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Automation
It Takes a Villiage

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.”

 

When to use UL489 vs UL1077 Circuit breakers - courtesy of Rockwell Automation

Modern electrical equipment continues to increase in complexity and importance in industrial, commercial, and residential installations. This equipment is often considered critical for normal system operations. As such, the importance of circuit protection and overall equipment protection
continues to increase and is a very important topic to understand.

Determining whether a circuit is adequately protected can require a high-level view of the electrical distribution system, from the fault current available at the source of supply down to the end device connected in the system. Circuit protection includes protection from equipment overload conditions, undervoltage and overvoltage conditions, ground faults, and short-circuits. Although mandated by code for any electrical installation, the proper implementation of circuit protection products can be confusing at times. Occasionally this confusion results in circuit protection products that are installed in circuits where their use is not appropriate.

Products addressed in this white paper will include circuit breakers made in accordance with UL 4891, supplementary protectors made in accordance with UL 10772, and manual motor controllers as defined in UL 5083. Application and product use will be explained as suitable for North American installations. Continue reading.

View an application example of UL489 & UL1077 circuit breakers

Is your Allen Bradley equipment up to date?

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

Energy Savings and Motors - Courtesy of the Department of Energy

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.

Optimizing Exceptional Machines: Sustainable Production Matters - Rockwell Automation

Many people use the terms sustainability and going green synonymously, but Rockwell Automation believes that sustainable production encompasses manufacturing practices that transform materials with significantly lower emission of greenhouse gases (GHG), minimize use of nonrenewable or toxic materials, reduce waste, and increase workplace and product safety while optimizing yield and supply-chain integrity. A successful sustainability program reduces environmental impact, achieves genuine economy in the use of resources, delivers a return on investment (ROI), and improves a company’s quity — for both you and your end users. Distinct trends are emerging as both manufacturers and machine builders increase their sustainable production activities, and automation
plays a key role in supporting these initiatives.

No matter where you are in building your sustainability program, a holistic approach is more than being green. It involves optimizing every aspect of how you make machines, by doing more with less. By investing in safer products and processes, resource-efficient technologies, and processes and traceability tools, machine builders and manufacturers thrive.

And it’s easier for machine builders to start building sustainability initiatives. First, ask your customers about their sustainability goals and what they want from you. Next, approach your Rockwell Automation sales representative and get the company’s OEM support team engaged. Rockwell Automation regional teams have the technical resources to support conversions or new designs so you can get equipment operating quickly to your customers’ specifications. Read Full Article

Machine Safety Starts with Design - By Kelly Schachenman, Rockwell Automation

New safety technologies, such as Safety programmable logic controllers (PLC), allow manufacturers to streamline their machine access strategies and improve their machine productivity by tailoring the operation of safety systems to the required task. This allows employees to more quickly diagnose, perform minor service on and restore machinery to production, which can yield major improvement to machine uptime. Many contemporary safety designs use Safety PLCs to assist with streamlining service procedures. Like standard controllers and networks, Safety PLC systems are devices that can be programmed to function differently depending on the task the employee is trying to perform. Read the full article on page 26 of this month's edition of the Rockwell Automation Journal.

Switchgear
Being Selective - by Mark C. Ode,Underwriters Laboratories Inc

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.

Lighting
Successfully Transition from Probe to Pulse Start Ballasts

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
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LEED - The Growing importance of lighting controls to enhance energy savings

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

Supplies & MRO
Top 6 Places to look for energy losses in commercial Buldings - Article from Fluke

ThermalA considerable amount of energy loss is actually temperature related. Hot or cold air leaks from a building are an obvious issue. It took energy to heat or cool that air, and when it dissipates due to a leak, you've wasted that energy. But many other systems and pieces of equipment also manifest their wasted effort/energy in terms of heat.

Small, consistent changes can make a big difference in the profitability of any facility. Find problems fast, fix them, and win by realizing the cost savings. Thermal imaging experts suggest that building owners, building managers and/or facilities engineers inspect the following systems to identify energy losses:

  1. The Bulding envelope
  2. Boilers
  3. Motors & generators
  4. Steam heating systems
  5. HVAC system
  6. Electrical system

This short article will go over these top 6 places, what to look for and the expected savings. Read more

White Paper: Raw Materials Costs and Global Economic Trends Affecting Electrical Component Pricing
This white paper article from Emerson discusses the causes of rapidly rising market prices for raw materials and oil and their impact on the cost of electrical components. Read more
Improvements in MC Cable Fittings - Peter Walsh, PE

arlington fittingsManufacturers 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