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41 Selective coordination 47 Pipe joining systems 54 Fall arrest solutions

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www.plantengineering.com PLANT ENGINEERING March 2013 3

Whats INsideWhats INside

6 Interactive

9 In Focus

25 In Practice

56 Innovations

61 Product Mart

62 Internet Connection

63 Advertiser Contacts

64 In Conclusion

30

March 2013Volume 67, No. 2

17 Energy management

The average impact of unplanned downtime in process industries is $20 billion, or almost 5% of production, according to a 2011 ARC Advisory Group report. With every 10 workers retiring, only five will take their place, which means fewer skilled people will be trying to support ever more advanced and technical-ly interconnected plants. A strategic plan is in order, and it is in order right now if any facility is expecting to survive the continued national and international competitive pressures.

32 Selecting a maintenance vendor 35 Providing a saner approach to maintenance 36 Is your plant a profit center or a profit eater? 38 The evolution of work processes can deliver revolutionary results

Cover Story

Maintenanceas a pro t center

PLANT ENGINEERING (ISSN 0032-082X, Vol. 67, No. 2, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2013 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and addi-tional mailing offices. Circulation records are main-tained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: [email protected]. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: [email protected]. Rates for nonqualified subscrip-tions, including all issues: USA, $ 145/yr; Canada, $ 180/yr (includes 7% GST, GST#123397457); Mexico, $ 172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regard-less of whether such errors result from negligence, accident or any other cause whatsoever.

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9 In Focus New wave of technology moves beyond theory Checklist for robotics survival Putin to open Hannover Messe 2013 on April 7 ARC president: Pick up the pace of technology adoption Training, mentoring needed to address skilled worker shortage Innovative energy management strategies help a Maine paper mill stay competitive Reduced corrective maintenance is found money Staying ahead of the curve

In Practice25 Benchmark your manufacturing performance to deliver results Manufacturing leaders must establish production schedules, optimum workflows, effective maintenance procedures, and continuous improvement programs that will keep the organization moving forward.

Electrical Solutions41 Achieving effective selective coordination design The concept of full selective coordination has changed the way engineers must think when designing electrical distribution systems.

Mechanical Solutions47 Pipe joining systems get in the groove Of all the pipe joining methods available, maintenance on HVAC systems installed using grooved piping products is the fastest, most efficient, and simplest to perform.

Maintenance Solutions51 Fall arrest solutions require attention to detail, not scale Big or small, implementing a fall protection system requires considering a number of factors. The project size is not one of those factors.

53 Making sense of process safety A Process Safety Management (PSM) program and a more focused National Emphasis Program (NEP) are relatively new to U.S. manufacturing. While PSM-NEP makes sense, we must begin to make sense of it.

www.plantengineering.com












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MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 [email protected]

MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, [email protected]

RICK ELLIS, Audience Management Director 303-246-1250, [email protected]

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REPRINTS For custom reprints or electronic usage, contact: Wrights Media Nick Iademarco Phone: 877-652-5295 x102 Email: [email protected]





Richard A. Groth Jr., NJ/ E. PA [email protected] 12 Pine St. Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432

Stuart Smith, International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588

PLE1303_TOC_V7msFINAL.indd 5 3/14/13 1:52 PM

6 March 2013 PLANT ENGINEERING www.plantengineering.com

Exclusive blogs at www.plantengineering.com/blogs CMMS horror stories: Five reasons a CMMS implementation can fail Machine Safety: Serious machine guarding issues Machine-tool industry limiting growth in the motion control market Government in the power business

LinkedIn: Plant Engineering ProfessionalsPlant Engineerings LinkedIn audience has more than 2,200 manufacturing professionals from six conti-nentsand were working on nding our rst manufacturing professional from Antarctica. Join the discus-sion in the Plant Engineering Professionals group at www.linkedin.com.

Industry newsHere are the top stories for this month on www.plantengineering.com:

PMI surges to highest point in almost two years Automation project road map: Advice for the journey ARC study: Additive manufacturing creates powerful incentive Hot technology jobs: arti cial intelligence, robotics ABB to fund 40 global research projects

To keep up with important industry news, go to www.plantengineering.com/industry-news.

Point, click, watchSPECIAL REPORT: The electricalinfrastructure businessDon Rickey, senior vice president for the U.S. Infrastructure Business at Schneider Electric discusses the medium-voltage electrical distribution business and a host of other items. Scan the QR code or visit www.plantengineering.com/videos.


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PLE1303_INTERACTIVE_V6msFINAL.indd 6 3/14/13 11:23 AM

Facts about BlowersEnergy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of fi lters, belts and bearings. Here are some important facts:Filters must be replaced every one to three months.Belts must be replaced every three to six months.Typical bearing replacement is at least once a year at a cost near $1000.

Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate eff ective airfl ows.

Poorly designed seals that allow dirt and moisture infi ltration and environments above 125F decrease the one year bearing life.

Many bearings can not be replaced in the fi eld, resulting in downtime to send the assembly back to the manufacturer.

Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often diffi cult to control since mechanical adjustments are required.

To discuss an application, contact:

EXAIR Corporation11510 Goldcoast DriveCincinnati, Ohio 45249-1621(800) 903-9247Fax: (513) 671-3363email: [email protected]/79/423.htm

See the Super Air Knife in action.www.exair.com/79/akvideo.htm

Compare these Blowoffs ere are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four diff erent blowoff methods: drilled pipe, fl at air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. e following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff , cooling or drying application.

e goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). e compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off . e blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. e table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd confi guration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

The Truth About Compressed Air!

Drilled Pipe is common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. e initial cost of the drilled pipe is overshadowed by its high energy use. e holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

Flat Air NozzlesAs shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. e fl at air nozzle provides some entrainment, but suff ers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers off er fl at air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

EXAIR Super Air Knife e Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airfl ow. e sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

Blower Air Knife e blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and fl at air nozzle, but was comparable to EXAIRs Super Air Knife. e large blower with its two 3" (8cm) diameter hoses requires signifi cant mounting space compared to the others. Noise level was high at 90 dBA. ere was no option for cycling it on and off to conserve energy like the other blowoff s. Costly bearing and fi lter maintenance along with downtime were also negative factors.

Blowo ComparisonComp. Air Horsepower

Required

SoundLevel dBA

PurchasePrice

Annual Electrical

Cost*

Approx. Annual Maintenance

Cost

First Year CostType of blowo PSIG BAR SCFM SLPM

Drilled Pipes 60 4.1 174 4,924 35 91 $50 $4,508 $920 $5,478

Flat Air Nozzles 60 4.1 257 7,273 51 102 $208 $6,569 $1,450 $8,227

Blower Air Knife 3 0.2 N/A N/A 10 90 $5,500 $1,288 $1,500 $8,288

Super Air Knife 60 4.1 55 1,557 11 69 $534 $1,417 $300 $2,251

*Based on national average electricity cost of 8.3 cents per kWh. Annual cost re ects 40 hours per week, 52 weeks per year.



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The fourth wave of innovative technol-ogy jobs will involve computers, tele-communications, biotechnology, artificial intelligence, and robotics, according to Dr. Michio Kaku, American theoretical physicist, best-selling author, TV host, and Feb. 21 keynote speaker at the 2013 Robotics Industry Forum, held in Orlan-do, Feb. 20-22. He also praised engineers in general and physicists in particular, credited for inventing the transistor, laser, computer, Internet, World Wide Web, TV, radio, x-rays, radar, the microwave, PET scans, the space program, and GPS satel-lite, among other innovations.

Kaku, who is continuing work started by Einstein on a grand unified theory of the universe, has made the New York Times best seller list twice, with Physics of the Future, citing 300 top scientists, and Physics of the Impossible, a look at life and science 500 to 1,000 years in the future.

Even so, in his keynote presentation, The Future of Technology, Kaku cited Yogi Berra, credited with explaining that prediction is very hard to do, especially if its about the future.

Even so, hindsight is marvelous, show-ing that many economic downturns came after unsustainable economic speculation that followed waves of engineering inno-vation. Engineering innovation, he said, is the origin of all wealth.

He called the first wave of economic innovation the rise of steam power in the 1800s, which was followed by the crash of 1850, resulting from more than 200 stocks on the London exchange related to steam poweran unsustainable number.

The second wave resulted from inno-vations from electricity, magnetism, and the internal combustion engine, leading to speculation surrounding utilities and automotive stocks on the NYSE, a bubble that burst in 1929, Kaku said.

The third wave came 80 years later, with high technologies, such as lasers,

computers, satellites, telecommunica-tions, and the Internet, which led to the real estate bubble and what Kaku called the unsustainable Mediterranean lifestyle of Europe, leading to the 2008 recession, still felt in Europe today.

The fourth wave, Kaku said, will be telecommunications, computers, bio-technologies, artificial technologies, and nanotechnologies, driven and supported by motion control, machine vision, and robotics.

In each wave, there are those who resist, Kaku observed, and those who have resisted often faced bankruptcy and/or unemployment. The automobile put many blacksmiths and stable hands out of work, but new jobs were created. Kaku challenged attendees, noting that recent negative coverage of robots is the latest in this nay-saying trend: Who will define your industry? Will you define yourself or will you allow your competitors to do so?

Kaku said, Robotics and other auto-mation replace dull and dangerous jobs, and we should celebrate that. Innova-tion is the source of jobs. Dont let bad press by 60 Minutes define you, he said, talking about the piece that sug-gested use of robots results in fewer jobs, when examples and research suggestotherwise.

The progression of Moores Law is tied to the wealth and power of nations, Kaku said: Now, we have more comput-ing power in our pocket cell phone than all of NASA did in 1969 to put men on the moon. PE

Next wave of technology moves beyond theory2013 Robotics Industry Forum speaker takes a long look into the future of everything.

By Mark T. Hoske, CFE Media

INFOCUS

Robotics and otherautomation replace dull and

dangerous jobs and we should celebrate that. Innovation is the source of jobs. Dont let bad press by 60 Minutes

define you.Dr. Michio Kaku

Robot design-ers who ignore one or more of three principles are doomed to fail, according to a roboti-cist with 22 patents who has worked for three robot com-panies and MIT Robotic Lab. Joseph L. Jones, co-founder and chief technology officer, Harvest Automation, told attendees at the Robotics Industries Forum about a checklist for robot survival.

How are robots like sea turtles? For each 1,000 sea turtles hatched, only one lasts to adulthood. Its about the same statistic for robots. Robot

designers need to be really careful in choosing which robots to build, Jones said. He also worked at iRobot (which has sold 9 million Roomba robotic vacuums) and at Denning Mobile Robotics. In 30 years

of watching the robotic industry, hes observed three key elements that need to be present with any robot project for success.

1. Do something that lots of peo-ple want done

2. Be built with existing technol-ogy, and

Checklist for robotics survival

PLE1303_INFOCUS_V7msFINAL.indd 9 3/14/13 11:25 AM


INFOCUS3. Be cost-competitive

with current solutions.

While this seems perfect-ly logical, when in the thick of things, roboticists usu-ally ignore one and often all three, Jones said. In his talk, Small Mobile Robots for Agriculture, Jones dis-cussed his current efforts at Harvest Automation, found-ed in 2007, now with 40 employees. Hes making robots for agriculture. A nursery and greenhouse robot is the companys first product.

Plants sold in garden stores often are grown in pots in open fields that extend to the horizon. Armies of hard-to-find workers manually space pots in the field after the

pots are unloaded from wagons.

After I observed that, I thought, If we cannot build a cost-effective robot to do this, were in the wrong business, Jones said.

The first model, Harvest Automa-tion HV100, costs about $30,000, with return on investment after 12-18 months of use, Jones said. Addressing labor scar-city issues, Harvests robots are designed to work alongside people, not replace them, in a growers operation, to create a

sustainable workforce combining robots and people to increase efficiency, reliability, and plant quality, he noted. PE

companys first product.

The Harvest Automation HV100 nursery and greenhouse robot is flexible and scalable, fault tolerant, inherently safe for operation near people, and easy and intuitive to set up and operate. Allphotos courtesy of Harvest Automation.

PLE1303_INFOCUS_V7msFINAL.indd 10 3/14/13 11:25 AMPLE130301-MAG_Ads.indd 10 3/14/2013 1:13:23 PM

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12 March 2013 plant engineering

Russian president Vladimir Putin will help open Han-nover Messe 2013 as part of Russias status as partner nation at this years event, April 8-12 in Hannover, Germany.

The Russian head of state will be in the Hannover Con-gress Centrum for the opening ceremony on Sunday, April 7, and will also take part in the traditional opening tour of Hannover Messe on Monday, April 8. On both occasions, President Putin will be accompanied by German Chancel-lor Angela Merkel, who this year will again officially open the worlds most important technology event.

We are delighted to have received confirmation of President Putins visit, said Dr. Jochen Kckler, member of the Board at Deutsche Messe AG. His presence offers convincing evidence of the international status enjoyed by Hannover Messe and at the same time underlines the importance of the Partner Country program.

Every year a different country is invited to step into the spotlight and act as the Partner Country at Hannover Messe. This year, the Russian Federation will be the focus of attention, not only within the exhibition itself but also throughout the entire program of forums, conferenc-es, and events that traditionally accompanies the worlds leading trade show.

The lead theme of Integrated Industry signals Hannover Messes strong focus on the current trend toward integration across all areas of industry. Integrated Industry is about making industrial production smarter and more efficient. Its also about multidisciplinary cooperation between different industries and different enterprises, Dr. Kckler said.

Hannover Messe 2013 will comprise 11 flagship fairs: Industrial Automation; Motion, Drive & Automation (MDA); Energy; Wind; MobiliTec; Digital Factory; ComVac; Indus-trial Supply; IndustrialGreenTec; Surface Technology; and Research & Technology. PE

For more information, go to www.hannovermesse.de. Photo courtesy of Hannover Messe.

INfOCUS

Putin to open Hannover Messe 2013 on April 7


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Get more from your MRO products provider. Experience the independent difference with your local IDC Distributor at www.IDC-USA.coop/difference

Its not about the products Its not about the products Its not about the products on our shelves.on our shelves.on our shelves.

Its what we do with Its what we do with Its what we do with our productsour productsour products that that that makes the difference.makes the difference.makes the difference.

The speed of manufacturing informa-tion adoption is accelerating, and those who stay on the sidelines will find them-selves falling farther and farther behind a fully optimized plant.

That was the keynote message from ARC Advisory Group president Andy Chatha at the 2013 ARC Forum in Orlan-do Feb. 12. All of you have data, gather-ing information in real time. The chal-lenge is that we havent had good tools to analyze that data, Chatha told more than 600 attendees at the ARC event. Now we do have powerful analytical tools. We think information-driven manufacturing is the way to leverage the information. You have to be able to make sense out of the information.

Chatha noted that the accelerated use of smart devices, the pervasive influ-ences of Wi-Fi and cloud computing, and the connective nature of devices all have created enormous opportunities to leverage the data now available on the plant floor.

Its much easier now to get devices connected and add intelligence, Cha-tha said. In my view, one thing that is happening is that the cost of adding intelligence is coming way down. Com-

panies should be adding intelligence to all equipment. Data should be moving toward some sort of cloud.

But the key for manufacturing to take advantage of this technology is speed,

and Chatha noted manufacturing is slow to embrace speed.

Technology constantly is changing.Most manufacturing companies are very conservative. They only employ technol-ogy when it has been well-proven, he said. That strategy worked fine in the past. New technologies are more disruptive, and they are moving faster. Now you have to start testing technologies faster. If you are not testing technologies, it may take you too long to catch up. Youve got to start moving a little faster to develop new technologies.

Chatha sees a continuing evolution ofplant floor processes. With powerful tools, you can look at all processes in the plant and information outside the plantin your supply chain, for example, Cha-tha said. Look at how analyzing much larger amounts of information can opti-mize the performance of the plant.

Developing such a plan will require new relationships from existing suppli-ers. The automation business already is moving toward being more of a service business, Chatha said. One model is looking at signing some sort of perfor-mance-based service agreement with sup-pliers, based on key metrics. Systems are becoming more complex, and it is more difficult for manufacturers to upgrade them and manage them. PE

INfOCUSARC president: Pick up the pace of technology adoptionRapid growth of devices, technology use requires faster implementation on plant floor.By Bob Vavra, CFE Media

With powerful tools, you can look at all processes in the plant and information out-side the plantin your supply chain, for example.

Andy Chatha, ARC Advisory Group


Respondents to Plant Engineerings 2012 Salary Survey again placed workforce development on top of their list of plant floor issues. Attracting that next generation of workers requires not just a need to attract skills, but also to satisfy the changing nature of these workers.

That was the conclusion of a panel of experts at the ARC Advisory Group World Forum in Orlando Feb. 12. There is a skills gap, but also a generational gap in how workers operate and how they use technology. Dick Hill of ARC Group, who moderat-ed the session, noted that workers on the cusp of retirement may walk away with more than a pension or a 401K.

Experienced workers know how the plant runs, and know when its not running well, but its not written down, Hill said.

Citing a Pew Research report that called the millennial generation digital natives, Hill noted that the next genera-tion expects modern technology and progressive corporate culture to greet them on their arrival in the workplace.

Have you built necessary training tools and training environment? Hill said. Do you have a mentoring pro-gram? Is your plant equipment ready for them? Is your software application smart, because knowledge of your current workers is going to go away?

That reality has forced companies such as Momentive Specialty Chemicals to change the way they train and deploy employees. New employees are learning the right way to operate the plant, and we want them to be able to train cross-functionally. We can share resources between

plants, said Brooke Robertson, project manager for Momentive Specialty Chemicals. At Momentive within 5 years just in engineering, 17% of our workforce will be eli-gible for retirement. How are we going to be able to retain all of this information?

Mike Resetarits of Fractional Research Inc., a company that does distillation research for chemical and engineering companies, cited estimates of 10,000 workers a day for the next 20 years leaving the workforce.

That means were losing 400,000 years per day of experience, Resetarits said. The boomer generation puts

their job high on their list of priorities. It allows them to achieve all the other goals they have set for their lives.

Confronting a transition in the workforce at Fractional Research took some soul searchingand some

tough choices. We had a problem. We were on the verge of losing our best engineers and best technician opera-tors, Resetarits said. There were several things we did to prepare. It took us about a year.

The company put its experienced engineers and tech-nicians into a room and programmed all of the plants start-up and shutdown operations into the system. When new operators came on, the procedures were already pro-grammed, but Resetarits said it didnt change the opera-tional knowledge in the department.

They embraced it, he said. They never stop thinking. They dont just push the button. They think about the pro-cess, and the computer program corroborates what they were going to do anyway.

Within that transition were some veteran workers who were unwilling to change. We had some people who

Training, mentoring needed to address skilled worker shortageBy Bob Vavra, CFE Media

Were losing 400,000 years per day of experience.

Mike Resetarits, Fractional Research Inc.


Get more from your MRO products provider. Experience the independent difference with your local IDC Distributor at www.IDC-USA.coop/difference

Its not about the products Its not about the products Its not about the products on our shelves.on our shelves.on our shelves.

Its what we do with Its what we do with Its what we do with our productsour productsour products that that that makes the difference.makes the difference.makes the difference.


The speed of manufacturing informa-tion adoption is accelerating, and those who stay on the sidelines will find them-selves falling farther and farther behind a fully optimized plant.

That was the keynote message from ARC Advisory Group president Andy Chatha at the 2013 ARC Forum in Orlan-do Feb. 12. All of you have data, gather-ing information in real time. The chal-lenge is that we havent had good tools to analyze that data, Chatha told more than 600 attendees at the ARC event. Now we do have powerful analytical tools. We think information-driven manufacturing is the way to leverage the information. You have to be able to make sense out of the information.

Chatha noted that the accelerated use of smart devices, the pervasive influ-ences of Wi-Fi and cloud computing, and the connective nature of devices all have created enormous opportunities to leverage the data now available on the plant floor.

Its much easier now to get devices connected and add intelligence, Cha-tha said. In my view, one thing that is happening is that the cost of adding intelligence is coming way down. Com-

panies should be adding intelligence to all equipment. Data should be moving toward some sort of cloud.

But the key for manufacturing to take advantage of this technology is speed,

and Chatha noted manufacturing is slow to embrace speed.

Technology constantly is changing.Most manufacturing companies are very conservative. They only employ technol-ogy when it has been well-proven, he said. That strategy worked fine in the past. New technologies are more disruptive, and they are moving faster. Now you have to start testing technologies faster. If you are not testing technologies, it may take you too long to catch up. Youve got to start moving a little faster to develop new technologies.

Chatha sees a continuing evolution ofplant floor processes. With powerful tools, you can look at all processes in the plant and information outside the plantin your supply chain, for example, Cha-tha said. Look at how analyzing much larger amounts of information can opti-mize the performance of the plant.

Developing such a plan will require new relationships from existing suppli-ers. The automation business already is moving toward being more of a service business, Chatha said. One model is looking at signing some sort of perfor-mance-based service agreement with sup-pliers, based on key metrics. Systems are becoming more complex, and it is more difficult for manufacturers to upgrade them and manage them. PE

INfOCUSARC president: Pick up the pace of technology adoptionRapid growth of devices, technology use requires faster implementation on plant floor.By Bob Vavra, CFE Media

With powerful tools, you can look at all processes in the plant and information out-side the plantin your supply chain, for example.

Andy Chatha, ARC Advisory Group


Respondents to Plant Engineerings 2012 Salary Survey again placed workforce development on top of their list of plant floor issues. Attracting that next generation of workers requires not just a need to attract skills, but also to satisfy the changing nature of these workers.

That was the conclusion of a panel of experts at the ARC Advisory Group World Forum in Orlando Feb. 12. There is a skills gap, but also a generational gap in how workers operate and how they use technology. Dick Hill of ARC Group, who moderat-ed the session, noted that workers on the cusp of retirement may walk away with more than a pension or a 401K.

Experienced workers know how the plant runs, and know when its not running well, but its not written down, Hill said.

Citing a Pew Research report that called the millennial generation digital natives, Hill noted that the next genera-tion expects modern technology and progressive corporate culture to greet them on their arrival in the workplace.

Have you built necessary training tools and training environment? Hill said. Do you have a mentoring pro-gram? Is your plant equipment ready for them? Is your software application smart, because knowledge of your current workers is going to go away?

That reality has forced companies such as Momentive Specialty Chemicals to change the way they train and deploy employees. New employees are learning the right way to operate the plant, and we want them to be able to train cross-functionally. We can share resources between

plants, said Brooke Robertson, project manager for Momentive Specialty Chemicals. At Momentive within 5 years just in engineering, 17% of our workforce will be eli-gible for retirement. How are we going to be able to retain all of this information?

Mike Resetarits of Fractional Research Inc., a company that does distillation research for chemical and engineering companies, cited estimates of 10,000 workers a day for the next 20 years leaving the workforce.

That means were losing 400,000 years per day of experience, Resetarits said. The boomer generation puts

their job high on their list of priorities. It allows them to achieve all the other goals they have set for their lives.

Confronting a transition in the workforce at Fractional Research took some soul searchingand some

tough choices. We had a problem. We were on the verge of losing our best engineers and best technician opera-tors, Resetarits said. There were several things we did to prepare. It took us about a year.

The company put its experienced engineers and tech-nicians into a room and programmed all of the plants start-up and shutdown operations into the system. When new operators came on, the procedures were already pro-grammed, but Resetarits said it didnt change the opera-tional knowledge in the department.

They embraced it, he said. They never stop thinking. They dont just push the button. They think about the pro-cess, and the computer program corroborates what they were going to do anyway.

Within that transition were some veteran workers who were unwilling to change. We had some people who

Training, mentoring needed to address skilled worker shortageBy Bob Vavra, CFE Media

Were losing 400,000 years per day of experience.

Mike Resetarits, Fractional Research Inc.


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16 March 2013 plant engineering

INfOCUSproved to me that they did not want to work with us. Theyre gone, he said. We released 11 people and none of those were easy, but now we have a group of engineers who are as good. Change is an every-minute experience in our control rooms, Resetarits said. We decided to hire happy people. There are people who wake up angry every day, and they infect the entire organization. When we interviewed, we looked for people who liked to smile. We looked for people who like people. The number one thing we looked for was attitude.

One strategy was for Momentive to take a fresh look at its control system. Modernizing your control system will attract new workers but also will capture knowl-edge, Robertson said. Implement global DCS stan-dards. It makes modernizations quick, and the benefit for the operators is they can now switch between units. Theyre not about learning the control systems. All they have to pick up is the process.

She noted that many of the problems of data capture and system modernization are fixable through system alignment. When your engineering resources are low, your DCS vendor likely has a solution for you, Robert-son said. You need to train operators on how to run operations, but a key is to run simulations. But you also need to keep simulators up to date. But all of the chal-lenges we were faced with, there were solutions out there.In search of Gen X-ers

While the discussion in the workforce development issue revolves mostly around retiring baby boomers and up-and-coming millennials, a third group may actually hold the key to filling a widening Skills Gapif they can be found.

The Generation X group, generally born between 1960 and 1980, normally would be the next in line to fill in the jobs currently occupied by baby boomers, but fewer of those people took manufacturing jobs in the period from 1985 through 2005, when they most likely would have been heading into the workforce.

One thing that is not discussed is that if we look at workforce issues, as baby boomers retire, theres a big hole of Gen X-ers not there to fill in, said Peter Zornio of Emerson Process Management during the panel discussion. If you look at the timing, it was at a time when many of us werent hiring.

In the modern market, where Facebook profiles for both employers and job seekers are now the norm, the challenge seems to be getting manufacturing careers a seat at the kitchen table when careers are discussed.

How do we make what we do attractive to young people? asked Maurice Wilkins of Yokogawa. Do we need to bring apprenticeships back? We need to make young people believe what we do isnt boring. PE


Call. 800-526-9328Click. www.motionindustries.comVisit. Over 500 Locations

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Gray color masks drips and spills Heavy- and medium-weight alternatives For use with oil and water-based fluids Three-ply construction makes it stronger, more durable, reduces lint Dimpled and perforated, helps you use only what you need,

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Item # Mfr Part # Color Capability Keyboard05244420 BBP31 Single Standard

Item # Mfr Part # Color05244421 B30C-4000-595-WT White05226835 B30C-4000-595-OR Orange04724851 B30C-4000-595-YL Yellow05226834 B30C-4000-595-GN Green05226812 B30C-4000-595-BL Blue

Item # Mfr Part # Color04684956 B30-R10000 Black

Item # Mfr Part # Shackle Dia. Color Pkg Qty03869539 99552 1/4" Red One03869957 51339 1/4" Red Six

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Item # Mfr Part # Size Package02728818 MRO300 15" X 19" 100/case03882406 MRO315P 15" X 150 ft 1/case02567974 MRO350-DP 30" X 150 ft 1/case

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BatteriesAlkalineProfessionalProcell

Dependable, long-lasting power with up to a seven-year freshness guarantee; date coded to guarantee freshness

Operates reliably in temperature extremes of -20C to 54C

Economical bulk packaging for professional applications

Contains no added mercury Priced per each

Lantern Battery6 VoltAlkalineCopperTop

Alkaline lantern batteries last up to twice as long as super heavy duty zinc carbon batteries and provide an extra measure of leakage resistance for critical applications

Reliable performance at temperature extremes Date coding to ensure freshness and a long

shelf life No added mercury

BatteriesAlkalineULTRA Power

Seven-year guarantee in storage High battery output

Watch Batteries1.5 VoltSilver Oxide High capacity, low self-discharge for longer service life Longer lasting to increase productivity Mercury-free

Coin Cells3 VoltLithium For electronic devices including memory back-ups and testing meters High capacity, low self-discharge for longer service life Longer lasting to increase productivity Mercury-free

Lithium Photo Battery3 VoltULTRA Photo

For applications with a high current pulse and continuous drain Reliability with more consistent performance Longer lasting to increase productivity Wide operating temperature extremes (-40F to 140F)

Item # Mfr Part # Battery Size Pkg Count02537658 PC2400 AAA 24 02537657 PC1500 AA 24 02538037 PC1400 C 12 02452561 PC1300 D 12 02537659 PC1604 9 Volt 12

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Item # Mfr Part # Battery Size Package04784725 384/392 1.5V 384/5R41/K Single Blister Pack03139362 303/357 1.5 Volt

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Item # Mfr Part # Battery Size Package03844857 DL123 3 Volt Single Blister Pack05396741 DLCR2

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Energizer Industrial Alkaline Batteries

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No mercury addedspecial disposal is not required Operates well in temperature extremes (-30C to 55C) Excellent shelf lifealkaline cells are ready for use even

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Energizer Industrial 3 LED Headlight Two light modes: White

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Energizer Industrial 6 LED Headlight

Four light modes: Area, spot, flood and red (for night vision) Light pivots up to 90 Easy On/Off push button switch Adjustable head strap with two built-in pencil holders Grips to safety helmets Packed with 3 AAA Energizer MAX batteries

Item # Mfr Part # Battery Size Pkg Count02952094 EN92 AAA 24 02952092 EN91 AA 24 02952096 EN93 C 12 02952097 EN95 D 12 02952090 EN22 9 Volt 12

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BATTERIES / LIGHTING




1/2" 20V High-Torque Impact WrenchCordlessImpactool

780 ft-lbs of maximum reverse torque and 1100 ft-lb of nut-busting torquefrom cordless impact wrench that weighs only 6.8 lbs

High-power rare earth magnet (neodymium) motoroffers a long life and high power

Steel-lined aluminum hammer casedesigned to be strong and lightweight for maximum protection of the internal components

All-metal drive train and hammer mechanismrobust, durable, and optimized for maximum power and efficiency

2,300 impacts per minute at 1,900 RPM Variable speed switch with electronic brakeprovides maximum

control of the tool Patent-pending metal reinforced housingready to work even

after repeated drops Patent-pending soft touch over-molded gripminimizes vibration,

reduces fatigue, and enhances user comfort during extended use Best-in-class short length9.4" from tip to tail W7150-K2 Standard Anvil Two Battery Kit includes: One W7150

Impactool, one IQV20 Charger, two 20V Li-ion 3.0 Ah batteries and one blow-molded case

Vibration Reduced Air HammerLong Barrel Great for exhaust and front-end

jobs, general bolt cutting, pin driving and body shearing work

Anti-vibration feature reduces tool vibration by over 30% when compared to standard air hammers in its class, plus an ergonomic grip that provides comfort for extended use

15% increased in impact force over standard air hammers Quick-change retainer allows for faster chisel changeovers, so you

can get the job done

Air Angle Die Grinder300 Series Features a composite grip for superior ergonomics

and comfort, and can be used in various applications including porting, weld breaking, de-burring, polishing and grinding

Durable ball-bearing construction improves balance, reduces vibration, and ensures a longer life

Built-in lubricating wick increases angle gear life Lightweight, durable, ergonomic composite

housing protects tool from cold air and offers greater operator comfort

Integral safety-lock throttle lever prevents accidental start up Rear exhaust directs air away from the operator, piped-away

exhaust kit optional Tool comes with 1/4" and 6 mm collets and two wrenches

Air Chain HoistCLK Series Meets ASME B30.16 specifications Rugged, lightweight and compact design Disc brake is non-asbestos and spring engaged

with air release Quiet operation




Synthetic Air Compressor FluidsSynXtreme AC Series 100% Polyol Ester (POE)-based, high performance fluids ECO-friendly; readily biodegradable (Pw1) Extended drain intervals up to +10,000 hours, monitored by

Lubriplates complimentary fluid analysis program

Syn Lube Series 100% Synthetic, Polyalphaolefin (PAO)-based fluids Fully compatible OEM fluid replacement Extended drain intervals up to 8,000 hours, monitored by


Synac Series 100% Diester-based synthetic air compressor fluids High temperature fluids eliminate varnish buildup Extended drain intervals up to 8,000 hours, monitored by


Syncool 100% synthetic, Polyglycolester-based fluid ECO-friendly; readily biodegradable (Pw1) Superior heat transfer properties

SFGO Ultra Series NSF H-1 registered food machinery grade For food processing and bottling operations 100% synthetic, (PAO) based compressor fluids

Item # Mfr Part # Container Viscosity GradeSynXtreme AC Series

03450190 L0939-060 5 gallon Pail ISO 3203450191 L0939-062 55 gallon Drum ISO 3203450192 L0940-060 5 gallon Pail ISO 4603450193 L0940-062 55 gallon Drum ISO 4603450194 L0941-060 5 gallon Pail ISO 6803450195 L0941-062 55 gallon Drum ISO 68

Syn Lube Series04398031 L0968-062 5 gallon Pail ISO 2202338479 L0970-060 55 gallon Drum ISO 2202318930 L0970-062 5 gallon Pail ISO 3205067620 L0971-057 55 gallon Drum ISO 3205067619 L0968-060 1 gallon Jug ISO 4602309842 L0971-060 5 gallon Pail ISO 4602338480 L0971-062 55 gallon Drum ISO 4602338481 L0972-060 5 gallon Pail ISO 6802338482 L0972-062 55 gallon Drum ISO 6802248199 L0973-060 5 gallon Pail ISO 10002248200 L0973-062 55 gallon Drum ISO 100

Synac Series01467844 L0932-060 5 gallon Pail ISO 3201467846 L0932-062 55 gallon Drum ISO 3201467847 L0933-060 5 gallon Pail ISO 4601467848 L0933-062 55 gallon Drum ISO 4601467849 L0934-060 5 gallon Pail ISO 6801467850 L0934-062 55 gallon Drum ISO 6805067611 L0935-054 1 quart Bottle ISO 10004229150 L0935-057 1 gallon Jug ISO 10001467851 L0935-060 5 gallon Pail ISO 10001467845 L0935-062 55 gallon Drum ISO 100

Syncool03720571 L0964-060 5 gallon Pail ISO 32/4603855067 L0964-062 55 gallon Drum ISO 32/46

Item # Mfr Part # Container Viscosity GradeSFGO Ultra Series

03068409 L0912-057 1 gallon Jug ISO 702338483 L0912-060 5 gallon Pail ISO 705067605 L0912-061 16 gallon Drum ISO 702338484 L0912-062 55 gallon Drum ISO 704255094 L0930-057 1 gallon Jug ISO 1502946753 L0930-060 5 gallon Pail ISO 1505067607 L0930-061 16 gallon Drum ISO 1504371475 L0930-062 55 gallon Drum ISO 1505067608 L0931-057 1 gallon Jug ISO 2204745440 L0931-060 5 gallon Pail ISO 2205067609 L0931-061 16 gallon Drum ISO 2205067610 L0931-062 55 gallon Drum ISO 2203941473 L0915-057 1 gallon Jug ISO 3201277054 L0915-060 5 gallon Pail ISO 3202338485 L0915-061 16 gallon Drum ISO 3201302652 L0915-062 55 gallon Drum ISO 3205067606 L0916-057 1 gallon Jug ISO 4601303055 L0916-060 5 gallon Pail ISO 4602338486 L0916-061 16 gallon Drum ISO 4601303065 L0916-062 55 gallon Drum ISO 4602462236 L0917-057 1 gallon Jug ISO 6801303472 L0917-060 5 gallon Pail ISO 6802338487 L0917-061 16 gallon Drum ISO 6801303480 L0917-062 55 gallon Drum ISO 6802462231 L0983-057 1 gallon Jug ISO 10002475058 L0983-060 5 gallon Pail ISO 10002462238 L0983-061 16 gallon Drum ISO 10002475059 L0983-062 55 gallon Drum ISO 100

LUBRICANTS




Moly Chain LubricantLU 202

A high-viscosity oil that clings to moving parts Foaming action penetrates close tolerances of chain

drive bushings and pins to provide long-lasting lubrication Reduces friction wear on moving parts and in

metal-to-metal applications The moly additive improves its capacity to handle greater

pressure requirements of start up stress Spray Anyway Valve allows material to be applied to the surface

when the can is being held in either upright or inverted position

Heavy Duty Citrus DegreaserCD 757

Heavy-duty, multi-purpose degreaser, adhesive and graffiti remover

Non-chlorinated formula has the cleaning power of solvents to remove grime, dirt, grease and oil

An outstanding biodegradable cleaner for use in general maintenance, public buildings, transit systems, restrooms, locker rooms and schools

Ideal as a cleaner prior to painting Leaves a refreshing, pleasant scent

Heavy Duty Penetrant OilRust Breaker LU 103 Fast-acting product that quickly loosens rust while

penetrating grease and dirt A transparent, non-staining oil, its light film displaces

moisture and acts as a corrosion preventative Jet stream sprays up to two feet for safe, accurate application A one-coat rust and corrosion preventive compound Pleasant vanilla scent

Electronic Degreaser SolventEL 2205 Penetrates instantly to remove dirt, oil, grease

and wax Excellent cleaning properties on tools, electric

motors, brakes, bearings and electrical equipment A fast evaporating formula equipped with extension

tube for pinpoint application

All Purpose LubricantThe Protector LU 711

An ultra-thin film, transparent blend of high quality petroleum distillates specifically formulated to ensure maximum moisture displacement

Its film resists the collection of abrasive particles on delicate contacts and connectors

Forms a continuous film that spreads evenly over metal surfaces, giving uniform protection against corrosion attack

This spreadability also makes LU711 an excellent penetrant for freeing corroded parts and mechanisms and will not affect plastic, rubber, fabrics or painted surfaces

Open Gear Wire & Rope LubricantHeavy DutyLU 201

High-performance lube that penetrates the pores of metal surfaces to reach the core of wire rope

Provides a wide range of lubrication at high temperatures while adhering extremely well to surfaces

Travels on metal surfaces to displace water, resulting in excellent rust protection

Equipped with an extension tube for hard-to-reach areas or for use while equipment is in operation

Belt DressingSP 607

Has a proven record of effective performance, even when subjected to wet or outdoor conditions and will not glaze or collect dirt or dust

This formulation conditions belts while increasing pulling power up to 50%

Equipped with a Spray Anyway Valve which allows treatment to bottom surface of flat belts while the belt is running, or directly to sheaves of "V" belts

Reduces squeaky noise, caused by old "V" belts

Stainless Steel CleanerCD885

Cleans, polishes, brightens and protects stainless steel and other metal surfaces, such as chrome and aluminum; can also be used on porcelain, ceramic tile and laminated surfaces

Water spots, spills, food soils and oil based stains are easily removed

Invisible coating resists further soiling, fingerprints, watermarks and rusting and polishes to a non-greasy film

Item # Mfr Part # Container Pkg Qty00866776 S00202 11 fl oz Aerosol 12/case








LUBRICANTS




Heavy-Duty Hand Cleaner DispenserWall MountGreenLink

Heavy-duty hand care wall mount system For use with square gallons only

Soy Industrial Hand CleanerGreenLink

A green product that works Tough, yet gentle on hands No harsh petroleum solvents Walnut shell abrasive effectively loosens grime Will not clog drains

Industrial Hand Cleaner w/ Abrasive

Industrial strength phosphate-free pumice hand cleaner with mild, low-odor solvents and a clean, fresh cherry fragrance

Removes stubborn industrial soils, inks, resins, paint, general purpose adhesives, tar, carbon and asphalt easily

Enriched with emollients but fortified with pumice, tackles stubborn industrial soils leaving the hands feeling great after repeated washings

Alcohol Hand Sanitizing Gel

This environmentally friendly, alcohol-based hand sanitizer effectively controls harmful micro-organisms and helps prevent the spread of germs

For use in food plants, restaurants and food service areas

Formulated for use without water or towels, no rinsing required

May be used repeatedly throughout the day without irritation

Use as a supplement to regular hand washing

Glass CleanerReady-To-Use Save the time it takes to dilute concentrates with this

easy, ready-to-use non-streaking glass cleaning option A non-aerosol spray that effectively cleans glass and

any other surface not harmed by water Fortified with ammonia, this convenient spray quickly

removes fingerprints, dirt and smudges

General Purpose CleanerReady-To-Use Formulated for use on all surfaces not harmed by

water, this easy-to-use product has outstanding cleaning ability on a wide variety of soils such as wax build-up, black marks on floors, fingerprints and other types of soils encountered in daily cleaning

Spray Disinfectant Disinfects pre-cleaned surfaces or objects Kills TB, Salmonella, Paratyphoid B, Streptococcus

pyogenes, canine-related and other viruses Kills athletes foot fungus, E-coli and Staphylococcus

aureus as well as controlling mold and mildew Effective against HIV-1, Herpes and flu virus Dries instantly leaving no oily film Pleasant country garden fragrance attacks and destroys

malodors at the source

Disinfectant Deodorizing CleanerLemon Scented

Concentrated Quat-based cleaner, disinfectant and deodorizer can be used at different dilutions for most any cleaning/disinfection task

Effective against Staph, E-Coli, Salmonella and Canine Parvovirus

Dilute, spray on, let stand and rinse Economicaldilutes up to 2 oz per gallon of water

Broad Spectrum Disinfectant CleanerGreenLink A one-step disinfectant cleaner and deodorant,

kills 99.9% of germs and bacteria Just spray on, let stand, wipe or rinse Quickly cuts grease and heavy soils Kills Canine Parvovirus and HIV 1

Item # Mfr Part # Size05246455 R09701 Gallon

Item # Mfr Part # Container Pkg Qty05246454 R05325 Gallon Jug 4/case

Item # Mfr Part # Container Pkg Qty05246453 R04825 Gallon Jug 4/case

Item # Mfr Part # Container Pkg Qty04245162 R10901 500 mL Dispenser 12/case

Item # Mfr Part # Container Pkg Qty03972912 R04601 Quart Spray Bottle 12/case


Item # Mfr Part # Container Pkg Qty05415377 R15601 20 fl oz Aerosol 12 cans/case

Item # Mfr Part # Container Pkg Qty03972868 R02201 Qt Bottle 12/case


JANITORIAL SANITATION




Universal PadPrecutHeavy Weight, High AbsorbencyMRO Universal Mat Pads

Value-pric

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