Ensuring asset reliability isn’t what it used to be. Today, it requires the convergence of process control with work management. This convergence resolves weaknesses in one methodology, while being additive for both.
Consolidated Coupling Catalog
Emerson’s new Power Transmission Solutions industrial coupling catalog covers Kop-Flex®, Jaure®, Morse® and Brown-ing® products in bore sizes to 43.5” and torque ratings to 329,000,000 lbs-in. Styles range from simple rigid and sleeve units to multiple types of disc, gear, chain, elastomeric, barrel, U-joint, shear-pin and tapered grid couplings. This 300-pg., consolidated resource also addresses custom units like flexible-coupling drive shafts.
Power Transmission Solutions
A unit of Emerson Industrial Automation
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Arc Flash Protection System
The TVOC-2 from ABB’s Low Voltage Products division is a new generation of the company’s Arc Guard System™ that provides enhanced arc flash protection. It detects faults in low- and medium-voltage switchgear and disconnects power provided to the arc within 30 to 50 milliseconds. TVOC-2 is now UL-listed, and when installed with ABB’s Emax circuit breakers, carries a functional safety rating of SIL-2 that confirms the product has achieved the standard required to protect both humans and equipment.
New Berlin, WI
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Laser Alignment In Explosive Environs
LUDECA has introduced what it says is the first wireless module certified for laser alignment of machinery in explosive environments. The unit operates with the OPTALIGN smart EX or ROTALIGN smart EX laser shaft alignment systems by PRUEFTECHNIK. Measurement data is transferred between the measurement sensor and alignment computer using the ATEX/IECEx-certified EX RF module, which makes alignment jobs easier and more convenient without compromising operator safety. According to LUDECA, it and PRUEFTECHNIK are the only companies currently offering this capability for equipment alignment in the types of explosive atmospheres that can be found in petrochemical, mining and other process operations.
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Expanded Motor Lineup
Baldor has added 98 new ratings to its line of Reliance® Super-E motors with Internal AEGIS Bearing Protection Rings that offer off-the-shelf availability of units with pre-installed internal shaft grounding. The new ratings expand the company’s existing 4-pole line of TEFC & ODP designs through 100 hp, and add a number of 2- and 6-pole models. 575V TEFC motors from 1 to 50 hp in size have also been added to the lineup, as have TEFC & ODP close-coupled pump models.
Baldor Electric Co.
A member of the ABB Group
Fort Smith, AR
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Environmentally Friendly Removal Of Limescale
ScaleBlaster notes that its environmentally friendly product can eliminate limescale deposits in pipes, cooling towers, boilers and numerous other applications. An integrated circuitry system produces a complex modulating frequency waveform that hits the resonant frequency of calcium molecules, causing them to lose their adhesive properties. Existing scale is removed without the need of chemicals, salt or maintenance.
North Largo, FL
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Process Heating & Cooling Systems
Mokon’s Full Range process heating and cooling systems offer temperature ranges of 50 to 600 F (10 to 315 C). Combined with a chiller, a Mokon heat-transfer fluid system is a self-supporting unit providing heating and cooling in one compact package. The systems are suitable for jacketed vessels, mixers and reactors; multiple-zone processes; installations where rapid cooling is required; and other processes that require both heating and cooling.
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Sprayable Ceramic Coating
Henkel’s Loctite® Nordbak® 7255TM is a two-part, sprayable ceramic coating designed to protect metal surfaces on industrial equipment from wear, abrasion and corrosion. Packaged in a reusable dual-cartridge dispenser, it may be quickly and evenly applied to large surfaces and complex or intricate areas. The coating features a solvent-free, thixotropic formulation and is suited for use on tank linings, mixing vessels, pump housings, impellers, chutes, troughs and centrifuge components.
Rocky Hill, CT
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User-Friendly, 6-Tools-in-1 Handheld Troubleshooter
According to Test Products International (TPI), its feature-rich, easy-to-use handheld Model 440 combines the features of a multimeter with the waveform of a single-input 1 MHz bandwidth oscilloscope that offers true RMS auto-ranging DMM. Advanced capabilities include:
- Viewing waveform to verify power quality delivered to VSDs
- Measuring voltage and frequency at the same time
- 400µF for checking motor start and run capacitors
- DC µAmps for checking flame safety controls
- DC mV for checking thermocouples
Trend Mode allows surges and dropouts to be graphically displayed. Communication to a PC is available by using an optional RS-232 cable and software. The 440 comes standard with rechargeable battery and adapter. TPI offers a range of optional accessories.
Test Products International (TPI)
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Expanded Thermal Imaging Lineup
Milwaukee Tool continues to expand its product offerings with the introduction of its new 160×120 Thermal Imager, powered by M12™ for professional maintenance and troubleshooting applications. The device features 160×120-pixel, high-resolution thermal images, a visual camera for standard pictures and what the company says is the broadest temperature range in its class (-10 to
350 C/14 to 662 F). It incorporates a five-button interface and no-blur, no-wait display that updates the screen image 60 times a second. The 160×120 Thermal Imager kit includes Thermal Imager Report Software that makes analyzing images and generating reports quick and easy. Users can download images from the device with the included 2GB SD card or USB connection port. Powered by REDLITHIUM™ battery technology, the product leverages Milwaukee’s M12™ battery system for quick charging and easy field replacement.
Milwaukee Tool Corp.
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This month’s Technology Showcase is brought to you by:
An electrical-safety program is safer when workers can determine a zero-electrical-energy state without exposing themselves to voltage. Article 120.1(1)–(6) provides a six-step procedure for creating an electrically safe work condition. Here is a portion of the steps:
- 120.1(1) Identify all sources of electrical energy.
- 120.1(3) If possible, visually verify the isolator blades.
- 120.1(5) Use an adequately rated voltage detector.
- 120.1(5) Physically contact the voltage source.
- 120.1(5) Checks voltage phase-phase-ground.
- 120.1(5) Ensure the voltage detector functions before and after the procedure.
Permanent Electrical Safety Devices (PESDs) mounted to the outside of your control panel and wired to every voltage source entering your panel provide a way to verify and identify all sources of electrical energy without exposing workers to that energy (120.1). An illuminated 3-phase voltage indicator verifies the isolator blades of disconnects and circuit breakers while giving a visual indication outside the panel (120.3). The CAT III/IV rating of thru-door voltage indicators and non-contact voltage portals are adequately rated for use in power-distribution systems. Because both devices are physically wired to the voltage source, they meet the 120.1(5). A voltage indicator not only checks voltage phase-to-phase and phase-to-ground, but it performs this function every second of every minute of every day. When a non-contact voltage detector (NCVD) is used in conjunction with voltage portals, each device checks the other to ensure proper functionality before and after the procedure. Furthermore, the NCVD can be checked to another voltage source.
Voltmeters test voltage, then are put back in the tool belt, but a voltage indicator hardwired to the source voltage stays on the job and tests voltage all the time. It is like a lifeguard watching out for workers to make sure no voltage shows up during the work or task. It finds voltage so voltage doesn’t find you. MT
To learn more about specific recommendations and practices, email the author: firstname.lastname@example.org.
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The annual Forum sponsored by the ARC Advisory Group (ARC) took place February 6-9, in Orlando FL. This year marked my 15th trip to the information-packed event, where I again hoped to hear the latest thinking in production and manufacturing.
I’ve written before about my fascination with the CSI (Crime Scene Investigation)-franchised television series. Recognized as some of the most-watched TV dramas in the world in 2011, its plots are modeled on the classic “whodunit” format popularized in Sherlock Holmes stories.
Have you ever considered upgrading the efficiency of your motors but assumed it would take too much time to calculate potential energy savings? As it turns out, a product-neutral tool that quickly provides a back-of-the-envelope estimate of possible savings is just a few clicks away: Check out the recently updated “MDM Simple Savings Chart” (SSC) on the Motor Decisions Matter (MDM) Website, www.motorsmatter.org.
The SSC tool calculates estimated annual energy costs and potential savings from upgrading to a higher efficiency motor. Calcu-lations are based on two simple pieces of information that you enter: cost of electricity and annual operating hours. With these inputs, the SSC provides a side-by-side comparison of estimated annual operating costs and savings for 1-500 hp general-purpose motors, including 1200 RPM, 1800 RPM and 3600 RPM in both totally enclosed fan-cooled (TEFC) and open drip-proof (ODP), at different efficiency levels.
For 1-200 hp, the SSC calculates the costs of operating your motor currently (based on your electricity price and hours of operation), then compares the costs and potential savings associated with operating motors with the following different efficiency levels: Pre-Energy Policy Act (estimated motor efficiencies prior to 1997); Energy Policy Act (federal minimum efficiency levels required by the 1992 law, effective 1997); and Energy Independence and Security Act (higher federal minimum efficiency levels required by the 2007 law, effective 2010). For 201-500 hp motors, costs and potential savings associated with different efficiency levels are similarly calculated.
Consider a 200 hp, 1800 RPM, TEFC, general-purpose motor, running 8000 hours annually with electricity costs of $0.08 per kWh: Using the SSC, we can see that this costs approximately $102,083 per year, if the unit has a pre-Energy Policy Act efficiency level. The cost would be approximately $99,260, if the motor has an EISA efficiency level. The $2823 difference between these operating costs could be your annual savings if you upgrade to a higher-efficiency unit.
As this example demonstrates, using the right tools, it can take just a minute to consider higher efficiency—which could lead to thousands of dollars in savings annually. At the very least, you’ll gain peace of mind just from understanding your options. As most managers know, you can’t manage what you can’t measure, so why not take a minute to get started with an easy, virtually “on-the-fly” (but effective) measurement. Who knows how much you could be saving!
Download the updated Simple Savings Chart today from MDM’s Website and start estimating ROI from upgrading to higher-efficiency motors.
For other proactive motor management tools, visit: www.motorsmatter.org/tools/index.asp. MT