WWW.PLANTSERVICES.

COM

Raise Hazard
Awareness
Electrical Safety
Is Everyone's Job
SEPTEMBER 2010

See the Ball, Be the Ball / p.15

Manage Mobile Assets, Reduce Operating Costs / p.19

Best Practices Awards in Reliability / p.22

Solve Your Leaking HVAC Coil Problem / p.45

PS1009_covers.indd 1 8/25/10 3:30 PM

 Easy DAQ or SCADA with low-cost
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 Atlas Copco Compressors: The Air Auditing Specialists.

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 The First Name in
Power Transmission

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 table of contents
SEpTEMbER 2010 / VoL. 31, No. 9

features
28 / COVER STORY
Raise Hazard Awareness
Electrical safety is everyone’s job

22 / RELIABILITY
Best Practices Awards
Four companies exhibit the best in reliability

38 / POWER TRANSMISSION
Reliability Goes Green for Rotating Equipment
Four innovations can help you meet sustainability goals

45 / HVAC
A Discussion of HVAC Coil Coatings
The solution to leaking HVAC coil epidemic could be coatings

specialists
OSHA 10- and 30-hour training – Hard work that pays off
Training provides general awareness on primary safety and 17 / HuMAN CAPITAL
health matters. Owning Your Circumstances
www.plantservices.com/articles/2010/06osHatraining.html It’s the honorable thing to do

19 / ASSET MANAGER
ultrasound assisted lubrication
Adding ultrasound monitoring to standard lubrication best Fleet Asset Management
practices can lead to fewer failures, extend motor and bearing Your CMMS can be an active partner in minimizing mobile asset
life, and decrease the amount of lubricant used. operating cost
www.plantservices.com/articles/2010/07ultrasoundassisted
27 / TECHNOLOGY TOOLBOx
lubrication.html
Heat Exchanger Integrity
Multiple methods confirm the integrity of tubes and tube sheets
How VFDs save energy
Analysis and examples of power conversion by variable-frequency 58 / ENERGY ExPERT
drives. The Perfect Energy Storm
www.plantservices.com/articles/2010/06Vfdssaveenergy.html Reliability, cost, environmental factors can affect availability

On-Demand Webcast: Operational Excellence –

Capitalizing on the Economic Recovery columns and departments
Join the Aberdeen Group’s Matthew Littlefield, as he highlights 7 / FROM THE EDITOR Product Processor
the pressures that drive manufacturing operations and outlines Picks Premium Floor
Where Work Is Hell
strategic actions being used by best-in-class companies. Decision driven by traffic and
Coming to the end of a long,
www.video.webcasts.com/events/pmny001/viewer/index. antibacterial properties
hot summer
jsp?eventid=35447
15 / YOuR SPACE
9 / CRISIS CORNER
Keep Your Eye on the Ball
pLANT SERVICES (ISSN 0199-8013) is published monthly by putman Media, Inc., 555 West pierce Road,
Preventable Disasters Visualize goals to help your
Suite 301, Itasca, IL 60143. phone (630) 467-1300, Fax (847) 291-4816. periodicals postage paid at Itasca, Getting more people to fight team attain them
IL and additional mailing offices. Canada post International publications Mail product Sales Agreement No.
40028661. Canadian Mail Distributor Information: Frontier/bWI,po box 1051, Fort Erie, ontario, Canada, L2A the Maintenance Crisis
5N8. printed in U.S.A. poSTMASTER: Send address changes to pLANT SERVICES, putman Media, Inc., po
box 3435, Northbrook, IL 60065-3435. SUbSCRIpTIoNS: Qualified reader subscriptions are accepted from 49 / IN THE TRENCHES
pLANT SERVICES managers, supervisors and engineers in manufacturing plants in the U.S. and Canada. To
apply for qualified-reader subscriptions, please go to www.plantservices.com. To non-qualified subscribers in the 11 / WHAT WORKS Driven to drink
U.S., subscriptions are $96 per year. Single copies are $15, except the September and December issues which Acme learns what happens
are $36. Canadian and foreign annual subscriptions are accepted at $145 (Foreign airmail $200/yr). Single Warehouse Destratified
copies are $81. © 2010 by putman Media, Inc. All rights reserved. The contents of this publication may not be when an employee overindulges
reproduced in whole or in part without consent of the copyright owner. In an effort to more closely align with our in Canada
business partners in a manner that provides the most value to our readers, content published in pLANT SERVICES
magazine appears on the public domain of pLANT SERVICES’ Website, and may also appear on Websites that Large fans increase year-round 55 / MRO MARKETPLACE / AD INDEx
apply to our growing marketplace. putman Media, Inc. also publishes CHEMICAL pRoCESSING, CoNTRoL,
CoNTRoL DESIGN, FooD pRoCESSING, INDUSTRIAL NETWoRKING, THE JoURNAL, pHARMACEUTICAL comfort and cut energy costs 57 / CLASSIFIEDS
MANUFACTURING and WELLNESS FooDS. pLANT SERVICES assumes no responsibility for validity of claims
in items published.

www.PLANTSERVICES.Com SEPTEmbER 2010 5

PS1009_05_TOC.indd 5 8/27/10 9:59 AM

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 Putman media, inc.
555 W. pierce rd., ste. from the editor
301, Itasca, Il 60143 paul studebaker, cmrp
phone: (630) 467-1300,
Fax: (630) 467-1120

mike brenner
Group publisher

Where Work is hell

mbrenner@putman.net

editorial staff
paul studebaker, Cmrp
editor in chief
Coming to the end of a long, hot summer
pstudebaker@putman.net

russell l. kratoWiCz, p.e., Cmrp from the midwest to the eastern Sanitation immediately comes to
executive editor
russk@putman.net seaboard, the summer of 2010 has been mind, but sanity also is a major concern.
the hottest and most humid in 20 to 60 The Chicago Tribune reports that the
alexis GajeWski
associate editor, digital media years, depending on your location. Here men already have been trapped under-
agajewski@putman.net in Chicago, we had the longest string of ground longer than all but a few miners
stephen C. herner
80° F or above temperatures since 1955. I rescued in recent history. Survival after
V.p., creative services know that’s nothing compared to a regular 17 days is unusual, but because they’ve
sherner@putman.net southern summer, but crawling through made it this far, they should emerge
jennifer dakas the many road construction zones – with physically fine, Davitt McAteer, former
art director the windows open, because unlike me, assistant secretary for mine safety and
jdakas@putman.net
my A/C is taking a vacation – I have to health at the U.S. Labor Department,
david berGer, p.enG. sympathize with the workers getting it told the Tribune. But the stress of being
contributing editor
done under these conditions. And I can’t trapped underground for a long period
peter Garforth help but notice that, as a group, we’re not of time can be significant. “There’s a
contributing editor
getting any younger or thinner.
sheila kennedy But we do have more gizmos and gad- up here on the surfaCe,
contributing editor
gets. Manlifts and slings let us access diffi- the eConomy GroWs While
joel leonard cult locations with relative ease. Supports employment staGnates.
contributing editor
and braces allow us to work comfortably
bob sperber in odd positions. Sophisticated “zero
editor at large gravity” fixtures inspired by the movie psychological pattern there that we’ve
industry’s steady-camera technology can looked at,” said McAteer, but “there are
publiCation serviCes
hold heavy tools for precise work at arm’s people who can talk them through that.”
Carmela kappel reach (www.plantservices.com/zerogravity). Up here on the surface, the economy
assistant to the publisher
ckappel@putman.net Thanks to this summer’s Gulf of grows while employment stagnates.
Mexico oil spill, I’ve learned more than Factory and office staffs work harder and
jerry Clark
V.p., circulation I ever imagined I would about work- longer to increase production while skit-
jclark@putman.net ing at the bottom of the ocean. At the tish executives sit on their cash or use it
jaCk jones near-freezing temperatures and 2,400 psi for acquisitions, leading to another kind
circulation director water pressure a mile under the surface of survivors’ stress.
jjones@putman.net
of the Gulf of Mexico, remotely operated In the Middle East, combat troops are
rita fitzGerald vehicles (ROVs) serve as workers’ eyes now officially withdrawn from Iraq, or
production manager and hands. Operators can preprogram an renamed “advise and assist brigades.”
rfitzgerald@putman.net
ROV to park at a designated spot, anchor But it’s not clear how many will actually
jill kaletha itself by gripping framework, and reach come home, what opportunities they’ll
reprints marketing manager
Foster reprints out to adjust a set of valves designed to be have here, or how long before they’re
(866) 879-9144 ext.168 gripped by its high-torque, rotating claws. redeployed to Afghanistan. Or Iran.
jillk@fosterprinting.com
Meanwhile, about 2,300 ft. below the All in all, it’s not so bad to be stuck in
administrative staff surface of Copiapo, Chile, 33 workers traffic on a hot summer day, even with-
trapped for 17 days before they were out A/C.
john m. Cappelletti
president/ceO
located and found to be alive might
have to survive another four months on
julie Cappelletti-lanGe
Vice president
sustenance piped to them through a 6-in.
borehole while rescuers dig a shaft large paul studebaker, Cmrp, editor in Chief
keith larson enough to bring them up to the surface. pstudebaker@putman.net, (630) 467-1300 x433
V.p., content

rose southard
V.p., technology and Web development www.PLANTSERVICES.Com SEPTEmbER 2010 7

PS1009_07_Edit.indd 7 8/25/10 9:02 PM

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Preventable Disasters
Getting more people to fight the Maintenance Crisis
During the iCoMs Conference in Adelaide, Australia,
the Asset Management Council (AMC, www.amcouncil.
com.au) asked me to kick off a “find our theme song” contest
in hopes of fostering pride and passion for our profession.
I’m not “American Idol” material, but I gave it my best shot.
I played “The Maintenance Crisis Song” video (www.
plantservices.com/maintenancecrisis) and then sang
“Find Me a Maintenance Woman.” Music is, after all, a
powerful tool for influencing attitudes, perceptions, and
decisions. Some songs started major societal movements
and changes. Though my tonal quality might not be ready
for prime time, it inspired a quartet of engineers to write
their own version.
This group loved it and helped fill a void in the normally
dry engineering conference by adding what John Hardwick,
the chairman of the AMC, called “pizzazz.” I don’t portray
myself as a singer, but the attendees whooped, hollered, and
chuckled over the lyrics and video. I got a standing ovation.
Several approached me afterward to offer sage advice – “Hey
mate, don’t give up your day job.”
The next day, during my keynote address, they heard what
I do on my day job – supporting the economic transforma-
tion underway in an 11-county region surrounding Fort
Bragg, N.C. They agreed the interactive 3-D technology
used for technical skill development can serve as a bridge to
improve the skills and performance of a future workforce.
In fact, several consulting and contract maintenance
companies are helping me contact the leaders of P3I, the
public-private partnership for innovation based in Fay-
etteville, N.C. I participated in a panel discussion titled
“Strategic Asset Management – A Concept or Reality?” with
Hardwick, Anne Howe, CEO of South Australia Water Au-
thority (SAWA), and Penny Burns, principal director, AMQ
International. We agreed that organizations might be on
varying levels in the journey to implementing this strategy.
When asked if anyone had a formalized mentorship process
or succession plans, not a single person raised a hand.
This conference had wonderful speakers. One explained
that every second, across the world, we lose 1 ton of steel to
corrosion. Another said that Western Australia University
is adding engineering courses in its business curriculum.
The objective is to give future executives a grounding in
engineering strategies to better manage assets instead of
believing the traditional fallacy that maintenance is a cost,
PS1009_09_Crisis.indd 9
Crisis Corner
Joel leonard
not a contributor to profitability. Perhaps more U.S. schools
will implement similar programs.
The frighteningly common situation at engineering con-
ferences is that only a few new engineers are in the audience
each year. Most attendees were either practicing or masters
with one foot into full-time retirement.
When askeD if anYone haD a
forMalizeD MentorshiP ProCess
or suCCession Plan, not a sinGle
Person raiseD a hanD.
After witnessing the quality and depth of knowledge rep-
resented, I hope more efforts are implemented to recruit new
engineers to attend this dynamic event. I love the Australian
culture. As a smart aleck, I fit in and enjoyed some clever
repartee with the attendees.
And even though Australians’ most popular expression
is “No worries, mate, she’ll be alright,” some of the trends
underway are cause for great concern if action isn’t taken
to replenish and develop current and future workers. The
challenges are vast and deep, but if more of us confront the
issues head-on, we’ll make serious progress at mitigating
more preventable problems.
On the flight from Australia to Los Angeles, I met Juan
Ospina. He plays keyboard, and after hearing various versions
of “The Maintenance Crisis Song” via my laptop, he agreed to
join the fight. Most of his generation isn’t picking up skilled
trades, and he realized the Maintenance Crisis is a serious
problem. Upon his arrival home, he convinced Aguanilé Salsa,
a Latin-Grammy-Award-winning band, to produce a salsa ver-
sion of “The Maintenance Crisis Song.” This version will have
trombones, trumpets, bongos, and a Latin beat.
The first half of song will be in Spanish, the second half in
English. That should help acquire more supporters to fix the
crisis worldwide. It will be on SkillTV.net, so stay tuned.
Check the SkillTV blog if you’d like to join me during my
fall conference schedule. I’ll be keynoting the Facilities De-
cisions conference in Las Vegas and plan to attend the SMRP
conference in Milwaukee.
e-mail Contributing editor Joel leonard at joel@skilltv.net.
www.PLANTSERVICES.Com SEPTEmbER 2010 9
8/25/10 9:03 PM
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PS1009_FPA.indd 10 8/25/10 9:40 PM

 what works

warehouse DestratiFieD in CanaDa

Large fans increase year-round comfort and cut energy costs

Federated Co-operatives Ltd., much of the draft associated with fan

a retail cooperative with members circulation.
throughout western Canada, operates Carlson decided to conduct pilot
retail shops, fueling stations, building tests in the 80,000-sq.-ft. loading
material supply centers, and refiner- dock area of Federated’s 300,000-sq.-
ies, occupying numerous warehouse ft. warehouse in Saskatoon, Sas-
spaces to store products. According to katchewan, Canada. He installed
Trevor Carlson, environmental and five 24 ft.-diameter, low-speed Big
technical services manager at Feder- Ass Fans units. “After a short period
ated (www.fcl.ca), a fair amount of of operation, we noticed multiple
heat was being wasted at the ware- benefits,” says Carlson. “The work-
house ceilings. By bringing this heat ers in the warehouse actually wanted
downward, he thought, Federated the temperature decreased in the
could decrease the rate at which its winter because they were too warm.
buildings were shedding heat through That was very encouraging for us, as
the roofs. we were able to change the setpoints
A potential source of heating on the thermostats because the fans
energy savings is reducing the differ- were bringing the heat down, keeping
ence in air temperature between the workers comfortable while reducing
outdoors and the underside of the our costs. We looked at our degree-
roof. Thermal destratification can Destratifying air temperatures in a 300,000-sq.-ft. day data and calculated our heating
warehouse with large fans saved Federated
make the air temperature essentially index for the year prior and the year
Co-operatives Ltd. an estimated $19,800 the first year.
uniform within the conditioned after installing the Big Ass Fans.”
space, reducing the temperature at the underside of the roof. Carlson’s findings showed a significant reduction in energy use.
Estimated energy savings are based on the difference in heat Occupants of existing buildings can obtain fuel use data from
loss through the roof at the temperature differentials before and their utility companies, while local climate records can provide
after destratification. the average outdoor air temperature during a particular heating
“In the stratified condition, there will be a significant season. This data can be used to calculate the heat loss through
difference in air temperature between floor level and the the building envelope over a given period in the form of a heat-
underside of the roof,” explains Richard Aynsley, lead aero- ing index in Btu/ft.²/degree day. One degree day is accumulated
dynamics engineer, Big Ass Fans (www.bigassfans.com). for each difference of one degree between a day’s average tem-
Before destratification, the difference between the tempera- perature and a reference temperature, typically 65° F.
ture of air near floor level and at the underside of the roof deck Carlson tracked data concerning average energy consump-
can be as much as 30° F. A critical factor in destratification is tion and daily temperature changes from 2007 into 2009. For
that the indoor air is thoroughly mixed to an even tempera- the Saskatoon facility, the heating index before the installa-
ture, remarks Aynsley. Afterward, the difference between the tion of the fans was 4.49 Btu/ft²/degree day. The year the fans
temperature of air near floor level and at the underside of the were installed, consumption decreased to 3.99 Btu/ft²/°F. The
roof deck is usually no more than 1° F. Big Ass Fans’ units are following year was the first full year of using the fans, and
designed to provide a low-cost, energy-efficient cooling solution the heating index was 3.61 Btu/ft²/°F. “We noticed a pretty
coupled with the ability to significantly reduce energy usage in significant decrease, and it works out to a roughly 10% reduc-
winter months by destratifying the air within a building. In lieu tion in natural gas consumption,” says Carlson. “It was a 10%
of reversing the fan, which is common for most small, high- reduction when we saw a 20% increase in natural gas rates.
speed fans, large-diameter Big Ass Fans units are designed to We believe we saved $19,800 in the first year in natural gas
simply operate at a slower speed during the winter, eliminating consumption as a result of the fans.”

www.PLANTSERVICES.Com SEPTEmbER 2010 11

PS1009_11_12_Works.indd 11 8/25/10 9:03 PM

 what works

Produce Processor Picks Premium Floor

decision driven by traffic and antibacterial properties

when the floor finishing project came out for bid from
one of the local general contractors in charge of the ten-
ant improvement, there was no detailed specification for
the product type or criteria, only a small blurb in the finish
legend mentioning a white epoxy floor coating that would
meet USDA standards.
But long before work at the new Papa John’s Salad and
Produce facility in Tolleson, Ariz., began, Brian Whited,
key accounts manager, Techniquex (www.techniquex.com),
knew the correct flooring system to use for the large expan-
sion project. Three years earlier, Techniquex had worked
for Papa John’s Salad and Produce at its facility in Tempe to
solve a problem of concrete deterioration caused by exces-
sive water exposure. Knowing the exact conditions the new
flooring would face under excessive traffic, constant water
immersion, and low temperatures, he was sure the best
solution would be Diamond-Crete RT by DiamondStone
Products (www.diamondstoneproducts.com).
Whited, recalling the bid information was vague, con-
tacted the contractor directly to express his concern. “After
I spoke with the contractor and realized the new build-out
was for Kevin Jones at Papa John’s Salad and Produce, I im-
mediately told him of our past experience at their other fa-
cility. We agreed that giving the client a few options, includ-
ing the Diamond-Crete RT, would be the best approach.”
The estimating staff at Techniquex reviewed the plans
and construction schedule and quickly realized the project
needed to be fast-tracked. This was yet another indication to
use the Diamond-Crete RT system because of its short cure
and quick turnaround.
Once the contractor received the proposals for the proj-
ect, it was time to begin negotiations. Techniquex provided
several samples of the proposed systems and installed
mock-ups so Jones, the owner, could select colors and
texture. Techniquex recommended the Diamond-Crete
system, but the price was substantially higher than the
other options. Whited explained the advantages, including
unlimited moisture tolerance, thermal expansion quali-
ties, warranty duration, and installation timeframe. “Once
Kevin and the contractor were educated on the products
and the differences between them, the extra cost wasn’t an
issue,” says Whited.
The owner and contractor both agreed to use the system, a
three-component, rake-and-trowel, polyurethane-modified
Installing 40,000 sq. ft. of Diamond-Crete RT plus an additional
100,000 sq. ft. of sealed and burnished concrete took a 10-man
crew six weeks of 10-to-12-hr. days.
cement with chemical, thermal shock, and thermal cy-
cling resistance. A non-sacrificial antimicrobial additive is
integrated throughout the system to inhibit the growth of
microorganisms such as bacteria and its odors. The system
used at Papa John’s Salad and Produce also includes an
optional quartz aggregate broadcast along with a finish coat
of DiamondStone Aromatic Urethane 100.
Techniquex crews arrived on the job site in late June to
begin installing 40,000 sq. ft. of the Diamond-Crete system
along with an additional 100,000 sq. ft. of sealed and bur-
nished concrete.
The 10-man crew quickly sprang into action, prepping the
areas scheduled to receive the DiamondCrete RT. The prep
work took a little more than one week to complete. Once the
floors had been cleaned, the crew began installing the RT
system. The crew worked 10–to-12-hour days for six weeks
to complete the project.
The installation went flawlessly and Papa John’s Salad
and Produce now has a new facility with a beautiful floor
system designed to keep production areas safe and clean for
many years to come. In a letter of recommendation written
after project completion, Kevin Jones wrote: “I couldn’t be
more pleased. You’ve been responsive and have delivered a
finished product perfectly suited to my needs. Your recom-
mendations were spot-on, and you accomplished the job
with little disruption to my operation.”

12 September 2010 www.pLANtSerVICeS.Com

PS1009_11_12_Works.indd 12 8/25/10 9:04 PM

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PS1009_FPA.indd 14 1 8/10/10
8/25/101:36:29 PM
9:41 PM

Keep your eye on the Ball
Visualize goals to help your team attain them
By Bob call, cMrp, life cycle engineering
close your eyes for a second and think about your ride to
work this morning. If you’re driving right now, don’t really
close your eyes. You probably remember seeing the same things
that I saw on my way to work: cell phone users who had the
phone in one hand and making hand gestures with the other,
women putting on makeup while looking in the vanity mirror
and steering with their knees, people reading papers or books
with the book propped on the steering wheel, and people
texting while driving – sorry, nobody is that good, just lucky so
far. A crazy sight, no doubt, but a sign of the times. The people
who surround us every day really aren’t concentrating on the
primary goal, which is to arrive at their destinations alive and
in one piece, while putting no one else’s life in danger.
I remember my first opportunity to be coached by my dad
in Little League baseball. His most important bit of advice
was “keep your eye on the ball.” Good advice, as it turns out.
It works for any sport involving a ball. It also is pretty useful
when you are trying to plow that first straight furrow in a
field using a distant tree or fence post as a target. It works
pretty well for Navy pilots landing on an aircraft carrier – in
fact, pilots “call the ball” to ensure the correct landing ap-
proach. And it works very well in business when you have an
important initiative underway and need to maintain focus
on the ultimate goal.
Sometimes it’s difficult to visualize what the ball is going
to look like until we finally see it. In a new initiative, no mat-
ter how well we plan and execute, it’s hard to imagine what
the finished product is going to be without some type of
visual reference. In an operating facility, there are an endless
number of distractions each day that can easily take our eyes
off the ball and pull us into another, seemingly more impor-
tant issue that will deprive the primary initiative of critical
focus and effort toward completion.
As project or initiative leaders and managers, it’s our job
to make sure that everyone involved in the project has the
same vision of what the completed project will look like.
How will we know whether we’ve succeeded? Do we have
some measure by which we will know success, or will it just
be a guess on the part of the project team?
One of the best methods I’ve seen is to place the vision or
ball in a prominent and public place in the facility, where
everyone who walks in can see clearly what the goal is. Of
course, if you’re going to do this, you also must publish some
PS1009_15_Yours.indd 15
your space
type of progress board to indicate visually how close you are
to that goal. We routinely place our simulated thermometer
visuals in the lunch room and the lobby when we are in the
middle of Red Cross campaigns or United Way fund-raisers,
anythIng you can do to MaKe
the project More VIsIBle wIll
further Increase your chances
of sustaInaBle change.
showing everyone the increase in “temperature” as we gain
in donations for the year. Why not use something similar
for an improvement project to show the cumulative savings
it generated? Anything you can do to make the project more
visible will further increase your chances of sustainable
change and improvement.
Communication and feedback to everyone is critical to
success. You don’t want to hear little sound bites around the
lunch room like “I wonder what’s going on with Project X.
They never tell us anything.” Unless your project or initia-
tive is going to result in a global disaster, there should be
no reason to withhold information or otherwise keep your
people in the dark. Information is power, and information in
the hands of employees provides the power to move a project
forward much more quickly and efficiently than any small
group or team could manage.
When you set a goal or establish a vision for the future,
you have to keep your eye on the ball. More importantly, you
want everyone’s eyes to be on the same ball. It can’t be just
your personal goal or vision. If you want real change and
improvement, it must be shared with everyone around you
to leverage the best possibility for success.
So, go out and put the ball on the project wall and then
challenge all to look at the ball on the wall and help as they
can, so you don’t fall and miss the ball. And when you reach
the end, take the ball down from the wall and reinstall it on
the Victory Wall. My apologies to Dr. Seuss.
Bob call is a principal consultant with life cycle engineering, Inc.
e-mail him at bcall@lce.com.
www.PLANTSERVICES.Com SEPTEmbER 2010 15
8/25/10 9:05 PM
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PS1009_FPA.indd 16 8/25/10 9:41 PM


OwNINg yOUr CIrCUMsTANCes
It’s the honorable thing to do
“It’s not my fault. That’s not my job. Don’t blame me.
It wasn’t my decision. I forgot. I’m too busy to get to that.
I thought I told you about that. I told someone else they
needed to do that.”
Whether it’s your teenage kids who never seem to find the
dishwasher with their dirty glasses, an automobile accident
at an intersection, or an upset at the plant, people seem to
have a set of conditioned responses. Their responses are like
reflex actions.
I’ve always valued working with people who have the
ability to recognize their roles in disheartening situations.
For the parent who is annoyed by the teenager’s inability to
find the dishwasher, the parent’s role was in not being more
insistent in communicating the importance of cleanliness
and respecting others. For the person who was involved in
an accident, that person’s role might have been not being
a defensive driver, or even the consequence of leaving the
house 30 seconds later than planned.
In a plant upset situation, the operations manager who
doesn’t own the circumstances might believe an operator
was too slow to notice a flow rate or pressure change in a
process. In this case, the operations managers who own
their circumstances consider the fact that they allowed
shortcuts to the new employee orientation program, or that
the maintenance manager asked for time to fix a flow rate or
pressure sensor alarm last month.
I value working with people who own their roles in
situations because at their core they are realists. They see
various sides of issues and usually recognize opportunities
to improve as a result. Accountable people recognize that
they and others might have had a role in the problem; they
might be the direct cause of the problem, they might have
contributed to the problem, or they might have passively
allowed it to occur.
The benefit of owning reality is that you get past blame
and excuses. When you get past blame and excuses, you can
focus on solutions.
In their book, “The Oz Principle,” Roger Connors, Tom
Smith, and Craig Hickman use the terms “above the line”
and “below the line” to define when someone acts with ac-
countability (above the line) and when that person is stuck
in what the authors refer to as the “victim cycle” (below the
line). One quote from the book I particularly agree with: “A
person who owns his or her circumstances never allows the
PS1009_17_HumanCap.indd 17
HUMAN CAPITAL
Tom moriarTy, P.E., CmrP
actions of someone or something else to keep them below
the line. Instead, the accountable person accepts whatever
ways in which his or her own behavior contributed to the
situation and sets about overcoming the circumstances, no
matter how difficult.”
To be accountable, you must accept what is. That’s reality.
Reality doesn’t care if we’re aware of it or not. Reality exists
THe beNefIT Of OwNINg reALITy Is THAT
yOU geT PAsT bLAMe ANd exCUses.
independently of our judgment and opinions. When we
don’t recognize reality or become aware of reality and try to
live by what we want the reality to be, we will most often be
discouraged or disappointed. People who don’t recognize re-
ality are easily identifiable; they are the ones who complain,
blame, judge, resent, worry, regret, control, or procrastinate.
They are below the line.
When you don’t accept reality, it’s like not knowing about
a kick-me sign on your back. You can’t understand why
people keep kicking you in the butt. When you get clued
in to reality, you have choices about what to do with that
knowledge. If you know the kick-me sign is on your back,
you can, of course, leave it there (not smart) or you can
remove the sign and stop getting booted in the butt. When
you own your circumstances, you can move beyond negative
feelings and defensive actions.
What if you recognize and accept reality, but other
persons around you don’t? Aren’t you still going to have
people blaming and playing the victim? My answer is
“probably.” But your insight will be the path toward at
least minimizing the problem. You will be in a better po-
sition to influence others and the overall situation. As a
result, whether you’re a craftsman, foreman, or manager,
you will be seen as more professional and capable than
those who don’t embrace reality.
Help others to embrace reality. When problems arise,
don’t join in the blame game. Take the high road. Look for
solutions that lead to higher value outcomes.
Tom Moriarty, P.e., CMrP, is president of Alidade Mer Inc.
Contact him at tjmpe@alidade-mer.com and (321) 773-3356.
www.PLANTSERVICES.Com SEPTEmbER 2010 17
8/25/10 9:06 PM
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PS1009_FPA.indd 18 8/25/10 9:42 PM


fleet asset management
Your cmms can be an active partner in minimizing mobile asset operating cost
most companies have a range of asset types such as equip-
ment, buildings, infrastructure, computers, and fleet or mobile
assets to maintain. Although these asset classes have much
in common, there are some key differences in the processes,
systems, and resources used to manage them.
Defining fleet/mobile assets
For our purposes, mobile assets are any motorized equip-
ment on wheels. This includes fork lift trucks, automobiles,
trucks, and tractors. The vast majority of these assets con-
sume fuel or electricity to power their movement.
Many wheeled assets aren’t powered, for example, carts,
lift trucks, wagons, and trailers. These can be used for
transport, material-handling or people-moving applications.
Without a power source and drive system, these assets are
far less complex and not all that unique in terms of mainte-
nance management requirements.
The term “fleet” implies multiple mobile assets. Sometimes
fleet assets are identical, but not necessarily. For example,
a plant can have 20 or more different types of automobiles,
trucks, and transportation assets, with different specifications,
model years, attachments, and accessories.
Processes to suPPort fleet assets
As with any asset requiring maintenance, key high-level
processes include work order management, preventive
maintenance, condition-based maintenance, spare parts
inventory management, asset lifecycle management, and
managing equipment history. But there are some interest-
ing characteristics that apply to a fleet of mobile assets. One
of the most important differentiators of fleet maintenance
over maintenance of other asset classes is the relatively high
percentage of use-based or condition-based maintenance, as
opposed to unexpected failure-based maintenance.
Although numbers vary by fleet and application, the relative
percentage is typically greater than 80% maintenance triggered
by condition or usage – time, meter, or event. This might be
explained by a number of possible factors, but perhaps the most
significant is the high consequences of unplanned failure in
terms of health, safety, the environment, regulatory penalties,
or loss of revenue. This is especially true when failure occurs in
locations that are difficult to access.
Another factor is the relatively high number of similar
mobile assets making it easier to establish industry norms, such
PS1009_19_20_AssetMgr.indd 19
asset manager
david berger, P.eng.
as use of similar technologies for brakes, transmissions, and
exhaust systems, and specialized tools and facilities such as lube
pits, vehicle paint facilities, and wash bays. Standard operating
procedures and job plans often are based on the manufacturer’s
many hours of experience across multiple industries. Job plans
provide guidance as to when and how to do various inspec-
tions and preventive maintenance procedures, once a certain
historical Data can be comPileD
to Determine the oPtimal interval
between insPections.
milestone is reached in terms of time passed since purchase,
time driven, or distance traveled.
With many similar assets in the field, historical data can
be compiled to determine the optimal interval between
inspections or when it is best to perform maintenance tasks
such as changing the oil, replacing the timing belt, and
rebuilding the engine. The bigger the fleet and the more
similar the mobile assets maintained, the easier it should be
to achieve economies of scale. At least that is the theory.
However, in practice, there’s no lack of inefficiencies in
a typical fleet maintenance shop. In my experience, this is
in part because of the usual bureaucracy of big companies,
but it’s the attitude of management and workers that largely
prevents fleet maintenance shops from achieving their po-
tential, especially in the public sector. Although contracted
service garages are far more efficient because of their fleet
maintenance focus and profit motivation, they have a repu-
tation for sacrificing quality for price.
cmms requirements for fleet maintenance
A CMMS is certainly relevant to any fleet maintenance shop;
however, there are some specialized features and functions
that are highly desirable.
VMRS codes: The American Trucking Association estab-
lished the Vehicle Maintenance Reporting Standards codes to
standardize on the hierarchy of vehicle assets in terms of sys-
tems, subsystems, and components. As well, progress has been
made in building a hierarchy of essentially problem / cause /
action codes related to the asset hierarchy. Some of the CMMS
vendors ship their systems with VMRS codes loaded and allow
users to edit the coded fields to better match their specific fleet
www.PLANTSERVICES.Com SEPTEmbER 2010 19
8/25/10 9:31 PM
 asset manager

specifications or to provide greater detail.
Fuel management: One of the largest ongoing costs asso-
ciated with maintaining a fleet is fuel, as well as costs related
to fuel consumption such as maintenance of tires, fuel
systems, and engine. Modern CMMS packages that accom-
modate the needs of fleet maintenance can track odometer
readings and fuel consumption on work orders and then use
condition-based maintenance and asset history to adjust the
maintenance plan for better fuel management.
Campaigns and product recalls: Sometimes a vehicle
manufacturer has a product recall to address a safety-
related issue. Some CMMS vendors have features to help
manage the recall, such as ensuring that all of the vehicles
are brought in for service at the appropriate time and the
work is completed by a designated date. A campaign is the
internal version of a product recall – for example, a decision
by the engineering department to replace a given part with a
superior-quality, third-party brand.
Warranty claims and tracking: Although there’s a need
for warranty
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fleet assets are typically more acute and complex. Vehicles
can have different warranties for the overall vehicle, as well
as systems, subsystems, components, and even parts. Many
CMMS vendors recognized the value of a comprehensive
warranty management system. Their software has advanced
features such as tracking multiple warranty types per asset,
handling parent/child and master warranty relationships,
favoring parts closer to warranty expirations for stock issu-
ance, and preparing a warranty claim.
Facilities scheduling: Most CMMS packages can sched-
ule work orders – matching work backlog to available labor,
parts, and tools. However, few CMMS vendors also will
help users to book an appropriate garage bay as part of the
scheduling complexity. Fleet maintenance planners need to
ensure an asset brought in for service will have the appropri-
ate facilities, such as a bay with an inspection pit, heavy duty
lift, or paint booth.
e-mail Contributing editor David Berger, P.eng., partner, Western
management Consultants, at david@wmc.on.ca.

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 The Plant Services Best
Practices Awards recognize
management techniques, work
processes, and product and
service implementations that
exemplify the definition of a
best practice, which the Society
of Maintenance and Reliability
Professionals (SMRP) defines as “a process, technique, or in-
novative use of resources that has a proven record of success in
providing significant improvement in cost, schedule, quality,
performance, safety, environment, or other measurable factors
that impact the health of an organization.”
Entries must demonstrate how to implement a best practice,
show the potential payoffs in both qualitative and quantitative
terms, and provide inspiration for those who must overcome
cultural inertia and make effective changes. Entries may be
submitted by plant personnel, vendors, engineering firms, con-
sultants or anyone who is familiar with the application and has
permission to make it public knowledge. Our 2010 categories
also include Equipment, Management, and Energy Efficiency,
but this round’s focus is on Reliability.
Every contender offered an impressive reliability practice
that can increase productivity, improve efficiency, or reduce
costs. Judging criteria included percentage reductions or
ElEcTrical audiT cuTS coSTS
Competitive necessities prompted the Crown Candy Corp.
plant in Macon, Ga., to have Arrow Hart, a unit of Cooper
Wiring Devices, audit its electrical infrastructure. Arrow Hart’s
recommendations included watertight receptacles, plugs, and
connectors for areas regularly exposed to hosedown or spray
with cleaning agents and corrosion-resistant receptacles, plugs,
and connectors for areas exposed to incidental water spray,
humidity, and airborne contaminants. Many of the receptacles
and switches needed flip covers as additional protection. Wire
mesh grips were recommended where cable and conductors
are subjected to strain. Arrow Hart recommended an industrial
motor control for areas regularly exposed to sugars and syrups.
After the upgrade, downtime caused by electrical problems
and failing equipment should be reduced, and Crown Candy
should see as much as 25% improvement in productivity.
www.crowncandy.com
chain drivE To bElT drivE convErSion
PJ Food Service, the Papa John’s Quality Control Center,
in Des Moines, Iowa, produces pizza dough for roughly
230 stores in a nine-state region. The plant uses a chain-
driven dough bowl elevator to lift 600 lb. loads 360
starts a day. While the drive operated reliably with proper
maintenance, it posed two problems. Each start delivered
a shock load to the entire system. It was tough on the
equipment and produced an uncomfortable 85-dB noise
22 September 2010 www.pLANtSerVICeS.Com
PS1009_22_24_BPA.indd 22
cost savings, return on invest-
ment, and broadness of applica-
bility, with recognition given for
innovation and creativity.
The winning practice was sub-
mitted by Jayesh Patel, reliability
manager, Valero Refinery (www.
valero.com) in Paulsboro, N.J.
By managing its equipment below the alert level, the refinery
is able to be proactive in its machinery management, allowing
Valero to mitigate reactive work and the associated process
interuptions. The results of this shift to proactive maintenance
are improved product quality, improved machinery availability,
and increased profits.
Condition monitoring is combined with decision-support
capabilities that utilize prewritten rules, as well as additional
customized rules set by Valero.
The combination allowed the refinery to schedule mainte-
nance without the additional pressure of emergency conditions,
and Valero’s successful implementation won the votes of our
judges to become this round’s best practice for reliability.
More information about this round’s entries, past entries
and winners, how to enter, and the Plant Services Best Prac-
tices Awards in general may be found at www.plantservices.
com/bestpractices.
for nearby workers. The chain had to be lubricated and
carefully cleaned twice each week. Replacing the chain
drive with a synchronous belt drive solved both problems.
The conversion produced two immediate benefits – noise
reduction and no contamination risk from the twice weekly
need to lubricate and clean the chain – and one longer-
term benefit – eliminating mechanical stress on startup.
www.papajohns.com
aquaTic EnvironmEnTal ProTEcTion
The Trenton Wastewater Treatment Plant in Trenton, Mich.,
which processes an average of 4 million gallons of wastewa-
ter per day, faced a budget shortfall. Like most government-
run operations, wastewater plants must accept the lowest
bid for any project. This means the most affordable combi-
nation of process automation hardware and software wins.
Trenton upgraded its main process control system and
power distribution system. Redundant servers running HMI
software monitors the plant’s SCADA system wirelessly
to four remote pumping stations, and now management
can troubleshoot problems immediately and remotely.
A Rockwell Automation services and support contract gives
the plant monthly on-site visits and software upgrades.
When a main server meltdown blinded the plant, within five
hours the service technician transferred plant operation to a
redundant system.
www.trentonmi.org
8/25/10 9:10 PM
 Like new, all over again.

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Plant_Services_910_u957w.indd 1 8/10/2010 9:04:23 AM
 RULES-BaSEd MaINTENaNCE
Refinery uses decision-support system in conjunction with condition monitoring
Valero’s Paulsboro Refinery in New Jersey has a capac-
ity of 195,000 barrels per day and employs nearly 550 indi-
viduals. Condition-based maintenance is used extensively
and employs a mix of permanent and portable technologies,
depending on asset criticality. Low-criticality assets are
addressed by a portable data collection system. High- and
mid-criticality assets are addressed by online systems. For
its most critical assets, Paulsboro uses GE’s Bently Nevada
continuous machinery protection systems in conjunction
with System 1 software. These assets include gas turbines,
steam-driven and motor-driven centrifugal compressors,
hydrogen reciprocating compressors, utility air compres-
sors, and liquid ring compressors for flare gas recovery. Mid-
criticality assets in the refinery’s coker unit are addressed
by the Trendmaster system, a permanently wired “sensor
bus” architecture that monitors conditions several times
per hour. Both the continuous monitoring systems and the
Trendmaster architecture are tied into System 1 software for
a unified online condition-monitoring environment.
One of the keys to Paulsboro’s success with condition-
based maintenance is its practice of managing machinery
“below the alert level.” Alarms set to notify machinery
specialists of impending problems allow uninterrupted op-
eration while appropriate actions, such as scheduling main-
tenance, planning an outage, or recommending changes to
operating or process conditions, are taken.
Managing too many alarm levels can become onerous, and
Point where impending
failure is detected is Vibration
Oil Analysis
Potenial Failure (P) 1–9 months
1–6 months Thermography
3–12 weeks
P0 P1
P2
P3
P4
P–F Interval
The P-F curve shows qualitative time relationship between potential failure (P) and functional failure (F).
The further to the left (closer to P0) one can operate for any given asset, the easier it is to plan maintenance
and lower the likelihood of surprise functional failures.
24 September 2010 www.pLANtSerVICeS.Com
PS1009_22_24_BPA.indd 24
a balance must be found in the quest to move farther to the left
on the P-F curve. One way to achieve this is by relying not only
on level-type alarms, but also on technologies that automate
the data analysis and anomaly detection processes that human
experts would use if manually reviewing data. Paulsboro has
used the System 1 software’s decision-support capabilities to
embed subject-matter expertise for a particular asset or class
of assets and detect asset problems automatically. While many
users employ the decision-support module to detect anomalies
with the rotating machinery monitored by System 1 software,
what has set the Paulsboro facility apart is its use of the system
on non-rotating assets, as well. By bringing process data from
the plant’s distributed control system (DCS), turbine control
systems, and process historian into the System 1 database,
Paulsboro is able to apply the decision-support engine in ana-
lyzing and detecting anomalies on assets for which only process
measurements are available, addressing applications outside of
conventional condition monitoring, and detecting problems in
non-rotating portions of turbomachinery.
To address this mix of conventional rotating machinery,
fixed equipment, and process-related applications, Paulsboro
uses both GE’s machinery expertise in the form of pre-con-
figured RulePaks, and its own expertise in the form of custom
rules written by the resident subject-matter experts.
“These rules are what allows us to automate the diagnostic
process,” says Jayesh Patel, reliability engineer at the Paulsboro
facility. “We’re able to test our rules on historical data to make
sure that they fire when, and only when, we want them to.”
For example, the feed filter for the naptha hydrotreater has a
direct effect on product quality and operational problems,
and as such it is critical to production. Before imple-
Quantitative PM
mentation of the decision-support system, the filters
5–8 weeks were replaced every 45 days to 90 days, but more
Audible Noise than a third (35%) were replaced under an
1–4 weeks
emergency work order. In the past two
Heat by Touch years, the filters have been replaced 10
P5
1–5 days times, and not one was under emer-
gency conditions.
P6
Smoke
It’s also important to Valero
0 days that the stack emmissions ana-
P7
lyzer results agree with those
Point where asset obtained when the emissions
stops doing what its
are analyzed by a lab. The
users want it to do is
Failure (F) System 1 software rules are
used to make sure these re-
ports are in agreement, thus
avoiding penalties.
8/25/10 9:07 PM
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AD_ALWAYS AIR_PlantServices_20100824.qxd:Layout 1 8/24/10 3:00 PM Page 1

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PS1009_FPA.indd 26 8/27/10 9:26 AM


heaT exchangeR inTegRiTy
Multiple methods confirm the integrity of tubes and tube sheets
heat exchanger flaws and fouling increase fuel and
maintenance costs and put production at risk. New choices
in heat exchanger testing, design, and materials are alleviat-
ing these concerns.
Acoustic testing: Acoustic pulse reflectometry (APR), used
in seismic studies, duct investigation, and musical instru-
ment research, is the basis for AcousticEye’s non-invasive
heat exchanger testing systems. APR measures one-dimen-
sional acoustic-wave propagation and records and analyzes
the reflections produced by changes in the cross-sectional
area of the tubular system to detect flaws. AcousticEye’s
Dolphin 2000’s technology detects leaks, wall loss, full
or partial blockages, corrosion, and fouling. The Dolphin
system’s patented software identifies defect type, location,
and severity. The user can assign thresholds for each flaw
type so that only measurements exceeding the threshold are
categorized as flaws. Before accepting or rejecting flagged
items, the technician might drill down for further measure-
ment information, including the signal graph.
Because the analysis is automated, tubes can be tested in
less than 9 sec. without the aid of experts. The Dolphin’s
speed and suitability for any tube configuration, size, or ma-
terial makes 100% inspection coverage possible. By compari-
son, traditional sampling methods, such as standard eddy
current or ultrasound testing, are more time-consuming
and require skilled professionals to interpret test results.
Helium testing: Another non-destructive approach detects
leaks in heat exchanger tubes and tube-to-tube sheet con-
nections using helium. The leak testing process from SGS,
once limited to LNG carriers, has been extended to heat
exchangers by SGS Korea. The gas is introduced into the
exchanger’s internal space and overpressurized, the gas
passes through welding flaws, cracks, and pinholes before
entering a sniper attached to a helium mass spectrometer.
An ion chamber ionizes the gas, and the ion collector sends
its signal to the indicator.
Ultrasonic testing: Corrosion depth in a tube is an indica-
tor of the exchanger’s remaining life. The heat exchanger life
assessment system (HELAS) from SGS Group measures the
ultrasonic immersion length, which is converted into the
corrosion depth inside cooling water or air-fin type tubes.
It estimates the remaining life using two extreme-value
analysis methods: minimum variance linear unbiased esti-
mate (MVLUE) and maximum likelihood (MLH). HELAS
PS1009_27_TechTool.indd 27
Technology Toolbox
Sheila Kennedy
is faster and more efficient than nondestructive ultrasonic
testing, the internal rotating inspection system (IRIS). This
measures thinning and pitting in small-bore pipes using a
probe in a flooded tube, and data is displayed and recorded
as it’s removed.
The depTh of coRRosion WiThin
a Tube is an indicaToR of The heaT
exchangeR’s ReMaining life.
Corrosion avoidance: An all-aluminum evaporator
eliminates the problem of formicary corrosion in traditional
copper-tube evaporators. Delphi’s MCHX evaporator for
indoor settings performs in condensing and evaporating
modes, while consuming 40% less mass than a competitive
product. It has a brazed aluminum construction and micro-
channel condenser technology that requires less refriger-
ant. Delphi also announced a new condenser for outdoor
applications having an optimized corrosion-resistant alloy.
The MCHX condenser, launched in 2003, was updated to
improve robustness and simplify installation.
Anti-corrosive materials: A team of scientists at MIT’s
Pappalardo Micro and Nano Engineering Laboratories
recently discovered a way to transform polyethylene into a
material that conducts heat as well as most metals, while re-
maining an electrical insulator. The material’s high thermal
conductivity could someday be applied to heat-dissipating
applications such as heat exchangers. In large quantities,
the fibers could be potentially cheaper than metals for heat
exchanger fins. So far the researchers produced individual
fibers in a laboratory setting, and they hope to produce
whole sheets of material with the same properties and inte-
grate them into real-world applications.
e-mail contributing editor sheila Kennedy, managing director of
additive communications, at sheila@addcomm.com.
RefeRence Web siTes:
www.acousticeye.com www.mit.edu
www.sgs.com www.heatexchanger-fouling.com
www.delphi.com www.netl.doe.gov
www.PLANTSERVICES.Com SEPTEmbER 2010 27
8/25/10 9:12 PM
 Electricity has long been recognized as a serious work-
place hazard, exposing employees to shock, electrocution,
burns, fires, and explosions. According to the Occupational
Safety and Health Administration (OSHA), electrical ac-
cidents rank sixth among causes of work-related fatalities
in the United States, with more than 300 deaths and 4,000
workplace injuries reported each year. OSHA statistics indi-
cate that between 2003 and 2007, more than 13,000 workers
required time off from work caused by injuries from electri-
cal accidents. The fact that most of these accidents could
have been avoided easily makes these statistics all the more
needless and tragic.
Electricity is a necessary source of energy that we depend
on for our daily functions. When it’s installed and maintained
properly, it can be controlled easily and effectively. However,
when electricity is taken for granted and there is a lack of
understanding of the hazards it can produce, non-electrical
workers are far more likely to become exposed unknowingly.
Employers should ask this simple question: Are your
employees trained to protect themselves from exposure
to electrical hazards? If you think your electrical haz-
ards are covered by your qualified electrical workers,
think again. Non-electrical workers also can face serious
electrical hazards in their daily tasks. A job as simple as
picture-hanging can be a source of dangerous electric
shock if workers are unaware of wiring behind the walls.
Examples of potential exposure to electrical hazards by
non-electrical workers include:
• Saw-cutting and core-boring concrete walls and floors
• Seismic anchoring into walls and floors
28 SEPTEMBER 2010 WWW.PLANTSERVICES.COM
PS1009_28_36_CvrStry.indd 28
• Making penetrations into
metal/wood-framed and
drywall-covered walls
and ceilings
• Working in suspended ceiling
areas where exposed electrical
hazards are present (i.e., open-
ings in electrical boxes, missing
protective covers, abandoned
circuits that are still energized).
While many employers focus on
providing comprehensive electrical
training and evaluation for their qual-
ified workers, often they overlook the
potential exposure risk to non-electrical
personnel. Because many employees and
contractors aren’t directly involved in
the maintenance and repair of electrical
systems, they’re often unaware or unmind-
ful of the potential exposure to a variety of
electrical hazards.
OSHA standards require that employees
who work near any part of an electrical power
circuit or are exposed to electrical hazards be
protected. OSHA 1910.331 through 1910.335 specify
that employers provide training to employees – both
electrical workers and non-electrical workers – who can
be exposed to electrical hazards and to offer retraining or
updating as needed to maintain safety awareness. Employ-
ers that implement electrical safety awareness training for
8/25/10 10:00 PM
 SAFETY / ELECTRICAL

WWW.PLANTSERVICES.COM SEPTEMBER 2010 29

PS1009_28_36_CvrStry.indd 29 8/25/10 10:01 PM

 safety / electrical
non-electrical employees can not only
ensure their compliance with OSHA
safety standards but, more importantly,
reduce the risk of electrical accidents
and enhance the level of protection for
all their workers.
OrientatiOn, training,
and awareness
Because many companies provide a
general orientation program as part of
the new hire process, including electri-
cal hazard awareness training along
with general workplace safety instruc-
tion is the best way to guarantee that
new employees are alerted to potential
electrical hazards. A well-designed
initial orientation enhances worker
30 September 2010 www.pLANtSerVICeS.Com
PS1009_28_36_CvrStry.indd 30
safety awareness, can help prevent
serious injury or worse, and sends a
strong message that the employer is
serious about establishing and adher-
ing to safe work practices. Keep that in
mind if you have non-electrical work-
ers that don’t have electrical hazards
awareness training and will be work-
ing in and around hazards.
An effective electrical safety and
hazard awareness program provides an
overview of potential electrical hazards,
strategies for protection and avoidance,
and instruction on company policies
and procedures that support safe work
practices. While the specific elements of
an awareness program vary depending
on the industry, facility, machinery, and
psv
equipment, a useful training curriculum
could include a variety of elements.
• General electrical awareness
• Consequences of electrical hazards
• The safety model
• Major hazards and prevention
strategies
• Lockout/tagout (LOTO) awareness
• Basic personal protective equip-
ment (PPE) awareness
• Reporting hazards to a supervisor
• Follow-up training.
Because electricity is such a familiar
part of everyday life, this powerful en-
ergy source often is used with minimal
caution and little thought regarding its
potential hazards. Workers are espe-
cially vulnerable to electrical hazards
because they’re often operating in
fast-paced situations involving intricate
machinery, power tools, crowded work
areas, and exposure to variable weather
and other environmental factors.
Because the average worker often lacks
basic electrical knowledge, a general over-
view of how electricity works is a good
place to start electrical safety awareness
training. Just as the fire triangle provides
the three elements that produce a fire –
oxygen, heat, and a fuel source – there
are three basic elements that comprise a
complete electrical circuit – a source of
energy, a load, and a complete path. The
primary goal of awareness training is to
keep workers from becoming part of this
electrical circuit.
Topics that can be used in electrical
awareness training include:
• Electrical hazard awareness (see
Safety Model):
–What is the hazard?
–What are the risks and dangers?
–How can it be controlled?
• Basic electrical terms:
–Voltage and current
–Insulators and conductors
–Alternating and direct current
–How a transformer works
8/25/10 10:03 PM
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9:46 PM
 safety / electrical
–Grounding
–Protected and exposed
–Energized and deenergized
• Ground fault circuit interrupters
and assured grounding program
• Working clearances
• Use of flexible cords and extension
cords
• Overhead power lines and under-
ground utilities
• Barriers, approach boundaries, and
signage
• Required PPE and its proper use
• Inspection process for each worker’s
tools, extension cords, and ladders.
This process can happen at the same
time that the workers are getting
their needed tools out and placing
them in their work area.
Another important topic to incor-
porate into the training is a job hazard
analysis (JHA), which allows workers to
meet at the beginning of their shift to
identify the hazards they’ll be facing in
their tasks. JHA also identifies the tasks
other workers will be doing so that
affected workers are aware of the work
going on around them. A communica-
tion process also should be included so
that if changes occur in the work or the
process, workers would be notified.
ConsequenCes of hazards
It’s essential that electrical safety aware-
ness training provide workers with a
clear understanding of the consequenc-
es of unprotected exposure to electri-
cal hazards. While the intent isn’t to
foster fear that affects productivity, the
information on electrical hazard conse-
quences should be clear and detailed to
produce a healthy respect for the effect
of direct contact with electrical current.
The following is an example of a basic
approach to explain how electric cur-
rent affects the body.
Three primary factors affect the
severity of the shock when a person is a
part of an electrical circuit.
• Amount of current flowing through
the body (measured in Amperes)
and the amount of time the current
is flowing
32 September 2010 www.pLANtSerVICeS.Com
PS1009_28_36_CvrStry.indd 32
• Path of the current through the
body
• Length of time the body is in the
circuit.
Other factors that might affect the
severity of the shock are:
• Voltage
• Moisture in the environment
• The phase of the heart cycle when
the shock occurs
• The general health of the person.
Effects can range from a barely percep-
tible tingle to severe burns and immediate
cardiac arrest. There’s a difference of less
than 100 mA between a barely perceptible
current and one that can kill.
Although the exact injuries that
result from any given amperage aren’t
known, the table on the facing page
demonstrates this general relationship
for a 60-Hz, hand-to-foot shock of one
second duration.
Under dry conditions, human skin
has high ohmic resistance, but wet skin
dramatically drops the resistance, and
wet conditions are common during low-
voltage electrocutions. If an electric shock
excites the extensor muscles, the person
might be thrown, which can result in a
fall that could kill even when electrocu-
tion doesn’t. When muscular contraction
caused by stimulation doesn’t allow the
victim to get free from the circuit, even
voltages as low as 6 mA can be dangerous,
because the degree of injury increases with
the length of time the body is in the circuit.
Low voltage does not imply low hazard.
Examples of shock-related injuries
include burns, internal injuries, and
injuries caused by involuntary muscle
contractions. Electrical burns, the most
common shock-related injury and often
one of the most serious, are the result of
heat generated by the flow of electric cur-
rent through the body. High temperatures
near the body produced by an electric
arc or explosion cause arc or flash burns.
Thermal contact burns occur when skin
comes in contact with overheated electric
equipment, or when clothing is ignited in
an electrical incident.
Electricity flowing through the body
can cause serious damage to internal
8/25/10 10:04 PM
 safety / electrical

CUrrent level proBaBle effeCt on hUman Body

1 ma Perception level. Slight tingling sensation.
Still dangerous under certain conditions.
5 ma Slight shock felt; not painful but disturbing. average
individual can let go. However, strong involuntary reac-
tions to shocks in this range might lead to injuries.
6-30 ma Painful shock, muscular control is lost. this is called
the freezing current or “let-go” range.
50-150 ma extreme pain, respiratory arrest, severe muscular
contractions. individual can’t let go. Death is possible.
1,000-4,300 ma Ventricular fibrillation (the rhythmic pumping action of
the heart ceases). Muscular contraction and nerve
damage occur. Death is most likely.
10,000 ma cardiac arrest, severe burns and probable death.

organs, including hemorrhage or internal to emphasize that risk evaluation is an

bleeding, tissue destruction, and nerve or
muscle damage. Internal injuries might
not be immediately apparent to the vic-
tim or observers; however, left untreated,
they can result in death. Muscles contract
violently when stimulated by excessive
electricity. These involuntary contrac-
tions can damage muscles, tendons,
and ligaments and might even cause
broken bones. If the victim is holding an
electrocuting object, hand muscles might
contract, making it impossible to drop the
object to avoid prolonging contact with
the current. Injury or death might result
when violent muscle contractions cause
workers to fall from ladders and scaffolds
or strike other objects inadvertently.
the safety model
Introducing the classic safety model as
part of an electrical hazard awareness ori-
entation gives employees a framework for
safe work practices and encourages them
to understand their jobs well enough to
avoid the potential pitfalls of working
with or around electricity. The safety
model directs employees to:
1. Recognize the hazards in their envi-
ronment to avoid or control them. Dis-
cussion and planning with supervisors
and co-workers can increase awareness
of less obvious hazards and reduce the
risk of injuries for all.
2. Evaluate the risk of injury from each
identified hazard to apply the appropri-
ate method of control. It’s important
ongoing process because of constant
changes in the workplace, such as shift
changes and variability in weather.
3. Control hazards based on the evalu-
ation of risks associated with each job
and worksite. Methods of control might
range from posting warning signs in a
work area or replacing frayed extension
cords to bringing in qualified electri-
cal workers to execute more technical
safety procedures, such as locking out
and tagging electrical panels before
maintenance is done.
The safety model is a common-sense
approach to electrical safety awareness
that can establish a mindset of alertness
and vigilance in all workers and en-
courage consistent, safe work practices.
major hazards and appropriate
prevention strategies
Effective electrical safety awareness train-
ing should address the major hazards that
employees encounter and appropriate
strategies for avoidance or prevention.
While each facility has specific risks,
machinery, and other factors, OSHA
compiled a list of the hazards that cause
the most frequent electrical injuries.
Contact with power lines: Overhead
and buried power lines are especially haz-
ardous because they carry extremely high
voltage. Possible strategies to minimize
risk could include calling the local utility
to deenergize and ground the power lines
or to protect the overhead power lines

www.PLANTSERVICES.Com SEPTEmbER 2010 33

PS1009_28_36_CvrStry.indd 33 8/25/10 10:08 PM

 safety / electrical
with insulation, training workers as spot-
ters, using a service to locate the under-
ground power lines, requiring employees
to maintain a distance of at least 10 ft. from
power lines, and providing non-conductive
wood or fiberglass ladders when working
near power lines.
ITT.
Lack of ground-fault protection:
Regular and repeated use of electrical
for a total savings of 20 to 60 percent. For more information, call 1-800-734-7867, or visit ittpps.com. Think about
equipment can cause wear and tear that
results in insulation breaks, short circuits,
and exposed wires. Without protection, a
We’ll assess your system, perform upgrades, and cut your energy costs while improving reliability—
ground fault can send current through a
worker’s body, causing serious injury and
possibly death. Employees who regularly
To straighten out unnecessarily complex pump systems, call Energy Performance Services from ITT.
use power tools and other electrical equip-
ment should receive awareness training
about ground-fault circuit interrupters and
the assured grounding program. They also
should be trained to inspect all electri-
cal equipment visually before use and to
remove from service any equipment with
frayed cords, missing ground prongs, or
cracked tool casings.
Equipment not used according to
manufacturer’s requirements: If electrical
Inefficient pump system?
equipment is used in ways for which it’s
not designed, employers can no longer de-
pend on the manufacturer’s built-in safety
features. Common examples of misuse
include attaching ungrounded, two-prong
adapter plugs to three-prong cords and
tools; using modified cords or tools, such
as removed ground prongs, face plates, or
insulation; and using tools with worn insu-
lation or exposed wires. Employees should
be strongly advised in electrical safety
orientation to use equipment according
to the manufacturer’s instructions and
to refrain from modifying cords or using
them incorrectly.
Improper use of extension and flex-
ible cords: The normal wear and tear on
extension and flexible cords can loosen or
expose wires, producing hazardous condi-
tions. Cords that aren’t three-wire type,
not designed for hard-service, or have been
34 September 2010 www.pLANtSerVICeS.Com
PS1009_28_36_CvrStry.indd 34
modified increase the risk of contacting
electrical current. Also, improper use of
extension cords, such as anchoring them
with nails or staples, can pose a serious
risk. To avoid these common problems,
workers should be trained to inspect cords
continually and remove from service or
report to their supervisors cords that have
been modified or found not to be marked
for hard or extra-hard use. Employees also
can extend the life of cords by removing
them from receptacles by pulling on the
plugs, not the cords.
Lack of appropriate barriers and
warning/caution signs: Since many
employees who aren’t qualified electri-
cal workers face exposure to electrical
hazards every day, they should be trained
and encouraged to recognize risks and
respond appropriately to protect not only
themselves but also their coworkers. One
of the most obvious safety precautions
employers can take is setting up barri-
ers or warning signs to alert employees
to potential danger. Unfortunately, they
are sometimes overlooked. While non-
electrical workers don’t have the technical
training to correct many electrical hazard
situations, they should be trained not
only to heed barriers and warning signs
but also to alert management of the need
for barriers or signs when they recognize
potential danger.
LOtO and PPe
Lockout/tagout (LOTO) refers to a specific
process to safeguard employees from the
unexpected energization or startup of
machinery and equipment, or the release
of hazardous energy during service or
maintenance activities. An authorized
qualified electrical employee turns off and
disconnects the machinery or equipment
from its energy sources, locks and/or tags
the energy-isolating devices to prevent
the release of hazardous energy, and takes
steps to verify that the energy has been
8/25/10 10:08 PM
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PS1009_FPA.indd 35 8/25/10 9:47 PM


Get more out of it by
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36 SEPTEMBER 2010 WWW.PLANTSERVICES.COM
PS1009_28_36_CvrStry.indd 36
D far greater costs in injuries, liability, and
B
A After the initial orientation on electri-
C cal safety and hazard awareness, it’s vital
E to follow up with periodic updates as
F
G workplace that could affect their work.
A ) Full & half-height side/back panels
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©2010 Pentair Technical Products
isolated effectively. Affected employees are
required to use the lockout/tagout process
also. Employees should be trained to recog-
nize a locked and tagged electrical source
and to understand how the LOTO process
affects their specific work areas.
Employers are required to train qualified
electrical employees. Although non-
electrical employees shouldn’t be working
on electrical systems, they are nonetheless
often exposed to electrical hazards, and
should be wearing the same level of PPE
that the electrical workers wear. Offering a
brief overview of PPE with a demonstration
of the proper use of basic equipment might
prove beneficial, especially in case of an
electrical emergency.
REPORTING HAZARDS AND FOLLOW-UP
TRAINING
One of the most important aspects of
electrical safety awareness training is to
encourage employees to alert supervisors of
any concerns they have regarding potential
electrical hazards. Employees often feel
intimidated and reluctant to rock the boat,
but employers who encourage open com-
munication know that accident prevention
isn’t only the right approach, but a practi-
cal one as well. A company might sustain
lost time by ignoring employee concerns
than they would incur by listening to their
frontline workers and taking appropriate
protective measures to prevent accidents.
needed to maintain a safety mindset. Em-
ployees need to be notified on a regular
basis of changes in or additions to their
Electrical safety awareness information
can be incorporated as part of regular
staff meetings. Emergency response
preparedness also is a vital component of
hazard awareness, and basic drills should
be conducted so that employees are ready
for emergencies, including electrical.
Michael Sa is a safety consultant with the
OSHA Training Center. Contact him at otc@
clpccd.org and (866) 936-6742.
8/25/10 10:09 PM
 3 models
to choose from
mIT 510/2, 520/2
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PS1009_FPA.indd 37 8/25/10 9:47 PM

 RELIABILITY
GOES GREEN
FOR ROTATING
EQUIPMENT
Four innovations can help you
meet sustainability goals
By Paul Michalicka, SKF USA, Inc.

Energy-conserving rotating equipment components and

advanced maintenance technologies can help an enterprise meet its
environmental objectives and achieve greater overall sustainability.
Benefits include more efficient use of energy and raw materials, re-
duced waste in manufacturing processes, minimized environmental
assaults, and reduced carbon and other emissions.
Plant managers, maintenance professionals and others charged
with improving sustainability have a greater range of options
available than ever before. These include rolling bearings and
bearing units that are optimized for low-friction, energy-con-
serving operation, highly accurate lubricant-dispensing systems,
and laser-equipped alignment instruments.

ULTRA-EFFICIENT ROTATING COMPONENTS

Shaft bearings directly affect a plant’s productivity, energy use,
and overall sustainability. As more attention has focused on sus-
tainability during the past decade, technical innovations result in
new generations of highly efficient rolling bearings.
One example is energy-efficient deep-groove ball bearings de-
signed for light- and medium-load applications in electric motors,
pumps, conveyors, and fans.
Equipped with an optimized internal geometry, these bearings
consume 30% to 50% less energy than standard deep-groove ball
bearings in similar applications.
Their low-friction performance was confirmed by tests
conducted on a 3-kW electric motor. The free running time of
various bearings was measured after power to the motor was
switched off. The energy-efficient bearings ran 50% longer after
power shutdown than standard deep groove ball bearings.
Energy-efficient deep-groove ball bearings are shielded on
both sides and equipped with a snap-type cage made of a temper-
ature-resistant glass fiber-reinforced polymer. The bearings are
lubricated with a low-noise, low-friction grease.
In addition, you can upgrade to lubricated-for-life bearing units
designed for food-industry and related applications. These bearing
units reduce grease consumption during the bearing’s lifecycle and

38 SEPTEMBER 2010 WWW.PLANTSERVICES.COM

ps1009_38_43_pwrtrans.indd 38 8/25/10 9:20 PM

 Your equipment is your businesses’
lifeblood. Don’t let unexpected downtime
destroy your bottom-line. Routine inspections
and scheduled maintenance reduce the
likelihood of production failure. But when the
unpredictable happens and you’re down,
call Martin for unbelievable response to your
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products in the USA for nearly 60 years. Our
dedication to quality and service allows us
to offer the most reliable line of replacement
products in the industry.

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• Heavy Duty Conveyor Pulleys • Sintered Metal • Plastics
• Industrial Hand Tools • Custom Commercial Forgings
For More Information Contact Your Nearest Martin Distributor

PS1009_FPA.indd 39 8/27/10 10:05 AM

 reliability / power transmission
prevent grease from entering the waste stream.
In one case, a company in the northwestern United States
replaced cast-iron pillow blocks with lubed-for-life bearing
units on its multi-lane sorting machinery used for apple pro-
cessing. The conventional pillow blocks had sustained rusting
and lubricant washout and had a life expectancy of only three
months. The new bearings featured corrosion-resistant com-
posite housings.
After the test period proved successful, the company spec-
ified the lubed-for-life composite units as drop-in replace-
ments for the conventional cast-iron units. The composite
units feature specially coated insert bearings and stainless
steel sealing components. They withstand high-pressure
washdowns without purging grease and are lubricated with
USDA-approved food-grade grease.
Equipped with these bearing units, the upgraded apple
sorters have operated for a full year without requiring any
bearing-related service.
Studies estimate that, in a typical application, these lubed-for-
life units save more than 100 oz. of grease per unit annually. De-
pending on the number of units, in a single year a plant can keep
many thousands of ounces of grease out of the environment.
Waste-reducing lube dispensers
Most bearings require periodic relubrication. For reasons
of productivity and sustainability, it’s important to follow
correct lubrication practices and avoid underlubricating or
overlubricating.
Underlubrication can cause metal-to-metal contact between
bearing components and eventual bearing failure. Overlu-
brication causes churning, which results in higher operating
temperatures and lubricant degradation. On the macro level,
excessive lubrication throughout a plant increases lubricant
consumption and waste.
Automatic dispensing systems can keep lubricant usage
under control. They deliver a steady flow of lubricant di-
rectly to machine points, supplying just the right amount of
lubricant needed.
One popular type of single-point lubricator is a self-
contained, electromechanically driven unit consisting of a
battery-operated motor and a lubricant canister. The canis-
more resources at www.plantservices.com
tOpic searcH
selection algorithm “selecting the right bearing”
Wooden bearings “pick bearings off a tree”
graphite-metal bearings “five bearing killers”
powertrain pdm “avoid the rolling thunder”
bearings “How to not ruin fan bearings”
for more, search www.plantservices.com using the
keywords alignment, bearing, and lubricant.
40 September 2010 www.pLANtSerVICeS.Com
ps1009_38_43_pwrtrans.indd 40
getting it straigHt tHe first time
figure 1. a handheld laser shaft alignment tool can provide real-
time alignment values.
ter can hold 250 ml of either grease or oil. When activated,
the motor drives a piston that dispenses the lubricant at the
preset user-selected rate. This single-point lubricator can be
mounted remotely to lubricate bearings in areas with high
temperatures or excessive vibration.
Higher-capacity, multi-point lubricators are intended for
heavy-duty applications such as hot gas fans and calendar
rolls in paper mills. These systems distribute grease or oil
from a central canister through as many as eight feed lines.
Manual relubing is still the norm in many applications. It
can be difficult, however, to measure the amount of grease
injected using manual methods. Grease meters can provide
a sustainable solution. They can measure grease quantities
by volume or weight accurately and display the amounts on
built-in screens. They’re usually compatible with a variety of
grease guns and pumps.
green lubricants
Lubricant formulation represents another sustainability issue. A
growing number of biodegradable “green” greases are available
for applications if environmental contamination is a concern.
One such lubricant, a low-toxicity, synthetic ester oil-based
grease, is designed for water treatment, irrigation, agricultural,
forestry, construction, mining, and other such applications.
The grease, intended for use in ball and roller bearings
and spherical plain bearings, complies with government
regulations on toxicity and biodegradability. It exhibits good
performance in low-temperature startups and has superior
corrosion-inhibiting properties.
HigH-accuracy alignment instruments
The shafts on rotating machinery must be aligned properly
to maximize mechanical efficiency. Shaft misalignment and
related problems impair productivity and consume additional
8/25/10 9:21 PM
 FLIR’s Mission
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PS1009_FPA.indd 42 8/25/10 9:48 PM

 RELIABILITY / POWER TRANSMISSION

resources. Advanced alignment tech- lbs., consuming only 20 kVA of electric- nents are demagnetized automatically
nologies can improve and simplify the ity – a 50% reduction compared with after the heating cycle is complete.
alignment process. conventional induction heaters. Modern
A laser-equipped shaft alignment heaters have ergonomically designed Paul Michalicka is a sales manager for
tool, for example, displays live alignment yokes with a sliding arm, which allows SKF USA, Inc., in Lansdale, Pa. He can be
values, simplifies making instant adjust- users to load components without lifting reached at Paul.Michalicka@skf.com and
ments and corrections (Figure 1). This and removing the yokes. The compo- (416) 299-2894.
allows alignment to be completed more
quickly than with traditional methods.
The tool’s “soft foot” function verifies
that machine mountings are stable and
secure. The alignment values and set- The NeW
tings in these units can be stored easily
and uploaded via USB cable to a PC. INDUSTRIAL REVOLUTION:
A major food and beverage manu- it’s about MaXiMiZiNG PRoDuCtiVitY & saFEtY
facturer found that vibration analysis
revealed that alignment problems were
tHRouGH 5s VisuaL MaNaGEMENt
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plant used laser alignment instruments sPRaYoN® sYstEM MaGNEtiC CaN HoLDERs
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After the pumps and motors were is always used and improving productivity.
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by 30 kW per day, netting an annual
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WWW.PLANTSERVICES.COM SEPTEMBER 2010 43

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 Oscillation Sensation
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BAF_PlantServices_Pivot180.indd
PS1009_FPA.indd 44 1 8/17/10 9:49
8/25/10 2:39 PM
PM
 HVAC/R refrigeration coils are leaking at an alarming rate IT’S THE WATER
in industrial, commercial, and residential applications. While
the reasons are many, chemicals ranging from household clean-
ers to industrial process compounds are the main culprits that
produce leaks and pitting corrosion on all types of coils.
Many HVAC manufacturers, distributors, and contrac-
tors might not realize that corrosion caused hundreds of
thousands of coil failures during the past decade. The source
is environmental pollutants, household cleaning agents,
pesticides, formaldehydes, building materials, and even off-
gassing of food. Each contamination source can corrode coil
tubing in a year or less, if the conditions are right (Figure 1).
For example, refrigeration coils in a South American fruit
processing plant’s banana room were continually failing.
Figure 1. Continuous contact with contaminated condensate
The chamber used ethylene gas to ripen the fruit. Byprod- caused this corrosion.
ucts from the gas generator combined with moisture in the
ripening area to form a weak acid that produced pinhole SEA TO SHINING SEA
leaks in the coil tubing after a year or less.
Also, most coastal area HVAC equipment is bombarded
with corrosion caused by ocean salt (Figure 2).

TYPES OF COIL CORROSION

The most common forms of coil corrosion are pitting and
formicary corrosion. Both can occur in as little as a few
weeks, but most corrosion begins appearing within a one-to-
four-year period. The ability to distinguish pitting from for-
micary corrosion might help detect and eliminate the cause.
Pitting corrosion (Figure 3) is typically caused by chlo-
rides or fluorides. Chlorides are found in snow-melting
crystals, toilet bowl/tile cleaners, dishwasher detergents,
fabric softeners, vinyl fabrics, carpeting, and paint strippers. Figure 2. This corroded coil is from a coastal area.

WWW.PLANTSERVICES.COM SEPTEMBER 2010 45

PS1009_45_48_hvac.indd 45 8/26/10 10:56 AM

 Reliability / HVAC
Fluorides are used in municipal water treatment. Pitting
usually is visible to the naked eye on the exterior of a copper
tube. It’s caused by chloride/fluoride ions that condensate
carries to the metal surface. The cations attack the oxide
film the metal uses to protect itself, essentially forming a
corrosion-driven battery that consumes the copper. Once
pits form, they progress through the tube wall forming a
pinhole that leaks refrigerant.
Formicary corrosion (Figure 4), on the other hand, is
caused by organic acids. Acetic acid is abundant in numer-
ous household products such as adhesives, paneling, particle
board, silicone caulking, cleaning solvents, vinegar, foam
insulation, and dozens of other products. Formic acid can
be found in cosmetics, disinfectants, tobacco, wood smoke,
latex paints, plywood, and dozens of other materials. The
corrosion these substances cause usually isn’t visible to the
naked eye, although black or blue-gray deposits sometimes
appear. Formicary corrosion produces a network of micro-
scopic tunnels within the tubing wall. It resembles ant nest-
type structures that are substantially larger than the surface
pinholes. Eventually, one or more progresses to the surface
and forms a pinhole, which quickly results in coil leakage.
46 September 2010 www.pLANtSerVICeS.Com
PS1009_45_48_hvac.indd 46
Choosing the Right Coating
When confronting coil corrosion, first determine if it will
recur after replacement. It’s difficult to know if corrosion is a
one-time phenomenon or a continuing problem in that loca-
tion. In the case of the banana processing plant or a coastal
area unit, coils most likely will corrode continually, and
their replacement units should have a protective coating.
In less corrosive environments, you can attempt to pre-
vent corrosive materials from entering the return air stream.
You can store these materials in areas far from a return duct.
This might eliminate the need to coat a replacement unit.
Choosing the most appropriate coating could save thou-
sands of dollars and eliminate repeat treatments. The wrong
coil coating could degrade heat transfer and lead to higher
energy bills. Heat transfer is a major concern when coating a
coil, especially in a retrofit, because the coil might no longer
perform at its design specification. The thinner the coating,
the better the heat transfer. Another concern is the coating’s
hydrophobicity, or how well it sheds condensate. Ideally, water
would drain off of the coil quickly. Surface water accumulation
is detrimental because it can lead to mold and mildew. Most
coatings don’t resist biological growth, but high hydrophobicity
can passively deter such growth.
the ChoiCes
The four most prominent HVAC coatings are polyurethanes,
epoxies, fluoropolymers, and silanes. Each offers differing
corrosion resistance, scratch resistance, flexibility, weight,
thickness, hydrophobicity, and heat transfer.
Polyurethane (PU), invented in the 1940s, can be manu-
factured as hard as fiberglass, bouncy as rubber, sticky as
glue, and soft as upholstery foam. Many off-the-shelf PU-
based coil coatings can be field-applied. PU formulations are
fairly inexpensive, less viscous, more flexible, and thinner
– typically 25 microns to 50 microns – than most coatings.
But, they aren’t as resilient or long-lasting as other coatings.
Epoxy, or phenolic-based, coatings generally are the
cheapest. Developed in the late 1920s, they’re known for
excellent chemical and heat resistance and often are used
for coating floors and other surfaces. The high viscosity of
epoxy-based systems leads to thicker coatings – approxi-
more resources at www.plantservices.com
toPiC seaRCh
hePa filters “Waging the battle against dirty air”
Chiller tips “10 tips for improving chiller efficiency”
Finance “selling your hVaC project”
Refrigeration “10 cooler ideas”
Reheat coils “Watch those hVaC reheat systems”
For more, search www.Plantservices.com using
the keywords acid, corrosion, and refrigeration.
8/26/10 10:56 AM

Go deep
Figure 3. This cross-section shows the results of pitting corrosion.
mately 50 microns to 100 microns – with poor flexibility and
adherence. Epoxy is difficult to apply in the field. Typically,
the coil is disconnected and shipped to a contractor or OEM
for treatment. Because they’re thicker, epoxy coatings reduce
heat transfer, system efficiency, and capacity. Epoxy coatings
might best suit new installations where heat transfer losses
PS1009_45_48_hvac.indd 47
Reliability / HVAC
invisible to the naked eye
Figure 4. This cross-section shows how deep-seated formicary
corrosion can penetrate a copper tube.
are accounted for in the system design specifications.
Fluoropolymers, first developed in 1938 by DuPont, are
available in many forms under a variety of trade names.
They’re known for their high resistance to acids, solvents,
and bases. They’re most effectively applied to metal
through electrostatic powder coating or by a thermal sin-
www.PLANTSERVICES.Com SEPTEmbER 2010 47
8/26/10 10:56 AM
 Reliability / HVAC

tering, as is done for cookware and fluoropolymer-based field-use coatings haven’t gained traction in the industry
other non-stick products. typically is less than the more ad- because of the expense and the inabil-
Additionally, many field-applied vanced epoxy- and PU-based coatings, ity to apply those coatings in the field.
fluoropolymer sprays are available. but the lifetime and effectiveness are Silanes are excellent coupling agents
These sprays generally have poor ad- limited. Fluoropolymer coatings ap- that can bond dissimilar materials such
hesion, and their effectiveness quickly plied in the correct manner, through as paint (an organic material) and glass
diminishes significantly. The cost of thermal sintering or electrocoating, (an inorganic material). A variety of
silanes are available, many of which are
tailored for particular characteristics such
as flexibility, hydrophobicity, and scratch-
resistance. Thus, a properly formulated
FREE Hotel Nights and Spouse Pass for Early Bird silane coating can provide a flexible,
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copper (an inorganic material). Silanes
form an extremely thin coating – less
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to apply properly in the field if you’re not
a trained applicator. The coil surfaces
Our Keynote Speaker is Special guest apperance by must be cleaned thoroughly and prepared
America’s most trusted Sig Hansen, Capt. F/V NorthWestern properly for a successful application, and
contractor, Mike
Holmes, host of Bally’s Hotel, Las Vegas, therefore it’s best if the coating is applied
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off-site. Although silane coatings typi-
cally are somewhat more expensive than
the other coatings, they also exhibit the
best heat transfer properties and typically
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each day tection from the environment and has
maintenance, energy auditing,
building diagnostics, condition • Exhibits & networking events minimal effect on heat transfer while
monitoring, machine vision and • Renew your ITC certification remaining a long-lasting barrier that
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and gas detection, R&D, thermal Breakfasts, lunches, and gala sion for an extended time – typically
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five years or more.
Each coating technology carries
different levels of toxicity. A service
technician who is planning to apply
Register online now at www.inframation.org any of these coatings in the field
or call us at 866.872.4647 should be outfitted with proper OSHA
equipment and the appropriate breath-
ing apparatus.

Joshua D. Sole, Ph.D., is senior mechani-

cal engineer and alan H. brothers, Ph.D.,
is senior materials engineer at Mainstream
engineering Corp., Rockledge, Fla. Con-
tact them at (321) 631-3550.

48 September 2010 www.pLANtSerVICeS.Com

PS1009_45_48_hvac.indd 48 8/26/10 10:57 AM

 in the trenches

Driven to Drink
Acme learns what happens when an employee overindulges

Bo Degas was Acme’s regional sales manager operating

out of the company’s home office in Acmeville, a small town
at the end of the only railroad right of way in the county. His
job was to sell to and maintain good relations with some of
the larger customers in the state. He either drove to his ap-
pointments or flew out of the local airport, as appropriate.
A few years ago, Bo chaired the committee that implemented
Acme’s first codified standard operating practices. Among
other guidelines, the document said that a violation of any
federal, state, county, or municipal law constitutes grounds for
immediate dismissal of any Acme employee involved.
After work every Friday, Bo attended a gathering of his
fraternal lodge brothers at which he ate dinner and drank
the group’s famous barley wine. He always left his company
car with its identifying logo in a prominent location in the
lodge’s parking lot.
During the drive home one evening, Bo rear-ended an-
other vehicle, which wrecked his car and sent the passengers
of the other vehicle to the hospital. Bo’s blood alcohol level
was measured at the scene as 0.23 g/L, several times the
state’s legal limit. This triggered an immediate suspension of
his driver’s license.
On Saturday morning, he called Shannon D’Ore, his
supervisor, to tell her that he was involved in a vehicle ac-
cident, that he wasn’t hurt, and that he’d be in to work on
Monday morning.
On Monday, Bo gave Shannon more details about the ac-
cident and revealed that he might be charged for driving un-
der the influence of alcohol. Bo swore that he didn’t have an
alcohol problem, but Shannon suggested he take advantage
of Acme’s employee assistance program (EAP) for referral to
appropriate treatment, just in case. Bo agreed and enrolled
himself that morning.
Small towns being what they are, the newspapers began
making a big deal about the story of the DUI executive.
Later on Monday, Shannon contacted several Acme em-
ployees to ask if they would be interested in driving Bo on
some of his rounds to the local clients. None volunteered
for that job.
Late Monday afternoon, Shannon conferred with Acme’s
operations vice president to discuss Bo’s situation. They noted
his more or less frequent arguments with coworkers and his
apparent memory lapses. They concluded that Bo should be
placed on paid administrative leave until things settle down.
Bo was diligent about giving Shannon a daily update on
his progress with the EAP counseling and alcohol rehab.
Bo’s wife chauffeured him to and from work until his
driver’s license was returned to him.
The following Monday, Shannon sent Bo a registered let-
ter to inform him that he was terminated based on factors
that each justify termination. Shannon cited Bo’s various
documented errors in judgment, his inability to perform
the assigned work for lack of a driver’s license, and conduct
unbecoming an executive at Acme’s home office.
Bo replied that he hadn’t been convicted of the DUI and the
license had only been revoked temporarily. Nevertheless, Bo
filed a suit under the ADA, claiming that Acme discriminated
against his disability – alcoholism – and refused to provide him
any reasonable accommodation for his condition.
How could this situation have been prevented? Is this a case
of trying to dodge personal responsibility for one’s actions?
Would it have made any difference if Bo found his own ac-
commodation for a missing driver’s license? Does having an
employee assistance plan constitute sufficient accommoda-
tion? How closely should a company monitor an employee’s
off-hour activities?
A PLAnt enGineer sAYs:
This situation could have been prevented if Bo didn’t drive
while under the influence of alcohol. I believe he’s trying to
dodge personal responsibility for his actions. Acme has clear

www.PLANTSERVICES.Com SEPTEmbER 2010 49

PS1009_49_51_Trench.indd 49 8/25/10 9:13 PM

 in the trenches

standards in place concerning conduct. If Bo didn’t want to
abide by those standards, he should have left when they were
put in place. Does a company not have the right to expect
a certain standard of behavior for its executives? Bo drives
a company vehicle with the company identity on the side.
That carries a greater level of responsibility than most others
who work for the company but drive their own vehicles. Bo’s
if not most, companies. If Bo were operating a powered
industrial lift and had an accident, he’d have been tested for
drugs and alcohol. If the test were positive, he would have
been let go. The same standard should apply to those driving
company vehicles. Bo must go.
Jeffrey L. strasser, Bacova Guild
(540) 863-2656, strasser.jeff@bacova.com

how cLoseLY An eMpLoYer shouLD An AcADeMiciAn sAYs:

Both alcoholism and drug use are considered disabilities
Monitor An eMpLoYee’s off-hour AnD
and are covered by the Americans with Disabilities Act,
off-preMises conDuct hAs Been the and the employer must provide “reasonable accommoda-
suBJect of Much DeBAte. tion,” including adjustments to the work schedule to allow
for ongoing treatment, as well as adjustments in job duties.
However, the “disabled” worker is to be held to the same
driving status isn’t the case here. It’s the actions that led up work standards as workers who aren’t disabled, and failure
to the accident that are important. Having someone drive to perform at these standards is grounds for dismissal.
Bo isn’t the answer. Bo living up to company standards is. Acme’s process for handling Bo is pretty standard – a
People who operate company vehicles, whether automo- warning from HR, then a referral to an alcohol treatment
biles, trucks, or powered industrial lifts, can’t be allowed to facility, and then some way to monitor the employee’s par-
operate those vehicles while under the influence of alcohol ticipation in treatment. However, Acme might have been a
or drugs. ToAWdo
3640 halfso isadan
Horz for offense worthy
Ind Hyg News FINAL.pdfof1 dismissal in many,
6/29/2010 1:27:36 PM little quick to terminate Bo. He was on administrative leave

PS1009_49_51_Trench.indd 50 8/25/10 9:14 PM

 during the treatment, and thus Acme couldn’t determine
whether his behavior, after a reasonable time in treatment,
actually met Acme standards. My suggestion would have
been to bring Bo back to work, maybe with adjusted work
duties, after he completes a specified time in treatment and
monitor his performance. If he doesn’t meet standards post-
treatment, then termination is appropriate.
Professor Homer H. Johnson, Ph.D., Loyola University Chicago
(312) 915-6682, hjohnso@luc.edu
AN ATTORNEY SAYS:
As this scenario indicates, dealing with an employee having
an alcohol problem or predilection can be tricky. Even if
alcoholism is protected as a disability under state or federal
law, an employer need not take unreasonable measures to
accommodate an employee. It would be unreasonable to
allow an alcoholic to work while under the influence or to
let him drive a car while intoxicated or without a license, for
example. The most likely kind of accommodation an em-
ployer would be required to provide an alcoholic employee
would be a leave of absence to obtain treatment. Acme pro-
vided Bo with a leave, but while he was on leave, it reconsid-
PS1009_49_51_Trench.indd 51
ered the situation and made a decision to terminate him for
conduct unbecoming an executive. These issues can arise in
a variety of circumstances – an employee arrested for child
abuse, for example – when the wrongdoing has no relation-
ship to the employee’s work or his ability to perform the job
but merely affects the company’s reputation. There’s no law
that precludes an employer from terminating an employee
who has engaged in conduct reflecting adversely on the
employer. But if Bo could prove that Acme didn’t terminate
another employee who engaged in similarly inappropriate
conduct who was not an alcoholic, it would add fuel to his
ADA claim. How closely an employer should monitor an
employee’s off-hour and off-premises conduct has been the
subject of much debate. When employers began terminating
employees for overeating or smoking, for example, various
states passed laws to combat that trend. Typically, those
laws prohibit an employer from terminating an employee
for engaging in legal conduct while off work. But in the last
analysis here, Bo has no one but himself to blame for driving
under the influence and causing physical injury.
Julie Badel, partner, Epstein Becker & Green, P.C.
(312) 499-1418, jbadel@ebglaw.com
8/25/10 9:15 PM
PS1009_FPA.indd 52 8/25/10 9:49 PM
 product focus

fast-cure adhesive anchor

system meets the latest
building codes
HIT-HY 150 MAX fast-
cure adhesive anchor
system improves
productivity and fully
cures in 30 minutes at 68°
F. It meets ICC-ES Ac-
ceptance Criteria AC308
for anchoring and rebar
capture and analyze machinery problems applications and is designed
The Vibxpert II is rugged and lightweight, and it combines for use in uncracked concrete. It provides reliable fastening
a rapid processor with a color VGA display. It offers Fmax with in-service base materials up to 248° F (with appropri-
of 51 KHz and 102,400 lines of resolution. The one-channel ate reduction). It is compliant with the 2003/2006 IBC and is
device can be upgraded to two individually configured packaged in foil packs.
channels without hardware changes. Collect and store 8 GB hilti
worth of vibrations, bearing conditions, process data, and (800) 879-8000 / www.us.hilti.com
visual inspection information for report generation and
transfer to Omnitrend software for further analysis, report-
ing, and archiving. An icon-driven platform offers com-
prehensive functionality diagnosising vibration problems.
Capabilities include order spectrum, phase, cepstrum, cross-
channel phase, orbits, run-up and coast-down measure-
ments, bump test, and negative averaging.
ludeca
(305) 591-8935 / www.ludeca.com

auto-darkening helmets
Use these Miller Electric Digital
Elite Series auto-darkening weld-
ing helmets for welding, cutting,
and grinding. The Digital Elite
series also switches between
four modes – welding, cutting,
grinding, and X-mode – while
retaining the user’s prefer-
ences for shade, sensitivity,
and delay. The X-mode
uses four independent arc
sensors to sense the arc
electromagnetically in 50
msec, providing full protec-
tion when there’s an arc present, but the sensors are obstructed.
It’s available in three graphic designs, as well as in a standard
black. Weighing in at 18 oz., the helmets come with five outside
and two inside replacement cover lenses.
miller electric mfg. co.
(800) 426-4553 / www.millerwelds.com
designed for multiple cleaning challenges
StoneAge’s 3-D Torus for tank cleaning is designed for mul-
tiple cleaning challenges. It operates under pressures from
2k psi to 22k psi by simply changing the manifold and inlet
coupling. Four inlet couplings and three interchangeable
manifolds are adjustable to handle flows from 17 gpm to 80
gpm. The 3-D Torus comes with 2- and 8-in. arms - longer
extensions are also available. The Torus is designed to be
long-lasting and durable. Operators can adjust the magnetic
speed control to select rotation speed. The dial adjusts easily
to decrease the speed for difficult applications and increase
the speed for the easier applications. If the arms hit an
obstruction, the tool simply stops rotating, and there are no
broken gears to repair or replace.
stoneage
(866) 795-1586 / www.stoneagetools.com

www.PLANTSERVICES.Com SEPTEmbER 2010 53

PS1009_53_54_Products.indd 53 8/25/10 9:15 PM

 PRODUCT FOCUS

PReSSURe blOweRS have SelF-Cleaning bi-DiReCTiOnal PigS

CaST alUminUm wheelS
Continental Fan’s PRD radial blade pressure blowers are
dynamically balanced with a compact design, welded steel
housing, and motor base. The self-cleaning cast aluminum
wheels are suited for exhaust systems that are laden with dust
or grit. The blowers also are capable of supplying high-
pressure air for cooling applications and for convey-
ing systems. The radial blade pressure
blower’s features include polyester
powder coat finish, single-phase or
three-phase TEFC motors, CW
bottom horizontal discharge field-
adjustable to eight positions, sizes
from 8- to 14-in. diameter, and
capacities up to 2,100 cfm.
Continental Fan
manufacturing, inc.
(800) 779-4021 /
www.continentalfan.com
FOR PiPeline Cleaning
Process Pigging Systems
added several sizes of bi-
directional pigs for sanitary
pipelines. Constructed of
FDA-approved, medical-
grade silicone, these pigs
fit Schedule 10 pipe ranging 1 to 4 in. They achieve product
recovery rates of 99% and can negotiate 90° 1.5-diameter
elbows. They can be steam-cleaned to more than 120º C be-
tween batches without degradation. The bi-directional pigs
can be supplied as part of a pigging system, which allows the
injection of the pig into an encapsulated sanitary system to
recover product or remove cleaning fluids from the pipeline
between batches. Pigs are propelled through the pipeline by
compressed air, nitrogen, carbon dioxide, water, or the next
material to be used in production to achieve 99% recovery.
Process Pigging Systems
(513) 731-6005 / www.processpigging.com

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54 September 2010 www.pLANtSerVICeS.Com

PS1009_53_54_Products.indd 54 8/25/10 9:16 PM


oil Skimming applicationS Sourcebook
Abanaki’s 29-page handbook offers ap-
plication notes on 29 real-world implemen-
tations of oil skimming, the lowest cost
way to remove oil from water. Indexed by
industry and application, readers quickly
find case studies for their situations.
Sections include consulting engineering,
machining, manufacturing, utilities, coolant,
grease/water separation, groundwater re-
mediation, oil/water separation, and wastewater.
Call (800) 358-7546 (SKIM) or visit www.abanaki.com/008.
abanaki
1/4 ton oF reFrigeration
EXAIR Vortex Tubes produce up to 10,200 Btu/
hr. with no moving parts. Stainless Steel Vortex
Tubes convert an ordinary supply of com-
pressed air into two streams; one hot and one
cold. Temperatures are adjustable from -50° to
+250°F. Applications include cooling hot melts,
cutting tools, welding horns, electronic controls,
soldered parts and gas samples. Call 800-903-
9247 or visit www.exair.com/85/130.htm.
exair corporation
color DiSplaY Vibration analYZer/balancer
The new VIBXPERT II advanced analyzer
combines the advantages of a rapid pro-
cessor with a brilliant energy-efficient
full color VGA display. Enhanced with an
Fmax of 51KHz and up to 102,400 lines
of resolution, all machinery vibration and
balancing problems can be captured and
easily analyzed with VIBXPERT. Call (305)
591-8935 or visit www.ludeca.com/vibxpert.
ludeca inc.
mit400 SerieS 1-kV inSulation
anD continuitY teSterS
The Megger MIT400 Series meet the most
stringent requirements and are ideal for Cat-
egory IV 600V applications. The units feature
adjustable voltages providing 250V to 1000V
or 50V to 1000V. The top-of-the-range models
can store and download data. The instruments
are sealed to IP54, lessening the chance of wa-
ter ingress. Contact us at (866) 254-0962.
megger
PS1009_55_56_AdlitsRev.indd 55
mro marketplace
coxreelS catalog
Coxreels full-color catalog showcases the
expanding line of Coxreels high-quality pro-
fessional grade hose, cord, and cable reels.
The catalog’s clean format navigates easily
and makes ordering options and accessories
for your reel a snap. Choose from a variety
of mounting brackets, roller guide options,
motor speed controllers, and so much more.
Visit www.coxreels.com.
coxreels
liFt truck
The Hyster H50CT lift truck is cost effec-
tive and provides the right balance of pro-
ductivity, dependability and durability for
moderate-duty applications. Smart design
and solid construction strike the perfect bal-
ance between the number of loads and fuel
consumption. The H50CT features carefully considered opera-
tor comfort ergonomics and an electronically-controlled Pow-
ershift transmission. Visit www.hyster.com/americas/en-US.
Hyster company
energY eFFiciencY
The EES multiplies energy savings of the
already efficient Sullair compressors. Heat
of compression is recovered for heating or
pre-heated air for various processes. When
not required, heat is rejected out-of-doors.
Annual energy savings for a 100 hp EES
compressor may reach $10,993. Payback in
as little as 7 months. Call (800) SULLAIR.
Sullair corporation
tHermal imager SerieS For preDictiVe
anD preVentiVe maintenance
The testo 881 Thermal Imagers
testo 881
feature a range of convenient features
Thermal Imager
Testo 881 Thermal Imager for
Preventive and Predictive Maintenance
including <0.05ºC NETD sensitiv-
ity, voice recording, telephoto lens,
The testo 881 thermal imaging camera can quickly and
accurately discover thermal anomalies and weak spots in
industrial plants and manufacturing facilities. Used regularly
as a predictive maintenance and monitoring tool, it can save
you thousands of dollars by safely pinpointing potential
problems and avoiding costly downtimes and repairs.
and integrated digital camera. It also
Saving Time, Energy and Money.
FEATURES
includes an advanced software pack-
• 32° x 23° field of view scans a large area quickly
• High thermal sensitivity (0.05° C)
age and a Dynamic Motor Focus for
• Intuitive menu with 5 way joystick control
• Fast refresh rate
• Integrated camera captures thermal and visual images simultaneously
• TwinPix software technology blends thermal and visual image together
Unique TwinPix software blends both the thermal
and visual image together into one image true one-hand operation. For more
information visit www.testo.com/
thermal or call (800) 227-0729.
testo, Inc. • 800-227-0729 • e-mail: info@testo.com • www.testo.com/550
teSto
www.PLANTSERVICES.Com SEPTEmbER 2010 55
8/27/10 11:50 AM
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APC/Schneider Electric . . . . . . . . . . . . . . . . . . . . . . . 23
Atlas Copco Compressors . . . . . . . . . . . . . . . . . . . . . . 3
AutomationDirect.com. . . . . . . . . . . . . . . . . . . . . . 2,13
Baldor Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Big Ass Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cox Reels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CRC Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Denso Sales of California . . . . . . . . . . . . . . . . . . . 32,33
Endress + Hauser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Flir Commercial Systems . . . . . . . . . . . . . . . . . . . 41,48
Fluke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Goulds Pumps / ITT Industries . . . . . . . . . . . . . . . . . . 34
Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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56 September 2010 www.pLANtSerVICeS.Com
PS1009_55_56_AdlitsRev.indd 56
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Lubriplate Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 8
MacroAir Technologies. . . . . . . . . . . . . . . . . . . . . . . . 51
Martin Sprocket & Gear . . . . . . . . . . . . . . . . . . . . . . 39
Megger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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 energy exPerT
peter garforth
The PerfecT energy STorm
reliability, cost, and environmental factors can affect availability
reading recent headlines, it’s impossible not to ask
whether we’re in a perfect storm in which fears around
energy-supply reliability, cost, and environmental effects
are coming together. If we’re in that perfect energy storm,
deep and effective productivity improvement are needed in
energy management and innovation. If the fears are ground-
less, those that achieve the highest productivity and innova-
tion levels are likely to gain a substantial edge over their
rivals. This column was written on a transatlantic flight that
prompted thoughts about energy innovation, management,
and competition.
WITh a bILLIon chIneSe cITIzenS
geTTIng on The road, hoW much
Longer can our oIL-uSe PaTTernS
be SuSTaIned?
The oil spill in the gulf was the largest in history, with
the full effects still unknown, and draws attention to our
oil dependence. About 70% of our oil is imported and
mostly used in vehicles that, on average, use more than
twice as much fuel per passenger mile as in Germany. With
a billion Chinese citizens getting on the road, how much
longer can our oil-use patterns be sustained? Countries
are attacking this in many innovative ways. In the process,
they’re building new industries, including high-speed
rail, electric cars, super-efficient clean diesel hybrids, and
completely new ideas such as the Chinese “people mover”
concept that will straddle freeways with cars driving un-
derneath. Some ideas will go the way of the steam-powered
airship. Some will be the multi-billion-dollar corporations
of the future.
Electricity supply in the United States has grown vulner-
able. The number of blackouts is increasing. In the least
reliable regions, they total more than 200 minutes a year,
and in the most reliable regions they last more than 90
minutes annually. These exclude those caused by hurricanes
or ice storms. The imperative to slow or reverse demand is
triggering all kinds of innovation – from smart grids to new
approaches for building efficiency and management, distrib-
uted cogeneration, and renewable generation.
My hotel in Copenhagen, Denmark, had triple-glazed
58 September 2010 www.pLANtSerVICeS.Com
PS1009_58_Energy.indd 58
windows and integrated controls. It was clad with solar pan-
els and connected to district heating and cooling, energized
by a combination of renewable, waste, and fossil energy
supplies. It was within two minutes of light and heavy rail,
located in a business park that included hundreds of homes
and offices. It even had a current energy-performance cer-
tificate displayed in the lobby. This approach to building and
neighborhood design reduces electricity and other energy
consumption.
Some countries are reducing parasitic electricity demand
with deep-standby requirements. Some are developing net-
worked cooling systems fed by waste-heat from industry and
power plants. Helsinki, Finland, is considering using waste-
heat from a nuclear plant to heat and cool the city. Industry
is reacting to grid vulnerabilities with greater electrical
efficiency, improved management and control, and on-site
clean and renewable generation.
Globally, the past decade was the warmest in recorded
history, with June temperatures hitting an all-time record. A
heat storm caused fires across Russia, with record tempera-
tures and smoke causing 350 deaths a day in Moscow. The
Russian and the Ukrainian grain fields that feed millions
are damaged and exports are restricted. Floods of unprec-
edented levels destroyed the livelihood and infrastructure of
more than 20 million Pakistanis. China had the worst floods
in its history, stretching national rescue efforts and killing
hundreds in mudslides. The United States had record heat
storms, air-conditioning being one of the major contribu-
tions to increased blackouts.
Are these signs of human-induced climate change
through energy use? As a pattern, they’re consistent with the
climate scientist’s predictions, though any single event can’t
be linked definitively to energy use. If the patterns continue,
this will accelerate the imperative to fuel and energy ef-
ficiency, even faster innovation, and disaster mitigation.
The headlines tell us we’re in a perfect storm around
energy. Whether we are or we aren’t, management that fails
to consider this possibility might very well end up on the
wrong side of history. Assessing both the opportunities and
risks is no longer optional and clearly warrants CEO and
board-level accountability.
Peter garforth is principal of garforth International LLc, Toledo,
ohio. he can be reached at peter@garforthint.com.
8/25/10 9:17 PM
 WASHDOWN. DUST-TIGHT.
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