February 2013

WIDIA & partners Fastenal & Hi-Speed Corp. join the team

Three Simple Ways to Reduce Energy Consumption

Febr

uary

2013

Inside This Issue:

PUBLISHER Ed Bauer ed@handfmedia.net
mple e Si Thre ys to y Wa nerg ce E n edu mptio R su Con

IA & WID ers n part al & en . Fast Corp peed Hi-S the team join

DIRECTOR OF MARKETING Hank Underwood 205-733-1341 hank@theelectriccurrent.com CIRCULATION/EDITORIAL Brandon Greenhill 205-733-4343 brandon@tipsmag.net

4 12 24 28 30
Company Dee Zee Eagle Bending Gorbel Greaves Jesco Jet Edge Johnson Bros Krenz Vent LEDtronics Phase-A-Matic Provent Quick Screws Ram Mount

Electrical Cable Tray Fire Protection in Chemical and Petroleum Refineries Three Simple Ways to Reduce Energy Consumption WIDIA & partners Fastenal & Hi-Speed Corp. join the team SETCO EXPANDS GLOBAL SPINDLE SERVICE NETWORK INTO ASIA Lincoln Electric Welding Technology Takes Center Stage at Siemens Mobility Divisions Green Manufacturing Facility

CREATIVE DIRECTOR WEB DESIGNER Jacklyn Hobson Danny Thompson jacklyn@handfmedia.net danny@handfmedia.net FACILITATOR/ HEAD COORDINATOR Steven Hobson steven@tipsmag.net CEO Christy Hobson V.P. OF SALES Bart Beason 205-733-1342 bart@tipsmag.net PRESIDENT Glen Hobson

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Pg. 29 IBC 32 BC 21 25 19 11 10 IFC 17 31 7 15 5 1 27 9 10 23 6 Website www.continentalcutoff.com www.deezee.com www.eaglebendingmachines.com www.gorbel.com www.greaves-usa.com www.jescoonline.com www.jetedge.com www.johnsonrollforming.com www.krenzvent.com www.ledtronics.com www.phase-a-matic.com www.proventilation.com www.quickscrews.com www.ram-mount.com wwww.reverecontrol.com www.rigidlifelines.com www.shopbottools.com www.shopdata.com www.steelman.com www.tractel.com www.warehouseequipment.com Continentail Pipe & Tube

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Green Manufacturing Guide is published twelve times a year on a monthly basis by H&F Media, Inc., 2070 Valleydale Rd, Hoover Al 35244 USA. Green Manufacturing Guide is distributed free to qualified subscribers. Non-qualified subscription rates are $57.00 per year in the U.S. and Canada and $84.00 per year for foreign subscribers (surface mail). U.S. Postage paid at Birmingham, Alabama and additional mailing offices. Green Manufacturing Guide is distributed to to qualified owners and managers in the industrial industry. Publisher is not liable for all content (including editorial and illustrations provided by advertisers) of advertisements published and does not accept responsibility for any claims made against the publisher. It is the advertisers or agencys responsibility to obtain appropriate releases on any item or individuals pictured in an advertisement. Reproduction of this magazine in whole or in part is prohibited without prior written permission from the publisher. POSTMASTER: Send address changes to H&F Media, Inc., P.O. Box 382315 Birmingham, Alabama 35238-2315 PRINTED IN THE USA

Revere Controls Rigid Lifelines Shopbot Tools Shop Data System Steelman Industries Tractel Warehouse Equipment

Green Manufacturing Guide February 2013

Electrical Cable Tray Fire Protection in Chemical and Petroleum Refineries

Finding the best option for protecting cables and valves By Clay Booth, Fire Protection Market & Sales Manager, Morgan Thermal Ceramics One of the most significant fire protection requirements for refineries and other offshore locations is the need to protect control cables and control valves in the event of a fire. Several alternatives are on the market, including fire blanket systems, calcium silicate board, and flexible mats that absorb heat in the event of a fire. Each has its benefits and refinery operators need to weigh up the pros and cons of the available cable fire protection solutions to ensure that they select one that is the best for a particular application. designed to protect the cables from fire include: Vendor-certified fireproofed cable tray systems Standard cable trays completely enclosed with insulating, fire-resistant fiber mats, or endothermic mats Cable trays encased with calcium silicate insulating panels with calcium silicate sleepers to hold cables away from bottom of the cable tray Trays with exterior surfaces made of galvanized sheet metal coated with mastic or intumescent fireproofing material. The material used to provide 30-minute fire protection against a hydrocarbon pool fire for grouped electrical cables inside conduit or a cable tray must be tested before installation, using the ASTM E 1725-95 method, Standard Test Methods for Fire Tests of Fire-Resistive Barrier Systems for Electrical System Components. The method is based on a model of the type of fire that could happen at a refinery; one that gets to 1500F at 3 minutes, and between 1850 to 2150F after 5 minutes. Testing is carried out in accordance with hydrocarbon pool fire temperature-curve conditions outlined in ASTM E 1529 (50,000 +/-2,500 BTU/ft2hr). The test is run at positive pressure over at least half the test assembly. Thermocouples are

Protection By Separation
American Petroleum Industry (API) 2218, Fireproofing Practices in Petroleum and Petrochemical Processing Plants, provide guidelines for selecting, applying, and maintaining fire proofing materials that are designed to limit the extent of fire-related property loss in the petroleum and petrochemical industries. Separating refinery operations into fire zones that can be isolated and safely shut down is a key objective, so if a fire breaks out, the flow of the product being refined doesnt feed the fire. The API 2218 guidelines include a variety of protective measures, including fireproofing to improve the capacity of equipment and its support structure to maintain their structural integrity during a fire. Shielding essential operating systems when they are exposed to fire is another important measure. To protect the refinery and its components, the standard requires control valves that turn off the flow in the event of a fire, along with control cables that signal when to shut off the fuel. Under the API standards, this control valve and cable must itself be able to withstand a fire, usually for 20 minutes, but in some circumstances for 30 minutes or more. Examples of cable tray systems 4

Green Manufacturing Guide February 2013

arranged in sets, with thermocouples peened every 6 inches on both rails of the cable tray, and every 6 inches on a bare copper wire centered in the tray. The cable tray is intended to be run empty of cables, which provides approval for zero to 100 percent cable loading. Failure is determined when one set reaches an average temperature rise of 250F, or any single thermocouple reaches a temperature rise of 325F.

Options for meeting fire protection standards

A wide range of options are available to protect control valves and grouped electrical cables against extended exposure to fire and maintain control of equipment operated by the cables. One option involves wrapping cable trays and conduits with a nonflammable high temperature resistant insulating blanket. The fire exposure period is rated in proportion to the wrap thickness and the material is typically weatherproofed in the field. For example, FireMaster 607 Blanket (Figure 1) produced by Morgan Thermal Ceramics is a flexible blanket composed of high temperature fibers classified for applications to 2192F. The core fibers are manufactured using the patented Superwool fiber technology, which uses a low bio-persistent insulating wool, reducing the risk for installers. The blanket wrap system consists of a single layer of 2-inch, 8 pound per cubic foot material, and is designed for up to 12-inch cable trays and conduits. The lightweight flexible blanket wrap is easy to cut, reducing installation problems in 6 Green Manufacturing Guide February 2013

Figure 1

complex designs. A simple wrap design allows easy re-entry for cable modifications. The insulation is supplied with full encapsulation in a glass fiber reinforced foil and polypropylene (FSP) facing as standard, to provide superior handling strength for installation. Optional weather and mechanical abuse protection may be added. The FireMaster fire protection system results in significant material cost and labor savings compared to composite products or rigid board installations. It is also lightweight, preventing the need for additional support structures and associated costs. The blanket wrap system has achieved third-party certification through Factory Mutual (FM) Approval, a global program that includes objectively testing property loss prevention products and services and certifying those that meet rigorous loss prevention standards.

Figure 2 shows the material used in a cable tray application. Figure 3 shows a close-up of an application, demonstrating the materials versatility. Another available option is calcium silicate board, an inorganic, noncombustible high temperature insulation. The material can offer some weather resistance and durability in many environments, but it can be heavy (around 54 pounds per cubic foot), which together with the cutting and fastening methods required, makes it relatively difficult to install. In addition, while the board itself is relatively inexpensive, the waste from cutting and the additional labor required for cutting and fastening, makes it expensive to install. It is also less adaptive to complex cable tray runs. A third option is an endothermic mat

Figure 2- Cable fire protection using FireMaster Blanket Wrap

8 Green Manufacturing Guide February 2013

(e-mat), which protects structural steel, cable trays, and conduit circuits by chemically absorbing heat energy, blocking heat penetration. The product requires the installation of between three to five layers, resulting in increased weight and material costs up to five to ten times higher than insulation or board alternatives. These multilayer solutions also have additional labor costs. On the plus side, flexible mat solutions are not as insulating, so they can often be used to protect power cables, which generate heat. The other options discussed are more appropriate for use to protect control cables, which do not generate a significant amount of heat. The intent of petroleum industry standards is to separate refinery fire zones by enough distance so that if a fire breaks out, it is possible to turn off the flow of chemicals, oil, or gas to the affected area so the fire does not feed itself. In that scenario, the cables and valves controlling the shut-off valves must be adequately protected. When selecting the most appropriate options to maintain control over these components, be sure to evaluate the total material costs, labor and installation costs, durability under the particular facilitys location, and any associated differences in long term maintenance and replacement costs.

Figure 3- Installations in complex designs

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Green Manufacturing Guide February 2013

Thr ee Sim ple Way s...

12

Green Manufacturing Guide February 2013

...t Re o du En er ce gy

... Consumption

Welding Operations

in Your

by Matt Albright, Product Manager The Lincoln Electric Company

Todays manufacturers face a daunting challenge: Running a production line that not only delivers quality product on time and on budget but also meets various demands for energy efficiency and savings. Welding operations in any manufacturing facility are no exception. In fact, welding annually consumes at least $15 million worth of electricity in the United States and about $99 million worldwide. Todays manufacturing environments need an energy-efficient, reliable welding program that not only produces quality welds using multiple processes but also saves on operating and electricity costs. If youre ready to boost the overall efficiency and reduce energy requirements of your facilitys welding operations in efforts to achieve this goal, consider following these three, easy steps:

Welding equipment is no exception, seeing that it can be a major power consumer on the shop floor. Rather than living by the old adage, If its not broken, dont fix it, ask yourself this: Are our current welding power sources maximizing energy savings and efficiency?

1) Assess your existing equipments efficiency

Take a hard look at your welding shop and determine a time to make crucial upgrades that will increase overall productivity and quality as well as energy efficiency. Chances are if they are more than even five years old, theyre not. Even if theyre running in like new condition, older welding power sources lack the energy-saving capabilities of newer technology. While the upfront cost of upgrading might seem a bit daunting, the payback on upgrades may be faster than you think. The latest welding power sources offer many benefits on the production line from increased weld quality and deposition to increased energy efficiency. New software-driven production monitoring capabilities are also available.

To determine if your existing equipment is putting a dent in your bottom line, follow these steps:
14 Green Manufacturing Guide February 2013

Step 1 Calculate output power

Take the output voltage, which is given as volts on your welding power source, and then multiply it by the output current, found on your power source in amps. The total is known as output power.

Step 2 Calculate input power

Divide the total output power by the power sources efficiency, which is provided by the welding equipment manufacturer to yield input power in kilowatts (KW).

Step 3 Calculate daily operating costs during welding

To calculate KW hours used in one day, take the input power and multiply it by the hours per day that the power source is actively welding. Now, take this total and multiply it by the price per KW hour.

Step 4 Calculate the daily operating costs during idle periods

To calculate the idle consumption per day, first take the input power, multiplied by the idle hours per day. Youll need this number later in your calculations. Now find your power sources input power idle number provided on the rating plate or in the instruction manual in watts and multiply it by the idle hours. Then, multiply by the price per kilowatt hour of power.

Step 5 Calculate the total operating costs

Take the daily operating costs for welding as determined in Step 3 and add the daily operating costs for idle periods as calculated in Step 4. This equals the daily operating costs in dollars. By comparing this final number for an older welding power source with the estimated daily operating costs of newer, more efficient power source, you can easily tell which machine will provide cost savings and an ultimate return on investment. To calculate energy savings between a modern inverter-based welding power source and conventional welding power sources in your plant, try this handy calculator: http:// content.lincolnelectric.com/products/calculator/inverters/inverter-energy.html. 16 Green Manufacturing Guide February 2013

Inverter-based power sources allow manufacturers to deliver more power output from new power electronics technology, resulting in a better performance-to-size ratio. These models also deliver smooth operation with greater efficiency than many older, conventional welding power sources. In the past, welding power sources were based on conventional transformers. The power supply took in 60 Hz 230, 460 or 575 volt power. A metallic transformer changed it from the relatively high input voltage to 60 Hz current at a lower voltage. This current then was rectified by a device known as a rectifier bridge to get a DC welding output, which was controlled by relatively slow control systems. Older industrial power sources built on this technology are typically heavy and large, weighing in at 400 pounds or more. All tend to heat up during use and have limited ability to pulse any faster than 120 pulses per second due to control inefficiencies. With inverter technology, the incoming 60 Hz power is first rectified to DC and then is fed into the power supplys inverter section where it is switched on and off by solid-state switches at frequencies as high as 120,000 Hz. This pulsed, high-voltage, high-frequency DC then is fed to the main power transformer, where it is transformed into the low-voltage DC thats suitable for welding.

2) Consider switching to inverter technology

Some of the newest welding power sources, rated at 650 amps at 100 percent duty cycle with a range of 10 to 815 amps, weigh in at only 165 pounds vs. over 700 pounds for a single traditional power source of similar amperage. The new inverters also have a much smaller footprint than traditional welding power sources. Inverters also feature advanced input voltage protection a must for high-performance use on job sites where power supplied to the welding power source isnt always necessarily robust or reliable, and instead can be more erratic. Lincoln Electric worked with some large end user customers to develop the latest inverter technology so that it is capable of surviving as much as 1000-volt input spikes on the job, and their welding equipment has survived and continued to operate.

Portable and lightweight, inverter-based welding power sources provide precise arc-starting capabilities and advanced output controls that allow welders to fine tune their welding output to desired parameters. The technology behind these units provides manufacturers with a power source 18 Green Manufacturing Guide February 2013

that can perform high- and low-amperage fluxcored, stick, TIG and MIG welding, not to mention arc gouging and even CV submerged arc.

Another way to track energy efficiency, overall production efficiency and quality is to begin using production monitoring tools in your welding operations. The latest welding power sources provide data collection capabilities Todays re-imagined inverter models dethrough special weld data acquisition tools, allowliver multi-process welding capabilities, offering faster arc response, smoother arc action and a more ing monitoring of weld performance, equipment condition and efficiency. consistent bead appearance. This yields quality welds the first time around, eliminating the need to re-weld and also lessening the incidence of scrap. These tools provide immediate, user-friendly access to a wide array of data monitoring information regarding the welding arc, helping 3) Closely track shop floor fabricators deliver and verify procedure adherence, production & efficiency including current and voltage information, as well as True Energy and heat input verification, Green Manufacturing Guide February 2013

20

especially for those applications requiring heat input records. These units feature advanced digital controls to sample the welding arc parameters at extremely high speeds to deliver consistent and reliable statistics. The latest monitoring tools now use the cloud and Software-as-a-Service (SaaS) technology. No computer hardware is required saving on both capital expenditures and the energy to run such equipment and the welder information can be viewed anywhere, anytime, and with any web device, without any special software. With SaaS, the software application is not installed on a client computer or server like traditional licensed software. Instead the software is hosted remotely and accessible to a client over the Web. With SaaS, up-front expenses are minimal because of the subscription-based pricing model; implementation is quick, and software upgrades are easily accomplished. AlwaysOn alert systems in the newest monitoring programs can track and analyze weld-

er and facility faults, alerting you to issues even while you are away from the shop. This feature allows you to access your welder data anytime from anywhere giving you 24/7 production and efficiency statistics that can be crucial to business decisionsand savings.

Energy savings: Easier than you think

While the idea of revamping welding operations and equipment to reap much-needed energy savings might seem daunting at first, even a few simple changes can make a difference. No two manufacturing facilities are alike. And, thus, no two facilities have the same level of energy usage in their welding shop. Careful assessment of your plants needs and power usage is the first step in generating savings. From that point forward, you can decide to upgrade, streamline and monitor your welding equipment in the way that best suits your shops needs and overall savings goals.

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Green Manufacturing Guide February 2013

WIDIA and partners Fastenal and Hi-Speed Corp. join the team
The United States Bobsled & Skeleton Federation (USBSF) announced today that WIDIA, the worlds premiere manufacturer of metalcutting products, and their trusted partners Fastenal and HiSpeed Corp. have joined the team as sponsors for the 2012-2013 and 2013-2014 World Cup seasons leading up to the 2014 Winter Olympic Games in Sochi, Russia. They join BMW, Under Armour, National Guard and KOA as full sled sponsors. Right out of the gate the dynamic four-man bobsled team of Nick Cunningham, Adam Clark, Andreas Drbal and Chris Fogt won a bronze medal while racing the WIDIA sled in the World Cup season opener in Lake Placid, NY. The tour continues through Europe, culminating with the World Championships in St. Moritz, Switzerland (January 25 February 3, 2013) and then an Olympic dress rehearsal in Sochi, Russia (February 15-17, 2013). The WIDIA, Fastenal and Hi-Speed Corp. partnership goes beyond simple sponsorship, as this trio is also now USBSFs official metalworking champions, ensuring that USAs athletes are sliding down the track with the fastest machined bobsled runners possible. Bernie McConnell, Vice President of WIDIA, sees the partnership as an extension of his companys extreme engineering. 24 Green Manufacturing Guide February 2013

We're extremely excited about our USBSF sponsorship and their prospects for winning the World Cup," McConnell said. "This team personifies the strength and passion of the WIDIA brand, as well as our partners, Fastenal and Hi-Speed Corporation. Our company's brand is built on providing customers with the highest levels of productivity in the most extreme environments just like this team.
"In a sport thats often won by a mere hundredth of a second, a quality runner program can easily make the difference between a podium finish or placing outside the medals. It is an essential component for success and one of the reasons we are excited to have WIDIA behind us. Darrin Steele, CEO of USBSF and bobsled Olympian, said. The U.S. team are the reigning World Champions, winning four gold medals out of six events at the 2012 World Championships in Lake Placid; 86 medals during the 2011-2012 World Cup season; 24 Olympic Medals (nine gold, eight silver, seven bronze since 1928); and 56 World Cup Victories (19 gold, 16 silver, 21 bronze since 1985). For media inquiries, please contact Amanda Bird, USBSF Marketing & Communications Manager, at abird@usbsf.com, or at (518) 354-2250.

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Green Manufacturing Guide February 2013

SETCO EXPANDS GLOBAL SPINDLE

Setco is proud to announce the purchase of a majority interest in NEO Precision Tech. Co., Ltd., Taichung Taiwan, Taiwans premier builder of machine tool spindles and machining heads. After 100 years of serving North America, Setco extended its expertise to the India spindle market in June of 2012 acquiring majority interest in Ultra Precision Spindles Pvt., Ltd. (UPSPL), the largest independent rebuilder of precision machine tool spindles in India. This move further strengthens Setcos commitment to serving its global customer base. Jeff Clark, President of Setco, says NEO is another perfect fit for Setcos overall strategy of growing sales globally. Setco exhibited NEO Precision Techs spindles at IMTS and saw great interest from North American customers and customers across the globe. NEO Precision Tech. custom motorized spindle technology greatly enhances Setcos product offerings as well as support capabilities in Asia. The merging of these two great companies provides customers the best of both companies product offerings while bettering worldwide support. Setco - Setco is owned by Holden Industries, Inc., a 100% Employee-Owned Company headquartered in Deerfield, Illinois, USA. Holden Industries operates four wholly-owned subsidiaries which comprise four core business areas. For 100 years since 1912 Setco has designed, built, and serviced precision spindles and slides and is recognized worldwide as a technical leader in design and manufacturer of precision spindles 28

SERVICE NETWORK INTO ASIA

Cincinnati, Ohio-based manufacturer and servicer of precision machine tool spindles and slides expands globally acquiring Taiwans leading spindle builder. and spindle/slide combinations. Setco is a major spindle manufacturer with over 250,000 spindles in the field new and rebuilt which include belt-driven, geared, motorized, high speed and high frequency models. In addition, Setco offers a complete line of precision linear slides which include dovetail, hardened way and linear rail slides in 21 standard sizes and hundreds of standard catalog models. Setco products are used worldwide in a variety of industries; including automotive, aerospace, construction, die/mold, cabling and winding, plastics, woodworking, stone cutting and general metalworking industries. NEO Precision Tech. - With manufacturing and the corporate office located in Taichung, Taiwan, NEO is recognized as a leader in the design, manufacture and service of high performance precision motorized spindles and machining heads. NEO is only 7 years new but 75 employees strong and growing due to increasing market recognition from machine tool builders around the world for NEOs engineering application depth in building world class motorized precision spindles and machining heads. Its this foundation that Setco plans to build upon and make Setco the worlds most recognized name for precision spindles and machining heads.

Green Manufacturing Guide February 2013

Lincoln Electric Welding Technology Takes Center Stage at Siemens Mobility Divisions Green Manufacturing Facility
Energy efficient Flextec 450 welders proven energy savings makes impact at railcar manufacturers U.S. headquarters When Siemens Mobility Division incorporated solar energy into its U.S headquarters and railway manufacturing facility in Sacramento, Calif., the leading provider of transportation and logistics solutions demanded that sustainability be built into all areas of the plant. This focus on sustainability includes welding, a major component of the assembly line for the facilitys light rail production operations. So major, in fact, that 140 of the headquarters 700 workers are on the welding team for the plants car shell and bogie operations. Spanning 54 acres, the headquarters collective 385,000 square feet of facilities includes warehouse, subassembly, carshell welding, car body painting, cladding, final assembly, bogie assembly and testing areas. Products include traction electrification, propulsion systems, rail automation, rolling stock and integrated services for light rail, heavy rail, commuter rail and locomotives. Siemens supplies one out of every three light rail vehicles in North America and is the market leader. Siemens welding operators use MIG, TIG and stick processes on the carshells and bogies (trucks) for light rail vehicles. Each car shell starts 30

with 3,000 pieces of steel per vehicle, primarily assembled through welding operations one of the plants major energy consumers. Since 2008, Siemens Mobility has completed two construction phases for a solar energy system that generates 2 megawatts of clean, green and renewable electrical power for delivery directly to the manufacturing facility. The system is designed to produce more electrical energy than the facility requires, especially on weekends and holidays. Excess electricity is sent to the Sacramento Municipal Utility Districts (SMUD) grid system and is used to power area homes and businesses. The excess electricity is net metered, and Siemens accrues credits for what the solar system exports to the grid. Siemens turned to Lincoln Electric to pro-

Green Manufacturing Guide February 2013

vide an energy-efficient solution for its 40-booth welding area; namely, a welding power source that could withstand years of high-volume steel welding, while significantly reducing energy consumption with a substantial return on investment. The answer? Energy-efficient Flextec 450 multi-process welding power sources. The new Flextec machines deliver up to 500 amps of welding power, using the latest inverter and transformer technology for faster arc response and considerable energy savings thanks to lower power consumption. The Flextec 450s energy efficiency and welding process versatility was a perfect fit for Siemens welding operators, who handle carbon steel, low-alloy steel, high-tensile steel and stainless steel on a daily basis. 32

Energy efficiency was the driving factor for the purchase of this machine. We wanted the latest inverter technology that offers energy savings and lower power consumption, notes Mayk Lehmann, head of carshell production for Siemens Mobility. The Flextec is a real energy saver. And, an investment return calculation revealed that the payback time for us is only six months.

Green Manufacturing Guide February 2013