Plant Engineering articles from November 2004

Plant Engineering archives from November 2004

2004 Product of the Year awards.
November 1, 2004... Welcome to the 17th annual "Product of the Year" competition. In this issue, we present the 150 finalists to be judged by you, the readers of PLANT ENGINEERING magazine. This contest features some of the most innovative ideas introduced...

Sweating the small stuff.(READER FEEDBACK)(Letter to the Editor)
November 1, 2004... I for one was extremely happy to read your editorial comments in the September issue of PLANT ENGINEERING. Sweating the small stuff is certainly the only way to move toward operational and maintenance excellence. But by definition, paying...

Looking ahead.(Forum)
November 1, 2004... Early next year, PLANT ENGINEERING will be producing a couple of events that you might want to put on your calendar now. The first, our webcast on "New Directions in Electrical Safety," will take place on January 27 at 10 a.m. CST. Through...

On the horizon.(Forum)
November 1, 2004... It's not too early to start thinking about two important programs that can support your efforts toward improving your plant engineering and maintenance operations. Applications aren't due until summer, but now is a good time to begin planning....

Inflation now taking hold.(Forum)(Brief Article)
November 1, 2004... Inflation is running full throttle now as evidenced by the PLANT ENGINEERING construction and maintenance indexes. In the 12-month period ending August 2004, our price index increased 7%, which is up from a meager 0.8% inflation rate in 2003...

Price/cost/demand roundup.(Forum)(Illustration)
November 1, 2004... Price/cost/demand roundup Construction & Maintenance Supplies AVERAGE PRODUCT PRICES % CHANGE DURING 12 MONTHS ENDING Industry ...

A status report.(Comment)(Environmental Aspects)
November 1, 2004... Back in January of 1990, we had the audacity to declare the 90s as "the decade of plant engineering." Were we right? Well, yes and no. Much of what we predicted has come to pass--or at least we've made progress in those directions. ...

Good people keep quitting: what can management do to address it?(Human side)
November 1, 2004... Gazing at the latest Manpower Status Report on his desk, Maintenance Foreman Donald Fritchie was disturbed by the figures. Voluntary resignations of qualified employees during the past six months had exceeded the number of departmental...

Key workers on layoff: can you subcontract work?(Human side)(Brief Article)
November 1, 2004... Maintenance Supervisor Art Bowman and General Foreman Charley Rostoff agreed that it was apparent after last week's snowstorm that Building Two's roof was in need of repair. The problem was that both employees who normally would have been...

Must a steward be paid for representation after hours?(Human side)(Brief Article)
November 1, 2004... Recently appointed Shop Steward George Makos worked the 7 a.m. to 3 p.m. shift. Assistant Steward Murray Flakowitz worked the 2-10 p.m. shift Every Wednesday at 1 p.m. a union-management meeting was scheduled to review current cases,...

Is litigation getting you down?(Human side)(Brief Article)
November 1, 2004... Forget technicalities. Set aside right and wrong considerations. Let's talk about corporate image and morale. Let's talk about productivity. These thoughts ran through Plant Engineer Ernie Froelich's head when Maintenance Supervisor Al...

Take care when checking up on job applicants.(Human side)(Brief Article)
November 1, 2004... Chief Engineer Mark Wilson asked, "Well, Don, what did you think of the applicant?" The question was addressed to Project Leader Don Aronson who had just finished interviewing a young engineer for a staff job. "He's an affable guy and...

Is monitoring e-mail an invasion of policy?(Human side)
November 1, 2004... Maintenance Supervisor Al Gleister told Carpenter Grade II Henry Richter, "I don't want to make a big deal of this, but not only are you sending too many e-mail messages that have nothing to do with your job, some of your language is offensive...

Is lying grounds for dismissal?(Human side)(Brief Article)
November 1, 2004... Electrician Class II Harvey Richman didn't show up for work and failed to call in. Work was piled up and Maintenance Foreman Tony Gentoso didn't get around to calling his home until 11 a.m. "I got a toothache," Richman complained. "I have...

Is refusal to risk icy conditions grounds for dismissal?(Human side)(Brief Article)
November 1, 2004... It was snowing again with the weather expected to worsen as the day progressed. The roads were turning slick and icy. There was a backlog of projects in general and carpentry work in particular in the maintenance department. Of three...

Employee threatened becomes threatener.(Human side)(Brief Article)
November 1, 2004... Stockman Wade Handler was moving a skidload of parts down an aisle when his path was blocked by Utility Worker George Duke who was repairing a sweeper unit in the aisle. "How about moving it so I can pass?" Handler demanded. "Hold your...

Management misassigns overtime.(Human side)(Brief Article)
November 1, 2004... The ways of management are unfathomable at times. It was 5:45 p.m. The quitting buzzer had sounded 45 minutes ago. But Carpenter Grade II Jerry Lloyd was still working. Well, not exactly working. He was finding things to do: Straightening...

Project management in the real world.(Management side)
November 1, 2004... Who would have thought that project management (PM) would make it to primetime television? While the art of getting things done has hit the big time in "The Apprentice" and made it into mainstream media, it has been watered down for the masses....

Understanding surge suppression.(Plant electronics)
November 1, 2004... When thunderstorms occur, do you watch the natural pyrotechnics in awe and wonder? Or do you dread what could be happening back at the plant? [ILLUSTRATION OMITTED] Many plants are protected from the effects of lightning and other...

2004 Product of the Year Awards: Plant Engineering proudly presents the finalists in the 17th annual "Product of the Year" competition. Use the special ballot to vote for the best new products of 2004.(Cover Story)
November 1, 2004... They increase your productivity on the job, maximize your efficiency, and make your life less stressful. This month, we present 150 products that could impact the way you work--the finalists in our 17th annual "Product of the Year" contest. ...

Laser kit aligns rolls.(Maintenance Tools & Equipment)
November 1, 2004... RollAlign is a visual laser tool to facilitate quick yet accurate field replacement of process rolls. It fits rolls of almost any diameter spaced between 1/2-in. and 10-ft apart. Crowned rolls can also be measured and aligned. A laser emitter...

Vibration monitor can predict failures.(Maintenance Tools & Equipment)
November 1, 2004... Octavis vibration monitor detects rolling element bearing failures and shaft unbalance conditions on critical plant equipment such as pumps, motors, compressors, and fans. It is permanently mounted on equipment to continuously monitor a...

Hacksaw folds, protects blades.(Maintenance Tools & Equipment)
November 1, 2004... FS-303 Fold-A-Saw can be quickly folded to a compact size for carrying or storage. The saw is comprised of two, folding, blade-securing members that nest in a U-shaped channel. Space is provided inside the channel for storage of two hacksaw...

Utility blade stays sharp longer.(Maintenance Tools & Equipment)
November 1, 2004... Gold bimetal utility blade features a titanium nitride-coated edge, which offers up to five times more life compared to standard carbon steel blades. Users can extend the life of these blades by using the innovative Gold utility knife which has...

Advanced TIG welder includes pulser.(Maintenance Tools & Equipment)
November 1, 2004... Precision TIG 185 features patented Micro-Start Technology, which delivers extremely stable arc starting, even at low amperages, and minimizes excessive frequency and hot starting normally required to start the arc. The unit also provides an ac...

Rechargeable flashlight is small, light, bright.(Maintenance Tools & Equipment)
November 1, 2004... Strion flashlight features a lithium ion battery, which delivers unparalleled power in an ultracompact size. At just 5.3 in. long and 0.29 lb, with battery, it offers up to 50% weight reduction. The high performance light features a 12,000...

Welder improves productivity.(Maintenance Tools & Equipment)
November 1, 2004... XMT 350 welder features the CC/CV multiprocess inverter. Automatic primary power management technology provides the ability to maintain a rock-steady arc, accept any type of primary power, permits the use of smaller circuit breakers, allows the...

Digital tachometer measures remotely.(Maintenance Tools & Equipment)
November 1, 2004... PLT200 pocket laser is a digital, battery-powered, portable, optical tachometer, which operates up to 25 ft from a reflective target, using a laser light source. The ergonomic design allows safe, direct line-of-sight viewing of both target and...

Workstation for aerial lifts.(Maintenance Tools & Equipment)
November 1, 2004... Workstation in the Sky safely organizes tools and materials for working aloft. Unit has quick-disconnect performance tool packages to increase productivity. Packages include a storable bench, 110 V outlet for power tools, specially sized...

Floor cleaner is battery-powered.(Maintenance Tools & Equipment)
November 1, 2004... Captor Battery Rider Sweeper-Scrubber consists of a high performance sweeping system with dust control, high dump hopper, and a scrub deck that can be sized to match a facility. It can operate as a stand-alone sweeper or scrubber, or as a...

Chain vise easily goes to work.(Maintenance Tools & Equipment)
November 1, 2004... Model 425 Tristand chain vise weighs only 30 lb and is ideal for holding, threading, cutting, and welding pipe from 1/8 to 2 1/2 in. The integral handle allows opening and closing in one motion. A self-locking latch automatically engages when...

Nut drivers have hollow shafts.(Maintenance Tools & Equipment)
November 1, 2004... Rare earth, magnetic tip, hollow shaft nut drivers hold fasteners securely in place, allowing the user to easily turn nuts with just one hand. Standard features include: Cushion Grip handles for greater torque and comfort, color coded handle...

Wireless system monitors equipment.(Maintenance Tools & Equipment)
November 1, 2004... StatusCheck is a wireless condition monitoring system that transmits vibration and temperature data. Each system includes up to 100 wireless transmitters, a data receiver, and a companion software program. The software displays data in real...

Flashlight sees fluorescent dyes.(Maintenance Tools & Equipment)
November 1, 2004... Optimax uses breakthrough, super-hi-flux LED technology to deliver 10-times-brighter leak detection light than regular LED lights. The lamp is powered by a rechargeable NiMH battery that provides more than 6 hr of operation. The light makes all...

Portable analyzer measures vibration, more.(Maintenance Tools & Equipment)
November 1, 2004... VA3 is a portable single or dual-channel vibration data collector and analyzer with a large, high-resolution LCD display and a powerful processor for fast data analysis. The unit is equipped for bearing condition and mechanical defect analysis...

Wireless monitor watches rotating equipment.(Maintenance Tools & Equipment)
November 1, 2004... PROsmart continuously monitors, analyzes, and annunciates an alarm when critical equipment criteria are not met. Cost effective, 24/7 monitoring for vibration, temperature, speed, oil level, seal flush, and seal leak extends the life of...

Laser alignment system shows graphic display.(Maintenance Tools & Equipment)
November 1, 2004... LineLazer detector unit is a detector/transmitter for shaft alignment with a multifunction data logger. Using a horizontally spread laser beam in combination with a vertical detector makes fine-tuning unnecessary. The laser beam is modulated...

Portable pump powers hydraulic tools.(Maintenance Tools & Equipment)
November 1, 2004... Pumpac LT is 24-V, battery-operated pump that is easily carried to a job site to power hydraulic tools. It features 10,000 psi of continuous pressure, weighs 22 lb, and can be worn on one shoulder or strapped to a technician's back and operated...

Guard rails reduce costs.(Construction, Buildings, & Grounds)
November 1, 2004... Ultra-GuardRails made of thermoplastic and fiberglass materials provide strength comparable to steel but are virtually maintenance free. Lightweight, prefabricated lengths and end, line, and corner post kits provide fast, easy field fabrication...

Dock door absorbs impacts.(Construction, Buildings, & Grounds)
November 1, 2004... MxV dock door panels and guide system give way when impacted and are reset to operating condition by simply opening and closing the door. The 3-in. thick, foam-filled panels offer an R value of 16, and the guide system provides a 360-deg...

Bullards serve two purposes.(Construction, Buildings, & Grounds)
November 1, 2004... Smoker's Bollard serves as both a standard parking bollard and a cigarette receptacle. The all-welded, powder-coated units are especially useful near entrances, and encourage cleanliness while protecting facilities and equipment. Unit is...

Barrier increases dock safety.(Construction, Buildings, & Grounds)(Brief Article)
November 1, 2004... Dok-Guardian Safety Barrier is designed to increase dock-area safety by helping to protect employees and equipment from falling off a vacant loading dock. The 44-in.-high barrier manually extends across an opening up to 10 ft 5 in. Heavy-duty...

Guard prevents rack damage.(Construction, Buildings, & Grounds)
November 1, 2004... Rack Sentry Cutout is designed to protect racks than have support beams as low as 6 in. from the floor. The cutout design allows fitting the protectors over beams and around uprights. Units are not attached to the floor and can be removed for...

Coating speeds floor finishing.(Construction, Buildings, & Grounds)
November 1, 2004... Green Concrete Prime & Seal is a high-performance epoxy coating system that can be applied as early as 8 hr after pouring concrete and can be topcoated 8 hr later. User can go from green concrete to finished floor in less than 48 hr. The primer...

Roll door seals tight.(Construction, Buildings, & Grounds)
November 1, 2004... Pharma-Seal II high-speed roll door eliminates the need for coil cords and external photoeyes while significantly reducing space requirements for installing door and controls. Self-sealing door curtain surface virtually eliminates air...

Vinyl roll-up doors are inexpensive.(Construction, Buildings, & Grounds)
November 1, 2004... Power-Roll vinyl roll-up doors offer a low-cost, medium-duty alternative to other doors. Custom-extruded track with reinforced section traps rollers to maintain alignment and prevent blow-out. 110-V motor is mounted in roll-up tube for clean...

Door drive is 'maintenance free'.(Construction, Buildings, & Grounds)
November 1, 2004... RapidRoll 3000 high-speed roll-up metal door introduces Disc-Drive technology for almost frictionless, maintenance-free operation at opening speeds up to 80 in./sec. Aluminum slats wind up without contacting one another, reducing noise and...

Header keeps docks dry.(Construction, Buildings, & Grounds)
November 1, 2004... RainGuard RG-3000 effectively seals the tops of trailers anywhere from 12-ft 3-in. to 13-ft 6-in. tall and can accommodate 14-ft trailers without damage. Header seal adjusts automatically as trailer backs in and creates a tight seal across the...

Restraint adjusts automatically.(Construction, Buildings, & Grounds)
November 1, 2004... VBR-500 Dok-Lok vehicle restraint provides holding force of 32,000 lb while maintaining constant contact with the rear impact guard and adjusts automatically with trailer float motion associated with air-ride trailers. It also accommodates...

Frame system simplifies fastening.(Construction, Buildings, & Grounds)
November 1, 2004... Gatorjaw aluminum framework system has a continuous square thread running the entire length of frame rails on all four sides. Design enables attachments at any point, and fasteners can be loosened, moved, and retightened without damage to...

Coring system is compact, convenient.(Construction, Buildings, & Grounds)(Brief Article)
November 1, 2004... DD 200 diamond coring system cores holes up to 16 in. in masonry and reinforced concrete. Controls allow easy selection of optimum gear from the tool's three-speed gearing. Core bits are changed with a keyless, quick-release mechanism. Control...

Steel primer eliminates zinc.(Construction, Buildings, & Grounds)
November 1, 2004... Steel Spec epoxy primer is the first non-zinc-containing coating to be Class B rated for slip coefficient performance and bolted connections per ASTM and AISC specifications. Primer is easier to apply than inorganic zinc coatings, can be...

Suite provides real-time data.(General & Maintenance Software)
November 1, 2004... Proficy Intelligent Production Solutions software is an integrated suite for plant production and control. It allows data to be shared among business and plant floor applications, and features scalability, unified data model, shared security,...

RFID enhances CMMS.(General & Maintenance Software)
November 1, 2004... MicroMain XM with RFID is a CMMS with integrated radio-frequency identification (RFID) capability. Plants can use RFID in addition to, or in place of, bar codes for maintenance management, particularly in asset tracking, asset maintenance...

Software improves asset reliability.(General & Maintenance Software)
November 1, 2004... Ivara EXP-Release 4 reliability software incorporates predictive and condition-based maintenance capabilities. Release 4 features include analytical capabilities through the use of multiple data points with dates, sophisticated calculations and...

Trash bin lid activated by motion.(Environment, Safety, & Health)
November 1, 2004... Ultra-SmartBin features a motion-activated lid that opens automatically so that hands stay safe from biohazards and other wastes, as infrared sensors detect motion and provide touchless opening. Lid closes 3 sec after hand/object is removed...

Reverse air filter allows for simple operation.(Environment, Safety, & Health)
November 1, 2004... RAF-IS is a special design reverse air filter using a simple, effective cleaning mechanism to sweep the filter bag plate. Media is designed for highly combustible dust and high-temperature applications. Cleaning system recycles the filtered air...

Rail exceeds OSHA regulations.(Environment, Safety, & Health)
November 1, 2004... ParaRail is a non-penetrating, self-supporting system that allows workers full access to a leading edge on a flat roof or the roof's parapet. It provides fall protection for a variety of tasks, including maintenance for security cameras,...

System uses clean agent to fight fire.(Environment, Safety, & Health)
November 1, 2004... Sapphire is a fire suppression technology utilizing a chemical agent that looks exactly like water, but fights fire without causing water damage to electronics, tapes, and other critical assets. The fire protection fluid will quickly evaporate,...

Device puts control into permitting.(Environment, Safety, & Health)
November 1, 2004... Safety in Your Hand is a handheld computer with preinstalled safety software for lockout/tagout, confined spaces, and hot work permitting. Benefits include increased accident prevention, reduced risk management costs, ease of administration for...

Monitor warns when sound levels exceeded.(Environment, Safety, & Health)
November 1, 2004... Sound level monitor model SL120 assures occupational safety and protection by providing a warning when sound levels exceed the programmable set point. The set point is adjustable between 30 and 130 dB. Large LCD display (easily seen from more...

Program increases electrical safety.(Environment, Safety, & Health)
November 1, 2004... Safetyplus is a program designed to provide educational tools and training aids that will increase plant safety. A PowerPoint presentation is included, as well as a safety brochure, technical articles, arc flash hazard calculators, warning...

Coating helps speed evacuation.(Environment, Safety, & Health)
November 1, 2004... GlowGRIP is a cost-effective photo-luminescent, nonskid coating that can be painted on virtually any surface, including floors, ramps, and stairs, to provide slip resistance and illumination without electricity. Emergency illumination lasts up...

Modular shower sets up quickly.(Environment, Safety, & Health)
November 1, 2004... De-Con Pac instant modular decontamination shower sets up in 2 min. by one or two people and can be used as a single unit or as a staged, modular, multistation decontamination system. There is no need for air inflation, electricity, piping, or...

Device prevents suspension trauma.(Environment, Safety, & Health)
November 1, 2004... Relief Step safety device helps a worker suspended in a full-body harness avoid the effects of orthostatic intolerance, also known as suspension trauma. Relief Step deploys when the worker activates a clearly marked tab. The worker inserts one...

Mat offers comfort and support.(Environment, Safety, & Health)
November 1, 2004... BubbleZorb antifatigue mat absorbs most nonaggressive liquids while providing cushioned support for feet, legs, and back. Nonpermeable bottom layer features durable polyethylene-nylon air bubbles capable of withstanding more than 2000 lb/sq ft...

Dust collector is compact, versatile.(Environment, Safety, & Health)
November 1, 2004... BDC Series compact media dust collector is an economical and highly versatile system that is customizable and provides up to 99.9% filtration efficiency. This self-cleaning, continuous-duty system is available in eight sizes and uses a unique...

Clamp meter is easy to read.(Instruments)
November 1, 2004... Industrial Clamp Meters feature bottom display so users can keep head and face out of potentially dangerous panels while viewing measurements. Tapered jaws with hook tip can separate a single wire out of a bundle. Audible and visual indicator...

Sensor sends speed across network.(Instruments)
November 1, 2004... SpeedTalker DN speed sensor operates on DeviceNet and is designed to operate in hazardous environments to provide operating speed of rotating shafts along with under-speed and over-speed detection. Sensor conforms to ODVA specifications, uses...

Monitor senses arcing.(Instruments)
November 1, 2004... UE-ECM 586 cabinet monitor senses ultrasonic emissions produced by arcing, tracking, and corona and remotely alerts of these occurrences. Healthy electrical equipment produces little or no ultrasound energy. When a failure or arcing hazard is...

DMM measures adjustable speed drives.(Instruments)
November 1, 2004... Model 87 V digital multimeter (DMM) uses low-pass filter circuits that allow accurate voltage and frequency measurements on adjustable speed motor drive systems. DMM features built-in thermometer, large display digits, bright white backlight,...

Instrument transmits wirelessly.(Instruments)
November 1, 2004... XYR 5000 wireless transmitters measure and communicate process variables and asset status online without the need for wiring or external power. The wireless transmitter family includes devices for accurately monitoring gauge pressure,...

Sensor diagnoses itself.(Instruments)
November 1, 2004... Digi-Tel temperature transmitter offers field selection of 17 factory-scaled temperature ranges from -75 F to 1200 F. Transmitter features rugged stainless steel housing for RMI/RFI rejection, accuracy up to [+ or -]0.1% of full scale, 4-20-mA...

Sensor sees full-circle.(Instruments)
November 1, 2004... PresencePLUS P4 GEO vision sensor for 360-deg inspections features low cost, small size, and ability to inspect for correct features regardless of product orientation or position in the sensor's field of view. Vision sensor offers an intuitive...

Laser calculates volume.(Instruments)
November 1, 2004... PD 30 laser range meter measures distances from 2 in. up to 600 ft in less than 0.5 sec with accuracy of [+ or -]1/16 in. Meter calculates area, volume, and subtracts measurements to allow for offsets, square footage, or inaccessible heights....

IR camera records voice.(Instruments)
November 1, 2004... ThermaCAM P65 handheld infrared camera allows users to record up to 30 sec of voice with each image. Camera features high resolution; FireWire, USB, and IrDA connectivity; AVI file storage; removable CompactFlash memory card; color viewfinder;...

Clamp meter measures temperature.(Instruments)
November 1, 2004... Series 1000A ac clamp-on meters feature noncontact IR thermometer with laser pointer. Functions include ac/dc voltage, resistance, capacitance, frequency, diode, and continuity. Meters have 1-msec peak hold to capture inrush current and...

DMM selects function automatically.(Instruments)
November 1, 2004... PM 55 compact precision DMM is the world's smallest CAT III-rated multimeter, with one-touch function selection and noncontact ac voltage detector. It automatically selects among ac voltage, dc voltage, or resistance based on the test point to...

Compressor saves energy.(Compressed Air)
November 1, 2004... ZT-160-VSD-FF rotary screw air compressor combines a variable speed drive, with EMC compliance, and a heat-of-compression dryer to save energy. The unit provides 100% oil-free air with instrument-class pressure dewpoints. Other features...

Air dryer works with partial load.(Compressed Air)
November 1, 2004... VCD is a variable capacity, refrigerated compressed air dryer that combines variable speed and thermal cycling technologies to achieve unsurpassed energy savings at all loads. The unit provides a constant dew point under all part-load...

Flat air nozzle is adjustable.(Compressed Air)
November 1, 2004... 2" Super Air Nozzle is a highly efficient flat air nozzle that produces a wide air stream ideally suited for blowoff, cooling, and drying applications. The unique nozzle uses patented technology that permits adjustment of force and air volume...

Small compressor is variable speed.(Compressed Air)
November 1, 2004... Solo Series variable speed rotary screw compressors range from 7.5 to 20 hp. Controls vary the speed of the motor to match air demand and save up to 35% in energy costs compared to conventional compressors. The units are quiet, as low as 58...

Dryer adjusts to required load.(Compressed Air)
November 1, 2004... SRV refrigerated air dryer combines the most advanced features of variable speed drive with those of thermal mass storage to deliver maximum energy savings and the lowest possible dew point. For high airflows, the dryer uses variable speed...

Filter has low pressure drop.(Compressed Air)
November 1, 2004... Oil-X Evolution compressed air and gas filter has a smooth, 90-deg inlet elbow and turning vanes to reduce differential pressure. The pleated media pack boasts high dirt-holding capacity, lower pressure drop, and deep pleat media beds. The...