september 13 & 14, 2016 kalamazoo, mi. air zoo · kalamazoo, mi. air zoo september 13 & 14,...

Kalamazoo, MI.Air Zoo

September 13 & 14, 2016

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The reliability, Process, and Maintenance (RPM) Symposium, is a conference event that features industry leaders in the topics of process and innovation that assures the maintenance and reliability of industrial electric motors, automation components, and other rotating and fluid processing equipment. The conference will engage attendees in discussion, learning sessions, and networking opportunities focused on what solutions are available so that companies can increase their reliability.

The conference will include, but not be limited to:• Exhibit Booths from Siemens, HECO,

and their leading partners in electric motors, predictive maintenance, and the evolving technology of rotating and fluid processing equipment.

• Learning modules that will specialize in what other companies are doing to increase profitability by preventing failures in bearings, pumps, process equipment, gear boxes, and motors. The interactive seminars will be led by industry leaders who are implementing solutions that assure reliability in process and maintenance.

• Social Networking through receptions that include: two continental breakfasts, and two lunches.

RPM Symposium

Anyone who is interested in innovative solutions that will help them keep their plant up and running! Below are a few job titles of individuals who would find this event useful:

Who ShouldAttend?

Plant Managers & Superintendents Facilities & General ManagersMaintenance Managers, Supervisors & PlannersReliability Managers & EngineersPurchasing/Procurement Agents & ManagersElectrical Supervisors & EngineersMechanical Supervisors & EngineersMechanicsProcess TechniciansOperations & Area ManagersProject Managers & EngineersPdM Technicians & Team LeadersVibration AnalystsStore Room Managers & SupervisorsTool Room ManagerEngineering ManagerMRO BuyersElectricians

Register at www.rpmsymposium.com

Join us this September

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Welcome to Kalamazoo, Michigan.

The Air Zoo is a highly charged, multi-sensory atmosphere that goes beyond anything you’ve ever seen. It’s like no place else on Earth!

Voted the “Best Place to Take Out-of-Towners” and “Best Place to Spend a Day with Your Family” three years in a row, the Air Zoo features more than 50 rare and historic aircraft, amusement park-style rides, full-motion flight simulators, RealD 3D/4D missions theater, as well as historical exhibits and educational activities.

AboutAir Zoo

DiscoverMore at:The Air Zoowww.airzoo.orgKalamazoo, MI.www.discoverkalamazoo.comThe Moors Golf Clubwww.moorsgolf.com

The MoorsGolf OutingJoin us at The Moors Golf Outing! All registration forms (with fees) are due no later than September 1st, 2016!

To download the registration form, please visit: http://www.rpmsymposium.com/golf-outing.html

When: Monday, September 12, 2016 at 12:00PM Shotgun Start - after Lunch at 1:00PM

Where: The Moors Golf Club 7877 Moorsbridge Road Portage, MI 49024 Pro Shop: (269) 323-8873

Cost: $70.00 Per Person OR $280.00 Per Foursome

Includes: 18 Holes with a cart and lunch before golf

About Kalamazoo, MI Kalamazoo offers so much more than a memorable name. We like to think that we effortlessly blend energy and innovation with friendliness and a little bit of a humble attitude. We are about two hours from Chicago, and two hours from Detroit. Kalamazoo features a vibrant and progressive downtown that sets the stage for quality dining, eclectic shops and galleries, and live entertainment. We are a town completely dedicated to education with The Kalamazoo Promise, and the home of the Western Michigan Broncos and Kalamazoo College Hornets. We have professional sports and a heartfelt commitment to the arts.

While you are at the RPM Symposium at the Kalamazoo Air Zoo, you will be in the City of Portage where there are great hotels, restaurants and brew pubs. In fact, just less than a half of a mile is Latitude 42, a micro-brewery offering great beer and good food. There will be a host table at the conference with a multitude of things to do while you are in Kalamazoo - so think about staying an extra night. And in order to plan your trip, visit www.discoverkalamazoo.com for ideas and travel information.

We believe that once you come to Kalamazoo, you’ll be back. We Promise.

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Event Timeline

Agenda Day 1

Event Timeline

Agenda Day 2

Complete description of seminars found on pages 9-15

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Tuesday Sep 13, 2016

8:30AM

9:30AM

9:45AM

Room1 Room 2 Room 3 Room 4 Room 5 Non‐Classroom Option11:00AM Bearing Lubrication Energy Savings through Air

FiltrationNew 2016 DOE Electric Motor Efficiency Standards and Siemens motor update

How to "Fix" Vibration Problems

Optimizing the Design of AC Medium Voltage Form Coils

Guided Tour Of AirZoo's Main Campus Location

12:00PM

1:00PM

2:00PM AC Adjustable Speed Drives Motor Basics

Embedded Machinery Condition Monitoring

AEGIS Bearing Protection Rings ‐ Bearing Current Mitigation for Rotating Equipment

Repair Vs. Replacement Decision Making ‐ Best Practices

Case Study on 9000HP, 13.2KV BFP Motor with Rotor/Vibration Issues

3:00PM My Pump Called in Sick Today

A Critical Component to Improving Reliability Centered Lubrication

Medium Voltage Drives and Applications

Uncommon Balancing and Misalignment Concerns

Machinery Alignment Challenges

4:00PM Basics of Oil Analysis Power Transmission Basics

The War on Talent Repairing Electric Motors for Reliability

Gearmotor Solutions for Material Handling

Guided Tour Of AirZoo's Restoration Facility

5:00PM

RPM Symposium 2016 ‐ Agenda

Lunch (AirZoo Floor)

Conclusion of 1st Day of Event

Registration & Continental Breakfast (AirZoo Floor) ‐ Exhibition Open

Opening Welcome & Announcements (AirZoo Floor)Justin T. Hatfield, VP Operations, HECO ‐ All Systems Go

Session Sechedule

Kick‐Off Speaker (AirZoo Floor)You. In the Pilot's Seat

Elizabeth McCormick, Author, Speaker, and Former US Army Black Hawk Helicopter Pilot

Exhibiton Floor Open

HECO Electric Motor Repair Facility Guided Tour (Meet outside front of AirZoo)

Wednesday Sep 14, 2016

8:00AM

Room1 Room 2 Room 3 Room 4 Room 5 Non‐Classroom Option9:00AM Coupling Overview The War on Talent AC Adjustable Speed

Drives Motor BasicsOptimizing the Design of AC Medium Voltage Form Coils

Basics of Oil Analysis Guided Tour of AirZoo's Restoration Facility

10:00AM My Pump Called in Sick Today

Case Study on 9000HP, 13.2KV BFP Motor with Rotor/Vibration Issues


Repair Vs. Replacement Decision Making ‐ Best Practices


Guided Tour Of AirZoo's Main Campus Location

11:00AM

12:00PM

1:00PM Power Transmission Basics

New 2016 DOE Electric Motor Efficiency Standards and Siemens motor update


Uncommon Balancing and Misalignment Concerns

Gearmotor Solutions for Material Handling

2:00PM AEGIS Bearing Protection Rings ‐ Bearing Current Mitigation for Rotating Equipment

Energy Savings through Air Filtration


How to "Fix" Vibration Problems

3:00PMEvent Conclusion

Registration & Continental Breakfast (AirZoo Floor) ‐ Exhibition Open

Session Sechedule

HECO Electric Motor Repair Facility Guided Tour (Meet outside front of AirZoo)

Lunch (AirZoo Floor)

Exhibiton Floor Open

2016 Sponsors/ExhibitorsElectro Static Technology, a division of Illinois Tool Works, was founded in 1984 specializing in conductive micro fiber conduction technology and acquired by Illinois Tool Works Inc. in 1999. Specializing in the application of conductive micro fibers to solve static and stray voltage problems, we manufacture the patented AEGIS® Bearing Protection Rings for rotating equipment and electric

Alignment Supplies Inc. Is the premier distributor of the B.A.T. Belt Alignment Tool™ , Machinery Guard™ Monitoring Solutions and the Stealth Series™ Laser Shaft Alignment systems. ASI also provides solutions for vibration analysis, infrared, ultrasound and the most advanced wireless technology available for Condition Based Monitoring.

Bearing Service is the largest independent Michigan-based distributor of bearings and power transmission products. Bearing Service is focused on helping MRO & OEM customers by educating their employees, servicing hard-to-find products, and helping them to manage their inventories. We’ve been offering premium service & expert solutions since 1943.

Camfil is a global air filtration manufacturer focused on developing and manufacturing sustainable clean air solutions that protect people, processes, and the environment against harmful airborne particles, gases, and emissions. These solutions are used globally to benefit human health, increase performance and reduce energy consumption in a wide range of air filtration applications.

Since 1969, Electro-Matic has helped transform American industry by supplying automation components and solutions to leading U.S. manufacturers. Today, Electro-Matic continues to leverage the value of emerging technologies by developing practical applications for industrial, commercial and retail markets. As a technology company, we help our customers turn innovation into value. As a one-hundred percent employee-owned business, our customers enjoy the benefit of a supplier partner intently focused on delivering strong value-for-value

HECO is the industry’s “why” company. We specialize in custom systems that optimize the performance of the entire electric motor driven powertrain. When you tell HECO you’re having a motor problem, we want to find out why. Why did a failure occur? Why didn’t you know about it ahead of time? Why is a new motor really needed? Why isn’t the right spare on hand? We then use the answers to develop custom solutions through our repair, new equipment, predictive, and spares services and products.

ITT Goulds Pumps is among the most widely recognized and respected brands in the global pump industry, serving customers in the oil and gas, mining, power generation, chemical, pulp and paper, and general industrial markets. PRO Services is a sister brand of Goulds Pumps and provides a wide array of aftermarket products and services to improve customers’ equipment total cost of ownership. One of the products is the i-ALERT2 Bluetooth Equipment Health Monitor, a revolutionary product that allows customers to identify potential problems before the become costly failures.

Centrifugal and PD pump repair, sales, and on-site service up to 120”. Pump Reliability Training, Pump health audits, and pump energy audits. Industrial motor, VFD, and SCADA sales.

Since 1987, Pro Services has provided skilled trades and maintenance technicians to industrial, commercial, and residential customers nation-wide. We are deeply rooted in enhanced training, futuristic technology, and cutting-edge productivity: We offer 24/7 operations to ensure your needs are continuously satisfied.

Today, in industrial plants and systems around the world, many millions of Siemens motors are ensuring motion and efficient operation. In all sectors, applications and performance classes. Starting with energy efficient low-voltage motors through motion control motors with a high dynamic performance up to DC motors and powerful high-voltage motors. Through ongoing and persistent innovation, Siemens has always been able to prove its competence when it comes to electric motors. For instance, just recently with the development of a high-speed, high-voltage motor with up to 15,000 rpm in the Megawatt range.

TestOil is a full service oil testing laboratory operated by Insight Services. Since 1988 the company has been providing fast and reliable oil analysis results across all industries throughout the Americas. The firm’s comprehensive range of oil analysis services assists reliability engineers with condition monitoring and identification of machine wear. TestOil employs a sophisticated diagnostic technology that assists their Machine Condition Analysts in making equipment and lubrication condition assessments.

UE Systems manufacturers the Ultraprobe Series of ultrasonic test instruments ideally suited for both condition monitoring of rotating assets and condition based lubrication. Instruments are also used for energy conservation, applications such as compressed air leak detection, steam trap and electrical inspection

HECO’s Predictive Service Group (HECO PSG) provides on-site maintenance and reliability services for industrial facilities. Our engineers and technicians are experienced in a wide variety of equipment and associated technologies. From setting up and running predictive maintenance programs (PdM) to performing corrective actions such as balancing or alignment, HECO PSG has the experience that you can trust to help you keep your plant up and running.

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Precision Coils specializes in manufacturing competitively-priced, precision-engineered replacement coils and OEM coils that always fit and are always on-time. And that means you can get your customers up and running quicker – with minimal installation time.

Educational Session

Seminar Descriptions

SOAR 2 SuccessUS. Army Black Hawk Pilot, Elizabeth McCormick, shares the professional development secrets for business with her stories of overcoming overwhelming obstacles as a helicopter pilot. Creating an experience for your entire organization while inspiring YOU Soar 2 Success!

Presented by: Robert Meilinger, Account Manager, Siemens; Adjunct Professor, Technology Kalamazoo

Valley Community College

This class will discuss some of the key details required in applying AC motors on AdjustableFrequency Drives. The seminar will explore the inherent differences of applying an ACInduction Motor on across the line service vs. VFD. We will explore the effects on motor insulation life, heat and harmonic concerns and the ability to supply the rated torque and current needed to power your applications. We will also touch on the different types of applications and their specific profiles.

AC Adjustable Speed Drives Motor Basics

Elizabeth has flown government VIPs such as generals, governors, congressmen and women, and even the Secretary of Defense. She also supported UN peacekeeping operations in Kosovo as the S-4 Logistics Officer in Charge at the Battalion level, receiving the Meritorious Service Medal for her excellence in service.

A decorated pilot and officer, Elizabeth was also awarded the Army Commendation Medal twice, Army Achievement Medal two times, National Defense Service Medal, Humanitarian Service Medal, Army Service Ribbon, and the coveted Army Aviator Badge. She retired from the military as a Chief Warrant Officer 2, after a career-ending injury. Elizabeth was honored with the Congressional Veteran Commendation for her commitment to duty and community.

Keynote Speaker

Presented by: Doug Waetjen, VP Operations, UE Systems

Airborne & structure-borne ultrasound has evolved into a technology that many would consider to be the cornerstone of an effective condition based maintenance program. One application in particular that has seen a large increase in usage, is to use ultrasound for condition based lubrication of bearings. Studies have shown that the most common causes of premature bearing failures are related to lubrication.


Presented by: John Shepherd, Midwest Regional Sales Manager - Electro Static Technology/AEGIS

Conductive microfiber electrical discharge machining bearing damage prevention technology for rotating equipment

AEGIS Bearing Protection Rings – BearingCurrent Mitigation for Rotating Equipment

Presented by: David A. Kirkwood, Business Development Manager - TestOil

Review of the various testing methods used during routine oil analysis, the importance of each test and hot it “fits” into the overall scheme of determining the overall health of the lubricant and equipment.

Basics of Oil Analysis

Presented by: John Masek, Senior Vice President, Bearing Service Inc.

Understand the advantages and disadvantages of grease versus oil lubrication. Discuss grease compatibility and characteristics of greases with different bases. Provide direction on proper grease fill of bearings for different applications. Present an alternative to conventional grease and oil lubrication for bearings.

Bearing Lubrication

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Presented by: Keith Menges, Business Development Manager, ITT Goulds Pump Inc.

A brief overview of new sensor technology and wireless advancements followed by a discussion of ITT’s i-ALERT2 condition monitor product.


Presented by: Bob Bolhuis, Sr. Account Manager – HECOJoe Roorda, Principle Engineer – NiSource

Explore a case study with HECO and NiSource (NIPSCO), the end user, on a 9000HP, 1800RPM, 13,200V Boiler Feed Pump motor at one of NiSource’s coal fired power generation plants. A 30+ year old electric motor began to make a noise and vibrate, working together, HECO and NiSource were able to determine the cause and implement corrective actions in the motor repair process.

Case Study on 9000HP, 13.2KV Boiler Feed Pump Motor with Rotor/Vibration Issues


Learn the basics of shaft couplings, focusing on the misalignment capabilities of each. Included are the differences between rigid and flexible couplings, along with types of applications for which they are best suited. Information on proper installation, including fitting practices and lubrication will be discussed.

Coupling Overview

Presented by: Dennis Metz, Camfil USA, Michigan Branch

Explore air filter static resistance and impact to energy consumption. Demonstrate using small equipment for live comparison.

Energy Savings through Air Filtration

Presented by: Michael A. Olszewski, President, Alignment Supplies, Inc.

Often seemingly simple alignment tasks become difficult, challenging, time consuming and even impossible. In this presentation I will discuss some of the problems that can be encountered during alignment jobs, what they are, what our tools are telling us and how to interpret the results. The presentation will include narrated dialogue, an accompanying power point, and live demonstrations for both shaft and belt alignment.


Presented by: Kurt Covine, Siemens Industry

Brian Butler, Electro Matic Products This session will review the existing and latest medium voltage topologies and their practical applications. The issues that are most important to drive users in terms of their plant power grid, the motor and their process will be discussed and a list of actual questions that should be asked and answered by any drive manufacturer will be supplied. The goal is to provide users with the basic information required to mitigate the risk in applying medium voltage drives in their specific plant application. It is assumed that most attendees will have a basic understanding of what a variable speed drive is and why it is generally used but a brief review will be provided.


Presented by: Doug Weil, Repair Sales Manager, Kennedy Industries Inc.

Kennedy Industries introduction, pump history, theory of operation, mechanical support components, fluid dynamic disasters, mechanical mayhem, 3 step immunization, checkups, maintenance.

My Pump Called in Sick Today

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Presented by: Thomas E. Spettel, Sr. Engineer, HECO Predictive Service Group

ISO Certified Category IV Vibration Analyst Solving problems is the main focus of vibration predictive maintenance programs. Diagnosing vibration problems is the most difficult of the predictive technologies to master, and requires more time and training to become proficient than any of the other technologies. In addition, diagnosing a problem without correcting the underlying cause may not result in the desired improvement in reliability. This paper will use several case histories to demonstrate the use of advanced vibration analysis technique to diagnose the cause of the vibration and, with a little bit of engineering and common sense, “fix’ the problems.

Case History 1: Boiler Forced Draft Fan Structural Resonance - Construction mistakes result in a structural resonance preventing operation of a new boiler.

Case History 2: Boiler Feed Water Pump Motor Resonance - Installation of a used motor required baseplate modifications that resulted in excessive motor vibration.

Case History 3: Torsional Resonance Results in Broken Coupling Bolts - Operating a motor driven fan at a torsional natural frequency resulted in severe coupling damage.

Case History 4: Air Compressor Misalignment Causes Motor Thrust Bearing Damage - Failure to set a motor on magnetic center during coupling installation resulted in excessive vibration and damage to the motor bearing.

Case History 5: Diagnosing the Cause of Surge on a Large Centrifugal Air Compressor - Continuous vibration monitoring allowed diagnosis of failure in a compressor anti-surge system.

How to “Fix” Vibration Problems

Presented by: Scott Miklavcich, Channel Manager, Motors – Siemens Industry

A review of the new Department of Energy efficiency standards for electric motors and there effect on the industry. The Integral Horse Power Rule, which becomes effective June 1, 2016, will affect most users of electric motors. A history of efficiency and the new requirements will be reviewed in detail. Attendees will also be given an overview of Siemens comprehensive motor offering as well as what is new for 2016

New 2016 DOE Electric Motor Efficiency Standards and Siemens Motor Update


An overview of the fundamental principles and formulas of torque, speed, and ratio will be reviewed. Review belt drives, chain drives, and gear drives, discussing the features and benefits of each. Basic nomenclature for each type of component will be discussed, along with popular variations and new product innovations a compressor anti-surge system.

Power Transmission Basics

Presented by: Todd Hatfield, VP of Engineering & Repair – HECO

RPM 2015’s Best Attended Seminar! Obtain a basic understanding of induction electric motors: From component parts and types to what information the motor nameplate actually provides. Learn about operating characteristics such as Torque, NEMA designs, Starting conditions, and the Operating parameters that impact motor life. Learn about common failure types and detailed failure investigations and finally see proven engineering design assessments that lead to solving motor problems and providing longer motor life.

Repairing Electric Motors for Reliability

Presented by: Todd A. Hatfield, VP of Engineering & Repair – HECO

We will review the entire process involved in manufacturing of AC Medium Voltage Form Coils. To many end-users of medium voltage motors, there are many unknowns about “coils” and “winding” in general. This presentation is meant to explore all of the important factors in manufacturing medium voltage form coils. Starting with how and why the winding failed in the first place and moving into understanding the coil design, making improvements to the design, the actual manufacturing process, packaging/shipping and even checking the coil quality once it arrives at the repair facility. We will explore what this process looks like and what it means to end users that want reliable, quality coils in their motor.

Optimizing the Design of Medium Voltage Form Coils

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New 2016 DOE Electric Motor Efficiency Stan-dards and Siemens Motor Update

Presented by: Mark S. Hatfield, President – HECO

Motors are inherently reliable but over time they do need to be repaired or replaced. When motors fail, organizations must act quickly to get them running again. The decisions you make when a motor fails can significantly impact on the future reliability and efficiency of your equipment. This presentation outlines a best practice approach for dealing with repair and replacement decisions. This approach will enable you to act decisively when a failure occurs, with the confidence that your decisions will improve the performance of your motor inventory and provide maximum return for your organization.

Repair vs. Replacement Decision Making

Presented by: Mike Findley, Vice President, Business Development – Pro Services

Finding the right talent for the job has always been a constant struggle and is one of the most critical issues our industry faces today. Pro Services is the one-source solution to help manage labor resources and provide customers with the best talent in the industry. Whether it’s major capital projects, shutdowns, or managing an entire production maintenance team, Pro Services has the talent that can get the job done efficiently and professionally. Maximize your core production focus while we provide the talent to keep your lifeline running.

The War on Talent

Uncommon Balancing and Misalignment Concerns Presented by:

Jason T. Spettel, Sr. Reliability Engineer/Manager, HECO Predictive Service GroupISO Certified Category III Vibration Analyst

Vince Aldrich, Reliability Specialist, HECO Predictive Service GroupISO Certified Category III Vibration Analyst

Case studies of misdiagnosed alignment and imbalance. Thinking outside the box when all vibration data indicates misalignment or imbalance but systematic corrective actions do not produce positive results.

Hotel RegistrationThe 2016 RPM Symposium offers a group discount with three local hotels: Country Inn & Suites by Carlson, AmericInn, and Courtyard by Marriott Kalamazoo-Portage. Availability is limited.

1912 E. Kilgore Rd. Kalamazoo, MI 49002269-382-2303www.countryinns.com/kalamazoo-hotel-mi-49002/mikazooReservation Information: Call to reserve under the name RPM Symposium (by August 21)Highlights: Complimentary hot breakfast, wireless internet, & guest parking

Country Inn & Suites by Carlson

$85/night

1550 E. Kilgore Rd. Kalamazoo, MI 49001269-344-7774www.americinn.com/hotels/mi/kalamazooReservation Information: Call to reserve under the name RPM Symposium (by September 6)Highlights: Complementary home-style breakfast, wireless internet & guest parking

AmericInn

$119/night

400 Trade Centre WayKalamazoo, MI 49002269-382-5808www.marriott.com/hotels/travel/azcocy-courtyard-kalamazoo-portageReservation Information: Call to reserve and reference the RPM Symposium (by August 13) Highlights: Wireless internet & guest parking

Courtyard by Marriott

$159/night

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2016 Sponsors Notes

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september 13 & 14, 2016 kalamazoo, mi. air zoo · kalamazoo, mi. air zoo september 13 & 14,...

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