Just as the Pepsi bottling plant saw the need to use manufacturing intelligence tools to have better preparation for quality audits, one pharmaceutical coatings supplier also needed a better way to provide waste treatment reports to the township. Alex Jushchyshyn, plant support engineer with Colorcon, a provider of formulated coatings and other excipients for the pharmaceutical and dietary/food/nutritional supplement industries, assembled a team to accomplish the project. It consisted of an application specialist from Milwaukee-based supplier Rockwell Automation; Rumsey Electric, a Rockwell distributor in Consohocken, Pa.; and process industries system integrator EZSoft, based in Malvern, Pa.

Jushchyshyn describes the situation: “The project was data collection regarding the waste treatment process in our West Point, Pa. plant. We needed proper reports to the township. We developed schemes of how to collect data in an efficient manner. High availability of the data is a must. Manual data collection had to be limited. Operators should be running the plant not running around with clipboards.”

The project started in 2010. “Our networking is fairly integrated, so we figured we should be able to get data at the desk,” says Jushchyshyn. “What we needed included one-click reporting, no data manipulation to get summaries, and more. The other big piece—the system had to be expandable. We needed to work with the IT group to understand the networking requirements so that people in various locations, from headquarters to the production plant, could all see the information. It also had to enable us to meet regulatory requirements.”
Jushchyshyn reports he has a good relationship with Rumsey Electric. The plant is standardized on Allen-Bradley brand products from Rockwell, and Rumsey has Rockwell-qualified people on staff, excellent facilities and insight into local integrators. “Our engineering group consists of just three people,” Jushchyshyn explains. “We can’t do it all ourselves.”

Marty Fallon, EZSoft vice president of sales says, Colorcon was looking at a single application, “but they needed it to be a global system. As the integrator, we worked with Tim McCain, Rockwell Automation industrial software regional manager, and the distributor and customer. We produced system architecture drawings and functional specs. The scope of the project included integrating Rockwell’s FactoryTalk Historian and VantagePoint software, compiling trend and daily reports, and upgrading some other systems along with AssetCenter.”

Jushchyshyn says that “a year later, it feels like we’re partners. We chose wisely, so we now have a very good integrator to call on and know we’ll get the right thing.” The hardware architecture he describes as an instrument probe feeding data to a local PLC and a local display. Next the data goes to a corporate server some seven miles from the facility. The system includes DIN-rail mounted industrial PCs and Cisco Ethernet switches. “We have our own VLANs, so there are no collisions with our IP telephones. We had to balance our engineering requirements while satisfying the needs of IT. Our engineering group keeps track of eight servers—more than any other department outside IT,” he says.

In the end, Fallon says VantagePoint allows data to be presented from disparate systems and databases on one platform. Adds Jushchyshyn, “That was the real benefit. I could direct users to one interface for everything. I focus on things from an engineering perspective, but my bosses may not be as technical. So I wanted that single click where they can get the information they need. In fact, this is probably the first software package where I got what I asked for. I had five key points and got them all.”

Are you using PLC-2 or PLC-5 controllers?  How about 1336, 1305, or 160 VFDs?  If so, ask Rumsey how we can help you migrate to the latest technologies.  Rumsey has conversion guides and programs available to help transition these older products to Logix Controllers and PowerFlex drives quickly and easily.  The Allen Bradley’s Step Forward program to make the transition even more cost effective.  Contact your Rumsey sales representative or specialist for more information.

Drives Conversion Guide

Industrial fans, pumps and air compressors use more than 50% of the total motor-related electricity used in the U.S. According to the U.S. Department of Energy (DOE), industrial motor-system energy use could be reduced by 11% to 18% if all existing cost-effective technologies and practices for improved efficiency were implemented.
Variable Frequency Drives (VFDs) on motors can enhance process operations, especially for flow control, and can efficiently cut energy demand for pumps and fans. Motors are sized to fit a maximum load and operate at a constant speed. But, demand on motors fluctuates. Greater power is needed at start-up; air pressure changes in a paint booth because doors are opened; more-viscous product is pumped through process lines. VFDs control the difference between supply and demand by automatically matching the motor speed to the actual needs of the system based on input from sensors. VFDs control motors more efficiently than throttling or other means, which reduces energy bills. Contact Rumsey today for more information.

Selective coordination has been a requirement in the National Electrical Code (NEC) for many years but has been limited to a few required applications. With the adoption of the 2005 NEC, selective coordination will apply to a much broader application with an emphasis on coordinating overcurrent protective devices for emergency systems, as well as the original primary issue of minimizing electrical hazards to equipment.

In the 2002 and previous editions of the NEC, the primary requirements for selective coordination and the definition were found in Article 240, covering overcurrent protection of conductors. Selective coordination was normally required where an orderly shutdown was necessary to minimize the hazards to personnel and equipment. The definition in 240.2 read as follows: “Coordination: The proper localization of a fault condition to restrict outages to the equipment affected, accomplished by the choice of selective fault-protective devices.” This definition has been modified and moved to Article 100 in the 2005 NEC. The main goal of selective coordination is to isolate an electrical fault to the closest overcurrent protective device upstream while maintaining power to the remainder of the electrical system.

For example, if a ground fault or a short circuit were to occur in a 20-ampere circuit, a properly coordinated system would ensure that only the 20-ampere overcurrent protective device protecting the branch circuit would open.The branch circuit would be protected while maintaining power to the other branch circuits, feeders and service. If a fault occurred at the feeder level, only the feeder overcurrent protective device would open, leaving other feeders and the service energized. This ensures power loss to only the circuit directly affected by the fault. A short circuit or a ground fault will cause an overcurrent protective device, such as a circuit breaker or a fuse, to react in a certain amount of time, based upon the amount of fault current flowing in the faulted circuit. Read the full article at Electrical Contractor Magazine.

Under the Energy Independence and Security Act of 2007, all 150W-500W metal halide luminaires manufactured on or after January 1, 2009, must contain a ballast meeting the following levels of efficiency: 88% for magnetic or electronic pulse start ballasts or 94% for magnetic probe start ballasts.
Exclusions from the legislation include luminaires that utilize regulated lag or 480V electronic ballasts. Also excluded are luminaires rated for 150W lamps, wet locations and contain a ballast rated for use in an ambient temperature greater than 50°C.  Indicating compliance, affected luminaires produced after this date must exhibit a circled “E” on both product packaging, and on ballast labels. While non-compliant ballasts will no longer be available to our OEMs from Philips Lighting Electronics N.A. they are making identification of compliant product easier by adding an “EE” suffix to the end of every part number that meets EISA requirements.
Retrofitting will not be required for existing probe start metal halide installations, and replacement ballasts will continue to be available from Philips Lighting Electronics N.A. The stringent EISA minimum efficiency requirement of 94% for magnetic probe start ballasts will effectively make 175W - 400W probe start ballasts obsolete in new luminaires after January 1, 2009.  Empowering your efforts to move to EISA-compliant pulse start technology, Philips Lighting Electronics N.A has developed a full line of “EE” ballasts for your varied applications. Please call your Rumsey sales representative today for more information on Philips Lighting Electronics N.A. product offering and how we can help you make the transition to EISA-compliant ballasts.

LEED is a third-party certification program and the nationally accepted benchmark for the design, construction and operation of high performance green buildings. LEED gives building owners and operators the tools they need to have an immediate and measurable impact on their buildings’ performance. LEED promotes a whole-building approach to sustainability by recognizing performance in five key areas of human and environmental health: sustainable site development, water savings, energy efficiency, materials selection and indoor environmental quality. Find out more about LEED on the USGBC website

Manufacturers are refining the older technology of MC fittings to achieve economy and simplification. This is because of the increasing usage of MC cabling versus pipe and wire.

The traditional MC fitting was constructed of expensive steel or malleable iron. It had a one end-stop design and a limited wire application for each model number. The older design was good enough for traditional installations where MC cables were specified. However, new designs were necessary to reduce installation costs for common everyday use of MC cable.

In recent years the National Electrical Code encouraged more use of MC cable by permitting new installation methods. Now MC cable is more competitive with cables installed in pipe. MC cables cost more but the labor is less with MC systems. Electrical contractors have switched over to using MC cable in many projects because the total cost is less.

One company, Arlington industries, has redesigned their MC fittings for the cost competitive high use applications. Instead of steel or malleable iron, they use economical die cast zinc fittings. Instead of a traditional limited range of cable for each model, they have designed their fittings to accommodate a wider range of wire sizes through an interchangeable end stop.

Article courtesy of electricsmarts.com