The future of manufacturing also was recognized,
as 13 of the record 32 recipients of the 2015 Engineering Leaders Under 40 program received their plaques
at the dinner. The program, a joint effort between
Control Engineering and Plant Engineering, honored
the top North American manufacturing professionwww.plantengineering.com
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HonoringExcellence
Dave Skelton, vice president and general manager of Phoenix Contact

D&M, formally accepted the 2015 Top Plant award on behalf of Phoenix
Contact USA.
als under the age of 40 at manufacturing facilities

around the country. Recipients came from all over
the continent including California, Maine, Florida
and Calgary, Alberta, to receive this honor.
The days activities began with a series of presentations by marketing, content and manufacturing
experts at the fifth annual Marketing to Engineers
seminar, co-sponsored by Be Found Online. The discussions included panel talks with marketing and
manufacturing executives and a look at the most
effective ways to provide valuable content to manufacturing personnel.
While content marketing is a key component of
the marketing process today, Michael Balsam, vice
president and lead analyst for Outsell, noted the personal touch also is still necessary.
Its important to show up in a room with your
client, with your peers, with your prospects from
time to time, Balsam told more than 150 marketing
professionals at the seminar. It used to be show up
and then come back next year. What we see now is
continuous engagement with customers.
Part of that includes

an engaging Website.
Tracy Long, vice president of marketing for Baldor Electric, noted their
two-year experience included improving both the
content and the customer experience.
Youve got to be able to find content quickly,
and youve got to be able to get it when you want it,
Long said of the customer interaction with the Web.
Bring them to the destination and then bring them
home (to the content). Your customers deserve an
experience like this. It will work, and our customers and your business will be glad that you did it.
Steve Krull, founder and CEO of Be Found
Online, noted the use of content to attract and
retain customers at a Website continues to be the
new wave of marketing to manufacturing professionals. None of this works without content.
Content resonates with your audience, Krull said.
You should always be looking at the data to connect the dots, but dont kill yourself here. Youre
never finished. PE
Enter now for 2016 awards

The 2016 Plant Engineering Award programs are now open for nominations. Specific details about each of
the programs can be found at www.plantengineering.com/awards or on the Plant Engineering home page.
Engineering Leaders Under 40 deadline: June 24

Product of the Year deadline: Sept. 2
Top Plant deadline: Sept. 2
20 April 2016
PLANT ENGINEERING
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Category
Apps for
Engineers
Asset
Management
Automation &
Controls
Compressed Air
Electric Motors
& Drives
Electrical Safety
Energy
Management
Environmental
Health
Fluid Handling
Lighting
Maintenance
Software
Maintenance
Tools &
Equipment
Material
Handling
Systems
Productivity &
Training
Award Manufacturer
Product
GRAND
Infor
Infor CloudSuite Facilities Management
Fluke Corp.
Fluke Connect Assets
Gold
Silver
EZAutomation
EZ-RMC v1.3
Gold
Emerson Process Management
AMS Device Manager v13.0
Silver
SKF
Multilog WVT
Bronze
Forcam GmbH
Forcam Force
Gold
Rockwell Automation
Rockwell Software Studio 5000 Logix Designer v24
Silver
Bindicator Co.
Roto-Bin-Dicator Pro
Bronze
Bedrock Automation
Bedrock
Bronze
Schneider Electric
Building Insights
Gold
FS-Curtis
Nx Series
Silver
Atlas Copco
GHS VSD+ Series
Bronze
Exair Corp.
Back Blow Air Nozzle
Bronze
Ingersoll Rand
R-Series
Gold
Marathon Motors, a Regal brand
TEAO Cooling Tower Motors
Silver
Baldor Electric Co.
Tigear-2 Ultra Kleen
Silver
Rockwell Automation
Allen-Bradley Kinetix 5700 Servo Drive
Bronze
Leeson Electric
Extreme Duck Ultra
Gold
Littelfuse
Arc-Flash Relay
Silver
G&W Electric
CLiP-LV
Bronze
Eaton
Arc Resistant LV Switchgear with Type 2B Secondary Compartment
Bronze
Pepperl+Fuchs
Bebco EPS 5500 Series
Gold
Infor
Infor EAM Energy Performance Management
Silver
Kaeser Compressors Inc.
Sigma Air Manager (SAM) 2
Bronze
EZAutomation
Programmable Power Supply (EZPPS)
Gold
UltraTech International Inc.
Ultra-S3
Silver
Camfil APC
Handte EM Profi
Bronze
Exair Corp.
High Lift Reversible Drum Vac
Gold
Des-Case Corp.
IsoLink Oil Transfer Container
Silver
BJM Pumps
SKG Series with RAD-AX Dual Shredding Technology
Bronze
UltraTech International Inc.
Ultra-Containment Berm, Modular Model
Gold
Eaton
Crouse-Hinds Series Industrial High Bay LED
Silver
Eaton
Metalux Cruze LED Luminaire
Silver
Juno Lighting Group
Indy L-Series 3rd Generation
Bronze
energybank
model T
Smartware Group
Bigfoot CMMS
Gold
Silver
Azima DLI
WATCHMAN Reliability Portal v3
Gold
Weidmuller
stripax ULtimate
Silver
ITT Goulds Pumps
i-ALERT2 Equipment Health Monitor
Bronze
All-Test Pro
All-Test Pro 5 (AT5)
Bronze
GTI Predictive Technology Inc.
iPad Predictive Platform v7.2
Gold
Cascade Corp.
Magnetic Layer Picker
Silver
AeroGo Inc.
Air-Powered Stainless Steel Pallet
Bronze
Jungheinrich
ETV 110/112 Series
Bronze
Yale Materials Handling Corp.
ESC030AD Three-Wheel Stand
Gold
Rockwell Automation
FactoryTalk VantagePoint v6.0
Silver
Eaton
Short-Circuit Current Rating (SCCR) Protection Suite
Silver
Kimberly-Clark Professional
Jackson Safety Truesight II Auto-Darkening Filter Welding Helmet
Bronze
Safety
22 April 2016
Ramsay Corp.
Mechanical Apprentice Skills
Gold
Rockwell Automation
Allen-Bradley Guardmaster 440C-CR30
Silver
New Pig
PIG No-Trip Floor Mat
Bronze
Kimberly-Clark Professional
Jackson Safety Airmax Elite Powered Air Purifying Respirator (PAPR)
PLANT ENGINEERING
All cast-iron frame, conduit box, fan cover,

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Cant make it to the show?

Keep tabs on whats happening: Hannover Messe 2016
The worlds most important industrial

fair, Hannover Messe, kicks off April 25,
2016. But, if you cant be there, dont
worry: we have a full complement of
social outlets where you can keep
up with the latest from the show.
Phoenix Contact will be there, too, with
our wide range of electronic components
and solutions, valuable insight on IIoT,
Industrie 4.0, and more.
Dont miss a thing: #HM16USA
@hannover_messe
@SelectUSA
PhoenixContactUSA
Phoenix Contact USA
Integrated Industry Discover solutions!

Hannover Messe, April 25-29, 2016.
2016 PHOENIX CONTACT
To learn more:
www.phoenixcontact.com/GoMesse
THE ROAD TO
HANNOVER MESSE2016
American manufacturing
on a global stage
American manufacturing is ready

for its close-up on the worlds
largest industrial trade show
in Hannover, Germany.
CFE Media
PLANT ENGINEERING
April 2016 25
THE ROAD TO
HANNOVER MESSE2016
American manufacturing
in the spotlight
Partner Country status lets U.S. trumpet its industrial leadership.
By Bob Vavra
Content Manager, CFE Media
26 April 2016
t leads the world in manufacturing output

and helped lead the U.S. economy out of
recessionso it is a well-earned celebration
of U.S. manufacturing that will begin April
24 when President Barack Obama delivers
the keynote at Hannover Messes opening
ceremony. The designation of the United States
as the 2016 Partner Country at Hannover Messe
will bring the largest-ever U.S. contingent to
the worlds largest industrial trade show. Its
an effort to build bridges for U.S. companies
looking to expand into Europe and beyond, as
well as a way for global manufacturers to learn
more about the U.S. manufacturing innovations.
The weeklong event is expected to draw more
than 200,000 attendees, and the presence of
President Obama has added an air of excitement to this years festivities. The real work at
Hannover Messe for U.S. manufacturing leaders
will occur in meetings at the U.S. Investment
Pavilion and among the state economic development departments, industry leaders and more
than 350 U.S. companies making the journey
to Hannover Messe.
The United States is home to the most innovative and forward-thinking companies in the
world. But in todays global economy, it is not
enough to simply be the best. We must also
let the world know that America is open for
business, said U.S. Commerce Secretary Penny
Pritzker. Hannover Messe is a unique opportunity for American companies to showcase their
products and capabilities to thousands of global
advanced-manufacturing representatives.
Hannover Messe is a perfect platform for
small to midsized manufacturers looking to
reach potential global buyers, partners and
investors, said Deputy Assistant Secretary for
U.S. Operations for the Department of Commerce Antwaun Griffin. This is a great show
to connect to the latest digital manufacturing
trends, and to meet some of the strongest companies and innovators in the United States and
around the world.
plant engineering
Going global
At the press preview for Hannover Messe

2016 in January, fair officials and German
industry leaders were thrilled with the prospect of the U.S. as the Partner Country, and
with the attendance of the President. In the
70 years since Hannover Messe was first
staged in 1947, this will be the first time the
United States will be the Partner Country.
The key question over the last six months
had been, Is he coming, or isnt he? It was
actually fantastic news, said Jochen Kckler, the member of the managing board of
Deutsche Messe AG responsible for Hannover Messe, at the press preview. It also
is fantastic for the international character
of Hannover Messe. Weve been waiting 70
years to welcome the U.S. as Partner Country.
U.S. Ambassador to Germany John B.
Emerson also addressed the preview and
said the excitement over the U.S. status at
Hannover Messe was mutual. The United
States is honored to be the Partner Country
for the 2016 Hannover Messe, and I know
that Commerce Secretary Penny Pritzker and
our boss, President Obama, are excited to
be coming here in late April, Emerson told
more than 100 media members from around
the world who attended the preview.
Emerson touted the expanded U.S. presence at Hannover Messe, including representatives from 40 state and regional economic
development groups at the U.S. Investment
Pavilion in Hall 3 on the fairgrounds.
Emerson also focused on the existing
cooperation between Germany and the
United States around trade issues. As
you may know, last year the United States
became Germanys largest customer; and
Germany is Americas largest trading partner in Europe. The ambassador said. In
Continued on page 28
Right at home
On both sides of the Atlantic, Block builds for a global future.

By Bob Vavra, Content Manager, CFE Media
erden is just an hour away on the German Autobahn from distributor network and its existing relationship with compaHannover. So when Block, an electrical engineering and nies such as Wago and Rockwell Automation, where Block is an
manufacturing company, tucked into this German city of Encompass Partner.
27,000 residents in the center of Lower Saxony, travels to
We are expanding, Wesner added, The first step is to get
Hannover Messe each spring, company officials feel right at home. Blocks products into engineers hands.
Its the worlds biggest industrial trade fair and its right at
our front door, said Christoph Wesner, who heads standards
and approvals for the 77-year-old company that designs and
manufactures transformers, power quality devices and electrical filters. For more than 40 years, weve visited Hannover
Messe. Its our home.
Block also has a home in Franklin Park, Ill., a Chicago
suburb near OHare Airport, whose history also centers on
industrial manufacturing. Block opened its first U.S. manufacturing and sales center in Franklin Park in 2015 and looks
to expand its growing reputation in the United States.
So with the U.S. as the Partner Country at Hannover Messe
2016, Block officials see the year as a chance to celebrate its
history and its future. The American market has great interest for us, said Wesner. The drives and automation market Headquartered in Verden, Germany, but with a new manufacturis a very big market for Block. We are doing local production ing facility in the United States, electrical engineering company
and we can better meet the U.S. market requirements by Block has set its sights on global growth. Image courtesy: Block
building locally.
Expansion into the U.S.
The growth of Block as a global manufacturer with U.S. roots

will enable the company to expand on its philosophy of being a
custom manufacturer that can meet the individual needs of their
customers.
More than 80% of our work is customized, said Udo Leonhard
Thiel, who heads up Blocks research-and-development efforts.
They start out asking for standard products, but in the end, they
have their own needs. If were talking about drive manufacturers, they want accessories like filters that will match their system
perfectly. We can put them in different enclosures, and just make
slight modifications of a standard enclosure.
To have that kind of manufacturing flexibility, Blocks manufacturing operation focuses on hands-on quality control in the
plant. The companys Verden facility does its own metal cutting
and bending for enclosures, and transformers are wrapped by
hand as well.
Its a philosophy Block will bring to its growing manufacturing
operation in the U.S. We want U.S. production supported by
German manufacturing know-how to meet U.S. product requirements, said Wesner. We have new ideas for new products with
additional support through the German headquarters to meet
the extended market requirements in the U.S.
Ultimately, Wesner said, the growth in the U.S. market, in which
Blocks name is still becoming known, will be built through its
Growth curve
After Wolfgang Reichelt, chairman and CEO of Block, took over

the company in 1971, hes helped set the company on a course of
growth and expansion.
In a company interview, Reichelt noted the company is at that
unique intersection between manufacturing and family. People
are our most important resource, he said in the interview. Even
if you have state-of-the-art machinery, it will only give you the
edge over your competitors if its operated by motivated and competent employees. We must find innovative ways of ensuring our
employees are ready to face future challenges with us.
The global expansion of Block is part of those challenges. The
challenge is meeting the domestic electrical standards with locally
manufactured products while also providing U.S. machine builders and OEMs with access to European standards.
That growth potential is why Block officials see this particular
Hannover Messe as particularly exciting. It brings both the companys traditional home-field advantage as a Hannover neighbor
together with the U.S. Partner Country presence.
Were looking at sensible growth for Block USA and a stronger
U.S. market share of the Block brand, said Wesner. Were also
reaching out to U.S. customers in Germany. Were showing German and U.S. know-how by having worldwide products.
Hannover Messe is where the industrial world comes together,
he added. If you have a specific problem, or if youre in need of
a resource, youll find the resource at that show. PE
plant engineering
April 2016 27
THE ROAD TO
HANNOVER MESSE2016
Continued from page 26
The strong connection

between the U.S. and German manufacturing sectors
will be on display at Hannover Messe 2016 starting
April 24. All images courtesy: Hannover Messe
28 April 2016
other words, Germany and the United States

have a huge stake in the health and vitality of
each others economies. President Obamas
presence illustrates how important this show
will be for both the U.S. and German business communities.
From the U.S. point of view, it offers a
unique opportunity not only to showcase
American innovation and ingenuity, but to
plant engineering
strengthen the trans-Atlantic partnership at

a critical juncture, Emerson added.
Trans-Atlantic partnership
The Trans-Atlantic Trade and Investment

Partnership, or TTIP, has been a point of
discussion for many years at Hannover
Messe. The trade deal, which supporters
say would reduce trade barriers between
the U.S. and the European Union, has been
stalled in Congress for more than two years.
With or without TTIP, however,
there has been a steady stream of
manufacturing commerce going
on between the U.S. and Europe.
That includes foreign direct investment on both sides of the Atlantic,
something the U.S. economic development agencies from around the
country hope to continue to foster.
For German-based companies,
the need to not just sell to the U.S.,
but also to locate manufacturing on
U.S. soil, has long been a strategic
imperative.
As an example, Festo is an innovative manufacturing and robotics
company based in Germany, but
it sees a vital partner in the U.S.
market.
(Festo) has been investing in
the U.S. market for more than 40
years and is a reliable partner for
American enterprises, which now
not only require machinery and
production facilities, engineering
expertise, software and supplier
components for the establishment
and modernization of their production locations, but above all
technical education, the company said in a press release. In these
times of increasing automation, the
company is thereby securing jobs
and salaries as well as facilitating
industrialization in Germany and
America.
Festo has opened a $45 million
production and logistics center in
Mason, Ohio, that employs 150
workers and gives the company a
distribution and manufacturing
hub closer to its customers.
Major German industrial and
consumer manufacturers all have
significant facilities in the U.S. Siemens, for example, has more than
Visit Beckhoff at Hannover Messe 2016

in Hall 9, Booth F06!
THE ROAD TO
HANNOVER MESSE2016
Industrial Internet of Things

(IIoT), and its German
equivalent Industrie 4.0, is
a central topic for Hannover
Messe 2016.
700 individual facilities in North America.

Auto manufacturers, such as Volkswagen
and BMW (a past Plant Engineering Top
Plant award winner), have placed significant
investments in the U.S. market.
But those investments have worked both
ways. A 2014 Hannover Messe presentation
on German-American trade relations noted
there are about 1 million U.S. jobs dependent
on German-owned companies and approximately 600,000 German jobs dependent on
U.S.-owned companies.
It is the United States reputation as a
global manufacturing leader that moved
Hannover Messe to pursue the U.S. as this
years Partner Country, and the U.S. delegation is doing all it can to deliver a presence
that will not just last the week, but also will
foster relationships for the future.
A case in point: Ohio
A decade ago, Ohio was one of the few

U.S. states to send a delegation to Hannover Messe. Then-Ohio Gov. Bob Taft was
interviewed by Plant Engineering at Hannover Messe in 2006, and he mentioned the
importance of getting out there to tell the
story of all his state had to offer.
In 2006, there was a Republican in the
White House and a Democratically controlled Congress, but Tafts message was
strikingly similar to the environment today.
Its concerning to hear Congress talking
about controls on foreign investments in the
30 April 2016
plant engineering
U.S., Taft said that

year. We have 960
foreign companies
investing in Ohio.
Manufac tur ing is
one of our healthiest
sectors. Our manufacturing exports are
growing, and weve
got a lot of jobs tied
to exports. Ohio is
an integral part of
the world economy.
Wer e f e e l i n g
terrific competitive
pressure, Taft added
in that inter view.
We have to go out
and tell the story.
To d a y, O h i o
boasts more than
2,200 foreign companies533 f rom
Germany aloneand more than $12 billion on research-and-development investment in the state from public and private
companies. At Hannover Messe 2016, Ohio
will come with another large contingent of
civic, business and governmental leaders and
will participate in a dozen lectures, partner
events, and receptions.
Embracing IIoT
What is called Industrie 4.0 in Germany and

the Industrial Internet of Things (IIoT) in
the U.S. is the realization of an integrated
industry. That also is the theme for Hannover Messe 2016, and Kckler said during
the press preview the acceleration of that idea
is driving new growth in manufacturing.
Integrated industry is still at an early
stage, he said. I believe no other topic
established itself so quickly and has had
such a huge impact. We need to implement
integrated industry. We get more and more
excited with each year.
Exhibitors, who embraced the Industrie
4.0 concept at Hannover Messe 2015, plan
even more examples of application cases and
product offerings to offer fair attendees. Hall
9 is the center of the Industrial Automation
pavilion, and every vendor onsite in 2015
was promoting the Industrie 4.0 content,
including from the Hannover Messe perspective. In 2016, that presence should be
amplified as customers look to learn more
about the technology. PE
HANNOVER MESSE
25 29 April 2016
Hannover Germany
The USA will be highlighted at the worlds largest industrial
technology trade fair. To explore opportunities at HANNOVER
MESSE, call +1 (773) 796-4250 or visit www.hannovermesse.de.
Sign up for free tickets: www.hannovermesse.events/cfemedia
Get new technology first
THE ROAD TO
HANNOVER MESSE2016
Universities bring knowledge,

curiosity to Hannover
U.S. schools will showcase their research, look to develop new partners.
he Massachusetts Institute of Technology (MIT) in

Cambridge invented GPS, developed Doppler radar
and is a pioneer in 3-D printing. Carnegie Mellon
University, Pittsburgh, Pa., created the navigation
software used by NASAs Mars rovers, built robots
that can walk on water and is a birthplace of artificial
intelligence. Together, the two universities boast more than 100
Nobel laureates. In 2016, both will exhibit at Hannover Messe
in Germany for the first time.
Carnegie Mellon and MIT are two of Americas most storied
research universities. Their participation further spotlights the
innovative power of Partner Country USA at Hannover Messe,
said Marc Siemering, senior vice president of Hannover Messe.
The two universities join leading German institutions such as the
Fraunhofer Society and the Karlsruhe Institute of Technology.
MIT and Carnegie Mellon will exhibit at the U.S. Pavilion
in Hall 2. MIT will emphasize the universitys commitment to
Mens et Manus training, which leads to commercialization
and entrepreneurship as well as how MIT promotes technology
transfer. Carnegie Mellon will showcase research innovations in
robotics and additive manufacturing with a focus on emerging
university startup businesses in these fields.
An educational process
More than 20 of the United States top universities and industrial

technology institutes will take center stage in the U.S. Pavilion
at Hannover Messe 2016. In the Research and Technology trade
fair in Hall 2, exhibitors will showcase groundbreaking research,
business startups and global partnerships that line up with the
fairs emphasis on the Industrial Internet of Things (IIoT) and
the German initiative, Industrie 4.0.
As part of the United States Partner Country status at Hannover Messe 2016, U.S. academic and technology institutes will
showcase faculty members, student talents and research programs.
American universities are leading the way in research and
innovation, and in partnering with industry to bring innovations
to market, said Deputy Assistant Secretary of Commerce for Services Ted Dean. Hannover Messe presents a prime opportunity to
show the world how U.S. research universities are creating global
solutions that are revolutionizing how ideas become a reality.
For example, Virginia Tech will showcase its groundbreaking
research and the innovative partnerships it has formed with global
business and industry. Specifically, the Blacksburg, Va.-based
school will showcase its Smart Infrastructure Laboratory, which
examines the use of sensor information to improve the design,
monitoring and operation of civil and mechanical infrastructure
to investigate how humans interact with built environments. These
32 April 2016
plant engineering
researchers insights into the performance of concrete materials

are producing safer, less costly construction methods and a longer
life for bridges and other structures across the United States.
Virginia Tech is a partner with the German university Technische Universitt Darmstadt (TUD). Together, the institutions
offer a unique dual bachelors degree in mechanical engineering.
In this program, U.S. students complete their senior year at TUD
and German students finish at Virginia Tech, earning degrees
from both universities simultaneously.
Virginia Tech has a long history of working with businesses
throughout the world, said Guru Ghosh, the universitys vice
president for Outreach and International Affairs. These partnerships tap into practical applications of knowledge, allowing
businesses to solve problems, create new products, recruit highquality employees and develop new markets. We look forward
to sharing the best of Virginia Tech with the global audience at
Hannover Messe.
Partnering with business
Arizona Technology Enterprises (AzTE)the Scottsdale-based

IP management and technology transfer organization for Arizona
State University (ASU)is bringing several startups to Germany.
Joining the delegation will be Fluidic Energy, an ASU spinout company that is partnering with Caterpillar Inc. and PLN, Indonesias
state-owned electricity company, on a project to provide power to
500 remote villages throughout the island nation. The program
will deliver reliable, renewable power to 1.7 million people through
solar panels paired with Fluidics metal-air batteries.
Arizona State Universitys interdisciplinary approach to research
and entrepreneurship delivers truly novel solutions to persistent
societal and market challenges, said Annette Kleiser, PhD, the
AzTEs business development consultant. She will present Innovation and Impact: Facilitating Use-Inspired-Research Into the
Marketplace at Hannover Messe Hannover Messe 2016 is an
important global showcase for this work, and were very excited
to be part of the USA Research & Technology Pavilion.
As the largest recipient of U.S. federal government research funding, the University of California is attending Hannover Messe to
showcase the depth of its research related to energy and climate
solutionsto attract industries interested in collaborating with
researchers to create innovations that will help address this global
challenge.
School officials will demonstrate the U.S. governments commitment to leveraging its resources and talents to create global solutions
for the challenges of energy sustainability and climate change.
The University of California is proud to be part of U.S. participation in Hannover Messe, said William Tucker, interim
NEW
Single-channel
eBreakers
Researchers work in Virginia Techs Thomas M. Murray Structures Laboratory.

Virginia Tech researchers insights into the performance of concrete materials are
producing safer, less costly construction and a longer life for the nations bridges
and other structures. Image courtesy: HFUSA/Virginia Tech
vice president for Research and Graduate

Studies at the university. As the worlds
largest public research university and a
global leader in the search for solutions
to the challenge of energy sustainability
and climate stability, we want to share
our commitment to this cause and use
Hannover Messe to seek out other government, academic and industrial partners
to join us in this mission.
Growing global learning
As one of the United States leading institutes for research and commercialization, Georgia Tech, Atlanta, will highlight
its leadership in advanced manufacturing, robotics and energy. The university
will also showcase its basic and applied
research in manufacturing, trade and
logistics that is supported by its strengths
in materials and management.
Georgia Tech continues to be a leader
in establishing global innovation portals
and partnerships, research and education
hubs, and select branch campuses like
Georgia Tech Lorraine in Metz, France.
Through the use of distance learning
and other technologies to deliver educational and research products to students,
researchers, governments and businesses
around the world, Georgia Tech will showcase its global impact.
Georgia Tech is in the fortunate position of being one of a few global institutions continually called upon by universities, companies and governments from
around the world to assist in their efforts
to grow science, business and technolowww.plantengineering.com
gy in an increasingly innovation-centric
economy, said Georgia Tech President
G.P. Bud Peterson. We are proud to
join the U.S. Department of Commerces
SelectUSA initiative at Hannover Messe to
highlight the many advantages the United
States offers as a location for business and
investment.
Tech Parks Arizona, a unit of the University of Arizona based in Tucson, will be
showcasing Global Advantage, a unique
business development program designed
to assist fast-growth international technology companies entering the North American market. The program offers assistance
in market access, product development,
testing and demonstration, business
development and advanced manufacturing. Global Advantage also connects
companies to the University of Arizona,
a premier research university located in
Phoenix, and to its research parks, the
largest technology parks located along
the U.S.-Mexico border.
Tech Parks of Arizona recruits small
and midsized high-growth technology
companies to Southern Arizona in six
industry sectors: advanced energy, mining technology, defense and security, bioscience, arid lands agriculture and water.
These specializations make Tech Parks
Arizona a prime choice for companies in
cross-cutting industry sectors, such as sustainability, optics and imaging, advanced
manufacturing and informatics. PE
Compiled from Hannover Messe press
releases.
plant engineering
April 2016 33
All-pole
sine filters
Make it perfect
Line
reactors
TRANSFORMERS
POWER SUPPLIES
REACTORS
EMI FILTERS
Visit us at Hanover Fair on April 25-29,

2016 to experience our newest innovations for Advanced Manufacturing.
Hall 13
Booth C34
blockusa.com
THE ROAD TO
HANNOVER MESSE2016
Industrial security solutions
Siemens and Intel Security are expanding their collaboration to help protect industrial automation systems from
increased cyber threats. Siemens experts leverage Intel Security solutions such as anti-virus software, whitelisting and
security information and event management (SIEM) within the framework of plant security services. These tools are
designed to help detect security incidents promptly, enabling Siemens experts to notify plant operators without undue
delay and allowing them to implement counter-measures. The two companies are coupling their expertise in the area
of industrial automation and cyber security to provide industrial
plants with products and services designed to help minimize
cyber risks, while increasing system availability. Siemens offers a
range of plant security services that include carrying out security
assessments, implementing security, and continuous monitoring of industrial infrastructures. The offering now encompasses
Intel Security solutions including McAfee VirusScan, McAfee
Application Control, McAfee ePolicy Orchestrator (ePO) as well
as McAfee Enterprise Security Manager, the security information
and event management.
Siemens
www.siemens.com
Intelligent learning
The DUPLOcator camera follows the assembly of a structure from model building blocks. The robot is now able to
use its modern robot arm and build the recognized structure on its own.
Fraunhofer
www.fraunhofer.org
Technology test kit

The Smart Factory Starter Kit allows manufacturers to test
smart manufacturing technologies quickly and easily. It
provides a fast-to-implement Manufacturing Intelligence
solution that can help calculate and indentify ways to
improve overall equipment effectiveness (OEE) and to
monitor factory performance globally in real time?
FORCAM
www.forcam.com
34 April 2016
PLANT ENGINEERING
PRODUCTS
Superconductor applications
Festo is showcasing three new concepts for the industrial application of superconductor technology at the Hanover Messe 2016.
With these exhibits, superconductors enable the contact-free
transfer of carrier plates in the horizontal plane and their transport
across a surface of water, and they allow a gripper to be used in suspension and an object to be moved within an enclosed liquid-filled
tube. The unique characteristics of superconductors come to the
fore here by making low-energy, efficient motion possible in suspension even beyond walls or through media.
Festo
www.festo.com
Integrated solutions
Integrated solutions based on Industry 4.0 are at the heart of Sicks presentation at Hannover Messe 2016, with production applications presented in four different exhibits. Sick
displays will demonstrate how the intelligent use of sensor data is already boosting flexibility and productivity today. The data is also aggregated in a cloud in a live demonstration,
while various Web services show the possibilities of fully integrated solutions online.
Sick
www.sick.com
Our Heart Is Set On

Your Productivity!
FORCAM Never misses a Beat.
Hannover Fair 2016
April 25 29 I Hall 7 I Booth A11
Winner
2015
We Deliver Results In Productivity
www.forcam.com
THE ROAD TO
HANNOVER MESSE2016
PRODUCTS
Air conditioning units
The Blue e+ air conditioning units feature up to
75% energy savings compared to traditional ac
units for enclosure climate control. The Blue e+
hybrid process uses two parallel cooling circuits
working together, depending on temperature
difference. The integral heat pipe dissipates
heat from the enclosure as soon as the ambient
temperature falls below the setpoint, providing passive climatization. Active climatization
is achieved via the compressors cooling circuit
with speed-controlled components for demandbased cooling. This unique inverter technology
provides cooling output that is always exactly
the amount needed at the time. Not only is energy consumption far less than with conventional
technology, but the improved cooling leads to
longer service life of the components inside the
enclosure and the cooling unit itself. All Blue e+
units provide multi-voltage capability to connect
to all standard power grids worldwide.
Rittal
www.rittalenclosures.com
Linear position sensors

The E-Series of linear position sensors
support the IO-Link communication protocol (as outlined within the IEC 61131-9
standard. The IO-Link protocol offers
simple bi-directional point-to-point communication with both signal transmission
(at rates of up to 230.4 kbps) and power
delivery being handled. It enables consistent communication between sensors
and the controller, as well as providing
access to valuable diagnostic data that will
ensure ongoing reliable operation. These
sensor devices have a maximum stroke
length reaching up to 2,540 mm. They
exhibit a high degree linearity, keeping
deviation to within a margin of less than 0.02% (full scale).
MTS Sensors
www.mtssensors.com
36 April 2016
plant engineering
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THE ROAD TO
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Smart factory demonstrations
At the Beckhoff main booth in Hall 9, visitors can explore the expanded Industrie 4.0/ Industrial Internet of
Things (IIoT) forum. Beckhoff will demonstrate foundational technologies and ready-to-use products for the
smart factory. TwinCAT Analytics records industrial data synchronously with the process cycle and serves as
the basis for comprehensive analytics.
To enable enables easy-to-configure
connections between the Internet of
Things (IoT) and the Internet of Services, TwinCAT IoT supports common protocols used in cloud communication. In addition, visitors can
see the EtherCAT IP and TwinCAT
HMI, and I/O terminal technology
that integrates high-end measurement
technology.
Process control mappings, which
can be generated from the control
technology, make it easy for the user
to assess connected machines and
systems. The smart factory also introduces numerous requirements regarding online and offline state analysis,
predictive maintenance, pattern recognition, machine optimization and long-term data archiving. This requires
data capture to be as continuous as possible and in sync with the processing cycle. Beckhoff developed TwinCAT Analytics software of that all process data can be provided as needed, either locally or as a cloud-based
solution on a server, whether on an internal corporate network or in a public cloud.
Beckhoff
www.beckhoff.com
Frequency inverters
The i500 frequency inverters can be tailored to a wide
variety of machine application and industrial environment. Compliant with efficiency class IE2, the i500
inverters feature a peak energy efficiency in the 0.33 to
60 hp (0.25 to 45 kW) power range. It features a lower
housing depth along with a sophisticated cooling system to reduce heat losses and allow side-by-side installation with minimal wiring in a smaller control cabinet.
Inverters for control cabinet installation feature IP20
and IP31-rated protection. It also contains different
forms of field bus communication, including Ethernet,
multiple I/O interfaces, and plug options for a keypad,
a USB interface or a wireless LAN module.
Lenze
www.lenze.com
38 April 2016
plant engineering
PRODUCTS
Industrial connectors
Molex is focused on communication and connectivity for automation at Hannover Messe
and will be featuring a complete range of industrial automation solutions. Featured new
products/solutions include Brad M23 Signal and Power Connectors and MXMag Gigabit
Single-Port RJ45 Magnetic Jacks. In addition, the company will showcase its Flamar
cable assemblies, GWconnect Heavy Duty Connectors (HDC), FCT mixed layout connectors, Brad MX-PTL M12 Cordsets, CC-Link network interface cards, EtherNet/
IP Protocol Stacks, CIP Safety Protocol Stacks, and SST CompactLogix Modules
for Rockwell Automation. A live demonstration will showcase Molex capabilities
in protocols that include EtherNet/IP, Profinet, CC-Link, and IO-Link.
Molex
www.molex.com
Cloud gateway
Ethernet cables
Increased automation in production processes requires the volume of data transmitted to be much greater. Since movement
also plays a role in modern production
processes, special Ethernet cables have
been designed to ensure reliable movement and reliability. There are 27 cables
in the product range, from the chainflex
CF888 with a guaranteed service life of up
to five million strokes to the new chainflex
CFROBOT8.052, the first robot cable that
complies with the CAT7 standard.
Igus
www.igus.com
The Simatic IOT2000 is designed for industrial IT solutions that

acquire, process and transfer data directly in the production environment. For example, it can be used to connect the production to
a cloud-based analysis of machine and production data. This gateway can also be retrofitted in existing plants, where it then harmonizes communication between different data sources, analyzes the
data, and passes it on for evaluation in, for example, a cloud. The
Simatic IOT2000 complements the MindConnect Nano cloud
gateway from Siemens. This is already on the market, and is specifically designed for MindSphere and SAP Hana. The hardware
of the new Simatic IOT2000 gateway is based on rugged, reliable
and long-lasting industrial technology and has a compact design.
The device is suitable for mounting
on a standard rail,
and is equipped
with a powersaving Intel Quark
processor x1020
(+Secure Boot),
1 gigabyte RAM,
battery-backed real
time clock (RTC)
and a large number of interfaces,
including two x
Ethernet and two x RS 232/485 ports. Simatic IOT2000 can be
easily expanded for tailor-made solutions with Arduino Shields
and miniPCIe Cards. It also supports Yocto Linux and many other
options for programming in high-level languages.
Siemens
www.siemens.com
PLANT ENGINEERING
April 2016 39
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MECHANICALSOLUTIONS
Flow management solution:
Match the flowmeter to the application

Magnetic, vortex, and differential pressure (dP) flowmeters are the leading technologies
used to measure volumetric flow or flow velocity. Know when to use each.
By Wally Baker
olumetric liquid flow is one of the

most imp or t ant parameters for
process monitoring and control in
many industries including chemical, refining, oil and gas, water/wastewater,
power, pharmaceutical, food and beverage,
and others.
Flows must be kept within safe limits;
monitoring f low rates indicates when
low- or high -low conditions have been
breached. These excursions often are provided as alarms to operators. For real-time
control, the flow rate can be used as an

interlock within the control systemfor
example, to turn on a centrifugal pump
before a tank or vessel runs dry.
Perhaps the leading use of flow-measurement information is to optimize continuous
processes as the process variable in a proportional-integral-derivative (PID) control
loop. For example, a flow measurement can
be used as the process-variable feedback
in a control-valve positioning loop to keep
the setpoint at or near its desired value.
The three leading technologies used to measure
liquid volumetric flow are
differential pressure (dP),
vortex, and magnetic flowmeters. Selecting among
these three measurement
methods for a particular
application is often based
on w h i ch te ch n ol o g i e s
h ave b e e n su c c e ss f u l ly
used before under similar
circumstances. Consulting
with a flow-measurement
specialist at an engineering or system integration
Figure 1: This diagram
shows the dP flow-measurement principle of operation.
This dP flowmeter is measuring the pressure differential created by an orifice
plate from which the meter
will calculate volumetric
flow. All images courtesy:
Rosemount, a division of
PLANT ENGINEERING
April 2016 41
MECHANICALSOLUTIONS
Figure 2: This direct-mount dP
flowmeter eliminates the need for
impulse lines, reducing installation cost and maintenance.
firm or a trusted supplier can provide

additional insight, including the identification of alternatives or information
regarding recent innovations that may
further improve flow measurement and
plant performance.
Measurement challenges with dP, vortex,
and magnetic flow measurement can be
overcome by employing new technologies.
Measuring dP flow
Measuring flow via differential pressure

is the most common and proven flowmeasurement technique and has been in
use for decades. A dP flowmeter is a cost-effective way to

measure volumetric flow, especially in applications with large
line sizestypically 8-inch
diameters and moresuch as
those found in water-feed and
discharge lines. Unlike other
technologies, dP flow measurement can be used with conductive and nonconductive fluids,
allowing it to be used with a
wide range of gases and liquids.
The primary element in a dP
flowmeter creates a pressure
drop by introducing a restriction in a pipe. This pressure
drop is then measured by the
second componenta dP transmitter, which sends the readings
to the control system. Depending on the exact nature of the
dP f low meter, t he remaining components may include
impulse piping and the connectors routing the upstream
and downstream pressures to
the transmitter.
By creating an engineered
restriction in a pipe, typically an orifice
plate, a Pitot tube (which measures the difference between the static pressure and the
flowing pressure of the media in the pipe),
or an Annubar (an averaging Pitot tube that
takes multiple samples across a section of a
pipe), Bernoullis equation can be used to
calculate flow rate because the square root
of the pressure drop across the restriction
is proportional to the flow rate.
A dP flow measurement is widely applicable. Howe ver, challenges may aris e
depending on the particular application,
the chief among them being wet-leg issues.
The three leading technologies used to measure liquid volumetric

flow are differential pressure (dP), vortex, and magnetic flowmeters.
42 April 2016
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mechanicalSOLUTIONS
Figure 3: In a vortex meter, the
vortices created by the shedder bar resonate at a frequency
proportional to the velocity of
the fluid flow in the pipe.
be required upstream and 7

feet would be required downstream.
In many cases, bends in the
piping within these distance
limitations can cause measurement inaccurac y with
traditional orifice plates. In
these instances, a conditioning orifice plate can be used.
A conditioning orifice plate
requires only two pipe diameters upstream and downstream of the orifice plate
of straight-pipe run, which
greatly increases the number
of applications for dP flow
measurement.
Vortex meters
Wet leg is the term used to describe the

impulse-line connection between the dP
transmitter and the primary flow-sensing
element. A gasair, for examplecan
get trapped in a wet leg and impact flowmeasurement accuracy. In addition, wet
legs can become clogged and may freeze
in cold conditions.
Existing technology allows an integrally mounted pressure transmitter to connect directly to the primary flow element,
eliminating the impulse line and its wet-leg
issues. These assemblies can be installed
easily and quickly because no impulse lines
are required. In addition, maintenance
costs are decreased because leak points
are reduced.
Another dP flow-measurement issue can
be introduced by traditional orifice plates
because they require significant straight
runs of pipe to reduce flow disturbancesup to 44 pipe diameters upstream of
straight-run pipe and seven diameters
downst re am. For a 12-inch-diameter
pipe, 44 feet of straight-pipe run would
44 April 2016
plant engineering
Vortex meters measure fluid

flow according to the Von
Karman effect, where a fluid
striking an obstruction
(shedder bar) creates alternating vortices, or low-pressure areas,
behind the bar at a frequency proportional to the velocity of the fluid. The
measured frequency is converted to flow
velocity, which is then converted to the
volumetric-flow rate. Industrial vortex
meters were introduced in 1968 and have
been successfully used to measure the
flow of steam, gases, and clean liquids. As
with all flow-measurement technologies,
there are challenges and resolutions when
applying vortex meters.
Typical vortex designs have small free
spaces or crevices around sensors or shedder bars to create the movement needed
to create vortices. Coating or particulate
matter in the fluid can clog the crevices
and inhibit sensor movement, resulting
in inaccurate flow measurement. All-cast
vortex meters eliminate the need for free
sensor movement, thus, they are insensitive to coating and clogging. Therefore,
they can be used to reliably measure flows
of dirty fluids that would plug traditional
vortex sensors.
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ing workers to process
chemicals. For measuring these critical
flows, all-cast meters
with isolated sensors
e l i m i n at e c om m on
leak points and can be
safely serviced under
process conditions.
Mag meters
Mag meters operate

on the principle of
Faradays law of electromagnetic induction, where a voltage
is developed when
a conduc tive f luid
Figure 4: These four vortex meters are measuring steam flow in an
is passed through a
enhanced oil-recovery field.
magnetic field. The
voltage developed is
proportional to the
A minimum flow ratereferred to as the strength of the magnetic field, the length
low-flow cutoff is required to establish of the conductor, and the velocity of the
the vortices. Flow rates at the lower end conductor described by the equation:
of the desired measurement range may
E=KBLV
fall below this minimum, thus, they cannot be measured, frequently requiring the
Where:
flowmeter and piping size to be reduced to
E = voltage measured at the electrode
increase velocity.
Reducer vortex meters have concentric
K = the meter constant
reducers designed and built into the meter
body that enable measurement of lower
B = the field density (strength of the
flow rates without expensive and disrupmagnetic field)
tive process-piping modifications. Factory
calibration of the reducer vortex meter
L = the length of the conductor (length
ensures accuracy and eliminates the need
of the conductive path between elecfor additional upstream and downstream
trodes)
piping in the field.
In some cases, mass flow is the preferred
V = the velocity of the conductor (conmeasurement instead of volumetric flow.
ductive fluid).
For example, in process-steam efficiency
calculations, the preferred unit of measure
Flow velocity can thus be obtained, and
for saturated steam flow is pound per hour,
as opposed to a volumetric rate. Pressure or by extension, volumetric flow.
Mag meters were introduced in 1952 and
temperature compensation can be used to
enable a vortex meter to measure the mass are used to measure the flow velocity of a
flow of fluids. Integrating these compensat- vast number of conductive liquids. Because
ing measurements into the meter reduces they introduce no obstructions in the fluid
stream, they avoid many issues found with
installed cost and complexity.
Vortex meters are often used to measure insertion meters, such as pressure drop,
critical flows of aggressive chemicals. Tra- product shear, or wear and tear on the
ditional sensor designs provide potential meter from the flowing fluid.
Mag meters can measure abrasive and
leak paths, possibly allowing process fluids to escape from the line. These designs high-solid slurries. In addition, wetted
also cannot be serviced without shutting surfaces (liner and electrodes) can be
down the process and potentially expos- selected for compatibility with chemically
46 April 2016
plant engineering
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MECHANICALSOLUTIONS
Figure 5: The sensing electrodes on this mag meter
measure the magnetic field
produced by the flow of
conductive fluid through the
meter.
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aggressive or abrasive fluids. The wetted surfaces of

the meter can be selected to
match the characteristics of
the process fluid, extending
meter life.
Ad v a n c e s i n m at e r i a l
technologies and installation techniques can further
i mp r o v e r e l i a b i l i t y a n d
extend the life of the meter.
Using meters that feature
all-welded design and isolated compar tments t hat
protect against moisture and
contamination can improve
reliability.
L i n e r s w it h i n c re a s e d
temp erature resist ance, re duce d
permeation, and resistance to oil in
applications such as produced water
measurement in oil production, can
extend ser vice lifeas do options
such as lining protectors and hardened materials that protect against
abrasive wear. Installation practices
can manage velocities to further
reduce abrasion or to manage temperature gradients and reduce the
rate of permeation.
Quality and regulator y requirements often require periodic confirmation that the meters continue
to measure f low accurately. This
typically requires removing the meter
from the line and confirming accuracy at a flow lab or bringing additional equipment to the field so the
calibration can be verified with the
meter offline. Smart-meter verification is an accepted method where the
technology is built into the flowmeter
so it can verify performance without taking the flowmeter offline and
without special equipment.
Smart-meter verification validates
the hardware, software, coils, electrodes, and interconnecting wiring.
48 April 2016
PLANT ENGINEERING
Flows must be kept within safe limits;
monitoring flow rates indicates when low- or

high-low conditions have been breached.
Verification can run continuously
and can be initialized either through
the local operator interface or via a
remote software command. There
is typically a significant reduction
in downtime due to the elimination
of calibration verification as well as
errors associated with disconnecting
and reconnecting functional meters.
In addition, smart-meter verification
can simply and easily confirm initial installation, providing instant
feedback that the installed meter is
functioning as intended.
Fluids often contain particulates
that can cause noise that interferes
with the flow measurement. Examples include mining slurries, pulpand paper-mill slurries, and produced water with high levels of sand
carryover. Particulates striking the
electrode cause high levels of noise
(similar to the effect of tapping on a
microphone), which can result in low
signal-to-noise ratios, reduced accuracy, and poor loop performance.
Traditional means of dealing with
high process noise involves the addition of damping, which can reduce
loop response to unacceptable levels.
Modern noise-mitigation technologies can be used to provide a more
accurate and responsive flow signal.
These technologies include diagnostics that dynamically monitor signalto-noise ratios, adjustable coil-drive
frequencies to enable moving to a
less noisy frequency, and high-signal
mag meters with increased signal
power.
Wireless options
Mag, vortex, and dP meters are

available as wireless devices. The
transmitters in dP meters are available in versions with integral wireless while mag and vortex meters are
available with adapters to convert

their outputs to a wireless signal at
the transmitter. The primary value
of wireless is delivered with either
configuration.
Wireless installations transmit process data and diagnostic information
wirelessly, eliminating the need to
run signal wiring to the I/O panels.
Eliminating signal wiring allows a
much quicker and less expensive
installation as theres no need to run
wiresand it also reduces maintenance.
Wireless devices connect to a wireless gateway that can be located in
close proximity and connected to
the control system via hardwiring.
Wireless technology also eliminates
the need for additional analog input
points at the control system to accept
the signal wiring from the devices,
which can be very expensive, particularly if a new analog input card
needs to be added.
Closing the loop
Mag, vortex, and dP flowmeters

are the leading technologies used
to measure volumetric flow or flow
velocity. Each technology has its
place and each has its challenges.
The first decision is the selection
of the right flow technology for the
applicationa task where a trusted
supplier or system integrator can be
enlisted to provide assistance.
The next task is to ensure the proper meter is specified for the application, including required features
and options to overcome the flowmeasurement challenges inherent to
the application. PE
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Best practices in
preventive maintenance:
How one company did it
By Ken Staller
Daniel Penn Associates
ompanies with well-planned preventive maintenance (PM) programs enjoy

minimal unplanned downtime, minimal spare-parts costs, minimal manufacturing interruptions from breakdowns,
maximum manufacturing times, maximum
product quality and longer machine lifespans.
These companies have done their homework
upfront. They have chosen to take advantage of
the available physical and financial advantages
that a PM program can provide.
These companies have also made the commitment to getting a PM program in place
that is flexible, manageable, and sustainable
for the long term. What were the key drivers
of their success?
The manufacturer began its PM program

design by clearly defining what the company
wanted to achieve:
Uninterrupted manufacturing runs by
eliminating machine breakdowns
Increased product quality
LAST OF THREE
PARTS
Part 1: Why preventive
maintenance failsand
how to fix it
Decreased capital expenditures by increasing machine lifespans and reducing spareparts costs.
This exemplary manufacturer:
Part 2: Six steps to design

a preventive maintenance
program:
Made the tough decision to temporarily reassign their top mechanics to assist
in writing PM-inspection details. These
mechanics understood the machines
physical operation, which components
failed and why, and the mean time between
failures.
Part 3: Best practices in

preventive maintenance:
How one company did it
Purchased small inexpensive infrared

temperature guns for all mechanics. This
helped the mechanics check operating
temperatures of machine bearings, cou-
plings, motors and gearboxes during their

normal working shifts. The goal was to flag
and address above-normal temperatures
before failures occurred.
Used written feedback from corrective
work orders to constantly change and
enhance the existing PM program. For corrective-type work orders (WOs), mechanics were required to write their root-cause
analysis, and the solution applied, on the
hard copy of the corrective work order.
The PM program coordinator reviewed
all corrective WO feedback after they were
completed and made changes to PMs when
needed.
Kept equipment extremely clean, which
enabled the maintenance team to easily spot
any leaks or debris from component wear.
Installed small auto-lube units to provide automatic lube dispersion on a timed
basis. These units were installed on critical bearings and machine components
that received daily high-pressure washdowns and were subject to harsh environmental issues. More comprehensive
auto-lube systems were being engineered
for automatic lube dispersion on a larger
scale to many components throughout
the plant.
Worked with lubrication vendors to assist
in designing their lube program. The
manufacturer used these vendors on an
ongoing basis to help monitor lube effectiveness and make continuous improvements (CI) on possibly changing the lube
type, application quantity and frequency.
Published the individual successes of the
existing PMs to their maintenance tradesPLANT ENGINEERING
April 2016 51
mAINTENANCESOLUTIONS
The right professional assistance can help

ect Ad Repair Restore Return
companies
develop a PM correctly from the
Engineering all
April
2016
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start, support its internal PM team and
keep the momentum going.
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people and kept them up to date

with CI changes. This helped eliminate the old-school fix it when
it breaks mentality and encouraged the companys new preventive
maintenance culture.
Companies that have poor or no PM
programs certainly gain the most from
outside support, especially if the plant
equipment is old and not maintained,
if spare-parts storage is not well managed, if theres no maintenance training
or if theres no discipline within the
maintenance department.
PM cost savings will obviously vary
based on each companys unique products and manufacturing processes.
However, one frequent benefit of PM
is a reduction in overtime wages and
equipment run times to catch up on
production schedules that were interrupted by unplanned breakdowns.
These PM benefits are often overlooked
when companies accrue cost savings.
Bring in experts who have been there
A lack of implementation expertise is the

number one reason that PM programs
fail.
The right professional assistance can
help all companies develop a PM correctly from the start, support its internal
PM team and keep the momentum going.
Make sure the people helping have been
there and done that. The best team for
the job includes people who have held
maintenance management positions,
have gone through the steps and have
been held responsible for outcomes.
The size of the PM development team
will depend on the size and complexity
of the facility, but in general, it should
be relatively small: one project manager
and one or two people who will design
and implement the program and train
your internal team. PE
Ken Staller has more than 30 years of
project engineering, project management
and maintenance management experience in machine manufacturing, pulp
and paper, pharmaceutical and automotive industries. Daniel Penn Associates
is a CFE Media content Partner. Edited
by Erin Dunne, production coordinator,
CFE Media, edunne@cfemedia.com.
52 April 2016
plant engineering
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MAINTENANCESOLUTIONS
Define maintenance data value
to gain IIoT benefits
Maintenance offers great
potential value in the Industrial
IIoT is a new investment in existing plants or an
Internet of Things (IIoT). Getadditional investment for new plants. Careting the right data to the right
ful consideration has to be given to the overall
worker at the right time can head
off potential problems and point
maintenance plan and the specific-use cases
the way to more uptime. In the
where sensor data can provide returns.
first of a two-part discussion,
Chris LeBeau, global IT director at Advanced Technology Services (ATS), talks with Plant
constant flow of data versus periEngineering about how manufacturers can leverage IIoT to
odic readings. Technicians could
greater benefit.
then spend that time on activities
with more value to the operation.
PLANT ENGINEERING: What do you see as the potential for
IIoT as it relates to maintenance?
IIoT data can also be accessible outside of the plant. Centralized resources would have the ability to participate in
LeBEAU: IIoT technology represents a significant addition of
maintenance, providing support or advice remotely. Data
capabilities to existing plants and an important component of
from like machines across several locations can be aggregated.
new plants. The technology, however, is only the right answer
The combined data can create a clearer picture of machine
relative to the right questions. The questions are unique to
performance and be used to improve maintenance plans.
each implementation. Today, there is no one-size-fits-all scenario. The unique circumstance of each plant, line or machine
Benefits from IIoT can only be realized if the tangible value
has to be considered.
of the data to a maintenance organization and overall manufacturing operation are clearly defined. Failure modes need
There are some questions that do generally apply to most
to be identified along with realistic costs of downtime. The
plants. What machines fail most frequently or have the most
necessary measurements and sensor types need to be specified
impact on the operation? What conditions or indications
along with other observable information useful in improvwould be helpful to monitor on those machines to prevent
ing situational awareness. The cost of repetitive labor tasks
unplanned downtime? What preventive maintenance proshould also be factored. Then, any estimated benefits can be
cedures require regular meter readings or measurements
tested against the costs in a business case with realistic and
performed by maintenance personnel? What information
measurable objectives for each scenario.
indicates the health of the operation or can provide a leading indicator of any performance degradation?
PE: That said, what are the barriers to adoption?
The potential benefits of IIoT for maintenance come in

several forms. The overall situational awareness of plant
operations and equipment condition can be greatly improved.
Information can be presented in summary view as dashboards
or in detailed views with real-time measurements and performance trends over time. Automated alerts based on degraded
performance can provide time to act, preventing a more serious failure, or to schedule maintenance that avoids disruptive
downtime.
The labor required to collect meter readings and measurements can be reduced or eliminated with sensors providing a
LeBEAU: Any significant growth of IIoT and sensor connectivity within plants will be dependent on the establishment
of recognized standards. There is currently an overall lack
of industry-supported IIoT standards. This creates risk in
choosing solutions that will have broad support and longterm usability. There is also a low number of sensor options
supporting the wide variety of required measurements robust
enough to operate in harsh industrial environments.
Many plants are not sufficiently networked to support
the addition of hundreds of new sensor end points. Wide
IIoT adoption will require cost-effective connectivity. ScalPLANT ENGINEERING
April 2016 55
mAINTENANCESOLUTIONS
ing traditional Ethernet and Wi-Fi technologies to support
this requirement can rapidly become too costly. Options
based on less expensive radio-networking technologies that
leverage unlicensed spectrum (900 MHz and 2.4 GHz) offer
an alternative. Although also requiring agreement on standards, these technologies provide higher device density and
longer range than Wi-Fi supporting indoor and outdoor
applications.
In all cases, IIoT is a new investment in existing plants or
an additional investment for new plants. Careful consideration has to be given to the overall maintenance plan and the
specific-use cases where sensor data can provide returns. This
is more likely in process plants where there are equipment
dependencies and a higher cost per downtime hour, and
obviously less likely in discrete manufacturing environments.
PE: Specifically, we hear about change management being a
key challenge for plans to realize the full benefits of IIoT. How
will maintenance operations have to fundamentally change?
LeBEau: This change is often characterized as the need
for coordination between operational technology (OT) in
the manufacturing plant and information technology (IT).
Traditionally separate, these two disciplines will need to
cooperate to realize the benefits of IIoT.
In the IIoT model, sensors will generate data that is collected, contextualized, analyzed and ultimately sent as actionable information into applications supporting numerous
operational functionsincluding maintenance. Changes in
monitored conditions will generate alerts and status notifications, and drive automated actions to maintenance personnel.
To keep this information relevant, IT will need real-time
awareness of activity in the plant. This includes production
schedules and notification of all planned and unplanned
maintenance actions that could affect monitored data. Without this awareness, alerts and automated responses will cause
false alarms and wasted effort by personnel unnecessarily
reacting to events.
Maintenance personnel and the applications they use will
have to provide context and create this awareness. Maintaining an accurate production schedule will account for
times when the machines are not running or require different conditions to be measured. The start and stop times for
maintenance actions will have to be indicated. These time
frames also will have to be factored into calculations related
to operational metrics and historical trend analysis.
All of this will require changes in operational behaviors
for the maintenance personnel and increased coordination
with their IT counterparts. In return, IT will have to become
much more savvy about how OT functions and continually
work to provide easy-to-use applications that supply maintenance personnel with relevant and actionable information.
56 April 2016
plant engineering
The aging workforce dilemma in maintenance has been

well documented. Modernization in the manufacturing sector
and technological changes like IIoT combined with a younger
maintenance workforce will start to close the gap between
the OT and IT domains. Over time, the distance will shrink
through shared experience and knowledge transfer, ultimately
becoming a significant and complementary overlap.
PE: Whats your sense of maintenance data being captured
today, and how it is used? Are there still some manufacturers stuck with clipboards and paper?
LeBEau: Most maintenance-related data is collected, stored
and only used locally. Accuracy is also dependent on the
person or persons entering the data. In most cases, the information is maintained as separate forms or records within a
computerized maintenance management system (CMMS) and
not combined in any meaningful way for trending or analysis.
There is still a significant amount of this data being maintained on paper. In many cases, this works well for the people
at a plant, but it also creates risk. Data quality can be impacted
by personnel changes and paper records can be damaged or
lost. The data is also not readily usable by anyone not actually holding the document.
PE: Look five years down the road. How will an effective
maintenance department operate?
LeBEau: The reality of plant maintenance is that it is, and
will remain, a physical and mechanical occupation. Computerization and automation will continue to expand inside
plants of all kinds, but maintenance will still look a lot like it
does today. The conversation about maintenance, however,
will be much different. How it is planned, when it is done
and how effective it is will all be based on the vast amounts of
data coming from technologies like IIoT and the applications
that collect, correlate, analyze and leverage that information.
Centralized resources will play an integral role, providing
access to data and leveraging remote tools for coordination with onsite resources. This shift will provide options
to have advanced skill sets and capabilities available at any
plant, not just the ones that are large enough to afford people
onsite. This network effect will extend to a vast array of
new resources including access to knowledge and suppliers
providing instant parts creation onsite when combined with
3-D printing.
Effective maintenance departments will embrace these
changes to focus their work effort on the things that matter most. This will be driven by plant management having
increased transparency, allowing better decisions to be made
on what to do and when to maximize productivity and profit.
These capabilities will also demonstrate the significant business value of maintenance and create better alignment within
the operation. PE
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AUTOMATIONSOLUTIONS
IIoTs power found
in controllers, HMIs
Technology used to deliver information to the operators fingertips.
By Jeff Payne
AutomationDirect
he first step when implementing the

Industrial Internet of Things (IIoT)
in a manufacturing facility is generating data from sensors and actuators connected to components and equipment, the things in the IIoT often referred
to as edge devices. These devices can be
motors, drives, pumps, machines, valves
or any of the other hundreds of automation components found in industrial plants
(Figure 1).
The next step is collecting this device
data, a task usually performed by programmable logic controllers (PLCs) and
other advanced controllers. Once collected, this data can be shared with local and
remote users via the Internet and company
intranets in a variety of ways. By doing this,
plant personnel can create their own IIoT,
connecting their edge devices to the people
most in need of this information.
Edge into control
Figure 1: The first step in

any IIoT system is connecting to the edge device, such
as this soft starter. In this
case, the connection is via
an EtherNet/IP communication link. All images courtesy: AutomationDirect
The flow of data starts at the edge device,

whether its a temperature, current or
digital sensor; a variable
frequenc y or
ser vo drive;
or any other
sensor
or
component
containing
information
of interest.
These edge
devices can be
connected to
such devices
a s a dv an c e d
controllers.
Data
is
available in
many forms in
industrial automation applications. Each

data point is unique, and each is just as
valuable to a particular person. Advanced
controllers have the ability to not only read
these crucial data signals, but they also possess the processing power to act on them
internally by performing calculations, scaling values as needed, and storing the data
or presenting it to an upstream database.
Advanced controllers can handle a variety of signal types from a multitude of
edge devices (Table 1). These signals range
from ver y basic, discrete on/off signals
generated from simple sensing devices,
mechanical limit switches, and proximity and photoelectric sensors; to variable
analog signals, typically in milliamps or
low-voltage dc; to communications signals where device and application statuses
are updated over shielded, twisted pair of
wires using a variety of communication
transport protocols.
Digital sensors operate at a variety of
voltage ranges, but each is simply on or off
depending on the status of the data point
under measurement. This single bit of data
may not seem like much, but it can be crucial to machine and process operations
because it provides important information.
TABLE 1: TYPICAL EDGE DEVICES

Discrete sensors
Analog sensors, such as current,
voltage and other transducers
Temperature, pressure, flow
and other transmitters
Analyzers measuring chemical
composition of process flows
Motor drives
Control valves
PLANT ENGINEERING
April 2016 59
aUTOMaTIONSOLUTIONS
For example, the current mode of
operation (off, on, automatic, manual,
etc.), number of cycles, quantity of
finished goods, number of rejects and
more are each monitored and counted
by a single bit. With the use of highspeed counters, a sensor or encoder
can use this same discrete signal to
provide position, direction, speed or

distance.
An analog sensor provides the
variable data associated with a process measurement. Common signals
include temperature (most commonly
measured with a thermocouple, RTD
or thermistor sensor), pressure, flow,
Digital sensors
operate at a variety
of voltage ranges, but
each is simply on or
off depending on the
status of the data point
under measurement.
level, distance, voltage or current.

This data will be transmitted to the
controller input as an analog signal.
Industr y-standard analog signals
include 4-20 mA, 0-5 V dc, 0-10 V dc
and +/-10 V dc. These analog devices
are crucial in monitoring and controlling applications and are being used
more frequently because they deliver
more information than a simple onoff device.
Many controllers have analog input
modules with 16-bit resolution, meaning that the voltage or current signal
being transmitted back to the controller is converted into a high-precision
digital value between 0 and 65,535
counts (216). For a standard 0-10 V
dc analog sensor, the controller-count
variable will increase with every 0.153
mV of change in the process signal.
Consider a 0-10 V dc pressure transmitter calibrated to measure 0 to 100
psi. A 16-bit resolution analog input
module will detect a pressure change
down to 0.00153 psi, precise data
feeding the IIoT.
By using communication protocols,
smart edge devices can reveal more
about their status. Controllers can
read the built-in status registers of a
variable frequency drive, soft starter or other intelligent deviceand
gather multiple pieces of data directly
from the device. These components
typically include data registers with
continuously updated process values,
such as revolutions per minute, hertz,
voltage, acceleration time, deceleration time, etc.
Each of these connection and control methods provide valuable insight
into the machine or process and, by
60 April 2016
plant engineering
implementing and taking advantage of

IIoT, the controller can help decisionmakers by getting this data to them
sooner.
Data-handling at the controller
Advanced controllers have the capability to store data locally on standard

removable media ports. For example,
many advanced controllers have an
integrated microSD removable
flash memory card slot for up to 32
GB of local data storage. From the
standpoint of gaining access to raw
data, this is one of the easiest methods available for data collection.
A user can simply manually swap
out the microSD card to pull the data
from the process, or access the controller remotely using the integrated
Web server. This provides access to
the log files from any Web browser
with adequate security provisions
and connection to the network. Once
connected, the data can be viewed,
downloaded and deleted as necessary.
The built-in data collection on
advanced controllers provides an
excellent starting point for collecting
data and feeding the IIoT. On more
advanced machines and processes
with larger data-collection requirements, the data-logging capabilities
of a human-machine interface (HMI)/
SCADA software package can be used,
but the controller must first be connected to the HMI/SCADA system.
Connecting controllers to HMIs
Ethernet is the fastest-growing industrial communications network with,

like most communication methods,
typically many protocols to choose
from. In the North American market, EtherNet/IP protocol is by far
the most popular, with Modbus TCP
Table 2: HMI ClIents

Secure-viewer thin clients
Office PCs
Laptops
Tablets
Smartphones
a distant second. The advanced-productivity controllers support both of

these common protocols.
Support for an Ethernet protocol
shared by the controller and the HMI
is the first step, with the second step
being creation of the tag database.
Defining these data-exchange details
allows the controller and the HMI to

recognize data and put it in the right
place.
Using this built-in tag name-sharing feature, users can design a screen
layout and create objects by assigning a tag name and establishing a link
between the controller and the HMI.
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plant engineering
April 2016 61
EIG-PlantEngine Industrial 2/11/16 10:56 AM Page 1
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Connecting data from an edge device through the controller tag and into the HMI/SCADA over the configured communications protocol thus becomes a simple
tag name-selection step.
Distributing HMI information
Data in HMIs can be distributed to a variety of clients

(Table 2) using a number of standard protocols.
To facilitate the distribution of data, the Point of View
HMI/SCADA and other competing software systems offer
various thin client options so users can access data based
on their needs and a location relevant to the machine or
process.
A thin client is a device designed and used for remote
communications with a server. In the case of HMI/SCADA
software, the project is developed and the run time application is deployed on a server PC. Once the run time is
operational, the user has a few options for viewing and
interacting with the project.
The data can be viewed directly on the PC where the
run time application is installed. Using a utility called a
secure-viewer thin client, the run time application can
be deployed on a remote PC that is typically on the same
network as the run time PC.
Extending out from the local network, a Web thin
client application would be used and is very similar to
the secure-viewer thin client. However, the application is
actually running within a Web browser and is not a standalone utility like the secure-viewer thin client. This gives
62 April 2016
plant engineering
Figure 2: Advanced controllers can be used to

gather data from discrete,
analog and smart edge
devices in IIoT applications.
the user more flexibility,

as it allows access from
any Internet-connected
device capable of hosting
a Web browserincluding mobile thin clients,
such as laptops, tablets
and smartphones.
D at a log ge d at t he
HMI, stored on a connected SQL database or
provided to the cloud is
available for IIoT connections, allowing data
to be presented to those
who need it. Data can be
viewed and used by management, scheduling and
the enterprise resource
planning (ERP) system.
Additional connections
to the cloud can connect to field engineers and plant floor
personnel via tablet, smartphone or remote PC (Figure 3).
Figure 3: This IIoT implementation shows how a variety of
networks and protocols can be used to connect controllers
to various viewing platforms.
plant engineering
April 2016 63
aUTOMaTIONSOLUTIONS
Conclusion: Use data to improve
Many aspects of the IIoT are not breaking new ground.

However, combining all of these modern technologies will
allow IIoT implementations to be designed and installed
more quickly and at dramatically lower costs.
For an IIoT implementation to be effective, data must
be collected, presented and used to improve operations.
Most people are aware that having more data gives a clearer
picture of how the equipment or process is operating and,
in general, the overall health of the production facility. The
next step is using this information effectively, a subject
for another article.
The data is there and waiting to be used. Advanced
controllers have more capability, processing power and
memory than everso gathering, manipulating, storing
and presenting information is becoming a more integral
part of the automation system.
With Ethernet networking built-in, seamless interaction
among the advanced controller, the HMI/SCADA software
and the business systems is easier than everand the IIoT
puts all of this information at your fingertips. PE
Jeff Payne is product manager of the automation controls
group at AutomationDirect.
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Turning research into insights to make better business decisions

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Respondents to the Plant Engineering 2016 Maintenance Study
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According to the data in the 2016 Maintenance report, seventy-six
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IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
Incremental encoder
The DFS60S Pro incremental encoder is a certified safety product up to SIL2 (IEC
61508), SILCL2 (EN 62061), PL d (EN ISO 13849), Category 3 (EN ISO 13849). The
DFS60S Pro incremental encoder is ideal for mobile and stationary applications that
require safe motion monitoring. The encoder makes it easy to integrate safe motion
into machine safety architecture by reducing the amount of work required for verification, validation, and safety engineering. It features an IP65 enclosure rating, wide
temperature range, and wide set bearings for enhanced durability.
Sick
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Low-voltage drive
Load bank controller

The Sigma LT is designed to meet market
demand for entry-level, remote and local
controllers for portable, 100 kW resistive load
banks. The hand-held, remote controller networks can manage up to 25 load banks using
extremely fast and reliable industry-standard
CAN bus communications protocol. Operators
can monitor and control all networked load
banks, or a single unit in the network, up to
800 ft away. Single-unit control allows data
centers to simulate hot zones to determine
how an HVAC system reacts to temperature
changes at specific server rack locations.
A robust, aluminum case protects controller components. A 4.3in color touch screen
on the remote controller displays 3 phase
voltage, power, current and frequency readings, and selected load. It also provides true,
de-rated loading when the working voltage is
less than load bank nominal voltage.
The DCR Series is a low-voltage 4-quadrant drive that provides

control of PMDC motors in a variety of applications. The DCR
Series is able to maintain variable speed control while batteries
discharge, delivering an increased run time for battery-powered
devices. A wide power range 1/100 hp to 7.5 hp makes the
DCR Series ideal for mobile equipment and linear actuators. The
DCR Series also can control portable or remote products that utilize solar power. The microprocessor-based design offers flexibility
for customized OEM solutions with multiple I/O configurations,
wired and wireless control capabilities and packaging options.
American Control Electronics (ACE)
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Power Technologies
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PLANT ENGINEERING
April 2016 65
IN NOVATIONS
Capacitive sensors
An expanding its portfolio of capacitive sensors now includes 18 mm and 30 mm
capacitive barrel sensors with teachable capabilities. The new offering comes in
two variantsteach by wire or teach by button. The teach by button variant can be
taught by a single press of a button, saving valuable installation and configuration
time. Both present and absent media can be taught for a higher sensitivity teach.
The variant without a push button can be taught either by a teach adapter or teach
by wire (pin 5), which allows for a tamper-resistant installation. Each variant is
available in either PNP or NPN.
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Ethernet switches
The configurable Industrial Managed Switches reliably network Ethernet
devices ensuring reliable access to system data. Ring redundancy technologies with 300 ms or 50 ms recovery times and dual power supply
connections help ensure system reliability. The switches feature fully
managed switches with Web-based management or CCI configuration,
and security functions such as MAC Limitation, Port Security, Access Control List, IEEE 802.1x
Wago
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Helical in-line reducers

The expanded range of LeCentric helical in-line reducers offers advantages for OEM and MRO applications
alike, with quick delivery, high levels of customization, and the cost-effectiveness of pre-assembled
Gear+Motor units that combine the LeCentric reducer
with a choice of Regal electric motors. The four new
cast-iron models are torque-rated from 5,974 lb-in to
18,587 lb-in, with a maximum input of 1/3 hp to 40
hp. Units are available with ratios up to 680.03:1, with
double and triple reduction designs and efficiencies
as high as 97%. A wide range of removable bases and
mounting hardware makes the new reducers a drop-in
replacement for industry-standard configurations.
GroveGear
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66 April 2016
PLANT ENGINEERING
Send new product releases to: peproducts@cfemedia.com
Safety switch
The IEC 309 industrial product line with its new non-fusible safety
switch is available in a 30 amp capacity and comes with three
auxiliary contacts that provide
further control circuit applications
including the on/off control of pilot
lights or signal for programmable
controllers. The universal wiring of
contacts allows for each contact to
be wired either normally open or
normally closed for added functionality. This non-fusible safety switch
is a nonconductive, watertight
thermoplastic enclosure that meets
NEMA 4X and 12K ratings.
Legrand
www.legrand.com
Remote racking system

The RRS-3 is a single-application remote racking system for General
Electric (GE) Type AMH circuit breaker. The lightweight, portable RRS-3
AMH allows technicians to remotely
install and remove the circuit breaker
from a safe distance of up to 300 ft
while remaining stationed outside the
arc-flash boundary. Installation and
operation do not require any modifications to the existing electrical equipment thanks to the magnetic latching
system. The RRS-3 AMH is compatible
with Type AMH circuit breakers with
ratings of 1200-2000 A, including AMH4.76-100/250/350-OD-1D. The RRS-3
AMH consists of three parts, the racking
operator, the foot pedal operator, and
an interlock defeat tool. Typical applications of the GE AMH circuit breaker
include commercial, industrial, and service entrance applications to
protect and switch mains, feeders, and incoming lines.
CBS ArcSafe
CBSArcSafe.com
Racking platform
The RackPack IT platform, combines key
elements of advanced power and physical asset management into one simplified, integrated infrastructure. Designed
to provide customers in North America
with best-in-class power management,
the plug-and-play RackPack IT solution seamlessly integrates with major
virtualization and converged infrastructure platforms, in addition to traditional
information technology environments, to
maximize business continuity. The RackPack IT is designed to streamline the
process with a bundled solution to help
end-users save time and money while
avoiding common after-the-fact configuration mistakes.
Eaton
www.eaton.com
PLANT ENGINEERING
April 2016 67
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PLANT ENGINEERING
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donaldson.com
Compressed air purifications solutions, compressed air
filters, dryers and process water chillers.
Donaldson Company Inc.
dynatect.com
Dynatect designs and manufactures a complete line of
components to protect equipment and people.
Dynatect
70 April 2016
plant engineering
gardnerdenver.com
gtispindle.com
GTI Spindle Technology provides the highest quality and
most extensive range of machine tool spindle repair services.
GTI Spindle Technology
us.kaeser.com
Manufacturer of air system products, including rotary
screw compressors, portable compressors, rotary lobe
blowers, vacuum packages, refrigerated and desiccant
dryers, filters, and condensate management systems.
Kaeser Compressors Inc.
rogers-machinery.com
Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems.
Rogers Machinery
seweurodrive.com
One of the largest global suppliers of drive technology,
SEW-EURODRIVE specializes in gear reducers, motors
and electronic motor controls.
SEW-EURODRIVE USA
sullair.com
Sullair is a designer and manufacturer of stationary and
portable rotary screw air compressors, air treatment
equipment, and pneumatic tools.
Sullair Corp.
klsummit.com
Industry leader in synthetic lubricant technology with a line
of over 200 products that can service almost any industrial
application.
Summit Industrial Products
keysight.com
tpctrainco.com
Keysight Technologies is an electronic measurement company that offers wireless, modular, and software solutions.
Keysight Technologies Inc.
TPC Trainco delivers intensive, high-impact training on

30+ electrical, HVAC, plant management, and mechanical topics.
TPC Trainco
littelfuse.com
Littelfuse is the world leader in circuit protection offering
automotive fuses, automotive circuit protection, fuses,
electrical fuses, thyristors, and more.
Littelfuse Inc.
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.
motionindustries.com
Motion Industries is a leading distributor of industrial MRO
supplies.
Motion Industries Inc.
ustsubaki.com
U.S. Tsubaki is a leading manufacturer and supplier of
power transmission and motion control products and is the
worlds market share leader in roller chains.
U.S. Tsubaki Inc.
wildeck.com
Wildeck is an industry leader and quality manufacturer of
steel storage mezzanines, material lifts, and safety guardrail products.
Wildeck Inc.
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation
systems.
Yaskawa America Inc.
Place next to your computer as a reference or go online to www.plantengineering.com for hot links to these companies.
Remove at
Line
2016
April
CONTACTS
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.
Page
Number
Advertiser
Allied Electronics
800-433-5700
ALL-TEST Pro, LLC

860-399-4222
48
Atlas Copco Compressors

866-688-9611
21
RSC
Number
Send
Info
HANNOVER MESSE
www.alliedelec.com
AutomationDirect
800-633-0405
C-2, 16A-16D
26
19, 37
58
32
www.atlascopco.us
Keysight Technologies, Inc

800-829-4444
Littelfuse, Inc
773-628-1000
53
30
50
28
www.AzimaDLI.com
Lubriplate Lubricants Co
800-733-4755
Motion Industries/Nidec
800-523-9328
23
www.baldor.com
Orival, Inc
800-567-9767
12
Phoenix Contact
24
14
1
13, 21
40
Beckhoff Automation LLC

952-890-0000
29
Bimba Manufacturing Company

800-442-4622
47
BLOCK USA, Inc

847-260-9050
33
Caterpillar - Northeast
57
31
www.NECatDealers.com/power
CENTURY SPRING CORP

800-237-5225
49
27
17
www.beckhoff.com
25
www.us.kaeser.com/PE
www.keysight.com/find/dropit
www.littlefuse.com/arcflash
www.lubriplate.com
www.blockusa.com
www.orival.com
DYNATECT
800-298-2066
52
29
Electro Industies/GaugeTech
877-EIMETER
62
13
Rittal Corporation
800-477-4000
45
24
Rogers Machinery
800-394-6151
64
38
SEW-EURODRIVE, Inc.
864-439-7537
43
23
Sullair Industrial Products

219-879-5451
63
37
www.electroind.com
61
34
www.ErectAStep.com
Summit Industrial Products

800-749-5823
TPC TRAINCO
877-978-7246
62
www.exair.com
U.S. Tsubaki
800-443-4216
14
11
www.flexicon.com
15
12
www.forcam.com
Wildeck, Inc.
800-325-6939
www.dynatect.com
C-1, 11, 40
Exair Corp
800-903-9247
Flexicon Corp
888-353-9426
FORCAM
513-878-2780
35
Gardner Denver
10
35
8, 22
5
6
20
7
www.gardnerdenver.com
60
64
www.plantengineering.com/2016Maintenance
PRUFTECHNIK Inc.
856-401-3095
www.DonaldsonTorit.com
ErectAStep
888-878-1839
16
www.phoenixcontact.com/GoMesse
54
16
www.cfemedia.com/global-si-database
3
Plant Engineering Webcasts

630-571-4070
www.centuryspring.com
Plant Engineering
Maintenance Research Study
630-571-4070
15
www.MotionIndustries.com
www.bimba.com/smarter
19
Yaskawa America, Inc

800-927-5292
Send
Info
31
18
www.hannovermesse.events/cfemedia
1
C-4
CFE Medias
Global System Integrator Database
630-571-4070
RSC
Number
Kaeser Compressors, Inc

866-516-6888
Baldor Electric Company

800-828-4920
Donaldson Co., Inc

800-365-1331
Page
Number
www.alltestpro.com
www.automationdirect.com
Azima DLI
800-654-2844
GTI Spindle Technology

603-669-5993
Advertiser
10
www.pruftechnik.com
www.RittalEnclosures.com
www.knw-series.com
www.seweurodrive.com
www.sullair.com
www.klsummit.com
36
www.TPCTrainco.com
www.ustsubaki.com
WWW.WILDECK.COM
C-3
39
www.yaskawa.com
33
www.gtipredictive.com
Need More Info? FAX this page to: 630-214-4504
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
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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.
PLANT ENGINEERING
April 2016 71
INCONCLUSION
Data-driven maintenance transforms the plant
In the revolution that is the Industrial Internet of Things (IIoT), the
ability to capture, analyze and act
on data will be the key strategy
moving forward. How manufacturers will use this data may depend
on the makeup of their workforce
and their commitment to analytics
as a strategy.
Chad Stoecker, managed services
leader for GE Digital, discusses this
changing landscape and how manufacturers can best take advantage of the
growth in data management and the
generation gap that can exist in its
implementation.
PLANT ENGINEERING: So much has
been made about the loss of experience in manufacturing in the coming
years through retirement. Talk a little
about the value of experience in plant
maintenance.
STOECKER: The aging workforce is a
serious problem. There are many people with decades of experience who are
leaving industry today, and that expertise is almost impossible to replace.
Many of these people knew what was
wrong with a piece of equipment just
by touch and feel. Whats replacing
them is a generation of data-analytics
engineers who rely on data to tell them
what is going on with a machine.
Today, industry wants more efficient solutions. Plant personnel

have to use data to determine when problems start, instead of
waiting until the equipment is offline or has approached an alarm
limit. Acting early will allow customers the time to make better
economic decisions.
ment condition and trends faster and

more accurately. How can experienced
maintenance personnel make use of
this information?
STOECKER: In the old world, it used
to be enough to rely on alarms and
trips to start the maintenance and
troubleshooting process. This constitutes a reactive maintenance process that results in production losses
and unnecessary maintenance dollars
being spent.
Today, the industry wants more efficient solutions. Plant personnel have
to use data to determine when problems start, instead of waiting until the
equipment is offline or has approached
an alarm limit. Acting early will allow
customers the time to make better economic decisions.
PE: What areas of the plant will make
the most use of data analytics?
We are trying to bridge the two with

our solutions: offering the next-generation workforce a combination of
people, processes and technology built
into software solutions to help them
make good decisions every day. Our
solutions leverage the latest in cutting-edge data-analytics techniques,
and we support our solutions with
industry experts who have decades
of reliability engineer expertise.
STOECKER: All areas of the plant are

going to be data-driven. Maintenance
and reliability engineers can determine
which maintenance actions to take,
and which actions can be avoided.
Process and operations personnel can
use data to determine the most efficient way to run the plant and identify
activities that are costing the company
money.
PE: In this new day of data analytics, we get a better picture of equip-
Business executives can use data to

make better decisions related to the
72 April 2016
PLANT ENGINEERING
Chad Stoecker, GE Digital

demands they get from the market.
Data analytics can transform the plant
from end to end.
P E : Younge r peopl e coming into
plants have more comfort with data
and the tools they will use as part of
the IIoT. How will these tools help
bridge the gap between their experience and the work that needs to
be done?
STOECKER: GE believes that software and analytics empower people
to make better decisions. Younger
people will have more information
and knowledge at their fingertips, or
by a phone call to a managed resource
center, than any generation before
them. This wealth of data will help
bridge the experience gap of younger
engineers.
P E : What s the mo st ov e rl ooked
aspect of the use of data analytics
in maintenance?
STOECKER: In my opinion, the most
overlooked aspect of data analytics in maintenance is the ability
to reduce time-based maintenance
activities. There are many costly
time-based maintenance activities,
which sometimes introduce faults
into a system, that can be eliminated with an effective condition-based
monitoring program. This represents
a tremendous potential for cost savings in the industry. PE
ENTER THE
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DRIVES & MOTION DIVISION
YASKAWA.COM
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The New Standard

in Large Motors
Whether you pump it, compress it, blow it or

convey it, Baldor Large AC GPM motors are the
perfect choice for your application. Available in low
voltage or medium voltage configurations, Baldor
Large AC GPM motors are inverter ready and in
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2015 Baldor Electric Company

Plant Engineering - April 2016 Issue

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17 Honoring manufacturing excellence: The 2015 Product of the Year Winners

Hannover Messe 2016

Micro panels...Mega value!

C-more Micro Panels

NEW 6-inch TFT model features:

C-more Micro panels are one of the most popular

Micro touch panel and non-touch panel versions available

The 3-inch cost-conscious panels display standard or high

32K color TFT displays are available in 4-inch, 6-inch,

Several options, including plug-and-play keypad bezels,

Free programming software with simulator

Full 2-year product warranty

Research, price, buy at:

5.7-inch touch screen display

All C-more Micro panels support:

All AutomationDirect programmable controllers

See our webstore for the complete list

Order Today, Ships Today!

the #1 value in automation

KAESER SUCCESS STORY

Seize the Savings!

Annual Energy Costs of Previous System:

$59,780 per year

Reduction in Specific Power:

45.3 kW/100 cfm

Annual Energy Cost Savings:

$22,680 per year

Additional Savings in Maintenance Costs:

$7,240 per year

TOTAL ANNUAL SAVINGS:

Simple Payback Period:

Kaeser Compressors, Inc. 866-516-6888 us.kaeser.com/PE

2016 Kaeser Compressors, Inc.

Go with Donaldson Torit and get

2016 Donaldson Company, Inc.

Cover image courtesy: Hannover Messe

Hannover Messe 2016

26 American manufacturing in the spotlight

27 Manufacturer builds for a global future

30 Universities bring knowledge, curiosity to Hannover

You cant afford not to know. See it all at thinkallied.com/sensors

EMILY GUENTHER, Associate Content Manager

Honoring manufacturings future

It was a night to recognize the future in manufacturing in people and products as

TRUDY KELLY, Executive Assistant

ELENA MOELLER-YOUNGER, Marketing Manager

KRISTEN NIMMO, Marketing Manager

LETTERS TO THE EDITOR

Jerry Preston, West Coast

Stuart Smith, International

Preventive maintenance: How one company did it

Companies with well-planned preventive maintenance (PM) programs enjoy

Define maintenance data value to gain IIoT benefits

Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com

RICK ELLIS, Audience Management Director

Match the flowmeter to the application

IIoTs power found in controllers, HMIs

A sense of anticipation, and a sense of home

This month, Bob was in

The bustle of Monday mornings commuter

The tablet and digital

In this particular year, however, there is a sense

Join the discussion

for your continued support of our